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CVHH-SVX001A-EN

Waterbox Removal and Installation

Im port ant :

Only qualified technicians should perform
the installation and servicing of this
equipm ent.

Discussion

This section w ill discuss recom m ended lifting. Proper
lifting technique w ill vary based on m echanical room
layout.
•

It is the responsibility of the person(s) perform ing the
w ork to be properly trained in the safe practice of
rigging, lifting, securing, and fastening of the
waterbox.

•

It is the responsibility of the person(s) providing and
using the rigging and lifting devices to inspect these
devices to ensure they are free from defect and are
rated to m eet or exceed the published w eight of the
waterbox.

•

Always use rigging and lifting devices in accordance
w ith the applicable instructions for such device.

Procedure

Review m echanical room lim itations and determ ine the
safest m ethod or m ethods of rigging and lifting the
waterboxes.

1.

Determ ine the type and size of chiller being serviced.
Refer to Trane nam eplate located on chiller control
panel.

Im port ant :

This literature contains rigging and lifting
inform ation only for Trane CTV chillers built
in La Crosse. For Trane CTV chillers built
outside the United States, refer to literature
provided by the applicable m anufacturing
location.

2. The rated lifting capacity of the lifting shackle m ust

m eet or exceed the published w eight of the waterbox.
Verify the waterbox w eight from the latest published
literature.

3. Ensure that the lift connection device has the correct

size for the waterbox lifting hole.

4. Properly connect the shackle to the

waterbox.

Figure 54, p. 98

5. Disconnect water pipes, if connected.

6. Rem ove waterbox bolts.

7.

Lift the waterbox away from the shell.

8. Store waterbox in a safe and secure location and

position.

N ot e: Do not leave waterbox suspended from lifting

device.

WARNING

Heavy Objects!

Failure to properly lift waterbox could result in death or
serious injury. Each of the individual cables (chains or
slings) used to lift the waterbox must be capable of
supporting the entire weight of the waterbox. The
cables (chains or slings) must be rated for overhead
lifting applications w ith an acceptable w orking load
limit. Refer to

Table 24, p. 99

for waterbox weights.

Figure 54.

Waterbox lifting—condenser and evaporator
lifting points

WARNING

Overhead Hazard!

Failure to follow instructions could result in death or
serious injuries. Never stand below or in close
proximity to heavy objects w hile they are suspended
from, or being lifted by, a lifting device in case the
object drops.

LIFTING

LOCATION

LIFTING

LOCATION

Lift ing
locat ion

Lift ing
locat ion

LIFTING

LOCATION

LIFTING

LOCATION

Lift ing
locat ion

Lift ing
locat ion

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Содержание CVHH

Страница 1: ...d 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 a...

Страница 2: ...ection 608 sets forth the requirements for handling reclaiming recovering and recycling of certain refrigerants and the equipment that is used in these service procedures In addition some states or mu...

Страница 3: ...HA NFPA 70E or other country specific requirements for arc flash protection PRIOR to servicing the unit NEVER PERFORM ANY SWITCHING DISCONNECTING OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND A...

Страница 4: ...zed to perform start up and warranty of Trane products will perform or have direct on site technical supervision of the disassembly and reassembly work The installing contractor must notify Trane or a...

Страница 5: ...and Vents 22 Strainers 22 Required Flow Sensing Devices 22 Evaporator and Condenser Water Piping 25 Water Piping Connections 26 Waterbox Locations 26 Grooved Pipe Coupling 27 Flange Connection Adapter...

Страница 6: ...Cooling Cycle 67 Oil and Refrigerant Pump 68 Motor Cooling System 70 Tracer AdaptiView Display 70 RuptureGuard 71 EarthWise Purge 71 How a Purge System Works 71 Start up and Shut down 75 Chiller Seque...

Страница 7: ...Installation 98 Discussion 98 Procedure 98 Reassembly 99 Torque Requirements 99 Bolt Tightening Sequence for Waterboxes 101 Evaporator Waterbox Covers 101 Condenser Waterbox Covers 101 Heat Recovery...

Страница 8: ...umber when calling for service or during parts identification Service Model Number The service model represents the unit as built for service purposes It identifies the selections of variable unit fea...

Страница 9: ...required to identify internal and external compressor parts The model number begins with CCHH and the nameplate is located on the foot of the volute Note The serial number space on the compressor name...

Страница 10: ...igit 32 Special Options Digit 33 Water Flow Control Digit 34 Chilled Water Reset Digit 35 Control Heat Recovery Auxiliary Temperature Sensors Digit 36 Industrial Chiller Package INDP Digit 37 Control...

Страница 11: ...are covered or plugged to prevent contamination during shipment and handling Figure 3 p 14 shows an illustration of a typical unit and its components As soon as the unit arrives at the job site inspec...

Страница 12: ...nal only Terminal lugs Ground connection s Jum per bars BAS wiring optional IPC wiring AFD and remote m ounted starters only Control voltage wiring AFD and remote mounted starters only Oil pum p inter...

Страница 13: ...plastic coverings Do not remove any plastic coverings Do not remove any plastic cov erings Do not charge the chiller with refrigerant I f additional refrigerant is on site follow manufactures storage...

Страница 14: ...unit is always designated as the front side of the unit Figure 3 Typical Simplex CVHH CenTraVac chiller 1 Suction Elbow 2 Compressor 3 Terminal Box 4 Control Panel 5 Condenser 6 Motor Housing 7 Econo...

Страница 15: ...2 cm 3 feet Use a housekeeping pad to provide better service clearances refer to submittal for more information Per NEC Article 110 Unit mounted starters from 0 600V require a 107 cm 42 inch clearance...

Страница 16: ...166 1087 428 91 36 325 128 200L 200L 272 107 472 186 1217 479 86 34 282 111 200L 20HL 272 107 472 186 1217 479 94 37 333 131 200L 220L 272 107 472 186 1219 480 94 37 305 120 220L 220L 305 120 472 186...

Страница 17: ...the lifting cables are in place attach a safety chain or cable between the first stage casing of the compressor and the lifting beam Important There should not be tension on this safety cable the cabl...

Страница 18: ...18 then push or pull the unit across a smooth surface Should the chiller be on a shipping skid it is not necessary to remove the skid from the chiller before moving it into place If removal of the com...

Страница 19: ...Spring isolators should be considered whenever chiller installation is planned for an upper story location Base isolator placement is shown in Figure 7 also refer to Table 3 Spring isolators typically...

Страница 20: ...t on the isolator s lower housing refer to Figure 8 6 Check the clearance on each isolator If this dimension is less than 6 35 mm 1 4 in on any isolator use a wrench to turn the adjusting bolt one com...

Страница 21: ...lign 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 5 Once the unit is...

Страница 22: ...connection the openings are 19 05 mm 3 4 in 2 If necessary for the application install pressure relief valves at the drain connections on the evaporator and condenser waterboxes To do so add a tee wi...

Страница 23: ...4 turns Note When installed the tip of the ifm efector sensor probe must be at least 2 54 cm 1 in away from any pipe wall Placing the tip of the probe at the center of the pipe is preferred 3 Install...

Страница 24: ...vaporator and condenser proof of flow switches are required 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 trouble s...

Страница 25: ...tions arrange the water piping so that the water supply enters the shell at the lower connection and exits from the top connection Operational problems may result if this piping is not correct Some sh...

Страница 26: ...aporator or condenser can be switched end for end to obtain the desired piping arrangement If removal of waterboxes is necessary refer to Waterbox Removal and Installation p 98 If the waterboxes on an...

Страница 27: ...re not provided for CVHH units with 2068 4 kPa or 300 psig waterboxes that have 356 mm 14 in and larger piping connections All flange to flange assembly bolts must be provided by the installer Bolt si...

Страница 28: ...use gasket to pinch Figure 17 Modifying 300 psig or 21 bar flange adaptors for flat faced flange application Remove to mate to flat faced flanges Figure 18 Typical Victaulic flange gasket configuratio...

Страница 29: ...r of bolts to a snug tightness following the numerical sequence for the appropriate bolt pattern as shown below Next sequentially tighten the remaining half of the bolts in numerical order Pressure Te...

Страница 30: ...ased on ASHRAE Standard 15 ASHRAE Standard 15 provides specific requirements for the discharge piping that allows pressure relief devices to safely vent refrigerant to the atmosphere if over pressuriz...

Страница 31: ...flange bore Hand tighten all bolts assuring equal pressure Use a torque wrench set to 196 6 N m 145 ft lb with a 24 mm socket Tighten bolts in a star pattern one half turn each to maintain even press...

Страница 32: ...relief line requirements NOTICE Proper Refrigerant Vent Line Termination Failure to properly terminate a refrigerant vent line could result in equipment damage Improperly terminating a refrigerant ve...

Страница 33: ...Piping CVHH SVX001A EN 33 Figure 19 Illustrates rupture disk location cross section of rupture disk Note Pipe connection is 3 in NPT Rupture disk Suction connection Gasket Outside pipe assembly Cap B...

Страница 34: ...ormed within the valve body Provisions such as installing a set of flanges see Figure 22 or other disconnect means must be made in the discharge vent piping This will allow the piping downstream of th...

Страница 35: ...41 0 034 900 1200 130M 130M 0 932 0 412 0 346 0 141 0 034 900 1200 160M 200M 1 022 0 461 0 386 0 141 0 034 900 1200 200L 220L 1 222 0 575 0 473 0 141 0 034 900 1200 220L 220L 1 284 0 637 0 473 0 141 0...

Страница 36: ...elief device kPa P0 0 15 P atmospheric pressure Figure 23 Rupture disk vent pipe sizing SI units for use with Table 8 p 35 Note This figure provided as a reference is based on ASHRAE Standard 15 Vent...

Страница 37: ...L 200L 156 8 75 4 57 1 19 8 4 5 1500 1700 220L 220L 169 9 83 6 62 1 19 8 4 5 900 1200 100M 10HM 127 0 48 4 55 7 18 5 4 5 900 1200 130M 13HM 138 2 54 0 61 3 18 5 4 5 900 1200 160M 20HM 150 2 60 5 66 8...

Страница 38: ...P atmospheric pressure Figure 24 Rupture disk vent pipe sizing IP units for use with Table 9 p 37 Note This figure provided as a reference is based on ASHRAE Standard 15 Vent line size is typically d...

Страница 39: ...er insulation is completed Important Do not insulate the motor housing unit wiring or sensor modules Insulation Thickness Requirements Factory applied insulation All low temperature surfaces are cover...

Страница 40: ...arine waterboxes wrap waterbox shell insulation with strapping and secure strapping with seal 4 Apply 50 8 mm 2 in wide black tape on overlap joints Where possible apply 7 6 cm 3 in wide strip of 9 7...

Страница 41: ...24 Vac 210 mA power from the 1T3 power supply located in the chiller control panel Wiring and Port Descriptions Figure 26 illustrates the UC800 controller ports LEDs rotary switches and wiring termina...

Страница 42: ...machine LLIDs IPC3 Tracer bus 19 200 baud IPC3 Bus used for Comm4 using TCI or LonTalk using LCI C 5 Power 210 mA at 24 Vdc and ground terminations same bus as item 4 Factory wired 6 Not used 7 Marqu...

Страница 43: ...ion Controls CVHH SVX001A EN 43 Figure 28 Control panel Tracer AdaptiView main unit assembly showing low voltage and higher voltage areas for proper routing of field wiring 30 Volt Maximum 30 120 Volt...

Страница 44: ...Tracer AdaptiView display is horizontal Note Review Adjusting the Tracer AdaptiView Display Arm p 45 prior to attaching the display as some adjustments may be required prior to attaching the display...

Страница 45: ...loosen tighten or indicators Joint 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 and 2 are covered by a plastic...

Страница 46: ...c and connection information Do not modify or cut enclosure to provide electrical access Removable panels have been provided and any modification should be done away from the enclosure If the starter...

Страница 47: ...ures to ensure the power cannot be inadvertently energized For variable frequency drives or other energy storing components provided by Trane or others refer to the appropriate manufacturer s literatu...

Страница 48: ...t pump neutral 2X8 25 1X1 16 Starter to Oil Refrigerant Pum p Junction Box Starter Panel Term inals Oil Refrigerant Pum p Junction Box Low Voltage 3 Phase Pump Power 2X8 21 2X8 22 2X8 23 4X4 1 4X4 2 4...

Страница 49: ...5X12 10 1K23 J6 1 Transition com plete 5X12 14 1K23 J12 2 Solid State Starter Fault c 5X12 12 5X12 11 1K13 J2 2 1K13 J2 1 Low Voltage Circuits less than 3 0 Vac Starter Panel Term inals Unit Control P...

Страница 50: ...p 47 Wires lugs and fuses breakers are sized based on National Electric Code NEC NFPA 70 and UL 1995 Maxim um Lead Length Meters Feet 8 1627 5339 10 1023 3357 12 643 2112 14 404 1328 16 254 835 17 201...

Страница 51: ...supply wiring in accordance with NEC and local guidelines using the RLA value stamped on the chiller nameplate and transformer load on L1 and L2 Confirm that wire size iscompatible with lug size stat...

Страница 52: ...ustomer is required to follow all local national and or IEC codes for installation Service personnel must use proper PPE for servicing and should also use proper lockout tagout procedures during servi...

Страница 53: ...abling The customer is required to provide an overcurrent protective device upstream of all starters and drives in accordance with IECstandards and or any applicable local and national codes Service p...

Страница 54: ...or circuit are NOT inside of the starter For the low voltage CPTR option the single phase 4kVA transformer feeds the 120 V control power to all of the controls The three phase line power feeds a motor...

Страница 55: ...IP2X PFCCs must be wired one of two ways as shown as explained in the following Option 1 and Option 2 NOTICE Motor Damage Failure to wire PFCCs into the starter correctly could cause misapplication of...

Страница 56: ...points are downstream of the current transformers route the PFCC leads through the current transformers as shown in the following figure This ensures that the overloads register both line and capacito...

Страница 57: ...onduits 2 Remote mounted starter 3 Unit control panel 4 IPC Circuit conduit less than 30V and CT PT wiring for starters by others Note Must enter the low voltage Class 2 portion of the unit control pa...

Страница 58: ...ided on each motor terminal stud use the factory supplied Belleville washers on the wire lug connections Figure 32 illustrates the junction between a motor terminal stud and terminal lug Torque for th...

Страница 59: ...al for proper operation Separate low voltage less than 30V refer to Table 13 p 48 wiring from the 115V wiring by running each in its own conduit When routing the IPC circuit out of the starter enclosu...

Страница 60: ...ing RLA LRA 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 ensur...

Страница 61: ...wire sizing by the installer must be made in accordance with the National Electric Code or any other applicable codes Three terminals are provided on the chiller for the connection of power to the mo...

Страница 62: ...shaft Note 6 0kV and 6 6kV motors on 6800 or 6800L frames see compressor model number for motor frame use the same motor terminals as the 10kV 13 8kV motors The motor terminal on a 10 13 8kV motor has...

Страница 63: ...ary Input Norm ally Open External Hot Water Control Enable Input 1K8 J2 3 to 4 Binary Input Norm ally Open External Ice Machine Control Enable Input 1K9 J2 1 to 2 Binary Input Norm ally Open External...

Страница 64: ...g evaporator water temperatures When a secondary flow sensing device is used remove the factory jumper and install its contacts between 1X1 5 to 1K26 4 this places the secondary flow sensing device in...

Страница 65: ...module 2 Motor winding temperature 1 3 Motor winding temperature 2 4 Motor winding temperature 3 5 Oil pump discharge pressure transducer 6 Oil tank pressure transducer 7 Evaporator water differential...

Страница 66: ...16 cm 6 in between low voltage 30V and high voltage circuits Failure to do so could result in electrical noise that may distort the signals carried by the low voltage wiring including the IPC Optiona...

Страница 67: ...rigerant then passes through an orifice plate and into the economizer The economizer reduces the energy requirements of the refrigerant cycle by eliminating the need to pass all gaseous refrigerant th...

Страница 68: ...il pressure regulating valve designed to maintain a net oil pressure of 137 9 to 165 5 kPad 20 to 24 psid It is then filtered and sent to the braze plate heat exchanger oil cooler located above the oi...

Страница 69: ...ctors 9 525 mm 0 375 in OD 16 Liquid refrigerant to economizer 6 Oil return to tank 17 Liquid refrigerant to evaporator 7 Oil tank 18 Evaporator 8 Oil cooler braze plate heat exchanger 19 Oil reclaim...

Страница 70: ...The refrigerant pump is located on the front of the oil tank motor inside the oil tank The refrigerant pump inlet is connected to the well at the bottom of the condenser The well design ensures prefe...

Страница 71: ...nser pressure lowers the chillers efficiency and capacity A purge system is required on low pressure centrifugal chillers It is a device that is externally mounted on the chiller Its purpose is to rem...

Страница 72: ...and fan 3 Pressure relief device fusible plug 4 Pump out solenoid valve 5 Automatic expansion valve 6 Carbon tank 7 Carbon tank temperature sensor 8 Carbon tank heater 9 Exhaust solenoid valve 10 Pum...

Страница 73: ...losed float switch is open for more than 20 minutes the purge controls will turn off the refrigeration system and generate a non latching diagnostic Purge Liquid Level Too High Warning If the float sw...

Страница 74: ...ting If the limit temperature is reached the system shuts down and a Purge Carbon Regen Temperature Limit Exceeded diagnostic is generated Sensors The following sensors are used to enable control comm...

Страница 75: ...s a state chart with the arrows and arrow text depicting the transitions between states Descriptions The text in the circles are the internal software designations for each state The first line of tex...

Страница 76: ...76 Based on the Restart Inhibit function and the Differential to Start setpoint the oil and refrigerant pump is energized and the oil vent line valve is closed to the minimum position The oil pressure...

Страница 77: ...water pump will continue to run while the main processor module monitors leaving chilled water temperature preparing for the next compressor motor start based on the differential to start setpoint Fi...

Страница 78: ...or based on entering evaporator fluid temperature The control panel will not permit the Ice Building mode to be entered again until the unit is switched to the non ice building mode and back into the...

Страница 79: ...ration ice building stopped to ice to ice building complete Ice Making Command 1 Front Panel 2 Tracer 3 External Input Evap Entering Water Temp Falls Below the Ice Termination Setpoint Auto Run Inhibi...

Страница 80: ...ter setpoint Heating is the primary mission and cooling is a waste product or is a secondary mission This type of operation requires an endless source of evaporator load heat such as well or lake wate...

Страница 81: ...for CE application only Important Before servicing disconnect all power sources and allow at least 30 minutes for capacitors to discharge All electrical enclosures unit or remote are IP2X WARNING Live...

Страница 82: ...during start up unit operation will be locked out and a manual reset is required before the start up sequence can begin again If the fault condition has not cleared the control panel will not permit r...

Страница 83: ...ge is on the high pressure or low pressure side of the chiller Decrease energy usage by running the purge refrigeration circuit only when needed to remove non condensables rather than running it conti...

Страница 84: ...run 60 minutes without any pump out The purge control reviews the historical data and determine the Pumpout Time with the chiller On Pumpout Time from last 24 hours daily average over last 7 days whi...

Страница 85: ...Procedure Chiller Compressor On Figure 48 p 84 illustrates this process Submodes You can view up to six purge submodes from the Purge Settings screen The available purge submodes are Refrigeration Cir...

Страница 86: ...increases The purge controller monitors the compressor suction temperature and cycles or stops the pump out depending on the temperature that is present The 1 4 hp air cooled condensing unit of the re...

Страница 87: ...temperature sensor serves as the feedback to this control algorithm The compressor suction temperature pump out initiate and pump out terminate values are calculated by the purge control and are a fu...

Страница 88: ...with standard pump out compressors operation at low chiller condenser saturation temperatures may result in a system vacuum greater than the pump out compressor can overcome If the chiller experience...

Страница 89: ...nity when the chiller is shut down and no pump out minutes have accumulated for the previous 60 minutes 4 If there is no opportunity to regenerate as indicated by Rules 1 2 and 3 and the carbon capaci...

Страница 90: ...t 7 Days Indicates the average daily pump out time for the last 168 hours a moving 168 hour window Enables a comparison of present pump out times to past averages and can be another indication of the...

Страница 91: ...ure to disconnect power and discharge capacitors before servicing could result in death or serious injury Disconnect all electric power including remote disconnects and discharge all motor start run c...

Страница 92: ...level in the chiller oil sump using the two sight glasses provided in the oil sump head When the unit is operating the oil level should be visible in the lower sight glass Complete logs on a daily bas...

Страница 93: ...d be performed immediately to find and fix the leaks Measure the compressor motor winding resistance to ground a qualified service technician should conduct this check to ensure that the findings are...

Страница 94: ...lectrical enclosures unit or remote are IP2X Weekly Maintenance Perform thefollowing maintenance procedureon a weekly basis Figure 52 Purge operation under typical and leak conditions WARNING Contain...

Страница 95: ...several filter drier assembly changes may be required before a satisfactory moisture level is achieved A reoccurring or persistent wet indication is a sign of possible chiller air or water infiltrati...

Страница 96: ...d loose material from smooth bore tubes To clean other types of tubes including internally enhanced types consult a qualified service organization for recommendations WARNING Hazard of Explosion Failu...

Страница 97: ...mal treated and clean condenser water inspect the coating system within three months Only when initial inspections show no problems are present should subsequent maintenance intervals be increased Sac...

Страница 98: ...icable manufacturing location 2 The rated lifting capacity of the lifting shackle must meet or exceed the published weight of the waterbox Verify the waterbox weight from the latest published literatu...

Страница 99: ...95 21 8 0 858 130 Evaporator 1034 2 kPa 150 psi NA NA 347 766 11 9 0 469 NA NA 292 645 11 9 0 469 645 1423 21 8 0 858 Evaporator 2068 4 kPa 300 psi 431 950 11 9 0 469 NA NA 320 705 11 9 0 469 NA NA 69...

Страница 100: ...kPa 150 psi 1247 2750 21 8 0 858 NA NA NA NA NA NA NA NA 22H Heat Recovery Condenser 1034 2 kPa 150 psi 1747 3853 21 8 0 858 NA NA NA NA NA NA NA NA Table 24 CVHH waterbox weights continued Shell Size...

Страница 101: ...side Then apply final torque to each bolt in sequential order Condenser Waterbox Covers Condenser waterbox covers use a similar procedure to that which is used for the evaporator waterbox covers Use...

Страница 102: ...llation completion verification before Trane start up is scheduled and for reference during the Trane start up Where the form or check sheet also exists outside of this publication as standalone liter...

Страница 103: ...piping prior to the chiller commissioning by Trane service personnel The contractor is responsible for any foreign material left in the unit 2 Piping Chilled water piping connected to Condenser and he...

Страница 104: ...al ventilation Does the installation have properly placed and operating audible and visual refrigerant alarms If it is required by local code is a self contained breathing apparatus available 11 Ow ne...

Страница 105: ...Report Pre Start Operations Verify nitrogen holding charge Calibrate the high pressure cutout control HPC Meg compressor motor Check condenser installation Check evaporator installation Check electric...

Страница 106: ...erator is working properly and moves without binding Dry run test starter non AFD Remove separate source power and reconnect wiring Preparation for Start up Relieve nitrogen holding charge Confirm pro...

Страница 107: ...test tubes every three years Evaporator Inspect for fouling and scaling in tubes Check operation of evaporator water flow sensing device Factory recommendation to eddy current test tubes every three y...

Страница 108: ...ate factory installed gantries After the first month of operation inspect Heresite or Belzona coated waterboxes after first month thereafter inspect as needed Inspect anodes Inspect and lubricate hing...

Страница 109: ...iff Press Oil Tank Tem p IGV Position Outboard Bearing Pad Temperature 1 Outboard Bearing Pad Temperature 2 Outboard Bearing Pad Temperature 3 Motor RLA L1 L2 L3 Amps L1 L2 L3 Volts AB BC CA Power KW...

Страница 110: ......

Страница 111: ...lio of advanced controls and HVAC systems comprehensive building services and parts For more information visit www Trane com Trane has a policy of continuous product and product data improvement and r...

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