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CDHF-SVU01C-ENX39640670030
OperationMaintenance
Duplex CDHF, CDHGWater Cooled CenTraVac™
With CH530
© 2005 American Standard All rights reserved CDHF-SVU01C-EN
Warnings andCautions
Warnings and CautionsNotice that warnings and cautionsappear at appropriate intervalsthroughout this manual. Warningsare provided to alert installingcontractors to potential hazards thatcould result in personal injury or
death, while cautions are designed toalert personnel to conditions thatcould result in equipment damage.
Your personal safety and the properoperation of this machine dependupon the strict observance of theseprecautions.
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 indeath or serious injury.
����� CAUTION – Indicates a potentially hazardous situation which, if not avoided, may result inminor 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.
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Contents
CDHF-SVU01C-EN
Warnings and Cautions
General Information
Unit Control Panel (UCP)
Operator 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
CDHF-SVU01C-EN4
Typical Product Description Block
MODL CDHF DSEQ 2R NTON 2500 VOLT 575 REF 123HRTZ 60 TYPE SNGL CPKW 142 CPIM 222 TEST AIREVTM IECU EVTH 28 EVSZ 032S EVBS 280EVWC STD EVWP 2 EVWT NMAR EVPR 150EVCO VICT EVWA LELE CDTM IECU CDTH 28CDSZ 032S CDBS 250 CDWC STD CDWP 2CDWT NMAR CDPR 150 CDCO VICT CDWA LELECDTY STD TSTY STD ECTY WEOR ORSZ 230PURG PURE WCNM SNMP SPKG DOM OPTI CPDWHHOP NO GENR NO GNSL NO SOPT SPSHACCY ISLS HGBP WO LUBE SNGL AGLT CULCNIF UCP SRTY USTR SRRL 207 PNCO TERM
GeneralInformation
Unit Nameplate
The unit nameplate is located on theleft side of the unit control panel.The following information isprovided on the unit nameplate.
1. Serial NumberThe unit serial number provides thespecific chiller identity. Alwaysprovide this serial number whencalling for service or during partsidentification..
2. Service Model NumberThe service model represents the unitas built for service purposes . Itidentifies the selections of variableunit features required when orderingreplacements parts or requestingservice.
Note: Unit-mounted starters areidentified by a separate numberfound on the starter.
3. Product Coding BlockThe CDHF and CDHG models aredefined and built using the productdefinition and selection (PDS)system. This system describes theproduct offerings in terms of aproduct coding block which is madeup of feature categories and featurecodes. An example of a typicalproduct code block is given on thispage. The coding block preciselyidentifies all characteristics of a unit.
4. Identifies unit electricalrequirements
5. Correct operating charges and typeof refrigerant
6. Unit Test Pressures and MaximumOperating Pressures
7. Identifies unit Installation andOperation and Maintenance manuals
8. Drawing numbers for Unit WiringDiagrams
Literature changeApplicable to CDHF, CDHG
About this manualOperation and maintenanceinformation for models CDHF, CDHGare covered in this manual. Thisincludes both 50 and 60 Hz. CDHFand CDHG centrifugal chillersequipped with the Tracer CH530Chiller Controller system. Please notethat information pertains to all threechiller types unless differences existin which case the sections arebroken down by Chiller type asapplicable and discussed separately.
By carefully reviewing thisinformation and following theinstructions given, the owner oroperator can successfully operateand maintain a CDHF, or CDHG unit.
If mechanical problems do occur,however, contact a qualified serviceorganization to ensure properdiagnosis and repair of the unit.
5CDHF-SVU01C-EN
GeneralInformation
Model Number - An example of atypical duplex centrifugal chillermodel number is:
CDHF2100AA0BC2552613C0B203B0B20KJAC1GW40C111340A010
Digit: Description
1st-2nd CD = CenTraVac® Duplex - 2compressors
3rd H =Direct Drive
4th F = Development Sequence(F - 2 Stage) (G - 3 Stage)
5th-8th 2100 = Nominal totalcompressor tonnage
9th A = Unit VoltageA = 380V-60Hz-3PhB = 440V-60Hz-3PhC = 460V-60Hz-3PhD = 480V-60Hz-3PhE = 575V-60Hz-3PhF = 600V-60Hz-3PhG = 2300V-60Hz-3PhH = 2400V-60Hz 3PhJ = 3300V-60Hz-3PhK = 4160V-60Hz-3PhL = 6600V-60Hz-3PhM = 380V-50Hz-3PhN = 400V-50Hz-3PhP = 415V-50Hz-3PhR = 3300V-50Hz-3PhT = 6000V-50Hz-3PhU = 6600V-50Hz-3Ph
10th-11th A0 = Design Sequence
12th B = Compressor MotorPower, LH Circuit
13th C = Compressor MotorPower, RH Circuit.Compressor Motor codes:A = 588 KWB = 653 KWC = 745 KWD = 856 KWE = 957 KWF = 1062 KWG = 1228 KWH = 433 KWJ = 489 KWK = 548 KWL = 621 KW
M = 716 KWN = 799 KWP = 892 KWR = 403 KWS = 453 KWT = 512 KWU = 301 KWV = 337 KWW = 379 KWX = 1340 KW
14th-16th 255 = Compressor ImpellerDiameter LH Circuit
17th-19th 261 = Compressor ImpellerDiameter RH Circuit
20th 3 = Evaporator Tube BundleSize1 = 2100 nominal tonevaporator2 = 2300 nominal tonevaporator3 = 2500 nominal tonevaporator4 = 1610 nominal ton evaporator5 = 1850 nominal tonevaporator
21st C = Evaporator TubesA = 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 WaterboxA = 150 psig 1 pass marineB = 300 psig 1 pass marineC = 150 psig 1 pass non-marineD = 300 psig 1 pass non-marine
24th 2 = Evaporator WaterboxConnection;1 = Victaulic2 = Flanged
25th 0 = Not Assigned
26th 3 = Condenser Tube Bundle Size1 = 2100 nominal ton condenser2 = 2300 nominal ton condenser3 = 2500 nominal ton condenser4 = 1610 nominal ton condenser5 = 1760 nominal ton condenser6 = 1900 nominal ton condenser
27th B = Condenser TubesA = 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.G = I/E 90/10 CU/NI, 0.035” wall,0.75” O.D.
28th 0 = Not Assigned
29th B = Condenser WaterboxesA = 150 psig 1 pass marineB = 300 psig 1 pass marineC = 150 psig 1 pass non-marineD = 300 psig 1 pass non-marine
30th 2 = Condenser WaterboxConnection;1 = Victaulic2 = Flanged
31st 0 = Not Assigned
32nd K = Orifice Size, LH Circuit,
33rd J = Orifice Size, RH Circuit,Orifice Nominal Tons:A = 710B = 790C = 880D = 990E = 1100F = 1265G = 1400H = 1540K = 1810J = 1660L = 1970M = 2150N = 1045P = 1185R = 1335T = 1605U = 1735
CDHF-SVU01C-EN6
GeneralInformation
V = 1890W = 2060X = 1475Z = 560 - 3 stage 935 - 2 stageY = 500 - 3 stage 835 - 2 stage1 = 630 - 3 stage 2245 - 2 stage2 = 800 - 3 stage 2345 - 2 stage3 = 900 - 3 stage 2450 - 2 stage4 = 1000 - 3 stage 2560 - 2 stage5 = 1120 - 3 stage 2675 - 2 stage6 = 12507 = 16008 = 18009 = 750
34th A = Starter TypeA = Star-Delta Unit MountedC = Star Delta Remote MountedE = X-Line Full Volt Remote MountedF = Autotransformer RemoteMountedG = Primary Reactor RemoteMountedH = X-Line Full Volt Unit MountedJ = Autotransformer Unit MountedK = Primary Reactor Unit MountedL = Solid State Unit MountedM = Solid State Floor MountedN = Solid State Wall MountedP = Adaptive Freq. Drive-UnitMountedR = Customer Supplied
35th C = Control Enclosure;C = StandardS = Special
36th 1 = Control: Enhanced Protection;0 = None1 = Enhanced protection
37th G = Control: Generic BAS;0 = NoneG = Generic BAS
38th W = Water Flow Control;0 = NoneW = Water flow control
39th 4 = Tracer® Comm. Interface0 = None, 4 = COMM 4,5 = COMM 5, S = Special
40th C = Control: CondenserRefrigerant Pressure;0 = None, C = with
41st 1 = Control: Extended Operation;0 = None1 = Extended operation
42nd 1 = Chilled Water Reset -Outdoor Air Temperature Sensor0 = None,1 = Chilled water reset – with outdoorair temperature sensor,S = Special
43rd 1 = Control: Operating Status,0 = None,1 = Operating Status
44th 1 = Gas Powered Chiller;0 = No1 = Yes
45th 3 = Compressor Motor FrameSize LH Circuit
46th 4 = Compressor Motor FrameSize RH CircuitFRAME SIZE CODES: 3 = 440E, 4 =5000, 5 = 5800, 6 = 5800L, S = Special
47th 0 = Unit Insulation;0 = None1 = Insulation package
48th A = Spring Isolators0 = NoA = Yes
49th 0 = Not Assigned0 = Not assigned
50th 1 = Evaporator & Condenser Size1 = 210D - 2100,2 = 250D – 2500,3 = 250X - 2500 ,4 = 250M - 2500
51st 0 = Special Options0 = NoneS = Special Option
7CDHF-SVU01C-EN
GeneralInformation
Commonly Used AcronymsFor convenience, a number ofacronyms are used throughout thismanual. These acronyms are listedalphabetically below, along with the“translation” of each:
AFD = Adaptive Frequency Drive
ASME = American Society ofMechanical Engineers
ASHRAE = American Society ofHeating, Refrigerating and AirConditioning Engineers
BAS = Building Automation System
CABS = Auxiliary Condenser Tube-Bundle S
CDBS = Condenser Bundle Size
CDSZ = Condenser Shell Size
CH530 = Tracer CH530 Controller
DV = DynaView™ Clear LanguageDisplay, also know as the MainProcessor (MP)
CWR = Chilled Water Reset
CWR’ = Chilled Water Reset Prime
DTFL = Design Delta-T at Full Load(i.e., the difference between enteringand leaving chilled watertemperatures)
ELWT = Evaporator Leaving WaterTemperature
ENT = Entering Chilled WaterTemperature
GPM = Gallons-per-minute
HGBP = Hot Gas Bypass
HVAC = Heating, Ventilating, and AirConditioning
IE = Internally-Enhanced Tubes
IPC = Interprocessor Communication
LBU = La Crosse Business Unit
LCD = Liquid Crystal Display
LED = Light Emitting Diode
MAR = Machine Shutdown AutoRestart (Non-Latching where chillerwill restart when condition correctsitself.)
MMR = Machine Shutdown ManualRestart (Latching where chiller mustbe manually reset.)
MP = Main Processor
PFCC = Power Factor CorrectionCapacitor
PSID = Pounds-per-Square-Inch(differential pressure)PSIG = Pounds-per-Square-Inch(gauge pressure)
UCP = Unit Control Panel
LLID = Low Level Intelligent Device(Sensor, Pressure Transducer, orInput/output UCP module)
RLA = Rated Load Amps
RTD = Resistive Temperature Device
Tracer CH530 = Tracer CH530controller
TOD = Temperature Outdoor
Control Optional Packages
OPST Operating Status Control
GBAS Generic Building AutomationInterface
EXOP Extended Operation
CDRP Condenser PressureTransducer
TRMM Tracer Communications
WPSR Water pressure sensing
EPRO Enhanced Protection
CWR Chiller Water reset outdoor
CDHF-SVU01C-EN8
GeneralInformation
Figure 1. General Duplex unit components - front view
Overview
CDHF - CDHG
See Figure 1 for General Unitcomponents. Each Chiller unit iscomposed of the followingcomponents as viewed when facingthe control panel front side:• Common Evaporator and Common
Condenser
• Compressors and Motor 1 (Lefthand), 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) (notshown).
9CDHF-SVU01C-EN
GeneralInformation
Figure 2. General Duplex unit components (2 stage compressor)
CDHF-SVU01C-EN10
GeneralInformation
Cooling CycleDuplex Chillers have two refrigerantcircuits that operate as their ownindependent circuits. These circuitsare discussed as individual chillerrefrigeration units in the followingdiscussion. The sequence ofoperation of the two refrigerationcircuits is discussed in a latersection.
When in the cooling mode, liquidrefrigerant is distributed along thelength of the evaporator and sprayedthrough small holes in a distributor(i.e., running the entire length of theshell) to uniformly coat eachevaporator tube. Here, the liquidrefrigerant absorbs enough heat fromthe system water circulating throughthe evaporator tubes to vaporize.
The gaseous refrigerant is thendrawn through the eliminators(which remove droplets of liquidrefrigerant from the gas) and first-stage variable inlet guide vanes, andinto the first stage impeller.
Note: Inlet guide vanes are designedto modulate the flow of gaseousrefrigerant to meet system capacityrequirements; they also prerotate thegas, allowing it to enter the impellerat an optimal angle that maximizesefficiency at all load conditions.
Compressor 1 or 2 (3 Stage)Compressed gas from the first-stageimpeller flows through the fixed,second-stage inlet vanes and into thesecond-stage impeller.
Here, the refrigerant gas is againcompressed, and then dischargedthrough the third-stage variable guidevanes and into the third stageimpeller.
Once the gas is compressed a thirdtime, it is discharged into thecondenser. Baffles within thecondenser shell distribute thecompressed refrigerant gas evenlyacross the condenser tube bundle.Cooling tower water circulatedthrough the condenser tubes absorbsheat from the refrigerant, causing it tocondense. The liquid refrigerant thenpasses through orifice plate ‘‘A’’ andinto the economizer.
The economizer reduces the energyrequirements of the refrigerant cycleby eliminating the need to pass allgaseous refrigerant through threestages of compression. See Figure 3.Notice that some of the liquidrefrigerant flashes to a gas becauseof the pressure drop created by theorifice plates, thus further cooling theliquid refrigerant. This flash gas isthen drawn directly from the first(Chamber A) and second (ChamberB) stages of the economizer into thethird-and second-stage impellers ofthe compressor, respectively.
All remaining liquid refrigerant flowsthrough another orifice plate ‘‘C’’ tothe evaporator.
Compressor 1 or 2 (2 Stage)Compressed gas from the first-stageimpeller is discharged through thesecond-stage variable guide vanesand into the second-stage impeller.Here, the refrigerant gas is againcompressed, and then dischargedinto the condenser.
Baffles within the condenser shelldistribute the compressed refrigerantgas evenly across the condensertube bundle. Cooling tower water,circulated through the condensertubes, absorbs heat from therefrigerant, causing it to condense.The liquid refrigerant then flows outof the bottom of the condenser,passing through an orifice plate andinto the economizer.
The economizer reduces the energyrequirements of the refrigerant cycleby eliminating the need to pass allgaseous refrigerant through bothstages of compression. See Figure 6.Notice that some of the liquidrefrigerant flashes to a gas becauseof the pressure drop created by theorifice plate, thus further cooling theliquid refrigerant. This flash gas isthen drawn directly from theeconomizer into the second-stageimpellers of the compressor.
All remaining liquid refrigerant flowsout of the economizer, passesthrough another orifice plate and intothe evaporator.
11CDHF-SVU01C-EN
Figure 3. Pressure enthalpy curve (3 stage compressor)
Figure 4. 2-stage economizer (3 stage compressor)
GeneralInformation
CDHF-SVU01C-EN12
Figure 5. Pressure enthalpy curve (2 stage compressor)
Figure 6. Single stage economizer (2 stage compressor)
GeneralInformation
13CDHF-SVU01C-EN
Overview
Controls Operator InterfaceInformation is tailored to operators,service technicians and owners.
When operating a chiller, there isspecific information you need on aday-to-day basis — setpoints, limits,diagnostic information, and reports.
When servicing a chiller, you needdifferent information and a lot moreof it — historic and activediagnostics, configuration settings,and customizable control algorithms,as well as operation settings.
By providing two different tools –one for daily operation and one forperiodic service — everyone haseasy access to pertinent andappropriate information.
GeneralInformation
DynaView™ Human Interface— For the operatorDay-to-day operational information ispresented at the panel. Up to sevenlines of data (English or SI units) aresimultaneously displayed on the ¼VGA touch-sensitive screen.Logically organized groups ofinformation — chiller modes ofoperation, active diagnostics,settings and reports put informationconveniently at your fingertips. SeeOperator Interface Section for details.
TechView™ Chiller Service Tool— For the service technician oradvanced operatorAll chiller status, machineconfiguration settings, customizablelimits, and up to 60 active or historicdiagnostics are displayed throughthe service tool interface. Withoutchanging any hardware, we give youaccess to the latest and greatestversion of Tracer CH530! A new levelof serviceability using the innovativeTechView™ chiller service tool. Atechnician can interact with anindividual device or a group ofdevices for advancedtroubleshooting. LED lights and theirrespective TechView™ indicatorsvisually confirm the viability of eachdevice. Any PC that meets the systemrequirements may download theservice interface software and TracerCH530 updates. For more informationon TechView™ visit your local TraneService company, or The TraneCompany’s website atwww.trane.com.
CDHF-SVU01C-EN14
GeneralInformation
CTV Duplex Sequence Of OperationThis section will provide basicinformation on chiller operation forcommon events. Withmicroelectronic controls, ladderdiagrams cannot show today’scomplex logic, as the controlfunctions are much more involvedthan older pneumatic or solid statecontrols. Adaptive control algorithmscan also complicate the exactsequence of operation. This sectionand its diagrams attempt to illustratecommon control sequences.
The Sequence of Events diagramsuse the following KEY:
Software States: (Figure 7)There are five generic states that thesoftware can be in:1. Power Up, Stopped, Starting,Running, Stopping
Timeline Text: (Figures 8-11)
The large timeline cylinder indicatesthe upper level operating mode, as itwould be viewed on DynaView. Textin Parentheses indicates sub-modetext as viewed on DynaView. Textabove the timeline cylinder is used toillustrate inputs to the MainProcessor. This may include Userinput to the DynaView Touch pad,Control inputs from sensors, orControl Inputs from a Generic BAS.Boxes indicate Control actions suchas Turning on Relays, or moving theInlet Guide Vanes. Smaller cylindersindicate diagnostic checks, Textindicates time based functions, Soliddouble arrows indicate fixed timers,Dashed double arrows indicatevariable timers
Power Up Diagram:The Power up chart shows therespective DynaView screens duringa power up of the main processor.This process takes from 30 to 50seconds depending on the numberof installed Options. On all powerups, the software model always willtransition through the ‘Stopped’Software state independent of the lastmode. If the last mode before powerdown was ‘Auto’, the transition from‘Stopped’ to ‘Starting’ occurs, but itis not apparent to the user.
Software Operation OverviewDiagram:The Software Operation Overview isa diagram of the five possiblesoftware states. This diagram can bethought of as a State Chart, with thearrows, and arrow text, depicting thetransitions between states.
The text in the circles are the internalsoftware designations for each State.The first line of text in the Circles arethe visible top level operating modesthat can be displayed on Dyna View.The shading of each software statecircle corresponds to the shading onthe timelines that show the state thatthe chiller is in.
Figure 7. Sequence of operation overview.
15CDHF-SVU01C-EN
GeneralInformation
Figure 8. CDHE/F/G sequence of operation: auto to running
This diagram shows the sequence ofoperations for a start of the firstcompressor on a duplex chiller. The‘First’ compressor will be determinedby the type of duplex start selected.
Staging Second Compressor On:This diagram shows the sequence ofoperations where the ‘First’compressor is all ready running, andthe ‘second’ compressor is stagedon. The ‘First’ and ‘Second’compressor will be determined bythe type of duplex start selected
Figure 9. CDHE, CDHF, and CDHG sequence of operation: running
CDHF-SVU01C-EN16
GeneralInformation
Figure 11. CDHE, CDHF and CDHG sequence of operation: normal shutdown to stopped and run inhibit
Figure 10. CDHE/F/G sequence of operation: staging second compressor 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 itis 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 isstaged off.
17CDHF-SVU01C-EN
GeneralInformation
Duplex Compressor SequencingFour methods (Two fixed sequencemethods, a balanced start and hour’smethod, and a no staging method)are provided for order of acompressor sequencing on CTVDuplex chillers. The desired methodis selectable at startup via the servicetool. The application can decide toeither balance the wear burdenamong the unit’s compressors, tostart the most efficient compressor,or to simultaneously start and stopboth compressors to minimizestartup pull down time. Each methodhas specific applications were it canbe used advantageously.
If one compressor is locked out, inrestart inhibit, or generally not readyto start, the available compressor willbe started.
Note: The following descriptionassumes compressor 1 is the downstream compressor.
Fixed Sequence – Compressor 1/Compressor 2 (Default mode)If the chiller is in the Auto mode andall interlocks have been satisfied,compressor 1 will be started basedon the leaving water temperaturerising above the “Differential to Start”setting. Compressors 2 will stage onwhen the overall chiller averagecapacity exceeds Stage ON Loadpoint for 30 seconds. The stage onload point is adjustable (via servicetool) up to 50%. The default is 40%which means that a singlecompressor would have to load to80% (the average would be 40%)before the second compressor starts.Both compressors will run untilchiller average capacity drops belowStage off Load point for 30 seconds.The Stage OFF load point is also
adjustable (via service tool) (default =30%, range from 0 to 50%).Compressor 2 will be shut down andcompressor 1 will run until watertemperature drops below thedifferential to stop. Before shuttingdown, compressor 2 will beunloaded and compressor 1 will beloaded to maintain the same averagecapacity command.
When running chilled watertemperature at selected conditions,the downstream compressor usuallywill be the most efficient compressorto operate at part load becausecompressors on Duplex chillers arenot sized exactly the same.
Figure 12. CDHF/G sequence of operation: lead 1/lag 2
CDHF-SVU01C-EN18
GeneralInformation
Fixed Sequence – Compressor 2 /Compressor 1If the chiller is in the Auto mode andall interlocks have been satisfied,compressor 2 will be started basedon the leaving water temperaturerising above the “Differential to Start”setting. Compressors 1 will stage onwhen the overall chiller averagecapacity exceeds Stage on Loadpoint for 30 seconds. The stage onload point is adjustable up to 50%.The default is 40% which means thata single compressor would have toload to 80% (the average would be40%) before the second compressor
starts. Both compressors will rununtil chiller average capacity dropsbelow Stage off Load point for 30seconds. The stage off load point isalso adjustable. Compressor 1 willbe shut down and compressor 2 willrun until water temperature dropsbelow the differential to stop. Beforeshutting down, compressor 1 will beunloaded and compressor 2 will beloaded to maintain the same averagecapacity command.
If chilled water reset is used, theupstream compressor usually will bethe most efficient compressor tooperate at part load. If the leavingwater temperature is reset and thechiller only needs one compressor,then the upstream compressorwould be running closer to itsselection point and will be the mostefficient compressor to operate.
Figure 13. CDHE/F/G sequence of operation: lead 2 lag 1
19CDHF-SVU01C-EN
GeneralInformation
Sequencing - Balanced Starts andHoursWhen desired to balance the wearbetween the compressors. Thismethod will extend the time betweenmaintenance on the lead compressor.When balanced starts and hours isselected, the compressor with thefewest starts will start. If thatcompressor is unavailable to startdue to a circuit lockout (including
restart inhibit) or a circuit diagnostic,then the other compressor will bestarted. The second compressor willstage on when chiller capacityexceeds the Stage on Load point for30 seconds. When chiller capacityfalls below Stage off Load point for30 seconds, the compressor with themost hours will be shut off.
Figure 14. CDHF/G sequence of operation: equalize starts and hours
CDHF-SVU01C-EN20
GeneralInformation
Simultaneous Compressor Start/StopBoth compressors will start in closesuccession to minimize the time ittakes for the chiller to reach full load.Some process applications need thechiller to start and generate capacityas fast as possible. This method willstart both compressors, slightlystaggered to prevent doubling of thecurrent inrush, but will generallycontrol the chiller as if there wereonly one compressor.
If the chiller is in the Auto mode andall interlocks have been satisfied,compressor 1 will be started basedon the leaving water temperaturerising above the “Differential to Start”setting. When compressor 1 is atspeed, compressor 2 will start. Bothcompressors will run until watertemperature falls below thedifferential to stop, at that time bothcompressors will be shut down.
Figure 15. CDHF/G sequence of operation: combined start
21CDHF-SVU01C-EN
GeneralInformation
Compressor Load BalancingDuplex chillers with CH530 controlwill balance the compressor load bygiving each compressor the sameload command. The load commandwill be converted to IGV position thatwill be the same on eachcompressor.
Balancing compressor load results inthe best overall efficiency and withboth circuits operating with nearly thesame refrigerant pressures.
When both compressors are runningthe overall chiller load command willbe split evenly between the twocompressors unless limit controloverrides balancing. Whentransitioning between onecompressor operation and two-compressor operation, the loadcommands will be actively balancedat a rate slow enough to minimizecapacity control disturbances
Restart InhibitThe purpose of restart inhibit featureis to provide short cycling protectionfor the motor and starter.
The operation of the restart inhibitfunction is dependent upon twosetpoints. The Restart Inhibit FreeStarts (1-5, 3 default), and the RestartInhibit Start to Start Timer (10-30min,20 default). These settings areadjustable via the service tool.
Restart Inhibit Free StartsThis setting will allow a number ofrapid restarts equal to its value. If thenumber of free starts is set to “1”, thiswill allow only one start within thetime period set by the Start to StartTime Setting. The next start will beallowed only after the start to starttimer has expired. If the number offree starts is programmed to “3”, thecontrol will allow three starts in rapidsuccession, but thereafter, it wouldhold off on a compressor start untilthe Start to Start timer expired.
Restart Inhibit Start to Start TimeSettingThis setting defines the shortestchiller cycle period possible after thefree starts have been used. If thenumber of free starts is programmedto “1”, and the Start to Start TimeSetting is programmed to 20minutes, then the compressor will beallowed one start every 20 minutes.The start-to-start time is the time fromwhen the motor was commanded toenergize to when the next commandto enter prestart is given.
Clear Restart InhibitA Clear Restart Inhibit “button” isprovided within Settings; ManualOverride on the DynaView display.This provides a way for an operatorto allow a compressor start whenthere is a currently active RestartInhibit that is prohibiting such a start.The “button” press will have noother function than to remove therestart inhibit if there is one active. Itdoes not change the count of anyinternal restart inhibit timers oraccumulators.
The restart inhibit function, setpointsand clear features exist for eachcompressor and operateindependently of other compressorson that chiller.
During the time the start is inhibiteddue to the start-to-start timer, theDynaView shall display the mode‘Restart Inhibit’ and the also displaythe time remaining in the restartinhibit.
A “Restart Inhibit Invoked” warningdiagnostic will exist when theattempted restart of a compressor isinhibited.
CDHF-SVU01C-EN22
GeneralInformation
Oil and Refrigerant Pump
Compressor Lubrication System -A schematic diagram of thecompressor lubrication system isillustrated in Figure 16. (This can beapplied to circuit 1 or 2.)
Oil is pumped from the oil tank (by apump and motor located within thetank) through an oil pressure-regulating valve designed to maintaina net oil pressure of 18 to 22 psid. Itis then filtered and sent to the oilcooler located in the economizer andon to the bearings. From thebearings, the oil drains back to themanifold under the motor and thenon to the oil tank.
����� WARNING
Surface Temperatures!
MAY EXCEED 150°F. Use cautionwhile working on certain areas ofthe unit, failure to do so may resultin death or personal injury.
To ensure proper lubrication andprevent refrigerant from condensingin the oil tank, a 750-watt heater isimmersed in the oil tank and is usedto warm the oil while the unit is off.When the unit starts, the oil heater isde-energized. This heater energizesas needed to maintain 140° to 145° F(60-63°C) when the chiller is notrunning.
When the chiller is operating, thetemperature of the oil tank is typically115° to 160°F (46-72°C). The oil returnlines from the thrust and journalbearings, transport oil and some sealleakage refrigerant. The oil returnlines are routed into a manifoldunder the motor. Gas flow exits thetop of the manifold and is vented tothe Evaporator.
Note: A vent line solenoid is notneeded with the refrigerant pump. Oilexits the bottom of the manifold andreturns to the tank. Separation of theseal leakage gas in the manifoldkeeps this gas out of the tank.
A dual eductor system is used toreclaim oil from the suction coverand the evaporator, and deposit itback into the oil tank. These eductorsuse high pressure condenser gas todraw the oil from the suction coverand evaporator to the eductors andthen discharged into the oil tank. Theevaporator eductor line has a shut offvalve mounted by the evaporator andships closed. Open two turns ifnecessary.
Liquid refrigerant is used to cool theoil supply to both the thrust bearingand journal bearings. On refrigerantpump units the oil cooler is locatedinside the economizer and usesrefrigerant passing from thecondenser to evaporator to cool theoil. Oil leaves the oil cooler andflows to both the thrust and journalbearings.
Motor Cooling SystemCompressor motors are cooled withliquid refrigerant, see Figure 16.
The refrigerant pump is located onthe front of the oil tank (motor insidethe oil tank). The refrigerant pumpinlet is connected to the well at thebottom of the condenser. Theconnection is on the side where aweir assures a preferential supply ofliquid. Refrigerant is delivered to themotor via the pump. Motorrefrigerant drain lines are routed tothe condenser.
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GeneralInformation
Figure 16. Oil refrigerant pump - circuit 1 or 2
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GeneralInformation
Base Loading ControlAlgorithm:This feature allows an externalcontroller to directly modulate thecapacity of the chiller. It is typicallyused in applications where virtuallyinfinite sources of evaporator loadand condenser capacity are availableand it is desirable to control theloading of the chiller. Two examplesare industrial process applicationsand cogeneration plants. Industrialprocess applications might use thisfeature to impose a specific load onthe facility’s elecrical system.Cogeneration plants might use thisfeature to balance the system’sheating, cooling and electricalgeneration.
All chiller safeties and adaptivecontrol functions are in full effectwhen Base Loading control isenabled. If the chiller approaches fullcurrent, the evaporator temperaturedrops too low, or the condenserpressure rises too high, Tracer CH530Adaptive Control logic limits theloading of the chiller to prevent thechiller from shutting down on asafety limit. These limits may preventthe chiller from reaching the loadrequested by the Base Loadingsignal.
Base Loading Control is basically avariation of the current limitalgorithm. During base loading, theleaving water control algorithmprovides a load command every 5seconds. The current limit routinemay limit the loading when thecurrent is below setpoint. When thecurrent is within the deadband of thesetpoint the current limit algorithmholds against this loading command.
If the current exceeds the setpoint,the current limit algorithm unloads.The “Capacity Limited By HighCurrent” message normallydisplayed while the current limitroutine is active is suppressed whilebase loading.
Base loading can occur via Tracer,External signal, or front panel.
Tracer Base Loading:Current Setpoint Range:(20 - 100) percent RLARequires Tracer and Optional TracerCommunications Module (LLID)
The Tracer commands the chiller toenter the base load mode by sendingthe base load mode request. If thechiller is not running, it will startregardless of the differential to start(either chilled water or hot water). Ifthe chiller is already running, it willcontinue to run regardless of thedifferential to stop (either chilledwater or hot water), using the baseload control algorithm. While the unitis running in base loading, it willreport that status back to the Tracerby setting “Base Load Status = true”in the Tracer Status Byte. When theTracer removes the base load moderequest (sets the bit to 0). The unitwill continue to run, using thenormal chilled or hot water controlalgorithm, and will turn off, onlywhen the differential to stop has beensatisfied.
External Base Loading:Current Setpoint Range:(20 - 100) percent RLA
The UCP accepts 2 inputs to workwith external base loading. Thebinary input is at 1A18 Terminals J2-1and J2-2 (Ground) which acts as aswitch closure input to enter thebase-loading mode. The second
input, an analog input, is at 1A17terminals J2 – 1 and 3 (Ground)which sets the external base loadingsetpoint, and can be controlled byeither a 2-10Vdc or 4-20ma Signal. Atstartup the input type is configured.The graphs in Figure 13 show therelationship between input andpercent RLA. While in base loadingthe active current limit setpoint is setto the Tracer or external base loadsetpoint, providing that the base loadsetpoint is not equal to 0 (or out ofrange). If it is out of range, the frontpanel current limit setpoint is used.During base loading, all limits areenforced with the exception ofcurrent limit. The human interfacedisplays the message “Unit isRunning Base Loaded”. Hot GasBypass is not run during baseloading. If base loading and icemaking are commandedsimultaneously, ice making takesprecedence.
An alternative and less radicalapproach to Base Loading indirectlycontrols chiller capacity. Artificallyload the chiller by setting the chilledwater setpoint lower than it iscapable of achieving. Then, modifythe chiller’s load by adjusting thecurrent limit setpoint. This methodprovides greater safety and controlstability in the operation of the chillerbecause it has the advantage ofleaving the chilled water temperaturecontrol logic in effect. The chilledwater temperature control logicresponds quicker to dramatic systemchanges, and can limit the chillerloading prior to reaching an AdaptiveControl limit point.
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GeneralInformation
Figure 17. Base loading with external mA input and with external voltage input
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GeneralInformation
Ice Machine ControlUCP provides a service level “Enableor Disable” menu entry for the IceBuilding feature when the IceBuilding option is installed. IceBuilding can be entered from “FrontPanel”, or if hardware is specified theUCP will accept either an isolatedcontact closure (1A19 Terminals J2-1and J2-2 (Ground) ) or a remotecommunicated input (Tracer) toinitiate the ice building mode wherethe unit runs fully loaded at all times.Ice building will be terminated eitherby opening the contact or based onentering evaporator fluidtemperature. UCP will not permit theIce Building mode to be enteredagain until the unit is switched to theNon-ice building mode and back intothe ice building mode. It is notacceptable to reset the chilled watersetpoint low to achieve a fully loadedcompressor. When entering ice-building the compressor will beloaded at its maximum rate andwhen leaving ice building thecompressor will be unloaded at itsmaximum rate. While loading andunloading the compressor, all surgedetection will be ignored. While inthe ice building mode, current limitsetpoints less than the maximum willbe ignored. Ice Building can beterminated by one of the followingmeans:1. Front panel disable.2. Opening the external Ice. Contacts/
Remote communicated input(Tracer).
3. Satisfying an evaporator enteringfluid temperature setpoint. (Defaultis 27°F)
4. Surging for 7 minutes at full openIGV.
Figure 18. Sequence of operation: ice making: running to ice making
Figure 19. Sequence of operation: ice making: stopped to ice to ice buildingcomplete
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GeneralInformation
Hot Water controlOccasionally CTV chillers areselected to provide heating as aprimary mission. With hot watertemperature control, the chiller canbe used as a heating source orcooling source. This feature providesgreater application flexibility. In thiscase the operator selects a hot watertemperature and the chiller capacityis modulated to maintain the hotwater setpoint. Heating is the primarymission and cooling is a wasteproduct or is a secondary mission.This type of operation requires anendless source of evaporator load(heat), such as well or lake water. Thechiller has only one condenser.
Note: Hot water temperature controlmode does not convert the chiller toa heat pump. Heat pump refers to thecapability to change from a cooling-driven application to a heating-drivenapplication by changing therefrigerant path on the chiller. This isimpractical for centrifugal chillers asit would be much easier to switchover the water side.
This is NOT heat recovery. Althoughthis feature could be used to recoverheat in some form, there’s not asecond heat exchanger on thecondenser side.
The DynaView™ Main Processorprovides the hot water temperaturecontrol mode as standard. Theleaving condenser water temperatureis controlled to a hot water setpointbetween 80 and 140°F (26.7 to 60°C)The leaving evaporator watertemperature is left to drift to satisfythe heating load of the condenser. Inthis application the evaporator isnormally piped into a lake, well, orother source of constant temperaturewater for the purpose of extractingheat.
In hot water temperature controlmode all the limit modes anddiagnostics operate as in normalcooling with one exception; Theleaving condenser water temperaturesensor is an MMR diagnostic whenin hot water temperature controlmode. (It is an informational warningin the normal cooling mode.)
In the hot water temperature controlmode the differential-to-start anddifferential-to-stop setpoints are usedwith respect to the hot water setpointinstead of with the chilled watersetpoint.
UCP provides a separate entry at theDV to set the hot water setpoint.Tracer is also able to set the hotwater setpoint. In the hot water mode
the external chilled water setpoint isthe external hot water setpoint; thatis, a single analog input is shared atthe 1A16 –J2-1 to J2-3 (ground)
An external binary input to selectexternal hot water control mode is onthe EXOP OPTIONAL module 1A18terminals J2-3 to J2-4 (ground). Traceralso has a binary input to selectchilled water control or hot watertemperature control.
There is no additional leaving hotwater temperature cutout; the HPCand condenser limit provide for hightemperature and pressure protection.
In hot water temperature control thesoftloading pulldown rate limitoperates as a softloading pullup ratelimit. The setpoint for setting thetemperature rate limit is the samesetpoint for normal cooling as it isfor hot water temperature control.
The hot water temperature controlfeature is not designed to run withHGBP, AFD, or ice making.
The factory set PID tuning values forthe leaving water temperature controlare the same settings for both normalcooling and hot water temperaturecontrol.
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Unit ControlPanel (UCP)
Control Panel Devices and UnitMounted Devices
Unit Control Panel (UCP)Safety and operating controls arehoused in the unit control panel, thestarter panel and the purge controlpanel. The UCP ‘s operator interfaceand main processor is called theDynaView™ (DV) and is located onthe UCP door. (See Operatorsinterface section for detailedinformation)
Figure 20. Left control panel
The UCP houses several othercontrols modules called panelmounted LLID (Low Level IntelligentDevice), power supply, terminalblock, fuse, circuit breakers, andtransformer. The IPC (Interprocessorcommunication) bus providescommunication between LLID’s andthe main processor. Unit mounteddevices are called frame mountedLLID’s and can be temperaturesensors or pressure transducers,vane actuator. These and otherfunctional switches provide analogand binary inputs to the controlsystem.
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Unit ControlPanel (UCP)
Tracer CH530 Chiller ControllerRevolutionary control of the chiller,chilled water system, and your entirebuilding with unprecedentedaccuracy, reliability, efficiency, andsupport for maintenance using thechiller’s PC-based service tool.Chiller reliability is all aboutproducing chilled water and keepingit flowing, even when facingconditions that ordinarily would shutdown the chiller — conditions thatoften happen when you need coolingthe most.
Tracer CH530’s Main Processor,DynaView™, is fast and keeps thechiller online whenever possible.Smart sensors collect three rounds ofdata per second, 55 times the datacollection speed of its predecessor.Each device (a sensor) has its ownmicroprocessor that simultaneouslyconverts and accurately calibrates itsown readings from analog to digital.
Because all devices arecommunicating digitally with theDynaView™ main processor, there isno need for the main processor toconvert each analog signal one at atime. This distributed logic allowsthe main processor to focus onresponding to changing conditions— in the load, the machine, itsancillary equipment, or its powersupply. Tracer CH530 constantlyreceives information about key dataparameters, temperatures and
current. Every five seconds then amultiple objective algorithmcompares each parameter to itsprogrammed limit. The chiller’sAdaptive Control™ capabilitiesmaintain overall system performanceby keeping its peak efficiency.Whenever the controller senses asituation that might trigger aprotective shutdown, it focuses onbringing the critical parameter backinto control. When the parameter isno longer critical, the controllerswitches its objective back tocontrolling the chilled watertemperature, or to another morecritical parameter should it exist.
Variable water flow through theevaporatorChilled-water systems that vary waterflow through chiller evaporators havecaught the attention of engineers,contractors, building owners, andoperators. Varying the water flowreduces the energy consumed bypumps, while requiring no extraenergy for the chiller. This strategycan be a significant source of energysavings, depending on theapplication. With its faster and moreintelligent response to changing
conditions, Tracer CH530 water flowsensing option accommodatesvariable evaporator water flow and itseffect on the chilled watertemperature. These improvementskeep chilled water flowing at atemperature closer to its setpoint.
User-defined language supportDynaView™ is capable of displayingEnglish text or one of the twoalternate languages that are stored inDynaView™ at one time. Switchinglanguages is simply accomplishedfrom a settings menu.
Similarly, TechView™ accommodatesa primary and a secondary languagefrom the same list of availablelanguages.
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OperatorInterface
Figure 21. DynaView™ main processor
The DynaView™ (DV) OperatorInterface contains the “MainProcessor (MP)” and is mounted onthe unit control panel front doorwhere it communicates commandsto other modules, collecting data,status and diagnostic informationfrom the other modules over the IPC(Inter Processor Communications)link. The Main Processor (MP)software controls water flows bystarting pumps and sensing flowinputs, establishes a need to heat orcool, performs pre-lube, performingpost-lube, starts the compressor(s),performs water temperature control,establishes limits, and pre-positionsthe inlet guide-vanes.
The MP contains non-volatilememory both checking for valid setpoints and retaining them on anypower loss. System data frommodules (LLID) can be viewed at theDynaView™ operator interface. Suchas evaporator and condenser watertemperatures, outdoor airtemperature, evaporator andcondenser water pump control,status and alarm relays, externalauto-stop, emergency stop,evaporator and condenser waterpressure drops and evaporator andcondenser water flow switches.
DynaView™ presents three menutabs across the top which arelabeled “MAIN, REPORTS, andSETTINGS”.
The Main screen provides an overallhigh level chiller status so theoperator can quickly understand themode of operation of the chiller.
The Chiller Operating Mode willpresent a top level indication of thechiller mode (Auto, Running, Inhibit,Run Inhibit, etc.) The “additionalinformation” icon (arrow) willpresent a subscreen that lists infurther detail the subsystem modes.(See Machine Operating Modes.)
Main screen content can be viewedby selecting the up or down arrowicons. The Main screen is the defaultscreen and after an idle time of 30minutes.
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OperatorInterface
DynaView™ (DV) is the operatorinterface of the Tracer CH530 controlsystem utilized on the CTV machine.The DynaView™ enclosure is 9.75"wide, 8” high and 1.6” deep. TheDynaView™ display is approximately4” wide by 3” high. Features of thedisplay include a touch screen andlong life LED backlight. This device iscapable of operating in 0 - 95 percentrelative humidity (non-condensing),and is designed and tested with UVconsiderations consistent with anoutdoor application in directsunlight. The enclosure includes aweather tight connection means forthe RS232 service tool connection.
Touch screen key functions aredetermined completely in thesoftware and change dependingupon the subject matter currentlybeing displayed. The user operatesthe touch sensitive buttons bytouching the button of choice. Theselected button is darkened toindicate it is the selected choice. Theadvantage of touch sensitive buttonsis that the full range of possiblechoices as well as the current choiceis always in view.
Spin values (up or down) are agraphical user interface model usedto allow a continuously variablesetpoint, such as leaving watersetpoint to be changed. The valuechanges by touching the incrementor decrement arrows.
Action buttons are buttons thatappear temporarily and provide theoperator with a choice such as Enteror Cancel. The operator indicates hischoice by touching the button ofchoice. The system then takes theappropriate action and the buttontypically disappears.
DynaView™ consists of variousscreens, each meant to serve aunique purpose of the machine beingserved. Tabs are shown across thetop of the display. The user selects ascreen of information by touching theappropriate tab. The folder that isselected will be brought to the frontso it’s contents are visable
The main body of the screen is usedfor description text, data, setpoints,or keys (touch sensitive areas) Thedouble up arrows cause a page bypage scroll either up or down. Thesingle arrow causes a line by linescroll to occur. At the end of thescreen, the appropriate scroll buttonswill disappear. Wrap around will notoccur.
The bottom of the screen is thepersistent area. It is present in allscreens and performs the followingfunctions. The left circular area isused to reduce the contrast andviewing angle of the display. Theright circular area is used to increasethe contrast and viewing angle of thedisplay. The contrast control will belimited to avoid complete “light” orcomplete “dark”, which wouldpotentially confuse an unfamiliaruser to thinking the display wasmalfunctioning.
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OperatorInterface
The Auto and Stop keys are used toput the unit into the auto or stopmodes. Key selection is indicated bybeing darkened (reverse video).
The Alarms button is to the right ofthe Stop key. The Alarms buttonappears only when alarm informationis present. The alarm blinks to drawattention to the shutdown diagnosticcondition. Blinking is defined asnormal versus reverse video.Pressing on the Alarms button takesyou to the corresponding screen.
Persistent keys, horizontal at thebottom of the display, are those keysthat must be available for operationregardless of the screen currentlybeing displayed. These keys arecritical for machine operation. TheAuto and Stop keys will bepresented as radio buttons within thepersistent key display area. The
selected key will be dark. The chillerwill stop when the Stop key istouched, entering the stop sequence.Pressing the “Immediate Stop”button will cause the chiller to stopimmediately.
The AUTO and STOP, takeprecedence over the ENTER andCANCEL keys. (While a setting isbeing changed, AUTO and STOPkeys are recognized even if ENTER orCANCEL has not been pressed.Selecting the Auto key will enable thechiller for active cooling ( if nodiagnostic is present.)
Chiller Stop Prevention/InhibitFeatureA new chiller “Stop prevention/inhibit” feature allows a user toprevent an inadvertent chiller stopfrom the DynaView screen for thosechillers which are solely controlledby the CH530.
How It WorksThis new feature will be activatedafter the service tech sets a variableshut down timer in TechView to begreater that 0 seconds and up to 20seconds (i.e. 0 < Timer ± 20). Then,when the user presses the ‘STOP’button on the DynaView display andinitiates a chiller shutdown, awindow will now appear thatdisplays the “Unit Stop InformationScreen” as shown below.
TechView service tool is utilized toenable this feature.
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OperatorInterface
The machine-operating modeindicates the operational status of thechiller. A subscreen with additionalmode summary information will beprovided. When the user scrollsdown the screen the MachineOperation Mode will remainstationary
On DynaView™, the user will bepresented with a single line of textthat represents the ‘top-level’operating state of the machine. Thesetop-level modes are shown in thetable below. Additional information (ifit exists) regarding the machineoperating state will be available tothe user by selecting the “additionalinformation” button (double rightarrow) next to the top-level operatingmode. These sub-level modes areshown in the table at left.
The TOP LEVEL MODE is the textseen on the single top level chillersystem operating mode line. TheSUB LEVEL MODE is the text seen onthe operating mode sub-menu. Theoperating mode sub-menu may haveup to six (6) lines of text displayed.The BAS CODE is the code that willbe sent via COMM4 to the TracerSummit system as the chiller systemmode. Note that each top level modemay contain multiple sub levelmodes. In general, the BAS CODEwill reflect the top level mode and notthe sub level mode.
A general description of the top level modes is show in the following table.
Top Level Mode DescriptionStopped Unit inhibited from running and will require
user action to go to Auto.Run Inhibit Unit inhibited from running by Tracer,
External BAS, or an Auto Reset diagnostic.Auto Unit determining if there is a need to run.Waiting To Start Unit waiting for tasks required prior to
compressor start to be completed.Starting Compressor Unit is starting compressor.Running Compressor is running with no limits in
effect.Running – Limit Compressor is running with limit in effect.Preparing To Shutdown Unit is closing inlet guide vanes prior to
compressor shutdown.Shutting Down Compressor has been stopped and unit is
performing shutdown tasks.
Figure 22
CDHF-SVU01C-EN34
OperatorInterface
ReferenceTop Level Mode Sub Level Mode BAS CodeSYSTEM RESET Boot & Application software part number, self-test, and
configuration validity screens will be present. NAStopped Local Stop 00Stopped Panic Stop 00Stopped Diagnostic Shutdown – Manual Reset 00Run Inhibit Ice Building Is Complete 100Run Inhibit Tracer Inhibit 100Run Inhibit External Source Inhibit 100Run Inhibit Diagnostic Shutdown – Auto Reset 100Auto Waiting For Evaporator Water Flow 58Auto Waiting For A Need To Cool 58Auto Waiting For A Need To Heat 58Auto Power Up Delay Inhibit: MIN:SEC 58Waiting To Start Waiting For Condenser Water Flow 70Waiting To Start Establishing Oil Pressure 70Waiting To Start Pre-Lubrication Time: MIN:SEC 70
Figure 23
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OperatorInterface
ReferenceTop Level Mode Sub Level Mode BAS CodeWaiting To Start Motor Temperature Inhibit: Motor Temperature / Inhibit Temperature 70Waiting To Start Restart Time Inhibit: MIN:SEC 70Waiting To Start High Vacuum Inhibit: Oil Sump Press / Inhibit Press 70Waiting To Start Low Oil Temperature Inhibit: Oil Temperature / Inhibit Temperature 70Waiting To Start Waiting For Starter To Start: MIN:SEC 70Starting Compressor There is no sub mode displayed 72Running There is no sub mode displayed 74Running Hot Water Control 74Running Surge 74Running Base Loaded 74Running Ice Building 74Running Ice To Normal Transition 74Running Current Control Soft Loading 74Running Capacity Control Soft Loading 74Running – Limit Current Limit 75Running – Limit Phase Unbalance Limit 75Running – Limit Condenser Pressure Limit 75Running – Limit Evaporator Temperature Limit 75Running – Limit Minimum Capacity Limit 75Running – Limit Maximum Capacity Limit 75Preparing ToShutdown Closing IGV: IGV Position % 7EShutting Down Post-Lubrication Time: MIN:SEC 7EShutting Down Evaporator Pump Off Delay: MIN:SEC 7EShutting Down Condenser Pump Off Delay: MIN:SEC 7E
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OperatorInterface
Main ScreenThe main screen is provides “anoverall view“ of the chillerperformance in addition to the mainand sub operating modes. The tablebelow indicates other items found ,when specified by options, that canbe scrolled to via the up or downarrows.
Main Screen Data Fields Table
Description Units Resolution Dependencies1. Chiller Mode (>> submodes)2. Circuit 1 Mode (>> submodes)3. Circuit 2 Mode (>> submodes)4. Evap Ent/Lvg Water Temp F / C 0.15. Cond Ent/Lvg Water Temp F / C 0.16. Active Chilled Water Setpoint (>>source) F / C 0.17. Active Hot Wtr Setpoint (>>source) F / C 0.1 If in heat installed8. Active Current Limit Setpoint (>>source) % RLA 19. Active Base Loading Setpoint (>>source) % 1 If enabled10. Circuit 1 Purge Mode (status, i.e. on, off, See modes in Emumadaptive, auto)) purge manual11. Circuit 2 Purge Mode (status, i.e. on, off, See modes in Enumadaptive, auto)) purge manual12. Approx Chiller Capacity Tons / kW XXX If option installed13. Active Ice Termination Setpoint (>>source) F / C 0.1 If option installed14. Software Version 0.XX
Chiller Operating ModeThe machine-operating modeindicates the operational status of thechiller. A subscreen with additionalmode summary information will beprovided by selection of anadditional information icon (>>). Theoperating mode lines will remainstationary while the remaining statusitems scroll with the up/down arrowkeys.
Circuit Operating ModeThe circuit-operating modes indicatethe operational status of the circuits.A subscreen with additional modesummary information will beprovided by selection of anadditional information icon (>>). Theoperating mode lines will remainstationary while the remaining statusitems scroll with the up/down arrowkeys.
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OperatorInterface
Diagnostic ScreenThe diagnostic screen is accessibleby touching the Alarms enunciator.
When an alarm is present, the alarmenunciator is present next to the Stopkey. A flashing “alarm” indicates amachine shutdown and a nonflashing “alarm” indicates aninformational message.
Machine shutdowns can be of twotypes:
Latching - Machine ShutdownManual Reset Required (MMR)
or
Non-Latching - Machine ShutdownAuto Reset (MAR)
Latching (MMR) require correctiveaction and manual reset.
Non-Latching (MAR) will restartautomatically when conditioncorrects itself.
There are over 200 potentialmessages, too numerous toincorporate in this manual.
Up to ten active diagnostics can bedisplayed if required.
The reason for all diagnostics mustbe determined and corrected. Do notreset and restart the chiller as thiscan cause a repeat failure. Contactlocal Trane Service for assistance asnecessary.
After corrective action, the chiller canbe reset and/or restarted. In the caseof “Unit Shutdown - Reset Required”diagnostic types, the chiller will haveto be manually reset through theDiagnostics alarm menu.
When reset they become historic andviewable via the service toolTechView.
Performing a Reset All ActiveDiagnostics will reset all activediagnostics regardless of type,machine or refrigerant circuit.
A Manual Override indicator (sharesspace with the Alarms key) alerts theoperator to the presence of a manualoverride. An Alarm will takeprecedence over any manualoverride, until the reset of activealarms, at which point the Manualindicator would reappear if such anoverride exists.
Temperature settings can beexpressed in F or C, depending onDisplay Units settings.
Dashes (“- - - -”) appearing in atemperature or pressure report,indicates that the value is invalid ornot applicable.
The languages for DynaView™ willreside in the main processor. Themain processor will hold threelanguages, English, and two alternatelanguages. The service tool(TechView™) will load the mainprocessor with user selectedlanguages from a list of availabletranslations. Whenever possible,complete words will be used on thepersistent keys as described.
CDHF-SVU01C-EN38
OperatorInterface
The chilled water reset status area inthe right most column will displayone of the following messages:Return, Constant Return, Outdoor,None
The left column text “Front Panel”,“BAS”, “External”, Chilled WaterReset, and “Active Chilled WaterSetpoint” will always be presentregardless of installation or enablingthose optional items. In the secondcolumn “- - - -” will be shown if thatoption is Not Installed, otherwise thecurrent setpoint from that source willbe shown.
The “Back” button providesnavigation back to the chiller screen.
The active chilled water setpoint isthe setpoint that is currently in use. Itwill be displayed to 0.1 degreesFahrenheit or Celsius. Touching thedouble arrow to the left of the ActiveChilled Water Setpoint will take theuser to the active chilled watersetpoint arbitration sub-screen.
The Active Chilled Water Setpointthe result of arbitration between thefront panel, BAS, and externalsetpoints,
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OperatorInterface
The left column text “Front Panel”,“BAS”, “External”, and “ActiveCurrent Limit Setpoint” will alwaysbe present regardless of installationor enabling those optional items. Inthe second column “- - - -” will beshown if that option is Not Installed,otherwise the current setpoint fromthat source will be shown. The“Back” button provides navigationback to the chiller screen.
Note: This is the same for othersetpoints in the “Main” menu.
The active current limit setpoint isthe current limit setpoint that iscurrently in use. It will be displayedin percent RLA. Touching the doublearrow to the left of the Active CurrentLimit Setpoint will take the user tothe active current limit setpoint sub-screen. The active current limitsetpoint is that setpoint to which theunit is currently controlling. It is theresult of arbitration between the frontpanel, BAS, and external setpoints.
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OperatorInterface
Reports
To aid in comparing the status ofboth circuits, the heading on theReports list screen has buttons asindicated in the table above (i.e.,System, Ckt1, and Ckt2). The selectedbutton is darkened, presented inreverse video, or some how changedto indicate it is the selected choice.
When a report screen is selected, theappropriate circuit is displayed in thescreen heading as shown in thesample evaporator screen below:
Report Menu
Description Heading Buttons1. Evaporator System, Ckt 1, Ckt 22. Condenser System, Ckt 1, Ckt 23. Compressor Ckt 1, Ckt 24. Motor Ckt 1, Ckt 25. Purge Ckt 1, Ckt 26. ASHRAE Chiller Log System, Ckt 1, Ckt 2
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OperatorInterface
Report name: System Evaporator
Description Resolution Units Dependencies1. Evap Entering Water Temp + or – XXX.X Temperature2. Evap Leaving Water Temp + or – XXX.X Temperature3. Evap Water Flow Switch Status (Flow, No Flow)4. Evap Differential Wtr Press XXX.X Diff Pressure If option installed5. Approx Evap Water Flow XXXX Flow If option installed6. Approx Chiller Capacity XXXX Tons If option installed
Report name: Circuit Evaporator
Description Resolution Units Dependencies1. Evap Sat Rfgt Temp + or – XXX.X Temperature2. Evap Rfgt Pressure XXX.X Pressure3. Evap Approach Temp + or – XXX.X Temperature
Report name: System Condenser
Description Resolution Units Dependencies1. Cond Entering Water Temp + or – XXX.X Temperature2. Cond Leaving Water Temp + or – XXX.X Temperature3. Cond Water Flow Switch Status (Flow, No Flow)4. Cond Differential Wtr Press XXX.X Diff Pressure If option installed5. Approx Cond Water Flow XXXX Flow If option installed6. Outdoor Air Temperature + or – XXX.X Temperature If option installed
Report name: Circuit Condenser
Description Resolution Units Dependencies1. Cond Sat Rfgt Temp + or – XXX.X Temperature2. Cond Rfgt Pressure XXX.X Pressure3. Cond Approach Temp + or – XXX.X Temperature
Note: Approach temperatures shown are the mathematical difference between the chiller leaving water temperature andthe corresponding saturated refrigerant temperature of same circuit. When one compressor is operational the approachvalue will be similar to those values found on single compressor models. However when both compressors areoperating, the upstream compressor circuits approach will be the mathematical difference of the upstream chillersrefrigerant temperature and the leaving water temperature after the down stream chillers circuit. Therefore the approachof the upstream circuit will be a negative number in many instances, when both compressors are operating.
CDHF-SVU01C-EN42
OperatorInterface
Report name: System ASHRAE Chiller Log
Description Resolution Units Dependencies1. Current Time/Date XX:XX mmm dd, yyyy Date / Time2. Chiller Mode: Enum3. Active Chilled Water Setpoint: XXX.X Temperature4. Active Current Limit Setpoint: XXX % RLA5. Refrigerant Type: Enum6. Refrigerant Monitor: XXX.X PPM If option installed7. Evap Entering Water Temp: XXX.X Temperature8. Evap Leaving Water Temp: XXX.X Temperature9. Evap Water Flow Switch Status: Enum If option not installed10. Evap Differential Wtr Press: XXX.X Diff Pressure If option installed11. Approx Evap Water Flow: XXX.X GPM/LPM If option installed12. Approx Chiller Capacity: XXXX Capacity If option installed13. Cond Entering Water Temp: XXX.X Temperature14. Cond Leaving Water Temp: XXX.X Temperature15. Cond Water Flow Switch Status: Enum If option not installed16. Cond Differential Wtr Press: XXX.X Pressure17. Approx. Cond Water Flow: XXXX Flow If option installed
Report name: Circuit ASHRAE Chiller Log
Description Resolution Units Dependencies1. Circuit Operating Mode: Enum2. Amps L1 L2 L3 XXXX Amps XXX.X if less than
1000 Amps3. Volts AB BC CA XXXX Volts4. Purge Daily Pumpout –24 Hrs: XXX.X Min5. Purge Daily Pumpout Limit/Alarm XXX.X Min6. Purge Pumpout - Life XXXXXX.X Min7. Purge Operating Mode: Enum8. Purge Status: Enum9. Compressor Starts: XXXX Integer10. Compressor Running Time: XX:XX Hours:Minute11. Compressor Rfgt Discharge Temp: XXX.X Temperature If option installed12. Oil Pump Discharge Pressure: XXX.X Pressure13. Oil Tank Pressure: XXX.X Pressure14. Differential Oil Pressure: XXX.X Diff Pressure15. Oil Tank Temp: XXX.X Temperature16. Inboard Bearing Temp: XXX.X Temperature If option installed17. Outboard Bearing Temp: XXX.X Temperature If option installed18. Evap Sat Refrigerant Temp: XXX.X Temperature19. Evap Rfgt Pressure: XXX.X Pressure20. Evap Approach Temp: XXX.X Temperature21. Cond Sat Rfgt Temp: XXX.X Temperature22. Cond Rfgt Pressure: XXX.X Pressure23. Condenser Approach Temp: XXX.X Temperature
Historic Diagnostics Log
1 to 20 Historic Diagnostics (main processor 2.0 and later)
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OperatorInterface
Setting Tab screens provides a userthe ability to adjust settings justifiedto support daily tasks. The layoutprovides a list of sub-menus,organized by typical subsystem.
To change chilled water setpoint, firstselect the settings tab screen. Chilledwater setpoint to within the chillersub-menu. (See next page forsetpoint listing.)
Upon selecting a Settings list (i.e.Chiller, Circuit 1 Purge, System ModeOverride, etc.) a listing of allsetpoints available to change alongwith their current value will appear.The operator selects a setpoint tochange by touching either the verbaldescription or setpoint value. Doingthis causes the screen to switch toeither the Analog Settings Subscreenor the Enumerated SettingsSubscreen.
Header ScreenTo aid in comparing circuit levelsetpoints, the heading on theSettings list have buttons asindicated in the table above (i.e., Ckt1and Ckt2). The selected button isdarkened, presented in reverse video,to indicate it is the selected choice.
Settings screen for standard CTV :
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Chiller
Description Resolution or (Enumerations), Default Units1. Front Panel Control Type (Chilled Water, Hot Water), Chilled Water Enum2. Front Panel Chilled Water Setpt (3)
+ or – XXX.X Temperature3. Front Panel Hot Water Setpt (3)
+ or – XXX.X Temperature4. Front Panel Current Limit Setpt XXX (4) Percent RLA5. Front Panel Base Load Cmd On/Auto enum6. Front Panel Base Load Setpt XXX Percent7. Front Panel Ice Build Cmd On/Auto Enum8. Front Panel Ice Termn Setpt XXX.X Temperature9. Ice to Normal Cool Timer Setpt (0-10), 5 min Minutes10. Differential to Start XXX.X Temperature11. Differential to Stop XXX.X Temperature12. 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 Units1. Chilled Water Reset (Constant, Outdoor, Return, Disable), Disable Enum2. Return Reset Ratio XXX Percent3. Return Start Reset XXX.X Temperature4. Return Maximum Reset XXX.X Temperature5. Outdoor Reset Ratio XXX Percent6. Outdoor Start Reset XXX.X Temperature7. Outdoor Maximum Reset XXX.X Temperature8. Ext Chilled Water Setpoint (Enable, Disable), Disable Enum9. Ext Current Limit Setpoint (Enable, Disable), Disable Enum10. Ice Building Feature Enable (Enable, Disable), Disable Enum11. Ext Base Loading Setpoint (Enable, Disable), Disable Enum
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System Mode Overrides
Description Resolution or (Enumerations), Default Units Monitor Value1. Compressor XXX / (Auto,Manual [0-100] ), Auto Enum IGV % Open Control Signal Evap. LWT
AFD Freq.2. Evap Water Pump (Auto, On), Auto Enum 1) Evap Flow
status2) Override Time Remaining
3. Cond Water Pump (Auto, On), Auto Enum 1) Cond Flowstatus2) Override TimeRemaining
Circuit Mode Overrides
Description Resolution or (Enumerations), Default Units Monitor Value1. Oil Pump (Auto, On), Auto Enum 1) Diff press
2) Override TimeRemaining
2. Clear Restart Inhibit Timer3. Purge Exhaust Circuit Test (Off, On), Off Enum none4. Purge Regen Cycle (Off, On), Off Enum Carbon Temp5. Front Panel Ckt Lockout (Not Locked Out, Locked Out), Not Locked Out Enum
Purge
Description Resolution or (Enumerations), Default Units1. Purge Operating Mode (Auto, On, Adaptive, Stop), Adaptive Enum2. Daily Pumpout Limit XXX Minutes3. Disable Daily Pumpout Limit (0 to disable) 0, XX Hours4. Purge Liquid Temp Inhibit (Enable, Disable), Enable Enum5. Purge Liquid Temp Limit XXX.X Temperature
Display Settings
Description Resolution or (Enumerations), Default Units1. Date Format (“mmm dd, yyy”, “dd-mmm-yyyy”), “mmm dd, yyy” Enum2. Date3. Time Format (12-hour, 24-hour), 12-hour Enum4. Time of Day5. Keypad/Display Lockout (Enable, Disable), Disable Enum6. Display Units (SI, English), English Enum7. Pressure Units (Gauge, Absolute), Absolute Enum8. 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 Processor provides the minimum and maximum allowable value.(3) Terminates with 10 minutes if inactivity(4) The Date and Time setup screen formats deviate slightly from the standard screens defined above. See the time and date section for further details.(5) Enables a DynaView™ Lockout screen. All other screens timeout in 30 minutes to this screen when enabled. The DynaView™ Lockout Screen displays a 0-9 keypad to
permit the user to exit the lockout with a fixed password (1-5-9 + Enter). See lockout setion for further details.(6) Language choices are dependent on what has been setup in the Main Processor. Language selections will include English and qty 2 alternate as loaded by TechView™.
Language shall always be the last setting listed on the Display Settings menu. This will allow a user to find language selection if looking at an unrecognizable language.(7) Manual Compressor Control allows an operator to override the Auto Control and manually control the compressor while in operation. This is not active during Stop
mode.
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OperatorInterface
Each Settings Sub screen consists of a setpoints list and the current value.The operator selects a setpoint to change by touching either the description orsetpoint value. Doing this causes the screen to switch to the Analog SettingsSubscreen shown below.
Analog Settings Subscreen displays the current value of the chosen setpointin the upper ½ of the display. It is displayed in a changeable format consistentwith its type. Binary setpoints are considered to be simple two stateenumeration and will use buttons. Analog setpoints are displayed as spinbuttons. The lower half of the screen is reserved for help screens. To changethe setpoint the ENTER key must be touched, otherwise the new setting iscancelled.
{
Note: Spin buttons used to changesetpoint value.
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OperatorInterface
Settings with buttons only [screen has no cancel or enter key] do accept thenew selection immediately.
Mode Override for Enumerated Settings is shown below:
Note: Radio 1 and Radio 2 refer to“touch sensitive buttons.” The labelsdepend upon the setting beingcontrolled.
The analog setting subscreen is similar but offers an Auto/Manual radiobutton and value setting. An Auto/Manual selection is necessary to set themode to override. Subsequently, when an arrow key is depressed that newvalue is assumed.
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OperatorInterface
The mode override analog setting subscreen is similar but offers an Auto orManual radio button and value setting. An Auto or Manual selection isnecessary set to the mode to override. An Enter and Cancel Key will allow theuser 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 mustselect Day, Month, or Year and then use the up or down arrows to adjust.
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OperatorInterface
The time setpoint screen with a 12-hour format is shown below: The usermust 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 notshown.
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OperatorInterface
The DynaView™ Display Touch Screen Lock screen is shown below. Thisscreen is used if the Display and Touch Screen Lock feature is Enabled. 30minutes after the last key stroke this screen will be displayed and the Displayand Touch Screen will be locked out until “159enter” is entered.Until the proper password is entered there will be no access to the DynaView™
screens including all reports, all setpoints, and Auto and Stop and Alarms andInterlocks. The password “159” is not programmable from either DynaView™
or TechView™.
If the Display and Touch Screen Lock feature is Disabled, the following screenwill be automatically shown if the MP temperature is below 32°F (0°C) and ithas been 30 minutes after the last key stroke. Note: the main processor isequipped with an on-board temperature sensor which enables the iceprotection feature.
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Control Panel Internallymounted devicesFor visual identification InternalControl Panel mounted devices areidentified by their respectiveschematic designation number.Control panel items are marked onthe inner back panel in the controlpanel. Figure 24 illustrated below,identifies these devices. The ControlPanel Devices table corresponds tothe same device designators (seeright hand column). Optionalcontrols are present when a specificoptional controls package isspecified, as listed in the secondcolumn. Optional controls packagesare; OPST Operating Status, GBASGeneric Building Systems, EXOPExtended operation, CDRPCondenser Pressure, TRMM Tracercommunications, WPSR Water FlowPressure sensing, FRCL FreeCooling, HGBP Hot Gas Bypass , andEPRO Enhanced Protection
Figure 24 illustrates the Control PanelComponents Layout.
LLID Modules 1A1, 1A3, 1A4, 1A5,1A6, 1A7, and 1A13 are standard andpresent in all configurations. OtherModules vary depending on machineoptional devices.
InterprocessorCommunication
Inter ProcessorCommunications IPC3When using Tracer CH530, you willnot be required to know all thedetails about the structure of the IPC3bus. However this page givesdetailed information about thesystem for those of you that are reallyinterested in how it works. The IPC3protocol is based on RS485 signaltechnology. IPC3 was designed to bevery efficient. It communicates at 19.2Kbaud.
IPC3 Definitions:Bus Management:The DynaView™ provides the busmanagement having the task ofrestarting the link, or filling in formissing nodes when the normalcommunication has been degraded.This involves reassigning nodeaddresses and filling in for nodesthat are off-line. The DynaView™
always has a node number of 01.
Node Assignment:When a unit is factorycommissioned, the Low LevelIntelligent Device (LLID), or module,must have their node addressesassigned to them for storage in non-volatile memory. The node addressesare normally assigned sequentiallyduring factory commissioning.
Node Zero:
Node number zero is is a specialnode assignment that is reserved fordevices that are service selected. ALLID communicating on nodeaddress zero will also communicateon an assigned node address. A LLIDwill only communicate on nodeaddress zero if it is service selected.
Binding:Binding is the process of assigning anode number and functional IDs to aLLID. Binding is a simple process:1. Service selecting the LLID with a
magnet.2. Assigning functional IDs to that
LLID with TechView™.
Functional Identification:When each LLID on the bus is bound,its inputs and outputs are given afunctional ID. The Frame LLIDS haveonly one functional ID, but mostPanel LLIDs have more than onefunctional ID. A dual high voltagebinary input will have two functionalIDs, a quad relay output has fourfunctional IDs.
The DynaView™ Main Processor withits IPC3 Bus communicates to thecontrol panel devices, unit mounteddevices, and any remote devices onthe IPC3 bus network. The variousdevices are discussed in theupcoming sections.
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Figure 24. Control panel components layout
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Control Panel Devices
Standard DevicesControls Field Connection
Description Package Purpose Point Terminals
1A1 Power Supply Standard #1 Converts 24 vac to 24 vdc not for field use1A2 Power Supply (as required) #2 Converts 24 vac to 24 vdc not for field use1A3 Dual Relay Standard Relay #1 Oil Heater Relay not for field useOutput modules1A4 Dual High Standard High Pressure Cutout not for field useVoltage Input1A5 Quad Relay Standard Relay #1 Chilled water pump J2-4 NO, J2-5 NC,Output modules (Relay #1) J2-6 common1A5 Quad Relay Standard Relay #2 Condenser water pump control J2-1 NO, J2-2 NC,Output modules (relay #2) J2-3 common1A6 Dual High Standard Input 1 Condenser Flow Input J2-2 Condenser waterVoltage Input flow switch1A6 Dual High Standard Input 2 Evaporator Flow Input J3-2 Chilled waterVoltage Input flow switch1A7 High Power Standard Oil Pump and not for field useOutput Relay Refrigerant Pump1A13 Dual LV Binary Standard Signal #1 External Auto Stop, J2-1 Binary Input Signal #1, input module J2-2 Ground1A13 Dual LV Binary Standard Signal #2 Emergency stop J2-3 Binary Input Signal #2, input module J2-4 Ground1A26 Temp Sensor Standard Compressor Motor not for field useInput1F1 Standard LLID Power Supply Transformer not for field use
Primary Circuit protection1T1 Standard Control Panel Power not for field use
Transformer ; 120:24Vac1Q1 Standard Circuit Breaker Compressor not for field use
Motor Controller Control PowerBranch Circuit
1Q2 Standard Circuit Breaker - not for field usePurge System Branch Circuit
1Q3 Standard Circuit Breaker – not for field useModule [- LLID]Power Supply Branch Circuit
1Q4 Standard Circuit Breaker - not for field useOil System ControlBranch Circuit
1Q5 Standard Oil Pump Motor Branch not for field useCircuit protection
1X1 Terminal Block Standard Control Panel Terminal Block, 1X1-5 Chilled water flowFlow switch connections flow switch input
1X1-6 Condenser water flowswitch input
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Head Relief Request OutputWhen the chiller is running inCondenser Limit Mode or in SurgeMode, the head relief request relayon the 1A9–J2-6 to J2-4 will beenergized (1 minute default) and canbe used to control or signal for areduction in the entering condenserwater temperature. Designed toprevent high refrigerant pressure trip-outs during critical periods of chilleroperation.
If the unit is not equipped with theCDPR Enhanced Condenser LimitOption the unit will use thecondenser refrigerant temperaturesensor (input converted to saturatedrefrigerant pressure) to perform theStandard Condenser Limit function,
without the head relief request relay,by limiting inlet guide vane strokeand chiller capacity.
Keep in mind that Condenser LimitControl supplements the protectionprovided by the condenser pressurehigh pressure cutout switch 3S1.
Motor Temperature sensor moduleThe motor temperature module 1A26connects via unit wiring to the threemotor winding temperature sensors.This module is located in the controlpanel where the module is connectedto the IPC bus.
Default status relay selections areshown. Selections can be alteredusing service tool. Other choices are:Circuit 1 Running, Circuit 2 Running,Chiller Alarm, Circuit 1 Alarm, Circuit2 Alarm, and Purge Alarm.
Maximum Capacity RelayWhen the chiller has been operatingat maximum capacity for 10 minutes(TechView adjustable) this relay willactivate. Also upon being less thanmaximum capacity for 10 minutesthis relay will deactivate.
Compressor Running RelayRelay activates while compressor isrunning.
Machine Shutdown ManualReset (MMR)Limit warning machine shutdownauto reset relays will activate withsuch conditions for remote statusindication.
Control SystemComponents
OPST Operation Status OptionRelay output modules 1A8 and 1A9 provide relay defaults shown (For other selections, see Installation Manual):
1A8 Optional Quad Relay OPST Relay #1 Chiller Non-Latching Alarm J2-1 NO, J2-2 NC,Output Status J2-3 common1A8 Optional Quad Relay OPST Relay #2 Chiller Limit J2-4 NO, J2-5 NC,Output Status Mode Indicator J2-6 common1A8 Optional Quad Relay OPST Relay #3 Chiller Latching J2-7 NO, J2-8 NC,Output Status Alarm Indicator J2-9 common1A8 Optional Quad Relay OPST Relay #4 Chiller Running Indicator J2-10 NO, J2-11 NC,Output Status J2-12 common1A9 Optional Quad Relay OPST Relay #1 Chiller Maximum Capacity J2-1 NO, J2-2 NC,Output Status J2-3 common1A9 Optional Quad Relay OPST Relay #2 Chiller Head J2-4 NO, J2-5 NC,Output Status Relief Request J2-6 common1A9 Optional Quad Relay OPST Relay #3 Circuit 2 J2-4 NO, J2-5 NCOutput Status Purge Alarm to J2-6 common1A9 Optional Quad Relay OPST Relay #4 Circuit 1 J2-1 NO, J2-2 NC,Output Status Purge Alarm to J2-3 common
Chilled and Condenser WaterFlow Interlock Circuits
Proof of chilled water flow for theevaporator is made by the closure offlow switch 5S1 and the closure of
auxiliary contacts 5K1 on terminals1X1-5 and 1A6-J3-2. Proof ofcondenser water flow for thecondenser is made by the closure offlow switch 5S2 and the closure of
auxiliary contacts 5K2 on terminals1X1-6 and 1A6-J2-2.
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EXOP Extended Operation OptionThe following modules (1A17, 1A18, and 1A19) are provide when this control package is specified.
1A5 Quad Relay EXOP Relay #4 Ice Building Relay J2-10 NO, J2-11 NC,Output module J2-12 common1A17 Optional Dual Analog EXOP Signal #1 External Base Loading J2-1 Output #1,Input/Output Module Setpoint input J2-3 Ground1A17 Optional Dual Analog EXOP Signal #2 Refrigerant monitor inputs J2-4 Output #2,Input/Output Module J2-6 Ground1A18 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 Ground1A18 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 Ground1A19 Optional Dual LV EXOP Signal #1 Ice Building Control J2-1 Binary Input Signal #1,Binary input module Enable or Disable input point J2-2 Ground
Refrigerant Monitor Input 1A17Analog type input 4-20ma input signal to the 1A17 J2-4 to J2-6 (ground). This represents 0-100 ppm.
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TRMM TRM4 (Tracer Comm 4 interface)
1A14 Optional TRM4 Tracer Communications J2-1 COMM+, J2-2 COMM -J2-3,Communication or COMM +J2-4, COMM -,Interface Module LCI-C
CDRP (Condenser Refrigerant Pressure Output)
1A15 Optional Dual Analog CDRP Signal #2 Condenser Refrigerant J2-4 Output #2, J2-6 GroundInput/output Module Pressure output
EPRO (Enhanced Protection)
4R22 EPRO Condenser Refrigerant Pressure Transducer4R16 EPRO Compressor Discharge Refrigerant Temperature Sensor. (This is also included with HGBP).4R1 EPRO Inboard Bearing Temperature Sensor4R2 EPRO Outboard Bearing Temperature Sensor
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CDRP Refrigerant PressureOutput Option 1A15:Refrigerant Pressure Output can beconfigured at commissioning tocorrespond to either A) the absolutecondenser pressure, or B) thedifferential pressure of the evaporatorto condenser pressures.
This vdc output is located at 1A15 –J2 – 4 (+) to J2-6 (Ground)
The Voltage DC Output can source amaximum of 22 mA of current.
This output is Voltage DC only, 4-20mA is not supported.
A) Condenser Pressure Output.2 to 10 Vdc corresponds to 0 Psia tothe HPC (in Psia) setting.
Note: CH530 control allows for DeltaPressure, or, condenser pressure butnot both on one circuit.
Temperature basedOn standard machines the PercentCondenser Pressure IndicationOutput is based on the SaturatedCondenser Refrigerant and atemperature to pressure conversionis made.
If the Condenser SaturatedTemperature goes out of range due toan open or short, a pressure sensordiagnostic will be called and theoutput will also go to the respectiveout of range value. That is, for an outof range low on the sensor, theoutput will be limited to 2.0 VDC. Foran out of range high on the sensor,the output will be limited to 10.0VDC.
Pressure basedWith the Enhanced Protection EPROoption, a condenser pressuretransducer is installed and thepressure is measured.
If the Condenser Pressure sensorgoes out of range due to either anopen or short, a pressure sensordiagnostic will be called and theoutput will go to end of range low.That is, for an out of range low on thesensor, the output will be limited to2.0 VDC. For an out of range high onthe sensor, the output will be limitedto 2.0 VDC.
Figure 25. Condenser pressure based output
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B) Refrigerant Differential PressureIndication Output:A 2 to 10 VDC analog output isprovided instead of the previouscondenser pressure output signal.This signal corresponds to apredetermined minimum andmaximum pressure settings setup atcommissioning of this feature. Thisrelationship can be altered using theservice tool if required.
The “Minimum Delta Pressure “ istypically set to 0 psi and will thencorrespond to 2 vdc. The “MaximumDelta Pressure “ is typically set to 30psi and corresponds to 10 vdc.
The Minimum Delta PressureCalibration setting has a range of 0-400 psid (0-2758 kPa) in increments of1 psid (1kPa). The Maximum DeltaPressure Calibration setting has arange of 1-400 psid (7-2758 kPa) in
Figure 26. Delta pressure setting - differential pressure based output(Defaults shown)
increments of 1 psid (1kPa). Thecondenser refrigerant pressure isbased on the Condenser RefrigerantTemperature sensor if the CondenserPressure Option is selected as “NotInstalled” at the display.
The evaporator refrigerant pressure isbased on the Saturated EvaporatorRefrigerant Temperature Sensor.
See CTV-PRB006-EN for additionalinformation about condenser watertemperature control.
Note: In this example, 2 vdc corresponds to OPSI differential and 10 vdccorresponds to 30 psi differential. The minimum value of 0 psi, andmaximum value of 30 psi are individually adjustable via the service tool.
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GBAS (Generic Building Automation System)
1A15 Optional Dual GBAS Signal #1 Percent RLA Compressor Output J2-1 Output #1, J2-3 GroundAnalog Input/output Module1A16 Optional Dual GBAS Signal #1 External Current limit Setpoint J2-2 Input #1, J2-3 GroundAnalog Input/output Module1A16 Optional Dual GBAS Signal #2 Chilled Water Reset input, J2-5 Input #2, J2-6 GroundAnalog Input/ or External Chiller Water Setpointoutput Module
Percent RLA Output 2 to 10 Vdc corresponding to 0 to120% RLA. With a resolution of0.146%. The Percent RLA Outputconnections are on the terminals1A15 –J2-1 (+) to J2-3 (Ground). ThePercent RLA Output is polaritysensitive.
The following graph illustrates theoutput:
Figure 27. Voltage versus percent RLA
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External Chilled WaterSetpoint (ECWS)The External Chilled Water Setpointallows the chilled water setpoint tobe changed from a remote location.The External Chilled Water Setpointis found on 1A16 J2-5 to J2-6(Ground). 2-10 vdc and 4-20 macorresponds to a default 34°F to 65°F(-17.8 to 18.3°C) adjustable via servicetool.
External Current Limit SetpointThe External Current Limit is anoption that allows the current limitsetpoint to be changed from a remotelocation. The External Limit Setpointis found on 1A16 J2-2 to J2-3(ground), 2-10 vdc and 4-20 ma eachcorrespond to a 40 to 100 percentRLA range. UCP limits the maximumECLS to 100 percent.
Default 40 to 100%, adjustable viaservice tool.
WPSR (WFC Water Pressure Sensing Option)
1A21 Optional Dual WPSR = WFC Signal #1 Evaporator Differential Not for field useAnalog Input or output Water PressureModule1A21 Optional Dual WPSR = WFC Signal #2 Condenser Differential Not for field useAnalog Input or output Water PressureModule
Module Characteristics
1A1, 1A2 Power Supply :Unit Control Power Supply ModuleConverts 27 vac to 24 vdc.
Power Input Voltage: 23VRMSminimum, 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 24VDC, Rated Current 2.44 Amps.
Fused at 3 amps(FUS01513)
1A3, 1A5, 1A10 Dual Relay Outputmodules :Relay #1 J2-1 NO, J2-2 NC, J2-3common
Relay #2 J2 4 NO, J2-5 NC, J2-6common
Relay Outputs at 120 VAC: 7.2 Ampsresistive, 2.88 Amps pilot duty, 1/3HP, 7.2 FLA at 240 VAC: 5 Ampsgeneral purpose, 14 - 26 AWG with amaximum of two 14 AWG.
Power, 24 +/- 10 percent VDC, 60 mAmaximum, Trane IPC3 protocol. J1-1+24VDC, J1-2 Ground, J1-3 COMM +J1-4 COMM -
1A4, 1A6 Dual High Voltage Binaryinput module:Binary Input Signal #1 J2-1 to 2
Binary Input Signal #2 J3-1 to 2
High Voltage Binary Input: OffVoltage: 0 to 40 VAC RMS , OnVoltage: 70 to 276 VAC RMS
Input is not polarity sensitive (Hotand neutral can be switched), Inputimpedance 130K to 280K ohms
14 - 26 AWG with a maximum of two14 AWG
Power, 24 +/- 10 percent VDC, 20 mAmaximum. Trane IPC3 protocol. J1-1+24VDC, J1-2 Ground, J1-3 COMM +,J1-4 COMM -
1A7 High Power Output ModuleRelay contacts at 120 VAC:
16 amps resistive, 6.4 amps,pilotduty, 1 HP
J2-14-26 awg witha maximum of two14 awg
J2-1 J2-2 no, J2-3 NC, J2-4 com
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1A8, 1A9, 1A11, 1A12 Quad RelayOutput Status:Relay #1 J2-1 NO, J2-2 NC, J2-common
Relay #2 J2-4 NO, J2-5 NC, J2-6common
Relay #3 J2-7 NO, J2-8 NC, J2-9common
Relay #4 J2-10 NO, J2-11 NC, J2-12common
Relay Outputs: at 120 VAC: 7.2 Ampsresistive, 2.88 Amps pilot duty, 1/3HP, 7.2 FLA, at 240 VAC: 5 Ampsgeneral purpose 14-26 AWG, two 14AWG Maximum Power, 24+/-10 percent VDC, 100 mamaximum. Trane IPC3 protocol.
1A13, 1A18, 1A19, 1A20 Dual Binaryinput module:J2-1 Binary Input Signal #1, J2-2Ground, J2-3 Binary Input Signal #2,J2-4 Ground
Binary Input: Looks for a dry contactclosure. Low Voltage 24V 12 mA.
14 - 26 AWG with a maximum of two14 AWG
Power, 24 +/- 10 percent VDC, 40 mAmaximum Trane IPC3 protocol.
1A14 Communication interfaceModulePower, 24 +/- 10 percent VDC, 50 mAmaximum. Trane IPC3 protocol.
J1-1 +24 VDC J2-1 COMM +. J11-1+24 VDCJ1-2 Ground J2-2 COMM - J11-2 GroundJ1-3 COMM + J2-3 COMM + J11-3 COMM +J1-4 COMM - J2-4 COMM - J11-4 COMM -
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1A15, 1A16, 1A17, 1A21 Dual AnalogInput/output Module;Analog Output: The Analog Output isa voltage only signal. 2-10 Vdc at22mA
J2: 14 - 26 AWG with a maximum oftwo 14 AWG
J2-1 Output #1 to J2-3 (Ground), J2-4Output #2 to J2-6 (Ground).
UCP provides a 2-10 Vdc analogsignals as Outputs. The Output’smaximum source capability is 22mA.The maximum recommended lengthto run this signal is included in thetable below.
Recommended Length to Run external Output signals
Gauge Ohms per Feet Length (Feet) Maximum Length (Meters)14 0.00 2823 1062.7 32416 0.004489 668.3 203.818 0.007138 420.3 128.120 0.01135 264.3 80.622 0.01805 166.3 50.724 0.0287 104.5 31.926 0.04563 65.7 2028 0.07255 41.4 12.6
Note: the above table is for copper conductors only.
Analog Input:The analog input can be softwareswitched between a voltage input ora current input. When used as acurrent input a 200 Ohm load resistoris switched in.
2-10 Vdc or 4-24 mA Analog InputsUCP accepts either a 2-10 Vdc or 4-20analog input suitable for customerexternal control. The type isdetermined at unit commissioningduring feature installation.J2: 14 - 26 AWG with a maximum oftwo 14 AWGJ2-2 Input #1 toJ2-3 (Ground).J2-5 Input #2 toJ2-6 (Ground).Power, 24 +/- 10 percent VDC, 60 mAmaximum, Trane IPC3 protocol.
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Unit mounted devices
Vane Actuator ControlThe Stepper Module within thestepper vane actuator (4M2) (and 4M4extended capacity) pulses a DCvoltage to the windings of theStepper Motor Actuator(s) to controlinlet guide vane position. Whileoperation of this stepper motor isautomatic, manual control ispossible by going to the ModeOverrides settings menu within theDynaView™. Compressor ControlSignal allow the operator to manuallyincrease or decrease the compressorload by adjusting the compressorcontrol signal.
Note: If the chiller is operating in alimit mode (current limit, condenserlimit, evaporator limit, etcetera.) Thelimit operation has priority over allDynaView™ manual modes ofoperation.
On each UCP power-up, the inletguide vanes are driven full closed torecalibrate the zero position (Steps)of the Stepper motor vane actuator.
Temperature sensors,Evaporator sensors 4R6 and 4R7, andcondenser sensors 4R8, 4R9 enteringand leaving, bearing temperaturesensors 4R1, 4R2, oil temperaturesensor 4R5, outdoor air temperature4R13, and evaporator 4R10 andcondenser 4R11 saturated refrigeranttemperature sensors.Probe Operating Temperature Range -40 to 250°F (-40 to 121oC)Accuracy +/- 0.25oC over the range -4to 122°F (-20 to 50oC), +/- 0.50oC overthe range -40 to 250°F (-40 to 121oC)Power and Communications andTerminations Power 24 +/- 10% VDC,20 mA maximum.Trane IPC3 protocolCommunications.
Pressure sensorsOil tank sump 4R4 and oil pumpdischarge 4R3, evaporator andcondenser refrigerant pressure 4R22,Working Pressure Range: 0 to 50 PsiaAccuracy: ± 0.3% of full scale outputat 68°F (20°C)Power and Communications andTerminationsPower 24 +/- 10% VDC, 20 mAmaximum.Communications, RS485 PhysicalLayer, 19.2 Kbaud, Trane IPC3protocol.
Starter ModuleIn the hierarchy of modules theStarter module 2A1 (1A23 whencustomer supplied starter specified)is second only to the DynaView™.The starter module is present in allstarter selections (except AFD) .Thisincludes Wye Delta, Across the Line,Solid State whether remote unitmounted or supplied by others. Thestarter module provides the logic toprovide the motor protection forCurrent overload, phase reversal,phase loss, phase imbalance, andmomentary power loss. Thesefunctions are discussed in the motorprotection section of this manual.
EarthWise™ PurgeTrane has also revolutionized itscontroller-integrated purge, whichfeatures an automatic regenerationsystem for high-efficiency,maintenance-free refrigerantcontainment. Air andnoncondensables are pumped outfaster, and the lower temperaturerefrigeration system enhances thebase purge efficiency. See EarthWisepurge operation and maintenancemanual for details.
Unit-mounted medium - voltagestarterTake advantage of Tracer CH530’snew starter and save space in yourequipment room. There is no needfor a remote or floor-mounted starterwith our new, exclusive unit-mounted medium - voltage starterfrom Cutler-Hammer.
The following two figures illustratethe typical location of variousstandard and optional unit mountedcontrol and sensor devices.
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Control SystemComponents
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Control SystemComponents
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Electrical SequenceThis section will acquaint theoperator with the control logicgoverning CDHF/CDHG chillersequipped with Tracer CH530 UCPbased control systems. Whenreviewing the step-by-step electricalsequences of operation, refer to thetypical wiring schematics for Unitmounted Wye Delta starter shown inthe installation manual shipped withthe chiller.
Note: The typical wiring diagramsare representative of standard unitsand are provided only for generalreference. They may not reflect theactual wiring of your unit. Forspecific electrical schematic andconnection information, always referto the wiring diagrams that shippedwith the chiller.
With the supply power disconnectswitch or circuit breaker (2Q1 or 2K3)closed, 115-volt control powertransformer 2T5 and a 40-amp starterpanel fuse (2F4 ) to terminal (2X1-1)starter panel to terminal 1X1-1 in thecontrol panel. From this point,control voltage flows to:
1. Circuit Breaker 1Q1 whichprovides power to the startermodule (2A1) relay outputs and theHigh Pressure Cutout switch (3S1).
2. Circuit Breaker 1Q2 whichprovides power to the Purgecircuitry.
3. Circuit Breaker 1Q3 whichprovides power to Transformer(1T1) which steps down the 115Vac to 24 Vac. This 24 Vac thenpowers the 24 Vdc power supply1A1, and 1A2 if present. The 24 vdcis then connected to all modulesvia the Interprocessorcommunications Bus providingmodule power.
1Q3 also provides power to theexternal chiller water proof of flowdevice connected between terminalblock 1X1-5 to 1A6-J3-2, andcondenser water proof of flowdevice connected at 1X1-6 to 1A6-J2-2.
4. Circuit Breaker 1Q4 whichprovides power to the Oil Heater4HR1 circuit and to circuit breaker1Q5 oil and refrigerant pumpcircuits.
5. The DynaView™ display module1A22, receives 24 vdc power fromthe IPC bus.
UCP and Wye-Delta StarterControl CircuitsLogic Circuits within the variousmodules will determine the starting,running, and stopping operation ofthe chiller. When operation of thechiller is required the chiller mode isset at ‘‘Auto’’. Using customersupplied power, the chilled waterpump relay (5K1) is energized by the1A5 Module output at 1A5-J2-4, andchilled water flow must be verifiedwithin 4 minutes 15 seconds by the1A6 Module. The main processorslogic decides to start the chillerbased on the differential to startsetpoint. With the differential to startcriteria met module 1A5 thenenergizes condenser water pumprelay (5K2) via customer suppliedpower at 1A5 J2-1.
Based on the restart inhibit functionand the differential to start setpoint,oil and refrigerant pump (4M3) willbe energized by 1A7 Module (1A7-J1).The oil pressure must be at least 9Psid for 30 continuous seconds andcondenser water flow verified within4 minutes 15 seconds minutes for thecompressor start sequence to beinitiated.
Control Sequenceof Operation
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When less than 5 seconds remainbefore compressor start, a starter testis conducted to verify contactorstates prior to starting thecompressor. The following test orstart sequence is conducted for‘‘Wye-Delta’’ starters: Also refer toFigure 24.
A. Test for transition completecontact open (2A1-J12-2) –160 to 240msec. An MMR diagnostic will begenerated if the contact is closed.
B. Delay time - 20 msec.
C. Close start contactor (2K1) andcheck for no current - 500 msec. Ifcurrents are detected, the MMRdiagnostic ‘‘Starter Fault Type I’’ isgenerated.
D. Stop relay (2A1-J10-3 to 1) closesfor one second for test “C” above.
E. Delay time - 200 msec. (Opens2K1).
F. Close shorting contactor, (2K3) andcheck for no current - one second. Ifcurrents are detected the MMRdiagnostic ‘‘Starter Fault Type II’’ isgenerated. (Starter Integrity test)
G. If no diagnostics are generated inthe above tests, the Stop Relay (2A1-J10) is closed for 2 seconds and theStart Relay (2A1-J8) is closed toenergize the start contactor (2K1). Theshorting contactor (2K3) has alreadybeen energized from (F) above. Thecompressor motor (4M1) starts in the‘‘Wye’’ configuration, an auxiliarycontact (2K1-AUX) locks in the startcontactor (2K1) coil. Additonally,2K11 pulls in to hold the oil pumpon. This is parallel to 1A7 contacts.
H. After the compressor motor hasaccelerated and the maximum phasecurrent has dropped below 85percent of the chiller nameplate RLAfor 1.5 seconds, the starter transitionto the ‘‘Delta’’ configuration isinitiated.
J. The transition contactor (2K4) isclosed through relay 2A1-J2, placingthe transition resistors (2R1, 2R2, and2R3) in parallel with the compressormotor windings.
K. The shorting contactor (2K3) isopened through the opening of relay2A1-J4 100 msec after the closure ofthe transition relay 2A1-J2.
L. The run contactor (2K2) is closedthrough relay 2A1-J6, shorting outthe transition resistors 260milliseconds after the opening of theshorting relay 2A1-J4. This places thecompressor motor in the ‘‘Delta’’configuration and the starter modulewaits to look for this transition for2.35 seconds through the closure ofthe transition complete contacts 2K2-Aux at module 2A1-J12 input)
M. The starter module must nowconfirm closure of the transitioncomplete contact (2K2-AUX) within2.32 to 2.38 seconds after the runrelay (2A1-J6) is closed. Finally, thetransition relay (2A1-J2) is opened de-energizing the transition contactor(2K4) and the compressor motorstarting sequence is complete. AnMMR diagnostic will be generated ifthe transition complete contacts (2K2-AUX) do not close. A diagram of thistest or start sequence is shown inFigure 24.
Control Sequenceof Operation
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Now that the compressor motor(4M1) is running in the ‘‘Delta’’configuration, the inlet guide vaneswill modulate, opening and closingto the chiller load variation byoperation of the stepper vane motoractuator (4M2) 4M4 (extendedcapacity) to satisfy chilled watersetpoint. The chiller continues to runin its appropriate mode of operation:Normal, Softload, Limit Mode,etcetera. As explained in the GeneralInformation section.
If the chilled water temperature dropsbelow the chilled water set point byan amount set as the ‘‘differential tostop’’ setpoint, a normal chiller stopsequence is initiated as follows:(Refer to Figure 10.)
1. The inlet guide vanes are drivenclosed for 50 seconds.
2. After the 50 seconds has elapsed,the stop relay (2A1-J10) and thecondenser water pump relays (1A5-J2) open to turn off. The oil andrefrigerant pump motor (4B3) willcontinue to run for 3 minutes postlube while the compressor coaststo a stop. The chilled water pumpwill continue to run while the Mainprocessor module (1A22) monitorsleaving chilled water temperaturepreparing for the next compressormotor start based on the‘‘differential to start’’ setpoint.
If the STOP key is pressed on theoperator interface, the chiller will
follow the same stop sequence asabove except the chilled water pumprelay (1A5-J2) will also open and stopthe chilled water pump after thechilled water pump delay timer hastimed out after compressor shutdown.
If the “Immediate Stop” is initiated, apanic stop occurs which follows thesame stop sequence as pressing theSTOP key once except the inlet guidevanes are not sequence closed andthe compressor motor is immediatelyturned off.
Control Sequenceof Operation
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Interval Minimum Maximum Units Actual DesignA. (Test for transition completeinput open) 160 to 240 millisecondsB. (Just delay time) 20 millisecondsC. (Close 1M (2K1) Contactor and testfor no current.) (Starter integrity test) 500 millisecondsD. (Hold 1M (2K1) Contactor and testfor no current.) (Starter integrity test) 1 secondE. (Open 1M (2K1) Delay time 200 millisecondsF. (Close Shorting Contactor (2K3) andand test for no current, then wait forStart command.) (Starter integrity test) 100 milliseconds 1 second (Minimum)G. (Close 1M (2K1 and 2K11) 2.0 second 2 secondH. (Wait 1.5 seconds after phase currentsdrop to 85 percent) 1 2 second 1.5 secondJ. (Begin Transition sequence) 85 100 milliseconds 100 millisecondsK. (Open S (Shorting) Contactor) 250 300 milliseconds 260 millisecondsL. (Close 2M (2K2) Contactor 140 millisecondsM. (Wait to look for Transition complete) milliseconds 2.32 to 2.38 secondN. (Filtering time on Transitioncomplete input) milliseconds 160 to 240 milliseconds
Figure 24. Test and start timing sequence
Timing requirements to operate the“Stop”, “Start”, “Short”,“Transition”, and “Run” contactclosure outputs are shown below.Prior to closing the “Short” contact,the transition complete input shall beverified to be open, otherwise anMMR diagnostic shall be generated.
Control Sequenceof Operation
Steps A to F: Starter Integrity TestSteps G to N: Starter Timing
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Current passing through circuitbreaker 1Q5 reaches 2 normally openparallel sets of contacts: those ofrefrigerant and oil pump relay (1A7-J2-5 to 1), and the 2K11 interlockingrelay. Connected at module 1A7-J2-2to 4.
Note: While the (1A7-J2-5 to 1) relayautomatically is closed by the mainprocessor 1A22 as a part of the startsequence. It can also be closedmanually by changing the oil pumpstatus to “ON” in the manual override mode menu of DynaView™.
Closure of the (1A7-J2-5 to 1), or 2K11contacts also allows current to passthrough the coil of the refrigerant
pump starter relay (4K8), to the startwindings of the refrigerant pump.When motor 4M3 first starts, currentdraw is high: This causes currentsensing relay 4K8 to close itsnormally open contacts and pull in ofpump Capacitor 4C1. Increasingmotor speed and related decreasingcurrent through the main windingand relay coil reduce the magneticforce and the armature “Drops out”to open the start contacts anddisconnect the start windings andcapacitor. Current now flows only tothe Run windings of the oil pumpmotor or refrigerant and oil pumpmotor.
Control Sequenceof Operation
Maximum AccelerationTimer Setting
by Starter TypeWye-Delta 27 SecondsAuto-Transformer 16Primary Reactor 16Across the Line 6Solid State 15AFD 30
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Momentary Power Loss (MPL)Protection.Improved power measurement andprotection algorithms allow the unitto accommodate more poweranomalies than ever. If the chillermust shut down, faster restarts getthe machine up and running as soonas possible.
Momentary power loss (MPL) detectsthe existence of a power loss to thecompressor motor and responds byinitiating the disconnection of thecompressor motor from the powersource. Power interruptions of lessthan 30 line-cycles are defined asmomentary power losses. Tests haveshown that these short-term power
interruptions can be damaging to themotor and compressor if the chilleris reconnected to the line while themotor and line phases do not match.The chiller will be shut down when aMPL is detected and will display anon-latching diagnostic indicatingthe failure. The oil pump will be runfor the post-lube time period whenpower returns. The compressor andcompressor motor are protected fromdamage from large torques andinrush currents resulting fromreconnecting the compressor motorto the power source following amomentary loss of power.
MPL’s greater than 2 or 3 cycles aredetected resulting in unit shut down.Disconnection from the line isinitiated within 6 line cycles of thepower loss. MPL protection is activeanytime the compressor is in therunning mode. (The transitioncomplete input has been satisfied).
MPL is enabled however can bedisabled, if required via the servicetool.
Figure 29. Sequence of operation: momentary power loss, (DynaView™ and starter module remain powered)
Machine Protectionand AdaptiveControl
Enforce Stop to Start Timer(5 to 200 Seconds 7 Sec is Default)
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Current Overload ProtectionMotor currents are continuouslymonitored for over current protectionand locked rotor protection. Thisprotects the Chiller itself fromdamage due to current overloadduring starting and running modesbut is allowed to reach full loadamps. This overload protection logicis independent of the current limit.The overload protection willultimately shut the unit downanytime the highest of the threephase currents exceeds the time-tripcurve. A manual reset diagnosticdescribing the failure will bedisplayed.
Overload protection for the motorstarts based on the Maximum Timeto Transition permitted for aparticular motor .
Running Over Current Protection
In the run mode, a “time-to-trip”curve is looked at to determine if adiagnostic should be called. TheUCP continuously monitorscompressor line currents to providerunning over current and locked rotorprotection. Over current protection isbased on the line with the highestcurrent. It triggers a manuallyresettable diagnostic shutting down
the compressor when the currentexceeds the specified time-trip curve.The compressor overload time tripcurve is expressed as a percent of theRated Load Amps of the compressorand is not adjustable:
Overload Must Hold = 102 PercentRLA.Overload Must Trip in 20 (+0 -3)seconds = 112 Percent RLA(Note the above gives a nominal 20second must trip point of 107 PercentRLA.)Overload Must Trip in 1.5 seconds =140 Percent RLA (Nominal)
The linear time-trip curve is asfollows:
Figure 30. Overload trip time versus percent RLA
The Maximum Acceleration TimeSetting and Current TransformerSetting are factory set however canbe set with the service tool;
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Current Limit ProtectionCurrent Limit Protections exist toavoid motor current overload anddamage to the compressor motorduring starting and running.Compressor motor current iscontinuously monitored and currentis controlled via a limit function thatto prevent running into over currentdiagnostic trips.
The current limit control logicattempts to prevent the motor fromshutting down on a diagnostic trip bylimiting compressor current drawrelative to an adjustable current limitDynaView™ Current Limit Setpoint.This setpoint can also be lowered toprovide electrical demand limiting onthe unit as required. This could alsobe set to allow the Chiller to continueto run at a lower load to avoidtripping off via a diagnostic.
The Current Limit function uses a PIDalgorithm (Similar to the LeavingWater Temperature control) thatallows the chiller to run at theCurrent Limit Setpoint. At machinestartup, or with any setpoint changethe new current limit setpointreached after the is filtered setpointtime elapses. The minimum currentlimit setpoint is default set to 40percent RLA (20-100 percent). Thefiltering time is default set to 10minutes (0-120 minutes), howeverthese can be altered via the servicetool. This filtered setpoint allows forstable control if the Current Limitsetpoint is adjusted during a run.
The Current Limit Setpoint (CLS) canbe changed from: Front Panel,External Analog input (with GBAS(external) option), or Tracer (Traceroption). However, If present Tracercurrent setpoint has the highestpriority, unless disabled in theDynaView™ Setpoint source overridemenu. The External CLS has secondpriority, and will be used if Tracer isdisabled or not installed. The FrontPanel Setpoint has the lowestpriority, and will be used if Tracerand the External CLS are bothdisabled.
Phase Loss ProtectionLoss of phase detection protects thechiller motor from damage due to asingle-phasing condition. Thecontrols will shut down the chiller ifany of the three phase currentsfeeding the motor are lost. Theshutdown will result in a latchingdiagnostic indicating the failure. Themotor is protected from over-currentduring a single-phase condition bythe Current Overload Protectionfeature. Phase Loss Protectionprovides redundant protection and adiagnostic that more accuratelydescribes the fault.
Reverse Rotation ProtectionThis function protects thecompressor from being driven in thereverse direction. Incorrect phaserotation detection results in amanually resettable diagnostic.Phase Reversal protection is defaultto Enable, however can be disabledvia the service tool.
Machine Protectionand AdaptiveControl
75CDHF-SVU01C-EN
Differential to Start or StopThe Differential to Start setpoint isadjustable from 1 to 10°F (0.55 to5.55°C) and the Differential to Stopsetpoint adjustable from 1 to 10°F(0.55 to 5.55°C). Both setpoints arewith respect to the Active ChilledWater Setpoint. When the chiller isrunning and the LWT (Leaving WaterTemperature) reaches the Differentialto Stop setpoint the chiller will gothrough its shutdown sequence toAUTO. (Refer to Figure 10.)
SoftLoadingSoftloading stabilizes the startupcontrol during the initial chillerpulldown. Soft loading is used tobring the building loop temperaturefrom its start value to the ChilledWater or Hot Water Setpoint in acontrolled manner. Without softloading, the chiller controls will loadthe chiller rapidly and use the fullchiller capacity to bring the looptemperature to setpoint. Although thestart temperature of loop may havebeen high, the actual system loadmay be low. Thus, when the setpointis met the chiller must unloadquickly to the system load value. If itis not able to unload quickly enough,the supply water temperature will
drop below setpoint and may evencause the chiller to cycle off. Softloading prevents the chiller fromgoing to full capacity during thepulldown period. After thecompressor has been started, thestarting point of the filtered setpointis initialized to the value of theEvaporator Leaving Watertemperature and the percent RLA.
There are three independent Softloadsetpoints:• Capacity Control Softload Time
(default to 10 minutes, 0-120minutes) This setting controls thetime constant of the Filtered ChilledWater Setpoint.
• Current Limit Control Softload Time(default 10 minutes; 0-120 minutes)This Setting controls the timeconstant of the Filtered CurrentLimit Setpoint.
• Current Limit Softload StartingPercent (default is 40 percent RLA;20-100 percent): This settingcontrols the Starting point of theFiltered Current Limit Setpoint
Service tool provides access to thesethree setpoints, if it is determinednecessary to change from thedefaults.
Softloading is not active during IceMaking or during the Ice To normalTransition. Softloading will beenabled after the Ice to normalTransition timer has expired.
Minimum and Maximum CapacityLimitA Minimum Capacity can be set tolimit the unloading ability of thecompressor thus forcing differentialto stop to be reached cycling thechillers. Minimum capacity limit willbe displayed when in this limitmode. This indicates when the chilleris running fully unloaded.
Similarly a maximum capacity can beset to limit normal chilled watertemperature control, the maximumcapacity relay is energized which is asignal used by generic BAS systemsto start another chiller.
The minimum (default at 0 percent)and maximum (default at 100 percent)capacity are adjustable via the servicetool.
Machine Protectionand AdaptiveControl
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Evaporator LimitEvaporator refrigerant temperature iscontinuously monitored to provide alimit function that prevents lowrefrigerant temperature trips whichallows the chiller to continue to runat a reduced load instead of trippingoff at the Low Evaporator RefrigerantTemperature Cutout Setpoint (LRTC).
Evaporator limit could occur with aninitial pull down of a loop where theCondenser is colder than theEvaporator (Inverted Start), theEvaporator refrigerant temperaturemay drop below the Low RefrigerantTemperature Cutout (LRTC). This limitprevents the unit from shutting downon a diagnostic during this type ofpulldown. Another example is aChiller that is low on refrigerantcharge will run with low Evaporatorrefrigerant temperatures. This limitallows the chiller to continue to runat a reduced load.
Evaporator Limit uses the EvaporatorRefrigerant Temperature sensor in aPID algorithm (Similar to the LeavingWater Temperature control) thatallows the chiller to run at the LRTC +2 degree F.
When actively limiting machinecontrol “Evaporator TemperatureLimit” will be displayed as a sub-operating mode.
Leaving Water TemperatureCutoutLeaving water temperature cutout is asafety control that protects the chillerfrom damage caused by waterfreezing in the evaporator. The cutoutsetpoint is factory set however isadjustable with the Service tool.
The “Leaving Water TemperatureCutout Setpoint” is independentlyadjustable from the chilled watersetpoint and factory set. Shutdown ofthe compressor due to violation ofthe Leaving Water Temperature
Cutout results in an automaticallyresettable diagnostic (MAR). TheDynaView™ Operating Modeindicates when the “Leaving WaterTemperature Cutout Setpoint”conflicts with the chilled watertemperature setpoint by a messageon the display. The “Leaving WaterTemperature Cutout Setpoint” andchilled water setpoint, both activeand front panel, are separated by aminimum of 1.7°F. See CutoutStrategy, Figure 27. When eitherdifference is violated, the UCP doesnot permit the above differences tobe violated and the display exhibits amessage to that effect and remains atthe last valid setpoint. After violationof the “Leaving Water TemperatureCutout Setpoint” for 30°F seconds thechiller will shutdown and indicate adiagnostic.
Machine Protectionand AdaptiveControl
77CDHF-SVU01C-EN
Low Refrigerant TemperatureCutoutThe purpose of the low evaporatorrefrigerant temperature protection isto prevent water in the evaporatorfrom freezing. When the LowEvaporator Refrigerant TemperatureCutout (LRTC) trip point is violated, alatching diagnostic indicating thecondition is displayed. The LowEvaporator Refrigerant TemperatureDiagnostic is active in both theRunning and Stopped modes.
The Low Evaporator RefrigerantCutout Setpoint is factory set to 36°F.This can be altered via the servicetool. A Service Tool adjustablesetpoint that should be based on thepercentage of antifreeze used in thecustomer’s water loop. The Service
tool will display a warning messagesuch as “Warning: AdequateAntifreeze required” for anyEvaporator Refrigerant TemperatureCutout below 28°F and any LeavingWater Temperature Cutout below35°F.
The percent of antifreeze required is afunction of the leaving watertemperature setpoint and the worsecase (lowest permitted water flow)approach temperatures of thechiller’s evaporator design.
Head Relief RelaySurge, condenser limit, and certainconditions in ice mode can energizethe head relief relay. Note: There is aTechView programmable head reliefrelay filter time setpoint. The defaultis 1 minute.
Machine Protectionand AdaptiveControl
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Figure 31. Cutout strategy
Machine Protectionand AdaptiveControl
Limit Loading: The potential to limit loading increases as the saturatedevaporator temperature approaches the evaporator limit setpoint.
Unload: The potential to unload increases as the saturated evaporatortemperature 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)
79CDHF-SVU01C-EN
Condenser LimitCondenser pressure is continuouslymonitored to provide a limit functionthat prevents High Pressure Cutout(HPC) trips. This protection is calledCondenser Refrigerant PressureLimit, or High Pressure Limit. A fullyloaded compressor, operating at highEvaporator Leaving WaterTemperature (ELWT) and highcondenser temperatures causes highcondenser pressures. The purpose ofthis limit is to avoid High PressureCutout (HPC) trips by allowing theChiller to continue to run at a lowerload instead of tripping off via HPC.
The Condenser Limit will be basedfrom a pressure conversion from theCondenser Refrigerant Temperaturesensor, unless there is a CondenserRefrigerant Pressure sensor installed(CDRP option). If the CondenserRefrigerant Pressure Sensor isinstalled, then the limit will be basedfrom the Pressure sensor.
When limited by this action,“Condenser Pressure Limit” will bedisplayed as a sub-operating mode.The Condenser Limit Setpoint isfactory set (93 percent of HPC),however can be altered via theservice tool.
Machine Protectionand AdaptiveControl
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Restart InhibitThis function provides short cycleprotection for the motor, andindirectly also short cyclingprotection for the starter since thestarter is designed to operate themotor under all the conditions ofmotor performance.
The operation of the restart inhibitfunction is dependent upon twosetpoints. The Restart Inhibit FreeStarts (1-5, 3 default), and the RestartInhibit Start to Start Timer (10-30min,20 default). These settings areadjustable via the service tool.
Restart Inhibit Free StartsThis setting will allow a number ofrapid restarts equal to its value. If thenumber of free starts is set to “1”,this will allow only one start withinthe time period set by the Start toStart Time Setting. The next start willbe allowed only after the start to starttimer has expired. If the number offree starts is programmed to “3”, thecontrol will allow three starts in rapidsuccession, but thereafter, it wouldhold off on a compressor start untilthe Start to Start timer expired.
Restart Inhibit Start to Start TimeSettingThis setting defines the shortestchiller cycle period possible after thefree starts have been used. If thenumber of free starts is programmedto “1”, and the Start to Start TimeSetting is programmed to 10minutes, then the compressor will beallowed one start every 10 minutes.The start-to-start time is the time fromwhen the motor was commanded toenergize to when the next commandto enter prestart is given.
Clear Restart InhibitA Clear Restart Inhibit “button” isprovided within Settings; ManualOverride on the DynaView display.This provides a way for an operatorto allow a compressor start whenthere is a currently active RestartInhibit that is prohibiting such a start.The “button” press will have noother function than to remove therestart inhibit if there is one active. Itdoes not change the count of anyinternal restart inhibit timers oraccumulators.
The restart inhibit function, setpointsand clear features exist for eachcompressor and operateindependently of other compressorson that chiller.
Machine Protectionand AdaptiveControl
During the time the start is inhibiteddue to the start-to-start timer, theDynaView shall display the mode‘Restart Inhibit’ and the also displaythe time remaining in the restartinhibit.
A “Restart Inhibit Invoked” warningdiagnostic will exist when theattempted restart of a compressor isinhibited
If all three motor windingtemperatures are less than the“Restart Inhibit Temperature”Setpoint (default 165°F/74°C) thenrestart is allowed.
Restart inhibit mode exist when atleast one of the three motor windingtemperatures is greater than or equalto the “Restart Inhibit Temperature”Setpoint but less than 265°F/129.4°C.Restart inhibit mode is entered untilall three motor winding temperaturesare less than the ‘Restart InhibitTemperature’ Setpoint
Note: When one of the three motorwinding temperatures is 265°F/129.4°C or greater, a High MotorWinding Temperature diagnostic willoccur.
Note: When the start is inhibited bythe restart inhibit function, the timeremaining will be displayed alongwith the restart inhibit mode.
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High Vacuum LockoutThe oil sump pressure is below thelockout setpoint. Starting ofcompressor is inhibited as a result.
Low Oil Temperature Start InhibitThe oil temperature is at or below thelow oil temperature start inhibitsetpoint (143°F/61.7°C). The heater isenergized to raise the oil temperature.
Low oil temperature is indicative ofrefrigerant dilution in the oil. Oiltemperature is used to estimate thisdilution since the oil temperaturedirectly corresponds to amount ofrefrigeration dilution in the oil. It isrequired that oil contains minimalrefrigerant in it. This is accomplishedby boiling the refrigerant out of theoil by maintaining a high enough oiltemperature.
If the oil temperature is at or below agiven Low Oil Temperature Inhibitsetting (default 95°F/35°C) thecompressor cannot be started. Thisis an inhibit mode and will bereported to the operator interface. Theoil heater is energized in an attemptto raise the oil temperature over thisinhibit temperature setpoint. Thecompressor is inhibited from startinguntil the oil temperature is raised 5 ormore degrees above this setpoint.
The Low Oil Temperature Start Inhibitis tested on every start unless a quickrestart is being performed duringpost lube.
If the Enhanced Oil TemperatureProtection setting is enabled, the LowOil Temperature Start Inhibit value isthe greater of 100°F/37.8°C or theSaturated Evaporator RefrigerantTemperature + 30°F/16.7°C.
If the Enhanced Oil TemperatureProtection setting is not enabled, theLow Oil Temperature Start Inhibitvalue is settable with the Low OilTemperature Start Inhibit Setpoint viathe service tool.
Machine Protectionand AdaptiveControl
CDHF-SVU01C-EN82
Oil Temperature ControlThe oil heater is used to maintain theoil temperature within +/- 2.5°F (1.4°C)of the oil temperature controlsetpoint. The oil heater iscommanded off when the oil pumpis commanded on.
If the oil temperature is at or belowthe Low Oil Temperature Cutoutsetpoint, this diagnostic will beissued and stops the compressor.
This diagnostic is ignored for the first10 minutes of compressor run. Afterthat, if the oil temperature falls belowthis cutout temperature for more than60 consecutive seconds thisdiagnostic is issued.
High Oil Temperature CutoutName: High Oil Temperature CutoutType of Diagnostic: Latching, resultsin Immediate Shutdown.Default Setpoint value: 180°F (82.2°C)
Implemented to avoid overheating ofthe oil and the bearings.
If the oil temperature is at or abovethe High Oil Temperature Cutoutsetpoint this diagnostic will be issued- which will stop the compressor.
If Oil Temperature violates thistemperature cutout for more than 120seconds this diagnostic is issued.
Manual Oil Pump ControlThe oil pump control acceptscommands to turn on the oil pump.The manual oil pump choices will be“Auto” or “On”. When the oil pumpis commanded “On”, it will revert to“Auto” in 15 minutes.
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Controls Chilled Water Reset(CWR)Chilled water reset is designed forthose applications where the designchilled water temperature is notrequired at partload. In these cases,the leaving chilled water temperaturesetpoint can be reset upward usingthe CWR features.
When the CWR function is based onreturn water temperature, the CWRfeature is standard.
When the CWR function is based onoutdoor air temperature, the CWRfeature is an option requiring anoutdoor temperature sensor moduleinstalled in the UCP panel, andsensor installed outdoors.
The type of CWR is selected in theOperator Interface settings Menualong with the Reset Ratio, StartReset Setpoint, and the MaximumReset Setpoint.
The following equations andparameters apply for CWR.
Return WaterCWS’ = CWS + RATIO (STARTRESET - TWE - TWL) and CWS’ > or= CWS and CWS’ - CWS < or =Maximum Reset.
Outdoor Air TemperatureCWS = CWS + RATIO (START RESET- TOD) and CWS’ > or = CWS andCWS - CWS < or = Maximum Reset.
WhereCWS’ is the new chilled watersetpoint.
CWS is the active chilled watersetpoint before any reset hasoccurred.
RESET RATIO is a user adjustablegain.
START RESET is a user adjustablereference.
TOD is the Temperature OutdoorSensor.
TWE is entering evaporator watertemperature.
TWL is the Leaving EvaporatorTemperature.
MAXIMUM RESET is a useradjustable limit providing themaximum amount of reset. For alltypes of reset, CWS - CWS < or =Maximum Reset.
Both Return and Outdoor Reset donot apply to Heating Mode where theUCP is controlling the LeavingCondensing Hot Water Temperature.
Constant Return Reset will reset theleaving water temperature setpoint soas to provide a constant enteringwater temperature. The ConstantReturn Reset equation is the same asthe Return Reset equation except onselection of Constant Return Reset,the UCP shall automatically setRATIO, START RESET, andMAXIMUM RESET to the following:
The RATIO = 100 percentThe START RESET = Design DeltaTemperatureThe MAXIMUM RESET = DesignDelta Temperature
The equation for Constant Return isas follows:
Machine Protectionand AdaptiveControl
CDHF-SVU01C-EN84
Table 3. Values for start reset types
The values for “RESET TYPE” are:Reset Outdoor Return Const ReturnType: Disable Air Reset Reset Reset
The values for “RESET RATIO” for each of the reset types are:Reset Reset Increment Increment FactoryType Ratio English SI Units Default
Range Units ValueReturn 10 to 120 percent 1 percent 1 percent 50 percentOutdoor -80 to 80 percent 1 percent 1 percent 10 percent
The values for “START RESET “ for each of the reset types are:Reset Start Increment Increment FactoryType Reset English SI Units Default
Range Units ValueReturn 4 to 30°F 0.1°F 0.1°C 10°F (5.6°C)
(2.2 to 16.7°C)Outdoor 50 to 130°F 0.1°F 0.1°C 90°F
(10 to 54.44°C) (32.22°C)The values for “MAXIMUM RESET” for each of the reset types are:Reset Maximum Increment Increment Factory
Reset English SI Units DefaultRange Units Value
Return 0 to 20°F 0.1°F 0.1°C 5°F(0.0 to 11.11°C) (2.78°C)
Outdoor 0 to 20°F 0.1°F 0.1°C 5°F(0.2 to 11.11°C) (2.78°C)
Constant ReturnCWS’ = CWS + 100 percent(Design Delta Temperature) - (TWE-TWL) and CWS’ > or = CWS andCWS’ -CWS < or = Maximum Reset
Notice that Constant Return isnothing more than a specific case ofReturn Reset offered for operatorconvenience.
When any type of CWR is enabled,the UCP will step the CWS towardthe desired CWS (based on the aboveequations and setup parameters) at arate of 1°F every 5 minutes until theActive CWS equals the desiredCWS’. This applies when the chilleris running only.
Using the Equation for calculatingCWR for Outdoor Air Temperature
Equation:Degrees of Reset = Reset Ratio*(StartReset - TOD)
The chiller will start at the Differentialto Start value above a fully reset CWSor CWS for both Return and OutdoorReset.
The graph on the next page, showsthe reset function for Outdoor AirTemperature: Note: This graphassumes that Maximum Reset is setto 20 degrees.
Degrees of Reset:Degrees of Reset = Active CWS -Front Panel CWSorDegrees of Reset = CWS’ - CWS
To obtain Active CWS from Degreesof Reset: Active CWS = Degrees ofReset + Front Panel CWS
Machine Protectionand AdaptiveControl
(* = multiply)
85CDHF-SVU01C-EN
Reset Ratio:The Reset Ratio is displayed as apercentage. To use it in the aboveequation it must be converted to it’sdecimal form.
Reset Ratio percent /100 = ResetRatio decimal
Example of converting Reset Ratio:
If the Reset Ratio displayed on theCLD is 50 percent then use (50/100)=.5 in the equation
TOD = Outdoor Air Temperature
Start Reset = Outdoor Air Start Reset
Example of Calculating Reset forOutdoor Air Temperature:
If:Reset Ratio = 35 percentStart Reset = 80TOD = 65Maximum Reset = 10.5
How many Degrees of Reset willthere be?
Degrees of Reset = Reset Ratio*(StartReset - TOD)Degrees of Reset = .35*(80-65)Degrees of Reset = 5.25
(* = multiply)
If:Reset Ratio = -70 percentStart Reset = 90TOD = 100Maximum Reset = 17
How many Degrees of Reset willthere be?
Degrees of Reset = Reset Ratio* (StartReset - TOD)Degrees of Reset = -7* (90-100)Degrees of Reset = 7
Figure 32. Outdoor air temperature versus degrees of reset
Machine Protectionand AdaptiveControl
CDHF-SVU01C-EN86
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 Protectionand AdaptiveControl
87CDHF-SVU01C-EN
Example of Calculating Return Reset:
If:Reset Ratio = 50%Start Reset = 25TWE = 65TWL = 45Maximum Reset = 8
How many Degrees of Reset willthere be?
Degrees of Reset = Reset Ratio*(StartReset - (TWE-TWL))Degrees of Reset = .5*(25-(65-45))Degrees of Reset = 2.5
If:Reset Ratio = 70%Start Reset = 20TWE = 60TWL = 53Maximum Reset = 14
How many Degrees of Reset willthere be?
Degrees of Reset = Reset Ratio*(StartReset - (TWE-TWL))Degrees of Reset = .7*(20-(60-53))Degrees of Reset = 9.1
Machine Protectionand AdaptiveControl
CDHF-SVU01C-EN88
Figure 35. Return CWR
Figure 36. Constant CWR
Machine Protectionand AdaptiveControl
89CDHF-SVU01C-EN
Unit Start-Up Procedures
Daily Unit Start-Up
1. Verify the chilled water pump andcondenser water pump starter arein “ON” or “AUTO”.
2. Verify the cooling tower is in “ON”or “AUTO”.
3. Check both oil tank oil level(s); thelevel must be visible in or abovethe lower sight glass. Also, besure to check the oil tanktemperature; normal oil tanktemperature before start-up is140°F to 145°F (60 to 63°C).
4. Note: Each oil heater is energizedduring the compressor off cycle.During unit operation, the oil tankheater is de-energized.
5. Check the chilled water setpointand readjust it, if necessary, in theChiller Settings menu.
6. If necessary, readjust the currentlimit setpoint in the ChillerSetpoints menu.
7. Press “AUTO”.
Unit Startup
The UCP also checks compressormotor winding temperature, and aminimum restart time is initiated ifthe winding temperature is less than265°F. The chilled water pump relayis energized and evaporator waterflow is proven.
Next, the UCP checks the leavingevaporator water temperature andcompares it to the chilled watersetpoint. If the difference betweenthese values is less than the startdifferential setpoint, cooling is notneeded.
If the UCP determines that thedifference between the evaporatorleaving water temperature and chilledwater setpoint exceeds the startdifferential setpoint, the unit entersthe initiate Start Mode and the oilpump and Refrigerant pump and thecondenser water pump are started. Ifcondenser water flow is not proven(flow switch 5S3 does not close)within 4-minutes 15 seconds, the unitis locked out on a MMR Diagnostic.
Oil pressure must be verified within 3minutes or a MMR diagnostic isgenerated.
When less than 5 seconds remain onthe restart inhibit, the pre-start startertest is conducted on Y-Delta starters.If faults are detected, the unit’scompressor will not start, and aMMR Diagnostic will be generated.
If the compressor motor starts andaccelerates successfully, “Unit isRunning” appears on the display. Atthis time the purge unit will startoperating on “Automatic” and willcontinue to operate as long as chillercompressor is running.
Note: Whenever the UCP detects aMMR diagnostic condition duringstart-up, unit operation is locked out,and manual reset is required beforethe start-up sequence can beginagain. If the fault condition has notcleared, the UCP will not permitrestart.
CDHF-SVU01C-EN90
When the cooling requirement issatisfied, the UCP originates a“Shutting down” signal. The inletguide vanes are driven closed for 50seconds, and the unit enters a 3-minute post-lube period. Thecompressor motor and condenserwater pump starter are de-energizedimmediately, but the oil pumpcontinues to run during this 3-minuteinterval; the evaporator pump willcontinue to run.
Once the post-lube cycle is done, theunit returns to auto mode.
Seasonal Unit Start-Up
1. Close all drain valves, and re-install the drain plugs in theevaporator and condenserheaders.
2. Service the auxiliary equipmentaccording to the start-up andmaintenance instructions providedby the respective equipmentmanufacturers.
3. Vent and fill the cooling tower, ifused, as well as the condenserand piping. At this point, all airmust be removed from the system(including each pass). Then closethe vents in the condenser waterboxes.
Unit Startup
4. Open all of the valves in theevaporator chilled water circuit.
5. If the evaporator was previouslydrained, vent and fill the evaporatorand chilled water circuit. When allair is removed from the system(Including each pass), close thevent valves in the evaporator waterboxes.
6. Lubricate the external vane controllinkage as needed.
7. Check the adjustment andoperation of each safety andoperating control.
8. Close all disconnect switches.
9. Perform instructions listed in“Daily Unit Start-up” section.
����� WARNING
Live ElectricalComponents!
During installation, testing, servicingand troubleshooting of this product,it may be necessary to work withlive electrical components. Have aqualified licensed electrician or otherindividual who has been properlytrained in handling live electricalcomponents perform these tasks.Failure to follow all electrical safetyprecautions when exposed to liveelectrical components could result indeath or serious injury.
����� WARNING
Toxic Hazards!
• Do not run evaporator water pumplonger than 30 minutes after thechiller is shutdown.
• Ensure that the evaporator isisolated from the hot water loopbefore changeover to heatingmode.
Do not allow the chiller to increaseabove 110°F in temperature whileunit is off. Failure to prevent highchiller temperature will cause theinside pressure to rise. The rupturedisk is designed to relieve anddischarge the refrigerant from theunit if the pressure in the evaporatorexceeds 15 PSIG (103.4 Kpa). Asignifcant release of refrigerant into aconfined space due to a rupture diskfailure could displace availableoxygen to breathe and causepossible asphyxiation. Should arupture disk fail, evacuate the areaimmediately and contact theappropriate rescue or responseauthority. Failure to take appropriateprecautions or react properly to apotential hazard could reuslt indeath or serious injury.
91CDHF-SVU01C-EN
Unit Shutdown Procedures
Daily Unit Shutdown
Note: Refer to Start-Run Shutdownsequence in General InformationOverview Sequence of Operation.
1. Press STOP.
2. After compressor and waterpumps shutdown turn PumpContactors to OFF or open pumpdisconnects.
Seasonal Unit Shutdown
CAUTION
Oil Pump HeaterOperation!
CONTROL POWER DISCONNECTSWITCH MUST REMAIN CLOSED TOALLOW OIL SUMP HEATEROPERATION. Failure to do this willallow refrigerant to condense in theoil pump.
3. Open all disconnect switchesexcept the control powerdisconnect switch.
4. Drain the condenser piping andcooling tower, if used. Rinse withclean water.
5. Remove the drain and vent plugsfrom the condenser headers todrain the condenser. Air dry bundleof residual water.
6. Once the unit is secured for winter,the maintenance proceduresdescribed under “AnnualMaintenance” in the PeriodicMaintenance section of thismanual should be performed byqualified Trane service technicians.
Note: During extended shutdown, besure to operate the purge unit for a 2-hour period every two weeks. Thiswill prevent the accumulation of airand noncompensable in themachine. To start the purge, changethe purge mode to ON in theDynaView™ Settings Purge Menu.Remember to turn the purge mode toAUTO after the 2-hour run time.
Trouble AnalysisIf the ALARM indicator on the controlpanel is flashing, an MMR diagnostichas occurred. Refer to Diagnosticsection for trouble shootinginformation.
Unit Shutdown
CDHF-SVU01C-EN92
OverviewThis section describes the basicchiller preventive maintenanceprocedures, and recommends theintervals at which these proceduresshould be performed. Use of aperiodic maintenance program isimportant to ensure the best possibleperformance and efficiency from aCenTraVac® chiller.
Recommended purge maintenanceprocedures for the EarthWise Purgeunit are covered by PRGD-SVU01A-EN or the latest revision which canbe obtained at the nearest Traneoffice.
Record Keeping FormsAn important aspect of the chillermaintenance program is the regularcompletion of records. Provided atthe end of this manual are copies ofthe “Annual Inspection Check Listand Report”, “CenTraVacCommissioning Checklist and a‘‘Start-Up Report’’ with a TechViewsettings record. When filled out
accurately by the machine operator,the completed logs can be reviewedto identify any developing trends inthe chiller’s operating conditions.
For example, if the machine operatornotices a gradual increase incondensing pressure during amonth’s time, he can systematicallycheck, then correct the possiblecause(s) of this condition (fouledcondenser tubes, noncondensable inthe system, etcetera)
Daily Maintenance and Checks[ ] Check the chiller’s evaporator andcondenser pressures, oil tankpressure, differential oil pressure anddischarge oil pressure. Compare thereadings with the values provided inthe Normal Chiller OperatingCharacteristics table.
IMPORTANT: IT IS HIGHLYRECOMMENDED THAT THEOPERATING LOG BE COMPLETEDON A DAILY BASIS.
CAUTION
Moisture Contamination!
IF FREQUENT PURGING ISREQUIRED, MONITOR PURGEPUMPOUT RATE, IDENTIFY ANDCORRECT SOURCE OF AIR ORWATER LEAK AS SOON ASPOSSIBLE. Failure to do so canshorten chiller life expectancy, due tomoisture contamination caused byleakage.
[ ] Check the oil level in the chiller oilsump using the two sight glassesprovided in the oil sump head. Whenthe unit is operating, the oil levelshould be visible in the lower sightglass.
PeriodicMaintenance
93CDHF-SVU01C-EN
����� WARNING
Hazardous Voltagew/Capacitors!
Disconnect all electric power,including remote disconnects beforeservicing. Follow proper lockout/tagout procedures to ensure thepower cannot be inadvertentlyenergized. For variable frequencydrives or other energy storingcomponents provided by Trane orothers, refer to the appropriatemanufacturer’s literature forallowable waiting periods fordischarge of capacitors. Verify withan appropriate voltmeter that allcapacitors have discharged. Failureto disconnect power and dischargecapacitors before servicing couldresult in death or serious injury.Note: For additional informationregarding the safe discharge ofcapacitors, see PROD-SVB06A-EN orPROD-SVB06A-FR
Normal Chiller Operating Characteristics
Operating Characteristic Normal ReadingApprox. 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°C)
Unit Running 80°F to 162°F(26.6°C to 72°C)
Differential Oil Pressure 18 to 22 psid
PeriodicMaintenance
Weekly Maintenance[ ] Complete all recommended dailymaintenance procedures and checks.Complete logs on a daily basis.
Every 3 Months[ ] Complete all recommendedweekly maintenance procedures.Refer to the previous sections fordetails.
[ ] Clean all water strainers in theCenTraVac water piping system.
Every 6 Months
CDHF-SVU01C-EN94
[ ] Complete all recommendedquarterly maintenance procedures.
[ ] Lubricate the vane control linkagebearings, ball joints, and pivotpoints; as needed a few drops of lightmachine oil (SAE-20) is sufficient.
[ ] Lubricate vane operator tango-rings as described in themaintenance section.
[ ] Lubricate the oil filter shutoff valveo-rings by removing the pipe plugand adding several drops of TraneOIL00022. Replace plug.
[ ] Drain the contents of the rupturedisc and purge discharge ventlinedrip-leg, into an evacuated waste
container minimally and more often ifthe purge is operated excessively.
Also, apply one or two drops of oilon the vane operator shaft andspread it into a very light film; thiswill protect the shaft from moistureand rust.
Off-Season MaintenanceDuring those periods of time whenthe chiller is not operated, be surethe control panel is energized. This isto keep the purge operational, the oilheater warm and will also keep airout of the machine.
Annual MaintenanceShut down the chiller once each yearto check the items listed ; a moredetailed inspection checklist is
provided on the ‘‘Annual InspectionChecklist and Report’’ illustrated inthis manual.
[ ] Perform the annual maintenanceprocedures referred to in theMaintenance Section of the purgemanual.
[ ] Use an ice water bath to verify thatthe accuracy of the evaporatorrefrigerant temperature sensor (4R10)is still within tolerance (+ or - 2.0° at32°F (1° at 0°C)). If the evaporatorrefrigerant temperature displayed onthe UCP’s read-out is outside this 4-degree tolerance range, replace thesensor.
Note: If the sensor is exposed totemperature extremes outside itsnormal operating range (0°F to 90°F) (-18°C to 32°C), check its accuracy atsix-month intervals.
PeriodicMaintenance
95CDHF-SVU01C-EN
Oil Maintenance
Compressor Oil ChangeIt is recommended to change the oiland oil filter:• After the first 1000 hours of chiller
operation. For a chiller operatedcontinuously this oil and oil filterchange may be performed as soonas 1.5 months after first start-up, fora chiller operated intermittently itmay be 4 or 6 months after firststart-up.
• Again at the first scheduled annualmainenance, preferably within 6 to12 months of the first oil change.
Note: Use only Trane OIL00022. A fulloil change is 9 gallons of OIL00022.
Beyond the first year,recommendations are to subscribe toan annual oil analysis program ratherthan automatically change the oil aspart of scheduled maintenance.Change the oil only if indicated bythe oil analysis. Use of an oilanalysis program will reduce thechillers overall lifetime waste oil
generation and minimize refrigerantemissions. The oil analysis shouldbe performed by a qualifiedlaboratory that is experienced inrefrigerant and oil chemistry and inthe servicing of Trane centrifugalchillers.
In conjunction with other diagnosticsperformed by a qualified servicetechnician, oil analyses can providevaluable information on theperformance of the chiller to helpminimize operating and maintenancecosts and maximize it’s operating life.A drain fitting is installed in the oilfilter top, after the oil filter, forobtaining oil samples.
Oil Change ProcedureWhen oil analysis indicates the needto change compressor oil, use thefollowing procedure for removingoil.
CAUTION
Heater Damage!
The oil sump heater must bedeenergized before draining thesump. Failure to do so couldpossibly burn out the oil sumpheater.
[ ] Draw the oil from the chillerthrough the oil charging valve on thechiller oil sump into an approved,evacuated tank; or,
[ ] Pump the oil from the chillerthrough the oil charging valve into anairtight resealable container, using amagnetically-driven auxiliary pump.
Forcing the oil from the oil sump bypressurizing the chiller (by raisingchiller temperature or addingnitrogen) is not recommended.
Refrigerant dissolved in the oil canbe removed and returned to thechiller by using an appropriate deep-vacuum recovery unit and heatingand agitating the oil container. Followall Federal, State and Localregulations with regard to disposal ofwaste oil.
CDHF-SVU01C-EN96
Oil Maintenance
Replacing Oil FilterReplace oil filter: (1) annually, (2) ateach oil change, (3) or if erratic oilpressure is experienced duringchiller operation.
Oil Filter ReplacementUse the following procedure toservice the oil filter. Refer to Figure34.
1. Run the oil pump for two to threeminutes to insure that the oil filteris warmed up to the oil sumptemperature.
2. Turn the oil pump motor off.
3. Pull the “D” handle on the rotaryvalve locking pin out of its detentand rotate the valve to the“DRAIN” position. An offsetpointer is located on top of thevalve with wrench flats to allowturning. The spring force on thelocking pin should allow the pin todrop into a detent at this position.
4. Allow at least 15 minutes for the oilto drain from the filter back intothe oil sump.
5. Pull the “D” handle to unlock thepin and rotate the valve to the“Change Filter” position. Thisisolates the filter from the unit. Thelocking pin should drop into adetent in this position.
6. Remove and replace the filter asquickly as possible. Tighten filter2/3 to 3/4 turn per instructionswritten on the filter. Place the usedfilter in a reusable container.Follow all local, state and federalregulations to dispose of the filter.Pull the “D” handle to unlock thepin and rotate the valve to the“RUN” position. The locking pinshould drop into a detent in thisposition. The chiller is now readyfor operation.
7. Purge unit.
8. Check oil pressure 18-22 psi.
97CDHF-SVU01C-EN
Maintenance
Other MaintenanceRequirementsCompressors using new sealtechnology will not use O-rings. TheO-ring has been replaced by Loctite515 applied at a minimum filmthickness of .010 applied across thewidth of the flange. The current jackbolt holes remain for disassembly.
CAUTION
Oil Supply SystemProblems!
Plugging of oil supply system couldlead to bearing failure. Failure to usecare could result in Loctite gettinginto the chiller which may causeproblems with the Oil supply systemand eductor system.
[ ] Inspect the condenser tubes forfouling; clean if necessary.
����� WARNING
Hazardous Voltage w/Capacitors!
Disconnect all electric power,including remote disconnects beforeservicing. Follow proper lockout/tagout procedures to ensure thepower cannot be inadvertentlyenergized. For variable frequencydrives or other energy storingcomponents provided by Trane orothers, refer to the appropriatemanufacturer’s literature forallowable waiting periods fordischarge of capacitors. Verify withan appropriate voltmeter that allcapacitors have discharged. Failureto disconnect power and dischargecapacitors before servicing couldresult in death or serious injury.Note: For additional informationregarding the safe discharge ofcapacitors, see PROD-SVB06A-EN orPROD-SVB06A-FR
[ ] Measure the compressor motorwinding resistance to ground; aqualified service technician shouldconduct this check to ensure that thefindings are properly interpreted.
Contact a qualified serviceorganization to leak-test the chiller;this procedure is especiallyimportant if the system requiresfrequent purging.
[ ] Use a nondestructive tube test toinspect the condenser and evaporatortubes at 3-year intervals.
Note: It may be desirable to performtube tests on these components atmore frequent intervals, dependingupon chiller application. This isespecially true of critical processequipment.
[ ] Depending on chiller duty, contacta qualified service organization todetermine when to conduct acomplete examination of the unit todiscern the condition of thecompressor and internalcomponents.
Note: (a) Chronic air leaks, which cancause acidic conditions in thecompressor oil and result inpremature bearing wear; and, (b)Evaporator or condenser water tubeleaks. Water mixed with thecompressor oil can result in bearingpitting, corrosion, or excessive wear.
[ ] Submit a sample of thecompressor oil to a Trane qualifiedlaboratory for comprehensiveanalysis on an annual basis; thisanalysis determines system moisturecontent, acid level and wear metalcontent of the oil, and can be used asa diagnostic tool.
LubricationThe only chiller component thatrequires periodic lubrication is theexternal vane linkage assembly andRotary oil valve.
Lubricate the vane linkage shaftbearings and rod end bearings asneeded with a few drops of light-weight machine oil.
The CenTraVac inlet guide vane tangoperators should be servicedannually with R123 compatiblegrease. Use only Rheolube 734A,available from Trane as LUB00033(16oz. standard grease gun cartridge)or LUB00063 (3oz. mini grease guncartridge)
To service the 1st stage tangoperator of all units except CDHFextended capacity chillers with 1470or 1720 compressors.1. The chiller must be off.2. Carefully remove any insulation
that may have been placed overthe two lubrication ports of thetang operator base. Thisinsulation will need to be replacedafter the service is complete.
3. Note the position of the tangoperator arm, note the placementof spacing washers etc., thendisconnect the linkage rod fromthe tang operator arm. Manuallymove the tang operator arm andnote the amount of effort requiredto operate the assembly.
4. Loosen but DO NOT REMOVE the1/16" NPT lubrication port plugthat is highest on the assembly.
5. Loosen and remove the remaininglower 1/16" NPT plug.
6. Using a grease gun with anappropriate fitting, insert ONLYRheolube grease into the openport until clean grease is seen toappear around the threads of theplug in the opposite port.
7. Tighten the plug that was loosenedin step 4. Tighten the plug to handtight plus 1/4 to 1/2 turn.
8. Remove the grease fitting, if used.
CDHF-SVU01C-EN98
Maintenance
DO NOT LEAVE GREASE FITTINGSINSTALLED.If grease fittings have been used forthis procedure then they MUST BEREMOVED before returning the unitto service. Grease fittings are notvacuum-tight and will become a leakpath.9. Using a clean wooden dowel or
other similar tool, remove excessgrease from the remaining openlubrication port.
10. Clean and then lightly coat thethreads of the plug with Rheolubegrease and re-install it into thelubrication port. Tighten theplug to hand tight plus 1/4 to 1/2turn.
11. Before reconnecting the vanelinkage, grasp the tang operatorarm and manually operate thevane assembly. If it is nowdifficult to move, then the tangoperator may have become“hydraulically locked” because ofexcess grease in the assembly.This situation could causedamage to the o-rings of theassembly. If this occurs thenremove one of the lubricationplugs, remove some of thegrease, then re-install the plug.
12. Reconnect the linkage to the tangoperator arm. Ensure the spacerwashers between the linkage andthe arm are properly placed andthat the assembly does not bind.Re-install any insulation that wascut or removed. The unit may berestarted.
To service the 1st and 2nd stage tangoperators on CDHF extendedcapacity chillers with 1470 or 1720compressors.The 1st and 2nd stage rotary inletguide vane tang operators of theextended capacity chillers alsorequire periodic lubrication, at leastannually, with R123 compatibleRheolube grease. These actuatorshave two 1/8" NPT plugs located 180degrees 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 theoperator base. Use the sameprocedure as described above,except that it will be necessary totemporarily disconnect the vaneactuators from the tang operatorarms in order to test for a“hydraulically locked” condition.
The oil valve block rotary valve usesdual O-Rings to seal to atmosphere.These should be manually lubricatedby removing the pipe plug at thevalve lubrication port and placing afew drops of Trane OIL00022 in thecavity. Be sure to reinstall the pipeplug when lubrication is completed.
99CDHF-SVU01C-EN
Maintenance
Refrigerant Charge
����� WARNING
Contains Refrigerant!
System contains oil and refrigerantand may be under positive pressure.Recover refrigerant to relievepressure before opening the system.See unit nameplate for refrigeranttype. Do not use non-approvedrefrigerants, refrigerant substitutes,or refrigerant additives.Failure to follow proper proceduresor the use of non-approvedrefrigerants, refrigerant substitutes,or refrigerant additives could resultin death or serious injury orequipment damage.
The refrigerant charging procedurefor Trane centrifugal chillers is:
1. If water is present in the tubes,break machine vacuum withrefrigerant vapor, or circulatewater, to avoid tube damage.
2. Always use refrigerant compatiblehoses or copper-tubing with self-sealing connections or shut-offvalves.
3. Transfer the refrigerant using oneof the following (listed in order ofpreference):
a. An approved Trane low-pressure refrigerant recoveryand recycle unit.
b. The available pressuredifferential.
c. Gravity. (Use a return vent lineto refrigerant drums to equalizepressure.)
5. Do not use dry nitrogen to pushrefrigerant into the chiller as wascommon practice in the past. Thiswill contaminate the charge andrequire excessive purging, whichwill result in unnecessary releaseof refrigerant.
6. Weigh in the proper charge.
7. Use recovery and recyle unit orvacuum pump to evacuate hoses;discharge outdoors.
8. If refrigerant is supplied in newreturnable cylinders, be sure andrefer to General Service BulletinCVHE-SB-48B for information onreturning cylinders. This servicebulletin is available at the nearestTrane office.
Depending on the chiller duty,contact a qualified serviceorganization to determine when toconduct a complete examination ofthe unit to discern the condition ofthe compressor and internalcomponents.
Note: If your chiller is covered by aTrane extended warranty, the terms ofthat warranty may require that theprocedures listed in the PeriodicMaintenance section of this manualbe followed for your extendedwarranty to remain in force. Theterms may also require that the chillerbe inspected by a Trane authorizedwarranty agent every4-years or 40,000 operating hours,whichever occurs first. Thisinspection will include, at aminimum, a review of the annualinspection checklists and the dailyoperating logs, as well asperformance of a leak test and ageneral inspection of the chiller. Theowner is then required to follow therecommendations made as a result ofthis inspection at the ownersexpense.
CDHF-SVU01C-EN100
Maintenance
Recovery and RecycleConnectionsTo facilitate refrigerant removal andreplacement, newer-design CDHF,CDHG units are provided with a 3/4-inch vapor fitting with shutoff valveon the chiller suction and with a 3/4-inch liquid connection with shutoffvalve at the bottom of the evaporatorshell. (Refer to Refrigerant HandlingGuidelines)
Leak TestingTo leak-test a chiller containing fullrefrigerant charge, raise chillerpressure using a controlled hot wateror electric-resistance system to amaximum of 8 psig. Do not usenitrogen, which will cause excessiverefrigerant discharge by the purgesystem.
Cleaning the Condenser
CAUTION
Proper Water Treatment!
The use of untreated or improperlytreated water in a CenTraVac mayresult in scaling, erosion, corrosion,algae or slime. It is recommendedthat the services of a qualified watertreatment specialist be engaged todetermine what water treatment, ifany, is required. Trane assumes noresponsibility for equipment failureswhich result from untreated orimproperly treated water, or saline orbrackish water.
See Figure 38 which shows a TypicalChemical Cleaning Setup.
Figure 38. Typical chemical cleaning setup
101CDHF-SVU01C-EN
Maintenance
Condenser tube fouling is indicatedwhen the approach temperature (thedifference between the condensingrefrigerant temperature and theleaving condenser watertemperature) is higher than predicted.
If the annual condenser tubeinspection indicates that the tubesare fouled, two cleaning methods,mechanical and chemical, can beused to rid the tubes ofcontaminants.
Use the mechanical cleaning methodto remove sludge and loose materialfrom smooth-bore tubes.
To clean other types of tubesincluding internally-enhanced types,consult a qualified serviceorganization for recommendations.
1. Remove the retaining nuts andbolts from the water box covers ateach end of the condenser. Use ahoist to lift the covers off the waterbox. (A threaded connection isprovided on each water box coverto allow insertion of an eyebolt).
2. Work a round nylon or brassbristled brush (attached to a rod) inand out of each of the condenserwater tubes to loosen the sludge.
3. Thoroughly flush the condenserwater tubes with clean water.
Scale deposits are best removed bychemical means. Be sure to consultany qualified chemical house in thearea (one familiar with the local watersupply’s chemical mineral content)for a recommended cleaningsolution suitable for the job.Remember, a standard condenserwater circuit is composed solely ofcopper, cast iron and steel.
CAUTION
Unit Corrosion Damage!
Proper procedures must be followedwhen using corrosive chemicals toclean water side of unit. It isrecommended that the services of aqualified chemical cleaning firm beused. Proper personal protectiveequipment as recommended by thechemical manufacturer should beused. Refer to the chemicals MSDSsheet for proper safety procedures.Failure to follow proper procedurescould result in corrosion damage tothe unit and tubes.
IMPORTANT: ALL OF THEMATERIALS USED IN THEEXTERNAL CIRCULATION SYSTEM,THE QUANTITY OF THE SOLUTION,THE DURATION OF THE CLEANINGPERIOD, AND ANY REQUIREDSAFETY PRECAUTIONS SHOULD BEAPPROVED BY THE COMPANYFURNISHING THE MATERIALS ORPERFORMING THE CLEANING.
REMEMBER, HOWEVER, THATWHENEVER THE CHEMICAL TUBECLEANING METHOD IS USED, ITMUST BE FOLLOWED UP WITHMECHANICAL TUBE CLEANING,FLUSHING AND INSPECTION.
Cleaning the EvaporatorSince the evaporator is typically partof a closed circuit, it does notaccumulate appreciable amounts ofscale or sludge. Normally, cleaningevery 3 years is sufficient. However,on open evaporator systems, such asair washers, periodic inspection andcleaning is recommended.
Control Settings andAdjustmentsTime delays and safety control cutoutsettings need to be checked annually.For control calibration and check-out,contact a Trane qualified serviceorganization.
CDHF-SVU01C-EN102
Maintenance
Purge SystemBecause some sections of thechiller’s refrigeration system operateat less-than-atmospheric pressure,the possibility exists that air andmoisture may leak into the system. Ifallowed to accumulate, thesenoncondensables become trapped inthe condenser; this increasescondensing pressure andcompressor power requirements,and reduces the chiller’s efficiencyand cooling capacity.
The Trane EarthWise Purge is theonly purge system available for thechiller. The purge is designed toremove noncondensable gases andwater from the refrigeration system.EarthWise Purge unit operation,maintenance and trouble shooting iscovered by a separate operation andmaintenance manual, which may beobtained from the nearest Traneoffice.
OverviewThis section describes extendedstorage requirements for installedchillers to be removed from servicefor an undetermined length of time.
Unit PreparationThe following steps are necessary inorder to properly prepare a unit forstorage.
1. Remove all liquid refrigerant if theunit is charged.
����� WARNING
Contains Refrigerant!
System contains oil and refrigerantand may be under positive pressure.Recover refrigerant to relievepressure before opening the system.See unit nameplate for refrigeranttype. Do not use non-approvedrefrigerants, refrigerant substitutes,or refrigerant additives.Failure to follow proper proceduresor the use of non-approvedrefrigerants, refrigerant substitutes,or refrigerant additives could resultin death or serious injury orequipment damage.
2. After the liquid refrigerant isremoved, using a recovery orrecycle unit or vacuum pump, pulla vacuum to remove remainingrefrigerant vapor from the unit.
3. After all traces of refrigerant are outof the unit, a positive nitrogencharge should be put into the unit(6 to 8 psig). This positive pressuremust be checked monthly toinsure no noncondensables getinto the unit. Use a pressure gageon the evaporator shell to verifythat the 6 to 8 psig dry nitrogenholding charge is still in thechiller. If this charge has escaped,contact a qualified serviceorganization and the Trane salesengineer that handled the order.
4. The refrigerant charge should bestored in proper refrigerantcontainers. Due to possibleleakage, do not store in useddrums.
5. Maintain control power to thecontrol panel. This will maintainoil temperature in the oil sumpand the capability of the controlpanel to present reportinformation. The Chiller Reportsshould be viewed once a week fornormal readings. Any abnormalobservation must be reported tothe Trane Sales Engineer thathandled the order.
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Maintenance
����� WARNING
Live ElectricalComponents!
During installation, testing, servicingand troubleshooting of this product,it may be necessary to work withlive electrical components. Have aqualified licensed electrician or otherindividual who has been properlytrained in handling live electricalcomponents perform these tasks.Failure to follow all electrical safetyprecautions when exposed to liveelectrical components could result indeath or serious injury.
6. Remove the factory installedjumper or the field installed wiringon terminals in the unit controlpanel. This will prevent unwantedchiller operation.
7. Set the purge operating mode toOFF on UCP chillers.
8. The oil can be left in the unit.
9. The water side should not cause aproblem if shut down and drained.There may be slight scaling insidethe tubes, but not enough to causea problem. The customer shouldinspect and clean tubes before theunit is returned to service.
IMPORTANT: DO NOT USEUNTREATED OR IMPROPERLYTREATED WATER, OR EQUIPMENTDAMAGE MAY OCCUR.
IMPORTANT: SCALE DEPOSITS AREBEST REMOVED BY CHEMICALMEANS. BE SURE TO CONSULTANY QUALIFIED CHEMICAL HOUSEIN THE AREA (ONE FAMILIAR WITHTHE LOCAL WATER SUPPLY’SCHEMICAL MINERAL CONTENT)FOR A RECOMMENDED CLEANINGSOLUTION SUITABLE FOR THEJOB.
10. Motor bearings: If the motor sitsfor a long time the bearingscould take a set and causebearing problems or replacementlater. Once every six months thechiller oil pump must be startedand the compressor motor bumpstarted to rotate the shaft. Contacta qualified service organization toperform this task. If thecompressor motor cannot bebump started, then the shaft mustbe rotated manually by aqualified service organization.
11. Obtain an oil analysis initiallyafter six months of storage, andonce each succeeding year. If nooil breakdown is evident do notchange the oil. If breakdown isevident, the oil must be replaced.
12. If the unit is stored for more thanfive years, and the storage isexpected to be indefinite, the unitshould be examined for leaksevery five years from the initialstorage date.
13. When the unit is to be returned toservice, the services of a qualifiedservice organization should beobtained to conduct all activitiesassociated with the startup of anew chiller.
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Trane has a policy of continuous product and product data improvement and reserves the right to change designand specifications without notice.
Only qualified technicians should perform the installation and servicing of equipment referred to in thispublication.
Literature Order Number
File Number
Supersedes
Stocking LocationTrane
A business of American Standard Companies
www.trane.com
For more information contact your local district officeor e-mail us at [email protected]
CDHF-SVU01C-EN
SV-RF-CTV-CDHF-SVU01C-EN-405
CDHF-SVU01B-EN 604
La Crosse