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STARTUP Chiller Report – Water Cooled CenTraVac

With UC800 Controller

Service Tool Records

Configuration

Unit Information

Unit Name

Unit Model Number

Unit Sales Order Number

Unit Serial Number

Application Firmware

Boot Firmware

Build Part Number

Date/Time

Chiller Configuration

Main

Unit Type (MODL)

UC800

Unit Capacity(PTON)

Compressor Size(NTON)

Manufacturing Location

Starter Type

Condenser High Pressure Cutout

Impeller Diameter

Options

Line Voltage Sensing

Free Cooling

Hot Gas Bypass

Second Condenser

Hot Water Control

Outdoor Air Temp Sensor

External Chilled Water Setpoint

External Current Limit Setpoint

Hardware

Ice Building

Refrigerant Monitor Type

Condenser Pressure Sensor

Evap Differential Wtr Press

Condenser Differential Water Pressure

Enhanced Oil Temperature Protection

Chiller Running Oil Temperature Control

Compressor Refrigerant Discharge Temperature Sensor

Bearing Temperature Sensors

IGV Actuators

TCVHE-SVX04D-EN

Forms

RELEASED 10/Mar/2020 06:59:20 GMT

Содержание CVHE

Страница 1: ...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...

Страница 2: ...e the same potential impact to the environment Trane advo cates the responsible handling of all refrigerants includ ing industry replacements for CFCs and HCFCs such as HFCs Responsible Refrigerant Pr...

Страница 3: ...fall protection electrical PPE and arc flash clothing ALWAYS refer to appropriate MSDS sheets and OSHA guidelines for proper PPE When working with or around hazardous chem icals ALWAYS refer to the ap...

Страница 4: ...iping Connections 23 PressureTesting Waterside Piping 24 Purge Piping 25 EarthWise Purge Requirements Purge Instal lation 25 Vent Piping 26 Refrigerant Vent Line 26 General Recommendations 26 Purge Di...

Страница 5: ...Machine Control 57 Free Cooling Cycle 59 Free Cooling FRCL 59 Hot Gas Bypass HGBP 59 Hot Water Control 60 Heat Recovery Cycle 60 Auxiliary Condensers 60 Control Panel Devices and Unit Mounted De vice...

Страница 6: ...e or during parts identification Service Model Number The service model represents the unit as built for service purposes It identifies the se lections of variable unit features required when ordering...

Страница 7: ...t Recovery Condenser Tube Bundle nominal tons 29 Heat Recovery Tubes 30 Heat Recovery Condenser Waterbox 31 Auxiliary Condenser Size Waterbox 32 Auxiliary Condenser Tubes 33 Orifice Size 34 Orifice Si...

Страница 8: ...from the factory as a hermetically assembled package it is factory piped wired and test ed All openings except for the waterbox vent and drain holes are covered or plugged to prevent contamination du...

Страница 9: ...condenser pressure interlock wiring AFD and remote mounted starters only Chilled water pump contactor and wiring including interlock Condenser water pump contactor and wiring including interlock Optio...

Страница 10: ...en pressure using gauge located on the evaporator shell reads 3 to 5 psig 21 to 34 5 kPa Notify the local Trane office if charge has escaped Verify dry nitrogen pressure using gauge located on the eva...

Страница 11: ...ol panel Figure 2 Typical CVHF CenTraVac Chiller 1 2 3 11 4 5 6 7 8 9 10 1 Suction Elbow 2 Compressor 3 Terminal Box 4 Control Panel 5 Condenser 6 Motor Housing 7 Economizer 8 OilTank Assembly 9 Purge...

Страница 12: ...liary condenser optional Cooling condenser Economizer Motor C B A D E Per NEC article 110 18 45 72 cm Right hand tube pull shown apply tube pull clearance dimension to left end for left hand tube pull...

Страница 13: ...27958 12682 24869 11281 650 910 957 080L 080L 32688 14827 28803 13065 34249 15535 30364 13773 650 910 957 080S 080L 30526 13847 27191 12334 32087 14555 28752 13042 650 910 957 080S 080S 2883 13070 257...

Страница 14: ...21 142M 142L 44434 20155 38539 17481 45516 20646 39621 17972 1100 621 210L 210L 57399 26036 49455 22432 58481 26527 50537 22923 C V H E 190 270 242 032L 032L 16719 7584 15173 6882 17801 8075 16255 737...

Страница 15: ...to lift the unit must be capable of supporting the entire weight of the unit Lifting cables chains or slings may not be of the same length Adjust as necessary for even unit lift Failure to properly l...

Страница 16: ...tempt to rotate chiller on to side When lifting the chiller is either impractical or unde sirable attach cables or chains to the jacking slots shown in Figure 4 p 16 then push or pull the unit across...

Страница 17: ...upper housing of each isolator down and could cause it to rest on the isolator s lower housing Figure 6 illustrates spring isolator construction 6 Check the clearance on each isolator If this dimen s...

Страница 18: ...table alternative method to level the unit Immediately report any unit damage incurred during handling or installation at the job site to theTrane sales office 18 TCVHE SVX04D EN Installation Mechanic...

Страница 19: ...taps in a straight length of pipe Place tap a minimum of one pipe diameter downstream of any elbow orifice etc Example for a 6 152 mm pipe the tap would be at least 6 152 mm from any elbow orifice et...

Страница 20: ...result in severe equipment damage Evaporator and condenser proof of flow switches either flow or Delta P are required in series with the pump contactor auxiliary shown on wiring diagrams These switch...

Страница 21: ...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...

Страница 22: ...nual AM FND 8 titled Heat Recovery Engineering Seminar 5 Install a bypass valve system to avoid circulating water through the auxiliary shell when the unit is shut down On multiple pass condensers ent...

Страница 23: ...cerning proper piping system de sign and construction methods for grooved water piping systems Note Flexible coupling gaskets require proper lubri cation before installation to provide a good seal Ref...

Страница 24: ...nsure that the water box head rests tightly against the tube sheet then snugly tighten the 26 bolts in sequential order If excessive tube sheet crown prevents the head from contacting the tube sheet t...

Страница 25: ...ome combustible in the presence of an ignition source leading to an explosion Excessive heat from soldering brazing or welding with refrig erant vapors present can form highly toxic gases and extremel...

Страница 26: ...a lent is recommended Vent Line Sizing Vent line size must conform to local codes and require ments In most cases local codes are based on ASHRAE Standard 15 ASHRAE Standard 15 provides specific requi...

Страница 27: ...to support the vent line piping 4 Use a flexible connection between the vent line and the rupture disc assembly to avoid placing stress on the rupture disc Stress can alter rupture pressure and cause...

Страница 28: ...ments and refer to CFC Guide 2 Figure 13 Illustrates rupture disc location cross section of rupture disc bolt rupture disc gasket outside pipe suction connection cap assembly Note Pipe connection is 3...

Страница 29: ...ooling or an auxiliary condenser add the applicable C values to this total With this new sum refer to Figure 15 p 30 to determine the vent line pipe diameter a EVSZ Evaporator shell size b CDSZ Conden...

Страница 30: ...PS 3 068 5 NPS f 0 0173 5 048 f 0 0155 ANSI ASHRAE Standard 15 2007 f C2 R L 214d 5 P2 0 P2 2 6f d ln P0 P2 P0 0 5 15 P2 P2 14 7 psia f Moody Friction Factor in fully turbulent flow Note This chart pr...

Страница 31: ...t 050 Short 385 63 398 72 050 Long 420 63 436 72 080 Short 505 84 515 97 080 Long 553 84 566 97 142 Medium 555 98 555 133 142 Long 578 98 578 133 142 Extended 603 104 629 133 210 Long 700 98 710 133 2...

Страница 32: ...ns must be accessible after insu lating 2 Evaporators with ASME nameplates must have insulation cut out around the nameplate Do not glue insulation to the nameplate 3 All units with evaporator marine...

Страница 33: ...corresponds to the numbered callouts in the illustration Figure 17 Wiring locations and connection ports LINK 24 VDC MBUS 6 Front View Bottom View 7 8 9 6 1 10 11 2 3 4 5 1 Rotary Switches for settin...

Страница 34: ...f the Marquee LED is green solid the UC800 is powered and no problems exist Low power or malfunction If the Marquee LED is red solid the UC800 is powered but there are problems present Alarm The Marqu...

Страница 35: ...24 1A17 1A18 1A13 1A14 1A15 1A16 1A22 X19091218 01 OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL 30V MAX 30V MAX 30V MAX...

Страница 36: ...Support Arm To prevent unexpected movement of the spring loaded support arm ensure that the support arm is in the full upright position when removing the Tracer AdaptiView display from the support ar...

Страница 37: ...20 Joint locations on the display arm 4 3 2 1 2 Joint 3 has a 6 mm hex screw controlling the tension on a gas spring which allows theTracer AdaptiView display to tilt up and down 3 Joints 1 and 2 are...

Страница 38: ...Voltage Circuits Medium and High Voltage Circuits Ambient Air Tem perature The temperature of indoor electric should be at 5o C 40o C and the average temperature measured during 24 hours should be no...

Страница 39: ...ng components provided by Trane or others refer to the appropriate manufacturer s literature for allowable waiting periods for discharge of capacitors Verify with an appropriate voltmeter that all cap...

Страница 40: ...mm2 20 Low Voltage Circuits less than 30 Vac Starter Panel Terminals Unit Control Panel Terminations Standard Circuits Inter Processor Communica tions IPC Remote Mounted 2A1 J3 3 4 or 2X1 12 to 13 if...

Страница 41: ...2 5 mm2 20 Transition complete 5X1 14 1A23 J12 2 14 ga 2 5 mm2 20 Low Voltage Circuits less than 30 Vac Starter Panel Termi nals Unit Control Panel Terminations Standard Circuits Current Transformers...

Страница 42: ...9 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 Note 1 Wire length is for copper conductors only 2 The above length is maximum round trip wi...

Страница 43: ...er nameplate and transformer load on U1 and V1 Confirm that wire size is compatible with lug size stated in unit submittal Make sure that the incoming power wiring is prop erly phased each power suppl...

Страница 44: ...ase unit capacitor Fused disconnector suitable breaker 1 Power 2 circuit 3 Current transformer Motor starter contactor Rule 2 PFCC wires routed through cur rent transformers Size motor overload protec...

Страница 45: ...st be field supplied Use field provided crimp type wire terminal lugs properly sized for the application Note Wire size ranges for the starter line and load side lugs are listed on the starter submitt...

Страница 46: ...tage circuits Failure to do so could result in electrical noise that may distort the signals carried by the low voltage wiring including the IPC wiring 1 If the starter enclosure must be cut to provid...

Страница 47: ...weld nuts are provided on the top of the terminal box to allow the use of properly rated lifting d rings if removal is needed for clearance purposes Note If the box is removed for installation purpose...

Страница 48: ...rovided on the motor terminals to retain the lugs and the final connection should be tightened to 22 25 ft lb 30 34 N m using a 7 8 22 mm socket on a torque wrench D D NOTICE Motor Terminal Damage Do...

Страница 49: ...d for normal operation Optional Low Voltage Circuits External Base Loading Enable Input 1A18 J2 1 to 2 Binary Input Normally Open External Hot Water Control Enable Input 1A18 J2 3 to 4 Binary Input No...

Страница 50: ...with the flow switch 5S2 installed in the condenser supply pipe 2 Connect circuit to control panel terminals 1X1 6 to 1A6 J2 2 Temperature Sensor Circuits All temperature sensors are factory installed...

Страница 51: ...service the controls Schematic Wiring Drawings The chart below consist of typical wiring drawings for a CenTraVac chiller available through e Library However please refer to the submittals and drawing...

Страница 52: ...through the condenser tubes absorbs heat from the refrigerant causing it to condense The liquid refrigerant then passes through orifice plate and into the economizer The economizer reduces the energy...

Страница 53: ...oil tank Figure 28 Oil refrigerant pump compressor lubrication system Compressor lubrication system Oil reclaim system Motor cooling system 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 Motor...

Страница 54: ...er and uses refrigerant passing from the condenser to evaporator to cool the oil Oil leaves the oil cooler and flows to both the thrust and journal bearings Motor Cooling System Compressor motors are...

Страница 55: ...relay with customer supplied power Based on the Restart Inhibit function and the Differen tial to Start setpoint the oil and refrigerant pump is energized and the oil vent line valve is closed to the...

Страница 56: ...o open and stop the chilled water pump after the chilled water pump delay timer has timed out after compressor shut down If the Immediate Stop is initiated a panic stop occurs which follows the same s...

Страница 57: ...ilding 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 communi cated input...

Страница 58: ...Figure 34 Sequence of operation ice making stopped to ice to ice building complete 58 TCVHE SVX04D EN Start up and Shut Down RELEASED 10 Mar 2020 06 59 20 GMT...

Страница 59: ...nk This tank is vented to the economizer sump through a small bleed line when the storage tank is full liquid refrigerant must flow through the bleed line restriction Because the pressure drop through...

Страница 60: ...setpoints are used with respect to the hot water setpoint instead of with the chilled water setpoint The control panel provides a sep arate entry at theTracer AdaptiView to set the hot water setpoint...

Страница 61: ...ing installation testing servicing and trouble shooting of this product it may be necessary to work with live electrical components Have a qual ified licensed electrician or other individual who has b...

Страница 62: ...rge will start running and will run as long as the chiller is running Note If a manual reset diagnostic condition is detected during start up unit operation will be locked out and a manual reset is re...

Страница 63: ...water circuit 5 If the evaporator was previously drained fill and vent the evaporator and chilled water circuit When all air is removed from the system including each pass close the vent valves in the...

Страница 64: ...ation and Maintenance Guide EarthWise Purge system withTracer AdaptiV iew Control for Water Cooled CenTraVac Chillers with R 123 Refrigerant PRGF SVX001 EN For R 514A chillers recommended purge mainte...

Страница 65: ...porator refrigerant temperature displayed on the control panel read out is outside this 4 degree tolerance range replace the sensor If the sensor is exposed to temperature extremes outside its normal...

Страница 66: ...Draw the oil from the chiller through the oil charging valve on the chiller oil sump into an approved evac uated tank or Pump the oil from the chiller through the oil charging valve into an airtight r...

Страница 67: ...ht plus 1 4 to 1 2 turn 8 Remove the grease fitting if used DO NOT LEAVE GREASE FITTINGS INSTALLED If grease fittings have been used for this procedure then they MUST BE REMOVED before returning the u...

Страница 68: ...e services of a qualified chem ical cleaning firm be used Proper personal protec tive equipment as recommended by the chemical manufacturer should be used Refer to the chemicals MSDS sheet for proper...

Страница 69: ...ge on the evaporator shell to verify that the 6 to 8 psig dry nitrogen holding charge is still in the chiller If this charge has escaped contact a qualified service organization and theTrane sales eng...

Страница 70: ...m with refrigerant vapor or circulate water to avoid tube damage 2 Always use refrigerant compatible hoses or cop per tubing with self sealing connections or shut off valves 3 Transfer the refrigerant...

Страница 71: ...arm water or heat blankets to raise the tank temperature Do not exceed a temperature of 150 F Do not under any circumstances apply direct flame to any portion of the cylinder Failure to follow these s...

Страница 72: ...lways be applied to eyebolts in the plane of the eye not at some angle to this plane Failure to properly lift waterbox could result in death or serious injury Review mechanical room limitations and de...

Страница 73: ...following all previous procedures in reverse Use new O rings or gaskets on all joints after thoroughly cleaning each joint 9 Torque waterbox bolts Refer toTable 16 CenTraVac Refer toTable 16 for torqu...

Страница 74: ...L Y 82 79 76 77 N 82 81 81 83 CVHF 870 910 080S 080L Y 82 79 77 78 N 82 82 81 83 142L Y 82 78 76 77 N 83 82 83 84 CVHF 1070 142L Y 82 79 77 77 N 82 81 83 85 210L 250L Y 82 79 77 78 N 82 82 83 85 CVHF...

Страница 75: ...7 75 74 72 70 69 69 66 25 77 76 74 72 69 68 67 66 CVHE 500 100 71 69 69 69 70 71 75 65 75 70 70 69 68 69 70 72 65 50 67 68 68 68 69 69 70 66 25 66 67 67 67 68 69 68 65 CVHF 350 100 75 75 73 71 71 70 7...

Страница 76: ...67 69 CDHF 1500 100 78 78 82 80 80 76 72 65 75 77 78 81 81 80 76 71 64 50 76 79 79 81 80 75 71 63 25 76 79 78 83 80 75 70 62 CDHF 2000 100 80 82 81 81 80 76 72 69 75 80 79 81 79 78 74 71 68 50 81 79 8...

Страница 77: ...100 78 78 78 75 75 73 68 64 75 77 77 77 75 75 72 66 64 50 78 78 77 75 74 73 68 65 25 79 79 79 76 77 73 69 65 CVHG 565 100 79 78 77 74 76 73 70 65 75 79 79 79 74 74 71 67 65 50 80 81 79 76 74 72 68 65...

Страница 78: ...e submittals and diagrams Are customer added external remote control circuits compatible Yes No D General Installation Observations 1 Is there any apparent shipping or rigging damage Yes No 2 Record t...

Страница 79: ...ation and flow valves installed Calibrated thermometers and pressure gauges installed in out condenser on machine side of any valve or elbow If condenser pump controlled by control panel is field wiri...

Страница 80: ...s free of dust debris etc Power Up the control panel Non AFD Starters 1 Starter disconnect locked open 2 Fuse 2F4 must be removed from the starter 3 Connect auxiliary 115VAC power cord toTerminals 1X1...

Страница 81: ...to the evaporator Check that all drums contain a full amount of refrigerant Amount charged lgs and kg 2 Electrical Disconnect all temporary power cords replace all fuses connect motor leads make final...

Страница 82: ...Instructions for starting operating and shutting down Instructions for logging the unit Instructions for periodic maintenance D After 2 weeks of operation International Units Only 1 Remove the water b...

Страница 83: ...e for pressure testing Water supply connected to filling system Trace gas amounts of Refrigerant 22 or R 134a Systems filled available for leak testing if necessary Pumps run air bled from system Stra...

Страница 84: ...ing rates This is to certify that the CenTraVac chiller s has have been properly and completely installed and that the applicable items listed above have been satisfactorily completed Checklist Comple...

Страница 85: ...ump motor ground continuity check Run oil pump and check net oil pressure Condenser Visually inspect for scaling and fouling in tubes Note findings and make recommendations for cleaning Evaporator Onc...

Страница 86: ..._______________________________ ________________________________________________________________ ________________________________________________________________ ______________________________________...

Страница 87: ...ts AB BC CA Power KW Load PF Winding 1 Temp Winding 2 Temp Winding 3 Temp with AFD only AFD Freq AFD Speed AFD Transistor Temp Purge Time Until Next Purge Run Daily Pumpout 24 hrs Avg Daily Pumpout 7...

Страница 88: ...High Pressure Cutout Impeller Diameter Options Line Voltage Sensing Free Cooling Hot Gas Bypass Second Condenser Hot Water Control Outdoor Air Temp Sensor External Chilled Water Setpoint External Cur...

Страница 89: ...tage Voltage Transformer Ratio Rated Load Amps CT Meter Scale Current Unbalance Trip Point Current Unbalance Grace Period Maximum Acceleration Setting Acceleration Time Out Action Overload Type Phase...

Страница 90: ...erence Acceleration Time Deceleration Time Starter Current Limit Current Limit Gain Power Loss Mode Power Loss Time Flying Start Flying Start Gain Use Trane Defaults RTD Type 90 TCVHE SVX04D EN Forms...

Страница 91: ...ic Heat Evap Low Water Flow Warning Setpoint Low Differential Oil Pressure Cutout Setpoint Check Oil Filter Diagnostic Check Oil Filter Setpoint Restart Inhibit Diagnostic Minimum Capacity Limit Maxim...

Страница 92: ...ge Exhaust Circuit Test Clear Restart Inhibit Timer Exhaust Circuit Pressure Test Exhaust Circuit Vacuum Test Adjustable Frequency Drive Maximum Frequency Minimum Frequency AFD Surge Capacity Increase...

Страница 93: ...Oil Level ____________________________________________________________ __________________________________________________________ Vibration Levels _____________________________________________________...

Страница 94: ...s Viewing Purge Operating Modes Data Graphs Viewing the Data Graphs Screen Viewing Data Graphs Changing the Scales on Data Graphs Creating Custom Data Graphs Editing Custom Data Graphs Deleting a Cust...

Страница 95: ...or more information please visit trane com or tranetechnologies com Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications wit...

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