Trane Duplex Water-Cooled Hermetic CenTraVac Installation Manual Download Page 2

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CDHF-SVN01B-EN

Warnings and
Cautions

Warnings and Cautions

Notice that warnings and cautions
appear at appropriate intervals
throughout this manual. Warnings
are provided to alert installing
contractors to potential hazards that
could result in personal injury or

death, while cautions are designed
to alert personnel to conditions that
could result in equipment 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 which, if not avoided, may result in

minor or moderate injury. It may also be used to alert against unsafe practices.

CAUTION

– Indicates a situation that may result in equipment or property-damage-only accidents.

Summary of Contents for Duplex Water-Cooled Hermetic CenTraVac

Page 1: ...Installation Duplex Water Cooled Hermetic CenTraVac With CH530 Controller CDHF SVN01B EN X39640669020 Cooling Only Direct Drive with CH530 Control Panel ...

Page 2: ...pment 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 w...

Page 3: ...iping Insulation Electrical Information Trane Supplied Starter Customer Supplied Starter Line Power Supply PFCC PFCC and Unit Mounted Starters Remote Starter Starter to UCP Control Wiring Control Circuit Wiring System Control Wiring Wiring Diagrams 2 4 25 35 41 43 44 45 47 48 50 51 53 54 56 59 ...

Page 4: ...ng the information in this manual and following the instructions given along with the submittal package provided for the unit will assure that the chiller is installed correctly General Information Product Description Block Trane 60 Hz Model CDHF hermetic CenTraVac units are defined by the product definition and selection system PDS Each unit is defined by the product description block which appea...

Page 5: ...on and Maintenance manuals Product description block identifies all unit components and unit design sequence used to order literature and make other inquiries about the unit Metric Conversion The following conversions apply for tables and charts in this manual In x 2 54 cm Ft x 30 48 cm Lb x 453 kg Commonly Used Acronyms ASME American Society of Mechanical Engineers ASHRAE American Society of Heat...

Page 6: ...23 ACTUALLY CHARGED WITH LBS OF R 123 MAXIMUM WORKING PRESSURE 15 15 PSIG HIGH SIDE MAXIMUM WORKING PRESSURE 15 15 PSIG LOW SIDE FACTORY TEST PRESSURE HIGH SIDE 45 PSIG LOW SIDE 45 PSIG FIELD LEAK TEST PRESSURE 8 PSIG MAX TESTED AT PSIG MANUFACTURED UNDER ONE OR MORE OF THE FOLLOWING U S PATENTS 4232533 4686834 4689967 4715190 4751653 4800732 5031410 5056032 5058031 5355691 5434738 5537830 5553997...

Page 7: ... downstream of evaporator and condenser water boxes to isolate shells for maintenance and to balance trim system Supply and install flow switches or equivalent devices in both chilled water and condenser water piping Interlock each switch with proper pump starter to ensure unit can only operate when water flow is established Supply and install taps for thermometers and pressure gauges in water pip...

Page 8: ... starter option only C PFCCs optional D Terminal lugs E Ground connection s F Jumper bars G BAS wiring optional H IPC wiring remote mounted starters only I Control voltage wiring remote mounted starters only J Oil pump interlock wiring remote mounted starters only K High condenser pressure interlock wiring remote mounted starters only L Chilled water pump contactor and wiring M Condenser water pum...

Page 9: ...h the corresponding ordering and shipping information to verify that the correct unit was shipped to the job site If a thorough inspection of the chiller reveals damage or material shortages be sure to file these claims with the carrier immediately Specify the extent and type of damage found and notify the appropriate Trane sales representative Do not install a damaged unit without the sales repre...

Page 10: ...CDHF SVN01B EN 10 Figure 2 Typical CDHF Chiller General Information ...

Page 11: ...idity Note that the maximum ambient temperature for chiller operation is 95 to 100 F 35 38 C CAUTION Equipment Failure CDHF operation at ambient temperatures exceeding 100 F 38 C can fatigue the unit s rupture disc causing it to break at a reduced refrigerant pressure i e 15 psig Starter component damage can also occur because of the panel s inability to dissipate heat adequately If any of these a...

Page 12: ...end of machine from Clearance1 and is required for service clearance 3 Clearance requirement for evaporator tube removal does not include water box Add water box dimension to this figure UCP Clearance Requirements for Standard CDHF CL1 CL2 Shell Width Entire Width Height Length Entire Length Clearance 1 Clearance 2 210 D 130 875 184 875 132 750 258 000 606 000 264 000 84 000 250 D 142 625 196 625 ...

Page 13: ...its EVSZ CDSZ A B C D E F G H 210 D 210 D 4 5 7 16 5 3 8 7 9 16 1 4 1 4 5 0 1 8 3 5 1 4 2 5 3 10 3 16 250 D 250 D 5 0 3 4 5 1 4 6 1 2 1 7 1 4 5 8 3 4 3 10 5 8 2 4 1 8 3 11 5 8 250 M 250 M 5 0 3 4 5 1 4 6 1 2 1 7 1 4 5 8 3 4 3 10 5 8 2 4 1 8 3 11 5 8 250 X 250 X 5 0 3 4 5 1 4 6 1 2 1 7 1 4 5 8 3 4 3 10 5 8 2 4 1 8 3 11 5 8 ...

Page 14: ...80 197710 78288 172595 CDHG 2150 892 250D 250D 96964 43983 82991 37645 CDHF 3000 1340 250M 250M 106659 48381 89425 40563 CDHF 3500 1340 250X 250X 114445 51912 95077 43127 Notes Weights shown above are accurate within 3 and are based on the following Operating weights include refrigerant oil charge and water Shells are with largest bundles and TECU 028 wall tubes Compressor weight with medium volta...

Page 15: ...is connections and safety chain then remove the eyebolt that was used to secure the safety chain to the compressor and reinstall the retaining bolt in its place If the chiller cannot be moved using the conventional rigging method just described consider these points 1 If job site conditions require rigging of the chiller at an angle greater than 45 from horizontal end to end dowel pin the com pres...

Page 16: ...0X 250X 199 in 31 5 ft 24 75 in Figure 5 Recommended Lifting Arrangements for CDHF X Y H LIFTING BEAM Safety Chain Safety Chain B A C Jacking Points Notes 1 Lifting chains or cables are not the same length between point A and B or between points A and C Adjust as necessary for an even lift 2 Lifting holes provided on chillers to attach chains are 2 1 2 inch in diameter 3 Attach safety chain or cab...

Page 17: ...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 selection and placement on the information presented in Figures 8 10a Notice that 3 types of spring isolators each with its own maximum loadi...

Page 18: ...D 250D 13287 14087 14895 CDHG 1250 1750 716 210D 210D 11792 12449 13112 CDHG 2150 892 210D 210D 58438 65808 73462 CDHG 2150 892 250D 250D 13916 14659 15407 CDHF 3000 1340 250M 250M 15208 16123 17049 CDHF 3500 1340 250X 250X 16318 17300 18294 Notes Isolator pad loading is based on the following Operating weights include refrigerant oil charge and water Shells are with largest bundles and TECU 028 w...

Page 19: ...Isolator Loading kg TYPE NTON CPKW EVSZ CDSZ LF MF RF LR MR RR CDHF 1500 2000 957 210D 210D 6405 6780 7160 5003 5339 5679 CDHF 2100 2500 1228 250D 250D 6287 6678 7072 7000 7409 7823 CDHG 1250 1750 716 210D 210D 6546 6892 7239 5246 5558 5873 CDHG 2150 892 210D 210D 34443 38422 42547 23995 27386 30915 CDHG 2150 892 250D 250D 6538 6899 7263 7379 7760 8145 CDHF 3000 1340 250M 250M 7196 7643 8095 8012 ...

Page 20: ...structions The weight of the chiller will force the upper housing of each isolator down perhaps causing it to rest on the isolator s lower housing Figure 10 10a illustrates spring isolator construction 6 Check the clearance labeled X in Figure 10 10a on each isolator If this dimension is less than 1 4 on any isolator use a wrench to turn the adjusting bolt one complete revolution upward Note When ...

Page 21: ... Adjusting Bolt 6 1 2 165 mm Free Height Adjust the isolator so that the upper housing clears the lower housing by at least 1 4 6 mm Acoustical nonskid neoprene pad top and bottom 8 3 4 222 mm C C foundation bolts 7 1 4 184 mm 9 3 4 248 mm Adjusting Bolt 6 5 8 168 mm Free Height Adjust the isolator so that the upper housing clears the lower housing by at least 1 4 6 mm Acoustical nonskid neoprene ...

Page 22: ...200 1 17 Purple CT 12 27 9 000 1 06 Orange CT 12 28 10 800 1 02 Green CT 12 31 13 200 0 83 Gray CT 12 32 15 600 0 74 White 2 Adjusting Bolts 8 1 8 206 mm Free Height Adjust the isolator so that the upper housing clears the lower housing by at least 1 4 6 4 mm Acoustical nonskid neoprene pad top and bottom 5 8 16 mm 5 8 16 mm 3 1 2 89 mm 7 178 mm 14 3 4 375 mm 12 1 2 318 mm 7 3 8 187 mm 6 1 2 165 m...

Page 23: ... 25 9 Green CT 16 31 17600 7983 0 83 21 1 Gray CT 16 32 20800 9435 0 74 18 8 White Isolator Max Deflection Spring Type Size Load lb kg inches mm Color Code CT 20 26 12000 5443 1 17 29 7 Purple CT 20 27 15000 6804 1 06 26 9 Orange CT 20 28 18000 8165 1 02 25 9 Green CT 20 31 22000 9979 0 83 21 1 Gray CT 20 32 26000 11794 0 74 18 8 White General Information CT 16 and CT20 Spring Isolators ...

Page 24: ...the level aligns with the punch mark at one end of the chiller then check the water level at the opposite mark If the water level does not align with the punch mark use full length shims to raise one end of the chiller until the water level at each end of the tube aligns with the punch marks at both ends of the chiller 4 Once the unit is level across its length repeat Steps 1 through 3 to see if u...

Page 25: ...ssure gauge taps in a straight run of pipe Place tap a minimum of one pipe diameter downstream of any elbow orifice etc Example for a 6 pipe the tap would be at least 6 from any elbow orifice etc Valves 1 Install field supplied air vents and drain valves on the water boxes Each water box is provided with a 3 4 NPTF vent and drain connection Plastic plugs are factory installed in both openings for ...

Page 26: ...mum to the equipment This will allow for proper fit up upon arrival of the unit at the job site Any adjustment that is necessary can be made to the piping at that time Figure 12 Flow Switch Installation 1 Pipe size larger bushing to avoid paddle interference Example Flow Switch Pipe half coupling 5 pipe diameters 5 pipe diameters Water piping connection sizes are identified in Tables 3 and 4 Remem...

Page 27: ... gauge between entering and leaving pipes A shutoff valve on each side of the gauge allows the operator to read either entering or leaving water pressure Legend of Field Supplied Installed Components 1 Pressure Gauge 2 Thermometer s If field supplied 3 Union s or Flanged Connection s 4 1 2 NPT Coupling s 5 Balancing Valve 6 Gate Isolation Valve s or Ball Valve s 7 Chiller Water Flow Switch 5S1 8 S...

Page 28: ...rature of the heat recovery condenser water circuit For application recommendations see Trane Applied Manual AM FND 8 titled Heat Recovery Engineering Seminar 4 Intalla bypass valve system to avoid circulating water through the auxiliary shell when the unit is shut down Legend of Field Supplied Installed Components 1 Pressure Gauge 2 Thermometer s If field supplied 3 Union s or Flanged Connection ...

Page 29: ...ns See Table 5 These are cut groove end NSP Victaulic style pipe connection Flanged connections for 300 PSI waterboxes use welded flanges Piping joined using grooved type couplings like all types of piping systems requires proper support to carry the weight of pipes and equipment The support methods used must eliminate undue stresses on joints piping and other components allow movement where requi...

Page 30: ... e braided steel elastomeric arch etc are usually not required to attenuate vibration and or prevent stress on the connections Water Piping Figure 16 Customer Piping Alternatives for CDHF Water Box Connections Refer to the coupling manufacturer s guidelines for specific information concerning proper piping system design and construction methods for grooved water piping systems Note Flexible coupli...

Page 31: ...eaks To provide effective seal gasket contact surfaces of adapter must be free of gouges undulations or deformities Victaulic Gasket Installation 1 Check gasket and lubricate Check gasket supplied to be certain it is suited for intended service Code identifies gasket grade Apply a thin coat of silicone lubricant to gasket lips and outside of gasket 2 Install Gasket Place gasket over pipe end being...

Page 32: ...CDHF SVN01B EN 32 Water Piping Figure 17 Typical Victaulic Flange Gasket Configuration Figure 18 Typical Shipping Location on Unit for Shipping Flange SCREW ADAPTER LEG SUPPORT ...

Page 33: ...st 12 bolts to a snug tightness Tighten the next 12 consecutively numbered bolts in sequence to the final torque Then apply final torque to the first 12 bolts and the bolts not yet tightened i e unnumbered bolts in Figure 19 Be sure to start with bolt 1 and move progressively around the flange in a clockwise direction Evaporator Water Box Covers See Figure 19 Ensure that the water box head rests t...

Page 34: ...CDHF SVN01B EN 34 Water Piping Figure 19 Bolt Tightening Sequences for Water Piping Flanges and Water Boxes Flanges with more than 24 bolts Evaporator Water Box Covers ...

Page 35: ...ge line Rupture Disc Vent Installation All CenTraVac chillers are equipped with carbon rupture discs A cross section of the rupture disc assembly appears in Figure 20A along with an illustration indicating the location of the rupture disc on the suction elbow There are two rupture discs on CDHF chillers one per refrigerant circuit See Figure 20 for locations If refrigerant pressure within the evap...

Page 36: ...chillers are used install a separate rupture disc vent line for each unit 7 Consult local regulations for any special relief line requirements and refer to CFC GUIDE 2 published by The Trane Company 8 The discharge of the vent line outside should not be in the general vicinity of any fresh air intakes to the building Any gas venting from the vent line should not be allowed to re enter the building...

Page 37: ...HF SVN01B EN Figure 20A Continued Vent Line Piping Figure 20 Illustrated Rupture Disc Location Cross Section of Rupture Disc and Recommended Rupture Disc Relief Piping Rupture Disc circled with dashed lines ...

Page 38: ...CDHF SVN01B EN 38 Vent Line Piping Figure 20B Continued ...

Page 39: ...39 CDHF SVN01B EN Vent Line Piping Figure 20C Continued ...

Page 40: ...CDHF SVN01B EN 40 Vent Line Piping Figure 21 Rupture Disc Vent Pipe Sizing ...

Page 41: ...th a refrigerant pump do not need insulation on the motor Do not insulate over unit wiring Raise the wiring harness and insulate underneath Do not insulate over sensor modules CAUTION Insulation Damage If the factory installed insulation will be painted in the field use only water based latex paints Thinners and solvents used in other types of paints may cause seams in the insulation to open as a ...

Page 42: ...CDHF SVN01B EN 42 Figure 22 Recommended Areas for Unit Insulation ...

Page 43: ...or amps is listed on the chiller nameplate 4 All field installed wiring should be checked for proper terminations and for possible shorts or grounds General Requirements WARNING Hazardous Voltage w Capacitors Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the power cannot be inadvertently energized For variable frequenc...

Page 44: ... Circuit Breaker 2Q1 L1 L2 L3 and GROUND Starter to Motor Power Wiring Starters Motor Remote Starter to T1 through T6 terminals T1 through T6 terminals Chiller Motor Junction Box Starter to UCP To Starter From Unit Control control wiring 120Vac Panel Terminals Panel Terminations 120VAC Power Supply from starter to UCP 2X1 1 1 1X1 1 8 gauge 2X1 2 1X1 12 minimum 2X1 20 Ground 1X1 18 Ground 40 amps c...

Page 45: ...ller Motor Junction Box terminals terminals Starter to UCP control wiring To Starter From Unit Control 120VAC Panel Terminals Panel Terminations 120VAC Power Supply from See Starter by starter to UCP others schematic 8 gauge minimum 5X1 1 1X1 1 40 amps circuit 5X1 2 1X1 12 5X1 20 ground 1X1 18 ground Power from UCP 1Q1 5X1 3 1X1 3 1A23 J6 3 14 ga Interlock Relay signal 5X1 4 1A23 J10 1 14 ga Start...

Page 46: ...ded total wire length for PT s in a single PT system Wire Gauge Max lead length ft Max lead length m 8 5339 1627 10 3357 1023 12 2112 643 14 1328 404 16 835 254 17 662 201 18 525 160 20 330 100 21 262 79 22 207 63 The maximum recommended total wire length to and from for PT leads in a dual PT system are Max Wire Max Wire Max Wire Max Wire Wire Length Length Length Length Gauge Primary ft Primary m...

Page 47: ...g the RLA value stamped on the chiller nameplate and transformer load on L1 and L2 Note All CDHF units are designed to comply with NEC guidelines 5 Make sure that the incoming power wiring is properly phased each power supply conduit run to the starter must carry the correct leads to ensure equal phase representation See Figure 23 6 As you install the power supply conduit make sure that its positi...

Page 48: ...ly Misapplication of these capacitors could result in a loss of motor overload protection and subsequent motor damage PFCCs are wired as shown in Figure 24 where the capacitor leads are run through the overload transformer Table 13 PFCC Design Voltage per Compressor Voltage Application PFCC Compressor Motor Voltage Design Voltage See CDHF Nameplate 240V 60 Hz 200V 60 Hz 208V 60 Hz 480V 60 Hz 380V ...

Page 49: ...f Capacitors After following the proper lockout tagout procedure it is important to verify that all applicable capacitors are discharged and rendered safe Many capacitors in HVAC equipment include internal bleeder circuits that will automatically discharge the capacitor These circuits must be allowed sufficient time to discharge the capacitor prior to performing service While most capacitors conta...

Page 50: ... 1 Refer to the unit field connection diagram for approximate UCP knockout locations Important To prevent damage to the UCP s components do NOT route control circuit conduit into the top of the UCP enclosure 2 IPC circuit conduit must enter the left back portion of the UCP 3 See Starter Submittal drawing for location of incoming wiring to the starter PFCC and Unit Mounted Starter ...

Page 51: ...1 Refer to the unit field connection for approximate UCP knockout locations Important To prevent damage to the UCP s components do NOT route control circuit conduit into the top of the UCP enclosure 2 IPC circuit conduit must enter the left back portio nof the UCP Electrical Information Remote Starter ...

Page 52: ...sizes for compatibility by the electrical engineer or contractor 2 A terminal clamp with a 3 8 bolt is provided on each motor terminal stud use the factory supplied Belleville washers on the wire lug connections Figure 27 illustrates the juncture between a motor connection pad and the wire terminal lug 3 Tighten each bolt to 24 foot pounds 4 Install but do not connect the power lead between the st...

Page 53: ...l wires carrying a higher voltage 5 The IPC Shielded Twisted Pair wiring should be grounded on one end only at UCP end The other end should be un terminated and taped back on the cable sheath to prevent any contact between shield and ground 6 Oil Pump Interlock Both starters must provide an interlock N O contact with the chiller oil pump connected to the UCP at Terminals 1A7 J2 4 and 1A7 J2 2 14 g...

Page 54: ... to 12 Binary Output Normally Open PROGRAMABLE OUTPUTS defaults Chiller Non Latching Alarm Relay Output 1A8 J2 1 to 3 Binary Output Normally Open Chiller Limit Mode Relay Output 1A8 J2 4 to 6 Binary Output Normally Open Chiller Latching Alarm Relay Output 1A8 J2 7 to 9 Binary Output Normally Open Chiller Running Relay Output 1A8 J2 10 to 12 Binary Output Normally Open Maximum Capacity Relay Output...

Page 55: ...alog Output 2 10 vdc External Current Limit Setpoint Input 1A16 J2 2 to 3 Analog Input 2 10 vdc or 4 20 mA External Chilled Water Setpoint 1A16 J2 5 to 6 Analog Input 2 10 vdc or 4 20 mA External Base Load Setpoint Signal 1A17 J2 2 to 3 Analog Input 2 10 vdc or 4 20 mA Generic Refrigerant Monitor input 1A17 J2 5 to 6 Analog Input 2 10 vdc or 4 20 mA Outdoor Air Temperature sensor IPC bus Connectio...

Page 56: ... the condenser pump Left panel only Condenser Water Proof of Flow Next use 14 AWG 600 volt copper wire to connect the auxiliary contacts of the condenser water pump contactor 5K2 in series with the flow switch 5S2 installed in the condenser supply pipe Connect this circuit to UCP terminals 1X1 6 to 1A6 J2 2 Left panel only When installed properly the condenser water lock circuit will only allow th...

Page 57: ...nnected to the UCP four wire bus using the Trane approved connectors provided The sensor will be configured given its identity and become functional at start up when the serviceman performs the start up configuration It will not be operational until that time Note If shielded cable is used to extend the sensor leads be sure to tape off the shield wire at the junction box and ground it at the UCP I...

Page 58: ...uration The starter module configuration settings will be checked and configured for Remote Starters during start up commissioning To configurate starter modules and perform other starter checks it is recommended that the line voltage three phase power be turned off and secured locked out and then a separate source control power 115 vac be utilized to power up the control circuits To do this remov...

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Page 80: ... continuous product and product data improvement and reserves the right to change design and specifications without notice Only qualified technicians should perform the installation and servicing of equipment referred to in this publication Literature Order Number File Number Supersedes Stocking Location CDHF SVN01B EN SV RF CTV CDHF SVN01B EN 105 CDHF SVN01A EN La Crosse ...

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