Operation Maintenance Water Cooled CenTraVac™ With CH530 X39640712050 CVHE-SVU01E-EN
Warnings and Cautions Warnings and Cautions Notice that warnings and cautions appear at appropriate intervals throughout this manual. Warnings are provided to alert installing contractors to potential hazards that could result in personal injury or death, while cautions are designed to alert personnel to conditions that could result in equipment damage. Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.
Contents Warnings and Cautions 2 General Information 4 Unit Control Panel (UCP) 26 Operator Interface 28 Chilled Water Setpoint 41 Inter Processor Communication (IPC) 49 Control System Components 50 Controls Sequence of Operation 63 Machine Protection and Adaptive Control 68 Unit Startup 85 Unit Shutdown 87 Periodic Maintenance 88 Oil Maintenance 91 Maintenance 93 Forms CVHE-SVU01E-EN 100 3
General Information Literature change Unit Nameplate Applicable to CVHE, CVHF, CVHG The unit nameplate is located on the left side of the unit control panel. The following information is provided on the unit nameplate. About this manual Operation and maintenance information for models CVHE, CVHF and CVHG are covered in this manual. This includes both 50 and 60 Hz. CVHE, CVHF and CVHG centrifugal chillers equipped with the Tracer CH530 Chiller Controller system.
General Information An example of a typical model number is: CVHF091NAL00ACU2758W7E8TB C0000000K01G14C10W1A03B1 Model Number Digit Identification C = (1st digit) CenTraVac® Hermetic V = (2nd digit) CenTraVac® Hermetic H = (3rd digit) Direct Drive C = (14th digit) Control Enclosure S = Special C = Standard Control Enclosure U = (15th digit) Compressor Motor Power (kw) 275 = (16th, 17th, and 18th digit) Compressor Imp Cutback 8 = (19th digit) Evaporator Shell Size 0 = (35th digit) Unit Option 1 = (36th dig
General Information Commonly Used Acronyms HGBP = Hot Gas Bypass Control Optional Packages For convenience, a number of acronyms are used throughout this manual.
General Information Overview CVHE, CVHG, CVHF Each CVHE, CVHG, or CVHF unit is composed of 5 basic components. — the evaporator, — 3-stage compressor on CVHE, CVHG or 2 stage compressor on CVHF, — 2-stage economizer on CVHE, CVHG, or single economizer on CVHF, See Figure 1 for Typical CVHE and CVHG, and Figure 2 for Typical CVHF major components. A heat-recovery or auxiliary condenser can be factory-added to the basic unit assembly to provide a heat-recovery cycle.
General Information Figure 1.
General Information Figure 2.
General Information Cooling Cycle CVHE, CVHG, CVHF When in the cooling mode, liquid refrigerant is distributed along the length of the evaporator and sprayed through small holes in a distributor (i.e., running the entire length of the shell) to uniformly coat each evaporator tube. Here, the liquid refrigerant absorbs enough heat from the system water circulating through the evaporator tubes to vaporize.
General Information Figure 3. CVHE, CVHG pressure enthalpy curve Figure 4.
General Information Figure 5. CVHF pressure enthalpy curve Figure 6.
General Information Overview Controls Operator Interface Information is tailored to operators, service technicians and owners When operating a chiller, there is specific information you need on a day-to-day basis — setpoints, limits, diagnostic information, and reports. When servicing a chiller, you need different information and a lot more of it — historic and active diagnostics, configuration settings, and customizable control algorithms, as well as operation settings.
General Information Figure 8. CVHE, CVHF, and CVHG sequence of operation: power up to starting Figure 9.
General Information Figure 10. CVHE, CVHF, and CVHG sequence of operation: satisfied setpoint Figure 11.
General Information Oil and Refrigeration Pump Compressor Lubrication System A schematic diagram of the compressor lubrication system is illustrated in Figure 12. Oil is pumped from the oil tank (by a pump and motor located within the tank) through an oil pressureregulating valve designed to maintain a net oil pressure of 18 to 22 psid. It is then filtered and sent to the oil cooler located in the economizer and on to the bearings.
General Information Figure 12.
General Information Base Loading Control Algorithm: This feature allows an external controller to directly modulate the capacity of the chiller. It is typically used in applications where virtually infinite sources of evaporator load and condenser capacity are available and it is desirable to control the loading of the chiller. Two examples are industrial process applications and cogeneration plants.
General Information Figure 13.
General Information Ice Machine Control The control panel provides a service level “Enable or Disable” menu entry for the Ice Building feature when the Ice Building option is installed. Ice Building can be entered 1) from the “Front Panel”, 2) if hardware is specified, will accept either an isolated contact closure (1A19 Terminals J2-1 and J2-2 (Ground) ) 3), a remote communicated input (Tracer) to initiate the ice building mode where the unit runs fully loaded at all times.
General Information Free Cooling Cycle Based on the principle that refrigerant migrates to the coldest area in the system, the free cooling option adapts the basic chiller to function as a simple heat exchanger. However, it does not provide control of the leaving chilled water temperature.
General Information it is then compressed and discharged to the condenser. Most of the condensed refrigerant initially follows the path of least resistance by flowing into the storage tank. This tank is vented to the economizer sump through a small bleed line; when the storage tank is full, liquid refrigerant must flow through the bleed line restriction.
General Information Hot Gas Bypass The hot gas bypass (HGBP) control option is designed to minimize machine cycling by allowing the chiller to operate stably under minimum load conditions. In these situations, the inlet guide vanes are “locked” at a preset minimum position, and unit capacity is governed by the HGBP valve actuator. Control circuitry is designed to allow both the inlet guide vanes and the HGBP valve to close for unit shutdown.
General Information Hot Water control Occasionally CTV chillers are selected to provide heating as a primary mission. With hot water temperature control, the chiller can be used as a heating source or cooling source. This feature provides greater application flexibility. In this case the operator selects a hot water temperature and the chiller capacity is modulated to maintain the hot water setpoint. Heating is the primary mission and cooling is a waste product or is a secondary mission.
General Information Heat Recovery Cycle ‘‘Heat recovery’’ is designed to salvage the heat that is normally rejected to the atmosphere through the cooling tower, and put it to beneficial use. For example, a highrise office building may require simultaneous heating and cooling during the winter months. With the addition of a heat recovery cycle, heat removed from the building cooling load can be transferred to areas of the building that require heat.
Unit Control Panel (UCP) Control Panel Devices and Unit Mounted Devices Unit Control Panel (UCP) Safety and operating controls are housed in the unit control panel, the starter panel and the purge control panel. The UCP ‘s operator interface and main processor is called the DynaView™ (DV) and is located on the UCP door.
Unit Control Panel (UCP) Tracer CH530 Chiller Controller Revolutionary control of the chiller, chilled water system, and your entire building with unprecedented accuracy, reliability, efficiency, and support for maintenance using the chiller’s PC-based service tool. Chiller reliability is all about producing chilled water and keeping it flowing, even when facing conditions that ordinarily would shut down the chiller — conditions that often happen when you need cooling the most.
Operator Interface Figure 17. DynaView™ main processor DynaView™ presents three menu tabs across the top which are labeled “MAIN, REPORTS, and SETTINGS”. The Main screen provides an overall high level chiller status so the operator can quickly understand the mode of operation of the chiller. The Chiller Operating Mode will present a top level indication of the chiller mode (Auto, Running, Inhibit, Run Inhibit, etc.
Operator Interface DynaView™ (DV) is the operator interface of the Tracer CH530 control system utilized on the CTV machine. The DynaView™ enclosure is 9.75" wide, 8” high and 1.6” deep. The DynaView™ display is approximately 4” wide by 3” high. Features of the display include a touch screen and long life LED backlight.
Operator Interface The Auto and Stop keys are used to put the unit into the auto or stop modes. Key selection is indicated by being darkened (reverse video). The Alarms button is to the right of the Stop key. The Alarms button appears only when alarm information is present. The alarm blinks to draw attention to the shutdown diagnostic condition. Blinking is defined as normal versus reverse video. Pressing on the Alarms button takes you to the corresponding screen.
Operator Interface Figure 18 The machine-operating mode indicates the operational status of the chiller. A subscreen with additional mode summary information will be provided. When the user scrolls down the screen the Machine Operation Mode will remain stationary On DynaView™, the user will be presented with a single line of text that represents the ‘top-level’ operating state of the machine. These top-level modes are shown in the table below.
Operator Interface Figure 19 Top Level Mode SYSTEM RESET Stopped Stopped Stopped Run Inhibit Run Inhibit Run Inhibit Run Inhibit Auto Auto Auto Auto Waiting To Start Waiting To Start Waiting To Start 32 Sub Level Mode Boot & Application software part number, self-test, and configuration validity screens will be present.
Operator Interface Top Level Mode Waiting To Start Waiting To Start Waiting To Start Waiting To Start Waiting To Start Starting Compressor Running Running Running Running Running Running Running Running Running Running – Limit Running – Limit Running – Limit Running – Limit Running – Limit Running – Limit Free Cooling Free Cooling Free Cooling Preparing To Shutdown Shutting Down Shutting Down Shutting Down CVHE-SVU01E-EN Sub Level Mode Motor Temperature Inhibit: Motor Temperature / Inhibit Temperature Re
Operator Interface Main Screen The main screen is provides “an overall view“ of the chiller performance in addition to the main and sub operating modes. The table below indicates other items found , when specified by options, that can be scrolled to via the up or down arrows.
Operator Interface Diagnostic Screen The diagnostic screen is accessible by touching the Alarms enunciator. When an alarm is present, the alarm enunciator is present next to the Stop key. A flashing “alarm” indicates a machine shutdown and a non flashing “alarm” indicates an informational message. Machine shutdowns can be of two types: Latching - Machine Shutdown Manual Reset Required (MMR) or Non-Latching - Machine Shutdown Auto Reset (MAR) Latching (MMR) require corrective action and manual reset.
Operator Interface The active chilled water setpoint is the setpoint that is currently in use. It will be displayed to 0.1 degrees Fahrenheit or Celsius. Touching the double arrow to the left of the Active Chilled Water Setpoint will take the user to the active chilled water setpoint arbitration sub-screen.
Operator Interface The active current limit setpoint is the current limit setpoint that is currently in use. It will be displayed in percent RLA. Touching the double arrow to the left of the Active Current Limit Setpoint will take the user to the active current limit setpoint subscreen. The active current limit setpoint is that setpoint to which the unit is currently controlling. It is the result of arbitration between the front panel, BAS, and external setpoints.
Operator Interface Reports Evaporator Report items Evaporator Entering Water Temperature Evaporator Leaving Water Temperature Evaporator Saturated Refrigerant Temperature Evaporator Refrigerant Pressure Evaporator Approach Evaporator Water Flow Switch Status Evaporator Differential Water Pressure, If installed Approximately Evaporator Water Flow, If installed Approximate Chiller Capacity, If installed Units °C or °F °C or °F °C or °F Psia or kPa °C or °F Flow or No Flow Psid Gpm or LPM Tons or kW Conden
Operator Interface Compressor Report Items Compressor Starts: Compressor Running Time: Compressor Discharge Temperature; If installed Oil Tank Pressure Oil Discharge Pressure Oil Differential Pressure Oil Tank Temperature Inboard Bearing Temperature, If installed Outboard Bearing Temperature, If installed Vanes Position Vanes Position Steps Hot Gas Bypass Time, If installed Units ### Hour and minute °C or °F Motor Report Items Percent RLA L1 L2 L3 Amps L1 L2 L3 Volts AB, BC, CA Power Consumption, If insta
Operator Interface ASHRAE Chiller Log 1. Current Time and Date Monitor 2. Operating Mode 3. Active Chilled Water Setpoint: 4. Active Current Limit Setpoint: 5. Refrigerant Type: 6. Refrigerant Monitor: If installed 7. Purge Daily Pumpout – 24 Hours: 8. Purge Daily Pumpout Limit and Alarm 9. Purge Pumpout - Life 10. Purge Operating Mode: 11. Purge Status: 12. Compressor Starts: 13. Compressor Running Time: 14. Compressor Discharge Temperature; If option installed 15. Discharge Oil Pressure; 16.
Operator Interface Setting Tab screens provides a user the ability to adjust settings justified to support daily tasks. The layout provides a list of sub-menus, organized by typical subsystem. Settings screen for standard CTV : Chilled Water Setpoint: To change chilled water setpoint first select the settings tab screen. Chilled water setpoint is within the chiller sub-menu. (See next page for setpoint listing.
Operator Interface Chiller Description Units notes 1. Front Panel Control Type (Chilled Water, Hot Water), Chilled Water default 2. Front Panel Chilled Water Setpoint Temperature 1 3. Front Panel Hot Water Setpoint Temperature 1 4. Front Panel Current Limit Setpoint Percent 2 5. Front Panel Base Load Command On or Auto 6. Front Panel Base Load Setpoint Percent 7. Front Panel Free Cool Command On or Auto 8. Front Panel Ice Building Command On or Auto 9. Front Panel Ice Termination Setpoint Temperature 10.
Operator Interface Purge Description 1. Purge Operating Mode 2. Daily Pumpout Limit 3. Disable Daily Pumpout Limit 4. Purge Liquid Temperature Inhibit 5. Purge Liquid Temperature Limit Display Settings Description 1. Date Format 2. Date 3. Time Format 4. Time of Day 5. Keypad and Display Lockout 6. Display Units 7.
Operator Interface 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 or setpoint value. Doing this causes the screen to switch to the Analog Settings Subscreen shown below. { Analog Settings Subscreen displays the current value of the chosen setpoint in the upper ½ of the display. It is displayed in a changeable format consistent with its type.
Operator Interface Settings with buttons only [screen has no cancel or enter key] do accept the new selection immediately. Note: Radio 1 and Radio 2 refer to “touch sensitive buttons.” The labels depend upon the setting being controlled.
Operator Interface The mode override analog setting subscreen is similar but offers an Auto or Manual radio button and value setting. An Auto or Manual selection is necessary set to the mode to override. An Enter and Cancel Key will allow the user to Enter or Cancel the entry. Mode Override for Analog Settings is shown below: The date setpoint screen for setting up the is shown below: The user must select Day, Month, or Year and then use the up or down arrows to adjust.
Operator Interface The time setpoint screen with a 12-hour format is shown below: The user must select Hour, or Minute and then use the up or down arrows to adjust. Adjusting hours will also adjust am and pm. Note: The 24-hour format setpoint screen is similar with the am and pm not shown.
Operator Interface The DynaView™ Display Touch Screen Lock screen is shown below. This screen is used if the Display and Touch Screen Lock feature is Enabled. 30 minutes after the last key stroke this screen will be displayed and the Display and 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 and Interlocks.
Interprocessor Communication Inter Processor Communications IPC3 When using Tracer CH530, you will not be required to know all the details about the structure of the IPC3 bus. However this page gives detailed information about the system for those of you that are really interested in how it works. The IPC3 protocol is based on RS485 signal technology. IPC3 was designed to be very efficient. It communicates at 19.2 Kbaud. This data rate will allow for three rounds of data per second on a 64 device network.
Control System Components Control Panel Internally mounted devices For visual identification Internal Control Panel mounted devices are identified by their respective schematic designation number. Control panel items are marked on the inner back panel in the control panel. Figure 20 illustrated below, identifies these devices. The Control Panel Devices table corresponds to the same device designators (see right hand column).
Control System Components CVHE-SVU01E-EN 51
Control System Components Control Panel Devices Standard Devices Description 1A1 Power Supply 1A2 Power Supply 1A3 Dual Relay Output modules 1A4 Dual High Voltage Input 1A5 Quad Relay Output modules 1A5 Quad Relay Output modules 1A6 Dual High Voltage Input 1A6 Dual High Voltage Input 1A7 High Power Output Relay 1A13 Dual LV Binary input module 1A13 Dual LV Binary input module 1A26* Controls Package Standard #1 (as required) #2 Standard Relay #1 Purpose Converts 24 vac to 24 vdc Converts 24 vac to 24 vdc
Control System Components Chilled and Condenser Water Flow Interlock Circuits Proof of chilled water flow for the evaporator is made by the closure of flow switch 5S1 and the closure of auxiliary contacts 5K1 on terminals 1X1-5 and 1A6-J3-2. Proof of condenser water flow for the condenser is made by the closure of flow switch 5S2 and the closure of auxiliary contacts 5K2 on terminals 1X1-6 and 1A6-J2-2.
Control System Components EXOP Extended Operation Option The following modules (1A17, 1A18, and 1A19) are provide when this control package is specified.
Control System Components FRCL (Free Cooling Option) 1A11 Optional Quad FRCL Relay Output Status 1A20 Optional Dual LV FRCL Binary input module 1A20 Optional Dual LV FRCL Binary input module Relay #1 Free Cooling Relay 1, J2- 4 NO to J2-6 common Signal #1 External Free Cooling Switch, Signal #2 Free Cooling Valves closed J2-1 Binary Input Signal #1, J2-2 Ground Not for field use Hot Gas Bypass input Not for field use Auxiliary relays Not for field use Tracer Communications J2-1 COMM+, J2-2 CO
Control System Components CDRP Refrigerant Pressure Output Option 1A15: Refrigerant Pressure Output can be configured at commissioning to correspond to either A) the absolute condenser pressure, or B) the differential pressure of the evaporator to condenser pressures. This vdc output is located at 1A15 – J2 – 4 (+) to J2-6 (Ground) The Voltage DC Output can source a maximum of 22 mA of current. This output is Voltage DC only, 420mA is not supported. A) Condenser Pressure Output.
Control System Components B) Refrigerant Differential Pressure Indication Output: A 2 to 10 VDC analog output is provided instead of the previous condenser pressure output signal. This signal corresponds to a predetermined minimum and maximum pressure settings setup at commissioning of this feature. This relationship can be altered using the service tool if required. The “Minimum Delta Pressure “ is typically set to 0 psi and will then correspond to 2 vdc.
Control System Components GBAS (Generic Building Automation System) 1A15 Optional Dual GBAS Signal #1 Analog Input/ or output Module CDRP 1A16 Optional Dual GBAS Signal #1 Analog Input/ output Module 1A16 Optional Dual GBAS Signal #2 Analog Input/ output Module Percent RLA Output 2 to 10 Vdc corresponding to 0 to 120% RLA. With a resolution of 0.146%. The Percent RLA Output connections are on the terminals 1A15 –J2-1 (+) to J2-3 (Ground). The Percent RLA Output is polarity sensitive.
Control System Components External Chilled Water Setpoint (ECWS) The External Chilled Water Setpoint allows the chilled water setpoint to be changed from a remote location. The External Chilled Water Setpoint is found on 1A16 J2-5 to J2-6 (Ground). 2-10 vdc and 4-20 ma correspond to a 34°F to 65°F (-17.8 to 18.3°C) CWS range. Default 34°F to 65°F, adjustable via service tool.
Control System Components 1A8, 1A9, 1A11, 1A12 Quad Relay Output Status: Relay #1 J2-1 NO, J2-2 NC, J2common Relay #2 J2-4 NO, J2-5 NC, J2-6 common Relay #3 J2-7 NO, J2-8 NC, J2-9 common Relay #4 J2-10 NO, J2-11 NC, J2-12 common Relay Outputs: at 120 VAC: 7.2 Amps resistive, 2.88 Amps pilot duty, 1/3 HP, 7.2 FLA, at 240 VAC: 5 Amps general purpose 14-26 AWG, two 14 AWG Maximum Power, 24 +/-10 percent VDC, 100 ma maximum. Trane IPC3 protocol.
Control System Components 1A15, 1A16, 1A17, 1A21 Dual Analog Input/output Module; Analog Output: The Analog Output is a voltage only signal. 2-10 Vdc at 22mA J2: 14 - 26 AWG with a maximum of two 14 AWG UCP provides a 2-10 Vdc analog signals as Outputs. The Output’s maximum source capability is 22mA. The maximum recommended length to run this signal is included in the table below. J2-1 Output #1 to J2-3 (Ground), J2-4 Output #2 to J2-6 (Ground).
Control System Components Unit mounted devices Vane Actuator Control The Stepper Module within the stepper vane actuator (4M2) (and 4M4 extended capacity) pulses a DC voltage to the windings of the Stepper Motor Actuator(s) to control inlet guide vane position. While operation of this stepper motor is automatic, manual control is possible by going to the Mode Overrides settings menu within the DynaView™.
Control Sequence of Operation Electrical Sequence This section will acquaint the operator with the control logic governing CVHE, CVHF and CVHG chillers equipped with Tracer CH530 UCP based control systems. When reviewing the step-by-step electrical sequences of operation, refer to the typical wiring schematics for Unit mounted Wye Delta starter shown in the installation manual shipped with the chiller.
Control Sequence of Operation When less than 2.5 seconds remain before compressor start, a starter test is conducted to verify contactor states prior to starting the compressor. The following test or start sequence is conducted for ‘‘Wye-Delta’’ starters: Also refer to Figure 24. A. Test for transition complete contact open (2A1-J12-2) –160 to 240 msec. An MMR diagnostic will be generated if the contact is closed. B. Delay time - 20 msec. C. Close start contactor (2K1) and check for no current - 500 msec.
Control Sequence of Operation Now that the compressor motor (4M1) is running in the ‘‘Delta’’ configuration, the inlet guide vanes will modulate, opening and closing to the chiller load variation by operation of the stepper vane motor actuator (4M2) to satisfy chilled water setpoint. The chiller continues to run in its appropriate mode of operation: Normal, Softload, Limit Mode, etcetera.
Control Sequence of Operation Figure 24. Test and start timing sequence Steps A to F: Starter Integrity Test. Steps F to N: Starter Timing Interval Minimum A. (Test for transition complete input open) B. (Just delay time) C. (Close 1M (2K1) Contactor and test for no current.) (Starter integrity test) D. (Hold 1M (2K1) Contactor and test for no current.) (Starter integrity test) E. (Open 1M (2K1) Delay time F. (Close Shorting Contactor (2K3) and and test for no current, then wait for Start command.
Control Sequence of Operation Current passing through fuse 1F2 reaches 2 normally open parallel sets of contacts: those of refrigerant and oil pump relay (1A7-J2-5 to 1), and the start contactor 2K1-aux. Connecter at module 1A7-J2-2 to 4. Note: While the (1A7-J2-5 to 1) relay automatically is closed by the main processor 1A22 as a part of the start sequence. It can also be closed manually by changing the oil pump status to “ON” in the manual over ride mode menu of DynaView™.
Machine Protection and Adaptive Control Momentary Power Loss (MPL) Protection. Improved power measurement and protection algorithms allow the unit to accommodate more power anomalies than ever. If the chiller must shut down, faster restarts get the machine up and running as soon as possible. Momentary power loss (MPL) detects the existence of a power loss to the compressor motor and responds by initiating the disconnection of the compressor motor from the power source.
Machine Protection and Adaptive Control Current Overload Protection Motor currents are continuously monitored for over current protection and locked rotor protection. This protects the Chiller itself from damage due to current overload during starting and running modes but is allowed to reach full load amps. This overload protection logic is independent of the current limit.
Machine Protection and Adaptive Control Current Limit Protection Current Limit Protections exist to avoid motor current overload and damage to the compressor motor during starting and running. Compressor motor current is continuously monitored and current is controlled via a limit function that to prevent running into over current diagnostic trips.
Machine Protection and Adaptive Control Differential to Start or Stop The Differential to Start setpoint is adjustable from 1 to 10°F (0.55 to 5.55°C) and the Differential to Stop setpoint adjustable from 1 to 10°F (0.55 to 5.55°C). Both setpoints are with respect to the Active Chilled Water Setpoint. When the chiller is running and the LWT (Leaving Water Temperature) reaches the Differential to Stop setpoint the chiller will go through its shutdown sequence to AUTO. (Refer to Figure 10.
Machine Protection and Adaptive Control Evaporator Limit Evaporator refrigerant temperature is continuously monitored to provide a limit function that prevents low refrigerant temperature trips which allows the chiller to continue to run at a reduced load instead of tripping off at the Low Evaporator Refrigerant Temperature Cutout Setpoint (LRTC).
Machine Protection and Adaptive Control High Evaporator Leaving Water Temperature Cutout (Main Processor Software Revision 6.0 and higher) A High Evaporator Water Temperature Diagnostic was implemented that will turn off the Evaporator Water pump relay if the relay is being forced on due to a Loss of Evaporator Water Flow Lost diagnostic (MAR Diagnostic) and the Evaporator Leaving Water Temperature exceeds an adjustable High Evaporator Water Temperature Cutout for 15 continuous seconds.
Machine Protection and Adaptive Control Figure 27. Cutout strategy Limit Loading: The potential to limit loading increases as the saturated evaporator temperature approaches the evaporator limit setpoint. Unload: The potential to unload increases as the saturated evaporator temperature falls further below the evaporator limit setpoint.
Machine Protection and Adaptive Control Evaporator Variable Flow Compensation This option includes transducers for the differential evaporator and condenser water pressures (psid). Flow switches or some other means to prove flow are still required and must be field connected. The following data will be shown at the DynaView and TechView displays and at Tracer Summit.
Machine Protection and Adaptive Control Restart Inhibit. This function provides short cycle protection for the motor, and indirectly also short cycling protection for the starter since the starter is designed to operate the motor under all the conditions of motor performance. The operation of the restart inhibit function is dependent upon two setpoints. The Restart Inhibit Free Starts (1-5, 3 default), and the Restart Inhibit Start to Start Timer (10-30 min, 20 default).
Machine Protection and Adaptive Control High Vacuum Lockout The oil sump pressure is below the lockout setpoint. Starting of compressor is inhibited as a result. Low Oil Temperature Start Inhibit The oil temperature is at or below the low oil temperature start inhibit setpoint (143°F/61.7°C). The heater is energized to raise the oil temperature. Low oil temperature is indicative of refrigerant dilution in the oil.
Machine Protection and Adaptive Control Oil Temperature Control The oil heater is used to maintain the oil temperature within +/- 2.5°F (1.4°C) of the oil temperature control setpoint. The oil heater is commanded off when the oil pump is commanded on. If the oil temperature is at or below the Low Oil Temperature Cutout setpoint, this diagnostic will be issued and stops the compressor. This diagnostic is ignored for the first 10 minutes of compressor run.
Machine Protection and Adaptive Control Controls Chilled Water Reset (CWR) The following equations and parameters apply for CWR. Chilled water reset is designed for those applications where the design chilled water temperature is not required at partload. In these cases, the leaving chilled water temperature setpoint can be reset upward using the CWR features. Return Water When the CWR function is based on return water temperature, the CWR feature is standard.
Machine Protection and Adaptive Control Table 3.
Machine Protection and Adaptive Control Reset Ratio: Start Reset = Outdoor Air Start Reset The Reset Ratio is displayed as a percentage. To use it in the above equation it must be converted to it’s decimal form. Example of Calculating Reset for Outdoor Air Temperature: Reset Ratio percent /100 = Reset Ratio decimal Example of converting Reset Ratio: If the Reset Ratio displayed on the CLD is 50 percent then use (50/100)= .
Machine Protection and Adaptive Control Figure 29. Reset function for return CWR Figure 30. Reset function for return CWR Note: This graph assumes Maximum Reset is set to 20 degrees.
Machine Protection and Adaptive Control Example of Calculating Return Reset: If: Reset Ratio = 50% Start Reset = 25 TWE = 65 TWL = 45 Maximum Reset = 8 CVHE-SVU01E-EN How many Degrees of Reset will there be? How many Degrees of Reset will there be? Degrees of Reset = Reset Ratio*(Start Reset - (TWE-TWL)) Degrees of Reset = .5*(25-(65-45)) Degrees of Reset = 2.5 Degrees of Reset = Reset Ratio*(Start Reset - (TWE-TWL)) Degrees of Reset = .7*(20-(60-53)) Degrees of Reset = 9.
Machine Protection and Adaptive Control Figure 31. Return CWR Figure 32.
Unit Startup Unit Start-Up Procedures Daily Unit Start-Up 1. Verify the chilled water pump and condenser water pump starter are in “ON” or “AUTO”. 2. Verify the cooling tower is in “ON” or “AUTO”. 3. Check the oil tank oil level; the level must be visible in or above the lower sight glass. Also, be sure to check the oil tank temperature; normal oil tank temperature before start-up is 140°F to 145°F (60 to 63°C). Note: The oil heater is energized during the compressor off cycle.
Unit Startup When the cooling requirement is satisfied, the UCP originates a “Shutting down” signal. The inlet guide vanes are driven closed for 50 seconds, and the unit enters a 3minute post-lube period. The compressor motor and condenser water pump starter are de-energized immediately, but the oil pump continues to run during this 3-minute interval; the evaporator pump will continue to run. 4. Open all of the valves in the evaporator chilled water circuit.
Unit Shutdown Unit Shutdown Procedures Daily Unit Shutdown Note: Refer to Start-Run Shutdown sequence in General Information Overview Sequence of Operation. 1. Press STOP. 2. After compressor and water pumps shutdown turn Pump Contactors to OFF or open pump disconnects. Seasonal Unit Shutdown CAUTION Oil Pump Heater Operation! manual should be performed by qualified Trane service technicians. Note: During extended shutdown, be sure to operate the purge unit for a 2hour period every two weeks.
Periodic Maintenance Overview This section describes the basic chiller preventive maintenance procedures, and recommends the intervals at which these procedures should be performed. Use of a periodic maintenance program is important to ensure the best possible performance and efficiency from a CenTraVac® chiller. Recommended purge maintenance procedures for the Purifier Purge unit are covered by PRGD-SVU01A-EN or the latest revision which can be obtained at the nearest Trane office.
Periodic Maintenance WARNING Hazardous Voltage w/ Capacitors! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s literature for allowable waiting periods for discharge of capacitors.
Periodic Maintenance [ ] Complete all recommended quarterly maintenance procedures. [ ] Lubricate the vane control linkage bearings, ball joints, and pivot points; as needed a few drops of light machine oil (SAE-20) is sufficient. [ ] Lubricate vane operator tang o-rings as described in the maintenance section. [ ] Lubricate the oil filter shutoff valve o-rings by removing the pipe plug and adding several drops of Trane OIL00022. Replace plug.
Oil Maintenance Compressor Oil Change on CVHE, CVHF, CVHG Recommendations are to subscribe to an annual oil analysis program rather than automatically change the oil as part of scheduled maintenance. Change the oil only if indicated by the oil analysis. Use of an oil analysis program will reduce the chillers overall lifetime waste oil generation and minimize refrigerant emissions.
Oil Maintenance Replacing Oil Filter Replace oil filter: (1) annually, (2) at each oil change, (3) or if erratic oil pressure is experienced during chiller operation. Oil Filter Replacement Use the following procedure to service the oil filter. Refer to Figure 34. 1. Run the oil pump for two to three minutes to insure that the oil filter is warmed up to the oil sump temperature. 2. Turn the oil pump motor off. 3.
Maintenance Other Maintenance Requirements Compressors using new seal technology will not use O-rings. The O-ring has been replaced by Loctite 515 applied at a minimum film thickness of .010 applied across the width of the flange. The current jack bolt holes remain for disassembly. CAUTION Oil Supply System Problems! Plugging of oil supply system could lead to bearing failure.
Maintenance DO NOT LEAVE GREASE FITTINGS INSTALLED. If grease fittings have been used for this procedure then they MUST BE REMOVED before returning the unit to service. Grease fittings are not vacuum-tight and will become a leak path. 9. Using a clean wooden dowel or other similar tool, remove excess grease from the remaining open lubrication port. 10. Clean and then lightly coat the threads of the plug with Rheolube grease and re-install it into the lubrication port.
Maintenance Refrigerant Charge WARNING Contains Refrigerant! System contains oil and refrigerant and may be under positive pressure. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant additives.
Maintenance Recovery and Recycle Connections Cleaning the Condenser To facilitate refrigerant removal and replacement, newer-design CVHE, CVHF and CVHG units are provided with a 3/4-inch vapor fitting with shutoff valve on the chiller suction and with a 3/4-inch liquid connection with shutoff valve at the bottom of the evaporator shell. (Refer to Refrigerant Handling Guidelines.
Maintenance Condenser tube fouling is indicated when the approach temperature (the difference between the condensing refrigerant temperature and the leaving condenser water temperature) is higher than predicted. If the annual condenser tube inspection indicates that the tubes are fouled, two cleaning methods, mechanical and chemical, can be used to rid the tubes of contaminants. Use the mechanical cleaning method to remove sludge and loose material from smooth-bore tubes.
Maintenance Purge System Unit Preparation Because some sections of the chiller’s refrigeration system operate at less-than-atmospheric pressure, the possibility exists that air and moisture may leak into the system. If allowed to accumulate, these noncondensables become trapped in the condenser; this increases condensing pressure and compressor power requirements, and reduces the chiller’s efficiency and cooling capacity. The following steps are necessary in order to properly prepare a unit for storage.
Maintenance WARNING Hazardous Voltage w/ Capacitors! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s literature for allowable waiting periods for discharge of capacitors. Verify with an appropriate voltmeter that all capacitors have discharged.
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Trane A business of American Standard Companies www.trane.com For more information contact your local district office or e-mail us at comfort@trane.com Literature Order Number CVHE-SVU01E-EN File Number SL-RF-CTV-CVHE-SVU01E-EN-0405 Supersedes CVHE-SVU01D-EN 604 Stocking Location La Crosse Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice.
