Trane CenTraVac Duplex CDHE Operation & Maintenance Manual Download | Manualshive

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CDHF-SVU01C-EN

98

Maintenance

DO NOT LEAVE GREASE FITTINGS
INSTALLED.
If grease fittings have been used for
this procedure then they MUST BE
REMOVED before returning the unit
to service. Grease fittings are not
vacuum-tight and will become a leak
path.

9. Using a clean wooden dowel or

other similar tool, remove excess
grease from the remaining open
lubrication port.

10. Clean and then lightly coat the

threads of the plug with Rheolube
grease and re-install it into the
lubrication port. Tighten the
plug to hand tight plus 1/4 to 1/2
turn.

11. Before reconnecting the vane

linkage, grasp the tang operator
arm and manually operate the
vane assembly. If it is now
difficult to move, then the tang
operator may have become
“hydraulically locked” because of
excess grease in the assembly.
This situation could cause
damage to the o-rings of the
assembly. If this occurs then
remove one of the lubrication
plugs, remove some of the
grease, then re-install the plug.

12. Reconnect the linkage to the tang

operator arm. Ensure the spacer
washers between the linkage and
the arm are properly placed and
that the assembly does not bind.
Re-install any insulation that was
cut or removed. The unit may be
restarted.

To service the 1st and 2nd stage tang
operators on CDHF extended
capacity chillers with 1470 or 1720
compressors.

The 1st and 2nd stage rotary inlet
guide vane tang operators of the
extended capacity chillers also
require periodic lubrication, at least
annually, with R123 compatible
Rheolube grease. These actuators
have two 1/8" NPT plugs located 180
degrees apart, with one on the top

Figure 37. Rotary valve in drain position

Front View with Refrigerant Pump

and the other on the bottom of the
operator base. Use the same
procedure as described above,
except that it will be necessary to
temporarily disconnect the vane
actuators from the tang operator
arms in order to test for a
“hydraulically locked” condition.

The oil valve block rotary valve uses
dual O-Rings to seal to atmosphere.
These should be manually lubricated
by removing the pipe plug at the
valve lubrication port and placing a
few drops of Trane OIL00022 in the
cavity. Be sure to reinstall the pipe
plug when lubrication is completed.

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Summary of Contents for CenTraVac Duplex CDHE

Page 1: ...CDHF SVU01C EN X39640670030 Operation Maintenance Duplex CDHF CDHG Water Cooled CenTraVac With CH530 ...

Page 2: ...ent damage Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions NOTICE Warnings and Cautions appear at appropriate sections throughout this manual Read these carefully WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation whi...

Page 3: ...rator Interface Chilled Water Setpoint Inter Processor Communication IPC Control System Components Controls Sequence of Operation Machine Protection and Adaptive Control Unit Startup Unit Shutdown Periodic Maintenance Oil Maintenance Maintenance Forms 2 4 28 30 38 51 52 67 72 89 91 92 95 97 104 ...

Page 4: ...F and CDHG models are defined and built using the product definition and selection PDS system This system describes the product offerings in terms of a product coding block which is made up of feature categories and feature codes An example of a typical product code block is given on this page The coding block precisely identifies all characteristics of a unit 4 Identifies unit electrical requirem...

Page 5: ...0 nominal ton evaporator 5 1850 nominal ton evaporator 21st C Evaporator Tubes A I E copper 0 028 wall 0 75 O D B I E copper 0 035 wall 0 75 O D C S B copper 0 028 wall 0 75 O D D S B copper 0 035 wall 0 75 O D E I E copper 0 028 wall 1 0 O D F I E copper 0 035 wall 1 0 O D 22nd 0 Not Assigned 23rd B Evaporator Waterbox A 150 psig 1 pass marine B 300 psig 1 pass marine C 150 psig 1 pass non marine...

Page 6: ...rotection 0 None 1 Enhanced protection 37th G Control Generic BAS 0 None G Generic BAS 38th W Water Flow Control 0 None W Water flow control 39th 4 Tracer Comm Interface 0 None 4 COMM 4 5 COMM 5 S Special 40th C Control Condenser Refrigerant Pressure 0 None C with 41st 1 Control Extended Operation 0 None 1 Extended operation 42nd 1 Chilled Water Reset Outdoor Air Temperature Sensor 0 None 1 Chille...

Page 7: ...r minute HGBP Hot Gas Bypass HVAC Heating Ventilating and Air Conditioning IE Internally Enhanced Tubes IPC Interprocessor Communication LBU La Crosse Business Unit LCD Liquid Crystal Display LED Light Emitting Diode MAR Machine Shutdown Auto Restart Non Latching where chiller will restart when condition corrects itself MMR Machine Shutdown Manual Restart Latching where chiller must be manually re...

Page 8: ...r unit is composed of the following components as viewed when facing the control panel front side Common Evaporator and Common Condenser Compressors and Motor 1 Left hand and 2 Right hand Economizers 1 LH and 2 RH Purge 1 LH and 2 RH Oil Tank Refrig Pump 1 LH and 2 RH Control Panel 1 LH and 2 RH And when specified Unit mounted Starters 1 LH and 2 RH not shown ...

Page 9: ...9 CDHF SVU01C EN General Information Figure 2 General Duplex unit components 2 stage compressor ...

Page 10: ...efrigerant causing it to condense The liquid refrigerant then passes through orifice plate A and into the economizer The economizer reduces the energy requirements of the refrigerant cycle by eliminating the need to pass all gaseous refrigerant through three stages of compression See Figure 3 Notice that some of the liquid refrigerant flashes to a gas because of the pressure drop created by the or...

Page 11: ...11 CDHF SVU01C EN Figure 3 Pressure enthalpy curve 3 stage compressor Figure 4 2 stage economizer 3 stage compressor General Information ...

Page 12: ...CDHF SVU01C EN 12 Figure 5 Pressure enthalpy curve 2 stage compressor Figure 6 Single stage economizer 2 stage compressor General Information ...

Page 13: ...cally organized groups of information chiller modes of operation active diagnostics settings and reports put information conveniently at your fingertips See Operator Interface Section for details TechView Chiller Service Tool For the service technician or advanced operator All chiller status machine configuration settings customizable limits and up to 60 active or historic diagnostics are displaye...

Page 14: ...ol actions such as Turning on Relays or moving the Inlet Guide Vanes Smaller cylinders indicate diagnostic checks Text indicates time based functions Solid double arrows indicate fixed timers Dashed double arrows indicate variable timers Power Up Diagram The Power up chart shows the respective DynaView screens during a power up of the main processor This process takes from 30 to 50 seconds dependi...

Page 15: ...hiller The First compressor will be determined by the type of duplex start selected Staging Second Compressor On This diagram shows the sequence of operations where the First compressor is all ready running and the second compressor is staged on The First and Second compressor will be determined by the type of duplex start selected Figure 9 CDHE CDHF and CDHG sequence of operation running ...

Page 16: ...essor off Staging Second Compressor Off This diagram shows the sequence of operations where there is no longer a need to run the Second compressor so it is staged off The First and Second compressor will be determined by the type of duplex start selected Satisfied Setpoint This diagram shows the sequence of operations where the setpoint has been satisfied and the last compressor is staged off ...

Page 17: ... will be started based on the leaving water temperature rising above the Differential to Start setting Compressors 2 will stage on when the overall chiller average capacity exceeds Stage ON Load point for 30 seconds The stage on load point is adjustable via service tool up to 50 The default is 40 which means that a single compressor would have to load to 80 the average would be 40 before the secon...

Page 18: ...ressors will run until chiller average capacity drops below Stage off Load point for 30 seconds The stage off load point is also adjustable Compressor 1 will be shut down and compressor 2 will run until water temperature drops below the differential to stop Before shutting down compressor 1 will be unloaded and compressor 2 will be loaded to maintain the same average capacity command If chilled wa...

Page 19: ...fewest starts will start If that compressor is unavailable to start due to a circuit lockout including restart inhibit or a circuit diagnostic then the other compressor will be started The second compressor will stage on when chiller capacity exceeds the Stage on Load point for 30 seconds When chiller capacity falls below Stage off Load point for 30 seconds the compressor with the most hours will ...

Page 20: ...revent doubling of the current inrush but will generally control the chiller as if there were only one compressor 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 When compressor 1 is at speed compressor 2 will start Both compressors will run until water tempe...

Page 21: ...ter the start to start timer has expired If the number of free starts is programmed to 3 the control will allow three starts in rapid succession but thereafter it would hold off on a compressor start until the Start to Start timer expired Restart Inhibit Start to Start Time Setting This setting defines the shortest chiller cycle period possible after the free starts have been used If the number of...

Page 22: ...re routed into a manifold under the motor Gas flow exits the top of the manifold and is vented to the Evaporator Note A vent line solenoid is not needed with the refrigerant pump Oil exits the bottom of the manifold and returns to the tank Separation of the seal leakage gas in the manifold keeps this gas out of the tank A dual eductor system is used to reclaim oil from the suction cover and the ev...

Page 23: ...23 CDHF SVU01C EN General Information Figure 16 Oil refrigerant pump circuit 1 or 2 ...

Page 24: ...lled water or hot water If the chiller is already running it will continue to run regardless of the differential to stop either chilled water or hot water using the base load control algorithm While the unit is running in base loading it will report that status back to the Tracer by setting Base Load Status true in the Tracer Status Byte When the Tracer removes the base load mode request sets the ...

Page 25: ...25 CDHF SVU01C EN General Information Figure 17 Base loading with external mA input and with external voltage input ...

Page 26: ...ng mode and back into the ice building mode It is not acceptable to reset the chilled water setpoint low to achieve a fully loaded compressor When entering ice building the compressor will be loaded at its maximum rate and when leaving ice building the compressor will be unloaded at its maximum rate While loading and unloading the compressor all surge detection will be ignored While in the ice bui...

Page 27: ...ther source of constant temperature water for the purpose of extracting heat In hot water temperature control mode all the limit modes and diagnostics operate as in normal cooling with one exception The leaving condenser water temperature sensor is an MMR diagnostic when in hot water temperature control mode It is an informational warning in the normal cooling mode In the hot water temperature con...

Page 28: ...rface section for detailed information Figure 20 Left control panel The UCP houses several other controls modules called panel mounted LLID Low Level Intelligent Device power supply terminal block fuse circuit breakers and transformer The IPC Interprocessor communication bus provides communication between LLID s and the main processor Unit mounted devices are called frame mounted LLID s and can be...

Page 29: ...algorithm compares each parameter to its programmed limit The chiller s Adaptive Control capabilities maintain overall system performance by keeping its peak efficiency Whenever the controller senses a situation that might trigger a protective shutdown it focuses on bringing the critical parameter back into control When the parameter is no longer critical the controller switches its objective back...

Page 30: ...odules LLID can be viewed at the DynaView operator interface Such as evaporator and condenser water temperatures outdoor air temperature evaporator and condenser water pump control status and alarm relays external auto stop emergency stop evaporator and condenser water pressure drops and evaporator and condenser water flow switches DynaView presents three menu tabs across the top which are labeled...

Page 31: ...es by touching the increment or decrement arrows Action buttons are buttons that appear temporarily and provide the operator with a choice such as Enter or Cancel The operator indicates his choice by touching the button of choice The system then takes the appropriate action and the button typically disappears DynaView consists of various screens each meant to serve a unique purpose of the machine ...

Page 32: ...Stop key is touched entering the stop sequence Pressing the Immediate Stop button will cause the chiller to stop immediately The AUTO and STOP take precedence over the ENTER and CANCEL keys While a setting is being changed AUTO and STOP keys are recognized even if ENTER or CANCEL has not been pressed Selecting the Auto key will enable the chiller for active cooling if no diagnostic is present Chil...

Page 33: ... operating mode sub menu may have up to six 6 lines of text displayed The BAS CODE is the code that will be sent via COMM4 to the Tracer Summit system as the chiller system mode Note that each top level mode may contain multiple sub level modes In general the BAS CODE will reflect the top level mode and not the sub level mode A general description of the top level modes is show in the following ta...

Page 34: ...al Reset 00 Run Inhibit Ice Building Is Complete 100 Run Inhibit Tracer Inhibit 100 Run Inhibit External Source Inhibit 100 Run Inhibit Diagnostic Shutdown Auto Reset 100 Auto Waiting For Evaporator Water Flow 58 Auto Waiting For A Need To Cool 58 Auto Waiting For A Need To Heat 58 Auto Power Up Delay Inhibit MIN SEC 58 Waiting To Start Waiting For Condenser Water Flow 70 Waiting To Start Establis...

Page 35: ...unning There is no sub mode displayed 74 Running Hot Water Control 74 Running Surge 74 Running Base Loaded 74 Running Ice Building 74 Running Ice To Normal Transition 74 Running Current Control Soft Loading 74 Running Capacity Control Soft Loading 74 Running Limit Current Limit 75 Running Limit Phase Unbalance Limit 75 Running Limit Condenser Pressure Limit 75 Running Limit Evaporator Temperature ...

Page 36: ...f See modes in Emum adaptive auto purge manual 11 Circuit 2 Purge Mode status i e on off See modes in Enum adaptive auto purge manual 12 Approx Chiller Capacity Tons kW XXX If option installed 13 Active Ice Termination Setpoint source F C 0 1 If option installed 14 Software Version 0 XX Chiller Operating Mode The machine operating mode indicates the operational status of the chiller A subscreen wi...

Page 37: ...started In the case of Unit Shutdown Reset Required diagnostic types the chiller will have to be manually reset through the Diagnostics alarm menu When reset they become historic and viewable via the service tool TechView Performing a Reset All Active Diagnostics will reset all active diagnostics regardless of type machine or refrigerant circuit A Manual Override indicator shares space with the Al...

Page 38: ...column will be shown if that option is Not Installed otherwise the current setpoint from that source will be shown The Back button provides navigation back to the chiller screen The active chilled water setpoint is the setpoint that is currently in use It will be displayed to 0 1 degrees Fahrenheit or Celsius Touching the double arrow to the left of the Active Chilled Water Setpoint will take the ...

Page 39: ...rovides navigation back to the chiller screen Note This is the same for other setpoints in the Main menu The active current limit setpoint is the current limit setpoint that is currently in use It will be displayed in percent RLA Touching the double arrow to the left of the Active Current Limit Setpoint will take the user to the active current limit setpoint sub screen The active current limit set...

Page 40: ...d presented in reverse video or some how changed to indicate it is the selected choice When a report screen is selected the appropriate circuit is displayed in the screen heading as shown in the sample evaporator screen below Report Menu Description Heading Buttons 1 Evaporator System Ckt 1 Ckt 2 2 Condenser System Ckt 1 Ckt 2 3 Compressor Ckt 1 Ckt 2 4 Motor Ckt 1 Ckt 2 5 Purge Ckt 1 Ckt 2 6 ASHR...

Page 41: ...erential Wtr Press XXX X Diff Pressure If option installed 5 Approx Cond Water Flow XXXX Flow If option installed 6 Outdoor Air Temperature or XXX X Temperature If option installed Report name Circuit Condenser Description Resolution Units Dependencies 1 Cond Sat Rfgt Temp or XXX X Temperature 2 Cond Rfgt Pressure XXX X Pressure 3 Cond Approach Temp or XXX X Temperature Note Approach temperatures ...

Page 42: ...installed Report name Circuit ASHRAE Chiller Log Description Resolution Units Dependencies 1 Circuit Operating Mode Enum 2 Amps L1 L2 L3 XXXX Amps XXX X if less than 1000 Amps 3 Volts AB BC CA XXXX Volts 4 Purge Daily Pumpout 24 Hrs XXX X Min 5 Purge Daily Pumpout Limit Alarm XXX X Min 6 Purge Pumpout Life XXXXXX X Min 7 Purge Operating Mode Enum 8 Purge Status Enum 9 Compressor Starts XXXX Intege...

Page 43: ...Purge System Mode Override etc a listing of all setpoints available to change along with their current value will appear The operator selects a setpoint to change by touching either the verbal description or setpoint value Doing this causes the screen to switch to either the Analog Settings Subscreen or the Enumerated Settings Subscreen Header Screen To aid in comparing circuit level setpoints the...

Page 44: ...ferential to Stop XXX X Temperature 12 Setpoint Source BAS Ext FP Ext Front Panel Front Panel BAS Ext FP Default Enum Follows hierarchy of selection from left to right except for ice building which is OR logic Feature Settings Description Resolution or Enumerations Default Units 1 Chilled Water Reset Constant Outdoor Return Disable Disable Enum 2 Return Reset Ratio XXX Percent 3 Return Start Reset...

Page 45: ...Enum 4 Time of Day 5 Keypad Display Lockout Enable Disable Disable Enum 6 Display Units SI English English Enum 7 Pressure Units Gauge Absolute Absolute Enum 8 Language English Selection 2 Selection 3 English 2 Enum 1 Temperatures will be adjustable to 0 1 degree F or C The Main Processor provides the minimum and maximum allowable value 2 Adjustable to the nearest whole number percent The Main Pro...

Page 46: ...log Settings Subscreen displays the current value of the chosen setpoint in the upper of the display It is displayed in a changeable format consistent with its type Binary setpoints are considered to be simple two state enumeration and will use buttons Analog setpoints are displayed as spin buttons The lower half of the screen is reserved for help screens To change the setpoint the ENTER key must ...

Page 47: ... Settings is shown below Note Radio 1 and Radio 2 refer to touch sensitive buttons The labels depend upon the setting being controlled The analog setting subscreen is similar but offers an Auto Manual radio button and value setting An Auto Manual selection is necessary to set the mode to override Subsequently when an arrow key is depressed that new value is assumed ...

Page 48: ...e setting An Auto or Manual selection is necessary set to the mode to override An Enter and Cancel Key will allow the user to Enter or Cancel the entry Mode Override for Analog Settings is shown below The date setpoint screen for setting up the is shown below The user must select Day Month or Year and then use the up or down arrows to adjust ...

Page 49: ...oint screen with a 12 hour format is shown below The user must select Hour or Minute and then use the up or down arrows to adjust Adjusting hours will also adjust am and pm Note The 24 hour format setpoint screen is similar with the am and pm not shown ...

Page 50: ...per password is entered there will be no access to the DynaView screens including all reports all setpoints and Auto and Stop and Alarms and Interlocks The password 159 is not programmable from either DynaView or TechView If the Display and Touch Screen Lock feature is Disabled the following screen will be automatically shown if the MP temperature is below 32 F 0 C and it has been 30 minutes after...

Page 51: ...aud IPC3 Definitions Bus Management The DynaView provides the bus management having the task of restarting the link or filling in for missing nodes when the normal communication has been degraded This involves reassigning node addresses and filling in for nodes that are off line The DynaView always has a node number of 01 Node Assignment When a unit is factory commissioned the Low Level Intelligen...

Page 52: ...CDHF SVU01C EN 52 Control System Components Figure 24 Control panel components layout ...

Page 53: ...53 CDHF SVU01C EN Control System Components ...

Page 54: ...dard Oil Pump and not for field use Output Relay Refrigerant Pump 1A13 Dual LV Binary Standard Signal 1 External Auto Stop J2 1 Binary Input Signal 1 input module J2 2 Ground 1A13 Dual LV Binary Standard Signal 2 Emergency stop J2 3 Binary Input Signal 2 input module J2 4 Ground 1A26 Temp Sensor Standard Compressor Motor not for field use Input 1F1 Standard LLID Power Supply Transformer not for fi...

Page 55: ...ximum capacity for 10 minutes this relay will deactivate Compressor Running Relay Relay activates while compressor is running Machine Shutdown Manual Reset MMR Limit warning machine shutdown auto reset relays will activate with such conditions for remote status indication Control System Components OPST Operation Status Option Relay output modules 1A8 and 1A9 provide relay defaults shown For other ...

Page 56: ...ant monitor inputs J2 4 Output 2 Input Output Module J2 6 Ground 1A18 Optional Dual LV EXOP Signal 1 External Base Loading J2 1 Binary Input Signal 1 Binary input module Enable or Disable input points J2 2 Ground 1A18 Optional Dual LV EXOP Signal 2 External Hot Water Control J2 3 Binary Input Signal 2 Binary input module Enable or Disable input J2 4 Ground 1A19 Optional Dual LV EXOP Signal 1 Ice B...

Page 57: ...r Refrigerant Pressure Output 1A15 Optional Dual Analog CDRP Signal 2 Condenser Refrigerant J2 4 Output 2 J2 6 Ground Input output Module Pressure output EPRO Enhanced Protection 4R22 EPRO Condenser Refrigerant Pressure Transducer 4R16 EPRO Compressor Discharge Refrigerant Temperature Sensor This is also included with HGBP 4R1 EPRO Inboard Bearing Temperature Sensor 4R2 EPRO Outboard Bearing Tempe...

Page 58: ...n the Saturated Condenser Refrigerant and a temperature to pressure conversion is made If the Condenser Saturated Temperature goes out of range due to an open or short a pressure sensor diagnostic will be called and the output will also go to the respective out of range value That is for an out of range low on the sensor the output will be limited to 2 0 VDC For an out of range high on the sensor ...

Page 59: ... 400 psid 0 2758 kPa in increments of 1 psid 1kPa The Maximum Delta Pressure Calibration setting has a range of 1 400 psid 7 2758 kPa in Figure 26 Delta pressure setting differential pressure based output Defaults shown increments of 1 psid 1kPa The condenser refrigerant pressure is based on the Condenser Refrigerant Temperature sensor if the Condenser Pressure Option is selected as Not Installed ...

Page 60: ... J2 3 Ground Analog Input output Module 1A16 Optional Dual GBAS Signal 2 Chilled Water Reset input J2 5 Input 2 J2 6 Ground Analog Input or External Chiller Water Setpoint output Module Percent RLA Output 2 to 10 Vdc corresponding to 0 to 120 RLA With a resolution of 0 146 The Percent RLA Output connections are on the terminals 1A15 J2 1 to J2 3 Ground The Percent RLA Output is polarity sensitive ...

Page 61: ...upply Unit Control Power Supply Module Converts 27 vac to 24 vdc Power Input Voltage 23VRMS minimum 27VRMS Nominal 30VRMS maximum Frequency 50 60 Hz Current Full load 27 VAC 4 30 A RMS Inrush 27 VAC RMS 30A RMS Power Output Class II Voltage 24 VDC Rated Current 2 44 Amps Fused at 3 amps FUS01513 1A3 1A5 1A10 Dual Relay Output modules Relay 1 J2 1 NO J2 2 NC J2 3 common Relay 2 J2 4 NO J2 5 NC J2 6...

Page 62: ...um Power 24 10 percent VDC 100 ma maximum Trane IPC3 protocol 1A13 1A18 1A19 1A20 Dual Binary input module J2 1 Binary Input Signal 1 J2 2 Ground J2 3 Binary Input Signal 2 J2 4 Ground Binary Input Looks for a dry contact closure Low Voltage 24V 12 mA 14 26 AWG with a maximum of two 14AWG Power 24 10 percent VDC 40 mA maximum Trane IPC3 protocol 1A14 Communication interface Module Power 24 10 perc...

Page 63: ...ers 14 0 00 2823 1062 7 324 16 0 004489 668 3 203 8 18 0 007138 420 3 128 1 20 0 01135 264 3 80 6 22 0 01805 166 3 50 7 24 0 0287 104 5 31 9 26 0 04563 65 7 20 28 0 07255 41 4 12 6 Note the above table is for copper conductors only Analog Input The analog input can be software switched between a voltage input or a current input When used as a current input a 200 Ohm load resistor is switched in 2 ...

Page 64: ...sensors Oil tank sump 4R4 and oil pump discharge 4R3 evaporator and condenser refrigerant pressure 4R22 Working Pressure Range 0 to 50 Psia Accuracy 0 3 of full scale output at 68 F 20 C Power and Communications and Terminations Power 24 10 VDC 20 mA maximum Communications RS485 Physical Layer 19 2 Kbaud Trane IPC3 protocol Starter Module In the hierarchy of modules the Starter module 2A1 1A23 whe...

Page 65: ...65 CDHF SVU01C EN Control System Components ...

Page 66: ...CDHF SVU01C EN 66 Control System Components ...

Page 67: ...cted to all modules via the Interprocessor communications Bus providing module power 1Q3 also provides power to the external chiller water proof of flow device connected between terminal block 1X1 5 to 1A6 J3 2 and condenser water proof of flow device connected at 1X1 6 to 1A6 J2 2 4 Circuit Breaker 1Q4 which provides power to the Oil Heater 4HR1 circuit and to circuit breaker 1Q5 oil and refriger...

Page 68: ...d the oil pump on This is parallel to 1A7 contacts H After the compressor motor has accelerated and the maximum phase current has dropped below 85 percent of the chiller nameplate RLA for 1 5 seconds the starter transition to the Delta configuration is initiated J The transition contactor 2K4 is closed through relay 2A1 J2 placing the transition resistors 2R1 2R2 and 2R3 in parallel with the compr...

Page 69: ...y 2A1 J10 and the condenser water pump relays 1A5 J2 open to turn off The oil and refrigerant pump motor 4B3 will continue to run for 3 minutes post lube while the compressor coasts to a stop The chilled water pump will continue to run while the Main processor module 1A22 monitors leaving chilled water temperature preparing for the next compressor motor start based on the differential to start set...

Page 70: ...ds after phase currents drop to 85 percent 1 2 second 1 5 second J Begin Transition sequence 85 100 milliseconds 100 milliseconds K Open S Shorting Contactor 250 300 milliseconds 260 milliseconds L Close 2M 2K2 Contactor 140 milliseconds M Wait to look for Transition complete milliseconds 2 32 to 2 38 second N Filtering time on Transition complete input milliseconds 160 to 240 milliseconds Figure ...

Page 71: ... coil of the refrigerant pump starter relay 4K8 to the start windings of the refrigerant pump When motor 4M3 first starts current draw is high This causes current sensing relay 4K8 to close its normally open contacts and pull in of pump Capacitor 4C1 Increasing motor speed and related decreasing current through the main winding and relay coil reduce the magnetic force and the armature Drops out to...

Page 72: ... will be shut down when a MPL is detected and will display a non latching diagnostic indicating the failure The oil pump will be run for the post lube time period when power returns The compressor and compressor motor are protected from damage from large torques and inrush currents resulting from reconnecting the compressor motor to the power source following a momentary loss of power MPL s greate...

Page 73: ...rmine if a diagnostic should be called The UCP continuously monitors compressor line currents to provide running over current and locked rotor protection Over current protection is based on the line with the highest current It triggers a manually resettable diagnostic shutting down the compressor when the current exceeds the specified time trip curve The compressor overload time trip curve is expr...

Page 74: ...vice tool This filtered setpoint allows for stable control if the Current Limit setpoint is adjusted during a run The Current Limit Setpoint CLS can be changed from Front Panel External Analog input with GBAS external option or Tracer Tracer option However If present Tracer current setpoint has the highest priority unless disabled in the DynaView Setpoint source override menu The External CLS has ...

Page 75: ...oint is initialized to the value of the Evaporator Leaving Water temperature and the percent RLA There are three independent Softload setpoints Capacity Control Softload Time default to 10 minutes 0 120 minutes This setting controls the time constant of the Filtered Chilled Water Setpoint Current Limit Control Softload Time default 10 minutes 0 120 minutes This Setting controls the time constant o...

Page 76: ...ator Temperature Limit will be displayed as a sub operating mode Leaving Water Temperature Cutout Leaving water temperature cutout is a safety control that protects the chiller from damage caused by water freezing in the evaporator The cutout setpoint is factory set however is adjustable with the Service tool The Leaving Water Temperature Cutout Setpoint is independently adjustable from the chille...

Page 77: ...able setpoint that should be based on the percentage of antifreeze used in the customer s water loop The Service tool will display a warning message such as Warning Adequate Antifreeze required for any Evaporator Refrigerant Temperature Cutout below 28 F and any Leaving Water Temperature Cutout below 35 F The percent of antifreeze required is a function of the leaving water temperature setpoint an...

Page 78: ...rator temperature approaches the evaporator limit setpoint Unload The potential to unload increases as the saturated evaporator temperature falls further below the evaporator limit setpoint Figure 31 illustrates these functions as follows chilled water setpoint top bold line evap leaving water temp cutout center bold line evap rfgt temp cutout bottom bold line ...

Page 79: ...ut HPC trips by allowing the Chiller to continue to run at a lower load instead of tripping off via HPC The Condenser Limit will be based from a pressure conversion from the Condenser Refrigerant Temperature sensor unless there is a Condenser Refrigerant Pressure sensor installed CDRP option If the Condenser Refrigerant Pressure Sensor is installed then the limit will be based from the Pressure se...

Page 80: ...ar Restart Inhibit A Clear Restart Inhibit button is provided within Settings Manual Override on the DynaView display This provides a way for an operator to allow a compressor start when there is a currently active Restart Inhibit that is prohibiting such a start The button press will have no other function than to remove the restart inhibit if there is one active It does not change the count of a...

Page 81: ...en Low Oil Temperature Inhibit setting default 95 F 35 C the compressor cannot be started This is an inhibit mode and will be reported to the operator interface The oil heater is energized in an attempt to raise the oil temperature over this inhibit temperature setpoint The compressor is inhibited from starting until the oil temperature is raised 5 or more degrees above this setpoint The Low Oil T...

Page 82: ...s this diagnostic is issued High Oil Temperature Cutout Name High Oil Temperature Cutout Type of Diagnostic Latching results in Immediate Shutdown Default Setpoint value 180 F 82 2 C Implemented to avoid overheating of the oil and the bearings If the oil temperature is at or above the High Oil Temperature Cutout setpoint this diagnostic will be issued which will stop the compressor If Oil Temperat...

Page 83: ... CWS or Maximum Reset Where CWS is the new chilled water setpoint CWS is the active chilled water setpoint before any reset has occurred RESET RATIO is a user adjustable gain START RESET is a user adjustable reference TOD is the Temperature Outdoor Sensor TWE is entering evaporator water temperature TWL is the Leaving Evaporator Temperature MAXIMUM RESET is a user adjustable limit providing the ma...

Page 84: ...C 5 F 0 2 to 11 11 C 2 78 C Constant Return CWS CWS 100 percent Design Delta Temperature TWE TWL and CWS or CWS and CWS CWS or Maximum Reset Notice that Constant Return is nothing more than a specific case of Return Reset offered for operator convenience When any type of CWR is enabled the UCP will step the CWS toward the desired CWS based on the above equations and setup parameters at a rate of 1...

Page 85: ...tart Reset Example of Calculating Reset for Outdoor Air Temperature If Reset Ratio 35 percent Start Reset 80 TOD 65 Maximum Reset 10 5 How many Degrees of Reset will there be Degrees of Reset Reset Ratio Start Reset TOD Degrees of Reset 35 80 65 Degrees of Reset 5 25 multiply If Reset Ratio 70 percent Start Reset 90 TOD 100 Maximum Reset 17 How many Degrees of Reset will there be Degrees of Reset ...

Page 86: ...CDHF SVU01C EN 86 Figure 33 Reset function for return CWR Note This graph assumes Maximum Reset is set to 20 degrees Figure 34 Reset function for return CWR Machine Protection and Adaptive Control ...

Page 87: ... there be Degrees of Reset Reset Ratio Start Reset TWE TWL Degrees of Reset 5 25 65 45 Degrees of Reset 2 5 If Reset Ratio 70 Start Reset 20 TWE 60 TWL 53 Maximum Reset 14 How many Degrees of Reset will there be Degrees of Reset Reset Ratio Start Reset TWE TWL Degrees of Reset 7 20 60 53 Degrees of Reset 9 1 Machine Protection and Adaptive Control ...

Page 88: ...CDHF SVU01C EN 88 Figure 35 Return CWR Figure 36 Constant CWR Machine Protection and Adaptive Control ...

Page 89: ... between these values is less than the start differential setpoint cooling is not needed If the UCP determines that the difference between the evaporator leaving water temperature and chilled water setpoint exceeds the start differential setpoint the unit enters the initiate Start Mode and the oil pump and Refrigerant pump and the condenser water pump are started If condenser water flow is not pro...

Page 90: ...ion of each safety and operating control 8 Close all disconnect switches 9 Perform instructions listed in Daily Unit Start up section WARNING Live Electrical Components During installation testing servicing and troubleshooting of this product it may be necessary to work with live electrical components Have a qualified licensed electrician or other individual who has been properly trained in handli...

Page 91: ...er 5 Remove the drain and vent plugs from the condenser headers to drain the condenser Air dry bundle of residual water 6 Once the unit is secured for winter the maintenance procedures described under Annual Maintenance in the Periodic Maintenance section of this manual should be performed by qualified Trane service technicians Note During extended shutdown be sure to operate the purge unit for a ...

Page 92: ...in the chiller s operating conditions For example if the machine operator notices a gradual increase in condensing pressure during a month s time he can systematically check then correct the possible cause s of this condition fouled condenser tubes noncondensable in the system etcetera Daily Maintenance and Checks Check the chiller s evaporator and condenser pressures oil tank pressure differentia...

Page 93: ...y Note For additional information regarding the safe discharge of capacitors see PROD SVB06A EN or PROD SVB06A FR Normal Chiller Operating Characteristics Operating Characteristic Normal Reading Approx Evaporator Pressure 6 to 9 PSIA 9 to 6 PSIG Approx Condenser Pressure 17 TO 27 PSIA 2 to 12 PSIG See Notes 1 and 2 Standard Condensers Oil Sump Temperature Unit Not Running 140 F to 145 F 60 C to 63...

Page 94: ...ring those periods of time when the chiller is not operated be sure the control panel is energized This is to keep the purge operational the oil heater warm and will also keep air out of the machine Annual Maintenance Shut down the chiller once each year to check the items listed a more detailed inspection checklist is provided on the Annual Inspection Checklist and Report illustrated in this manu...

Page 95: ...njunction with other diagnostics performed by a qualified service technician oil analyses can provide valuable information on the performance of the chiller to help minimize operating and maintenance costs and maximize it s operating life A drain fitting is installed in the oil filter top after the oil filter for obtaining oil samples Oil Change Procedure When oil analysis indicates the need to ch...

Page 96: ...g force on the locking pin should allow the pin to drop into a detent at this position 4 Allow at least 15 minutes for the oil to drain from the filter back into the oil sump 5 Pull the D handle to unlock the pin and rotate the valve to the Change Filter position This isolates the filter from the unit The locking pin should drop into a detent in this position 6 Remove and replace the filter as qui...

Page 97: ...ermine when to conduct a complete examination of the unit to discern the condition of the compressor and internal components Note a Chronic air leaks which can cause acidic conditions in the compressor oil and result in premature bearing wear and b Evaporator or condenser water tube leaks Water mixed with the compressor oil can result in bearing pitting corrosion or excessive wear Submit a sample ...

Page 98: ...tor arm Ensure the spacer washers between the linkage and the arm are properly placed and that the assembly does not bind Re install any insulation that was cut or removed The unit may be restarted To service the 1st and 2nd stage tang operators on CDHF extended capacity chillers with 1470 or 1720 compressors The 1st and 2nd stage rotary inlet guide vane tang operators of the extended capacity chi...

Page 99: ...actice in the past This will contaminate the charge and require excessive purging which will result in unnecessary release of refrigerant 6 Weigh in the proper charge 7 Use recovery and recyle unit or vacuum pump to evacuate hoses discharge outdoors 8 If refrigerant is supplied in new returnable cylinders be sure and refer to General Service Bulletin CVHE SB 48B for information on returning cylind...

Page 100: ...lectric resistance system to a maximum of 8 psig Do not use nitrogen which will cause excessive refrigerant discharge by the purge system Cleaning the Condenser CAUTION Proper Water Treatment The use of untreated or improperly treated water in a CenTraVac may result in scaling erosion corrosion algae or slime It is recommended that the services of a qualified water treatment specialist be engaged ...

Page 101: ...table for the job Remember a standard condenser water circuit is composed solely of copper cast iron and steel CAUTION Unit Corrosion Damage Proper procedures must be followed when using corrosive chemicals to clean water side of unit It is recommended that the services of a qualified chemical cleaning firm be used Proper personal protective equipment as recommended by the chemical manufacturer sh...

Page 102: ...before opening the system See unit nameplate for refrigerant type Do not use non approved refrigerants refrigerant substitutes or refrigerant additives Failure to follow proper procedures or the use of non approved refrigerants refrigerant substitutes or refrigerant additives could result in death or serious injury or equipment damage 2 After the liquid refrigerant is removed using a recovery or r...

Page 103: ...UR IMPORTANT SCALE DEPOSITS ARE BEST REMOVED BY CHEMICAL MEANS BE SURE TO CONSULT ANY QUALIFIED CHEMICAL HOUSE IN THE AREA ONE FAMILIAR WITH THE LOCAL WATER SUPPLY S CHEMICAL MINERAL CONTENT FOR A RECOMMENDED CLEANING SOLUTION SUITABLE FOR THE JOB 10 Motor bearings If the motor sits for a long time the bearings could take a set and cause bearing problems or replacement later Once every six months ...

Page 104: ...CDHF SVU01C EN 104 ...

Page 105: ...105 CDHF SVU01C EN ...

Page 106: ...CDHF SVU01C EN 106 ...

Page 107: ...107 CDHF SVU01C EN ...

Page 108: ...CDHF SVU01C EN 108 ...

Page 109: ...109 CDHF SVU01C EN ...

Page 110: ...CDHF SVU01C EN 110 ...

Page 111: ...111 CDHF SVU01C EN ...

Page 112: ...CDHF SVU01C EN 112 ...

Page 113: ...113 CDHF SVU01C EN ...

Page 114: ...CDHF SVU01C EN 114 ...

Page 115: ...115 CDHF SVU01C EN ...

Page 116: ...ld perform the installation and servicing of equipment referred to in this publication Literature Order Number File Number Supersedes Stocking Location Trane A business of American Standard Companies www trane com For more information contact your local district office or e mail us at comfort trane com CDHF SVU01C EN SV RF CTV CDHF SVU01C EN 405 CDHF SVU01B EN 604 La Crosse ...

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