Operation Maintenance Duplex CDHF, CDHG Water Cooled CenTraVac™ With CH530 X39640670030 CDHF-SVU01C-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) 28 Operator Interface 30 Chilled Water Setpoint 38 Inter Processor Communication (IPC) 51 Control System Components 52 Controls Sequence of Operation 67 Machine Protection and Adaptive Control 72 Unit Startup 89 Unit Shutdown 91 Periodic Maintenance 92 Oil Maintenance 95 Maintenance 97 Forms CDHF-SVU01C-EN 104 3
General Information Literature change Unit Nameplate Applicable to CDHF, CDHG 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 CDHF, CDHG are covered in this manual. This includes both 50 and 60 Hz. CDHF and CDHG centrifugal chillers equipped with the Tracer CH530 Chiller Controller system.
General Information Model Number - An example of a typical duplex centrifugal chiller model number is: CDHF2100AA0BC2552613C0B203B0 B20KJAC1GW40C111340A010 Digit: Description 1st-2nd CD = CenTraVac® Duplex - 2 compressors 3rd H =Direct Drive 4th F = Development Sequence (F - 2 Stage) (G - 3 Stage) 5th-8th 2100 = Nominal total compressor tonnage 9th A = Unit Voltage A = 380V-60Hz-3Ph B = 440V-60Hz-3Ph C = 460V-60Hz-3Ph D = 480V-60Hz-3Ph E = 575V-60Hz-3Ph F = 600V-60Hz-3Ph G = 2300V-60Hz-3Ph H = 2400V-60Hz 3
General Information V = 1890 W = 2060 X = 1475 Z = 560 - 3 stage 935 - 2 stage Y = 500 - 3 stage 835 - 2 stage 1 = 630 - 3 stage 2245 - 2 stage 2 = 800 - 3 stage 2345 - 2 stage 3 = 900 - 3 stage 2450 - 2 stage 4 = 1000 - 3 stage 2560 - 2 stage 5 = 1120 - 3 stage 2675 - 2 stage 6 = 1250 7 = 1600 8 = 1800 9 = 750 th 34 A = Starter Type A = Star-Delta Unit Mounted C = Star Delta Remote Mounted E = X-Line Full Volt Remote Mounted F = Autotransformer Remote Mounted G = Primary Reactor Remote Mounted H = X-Line
General Information Commonly Used Acronyms For convenience, a number of acronyms are used throughout this manual.
General Information Overview CDHF - CDHG See Figure 1 for General Unit components. Each Chiller unit is composed of the following components as viewed when facing the control panel front side: • Common Evaporator and Common Condenser • Compressors and Motor 1 (Left hand), 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) (not shown).
General Information Figure 2.
General Information Cooling Cycle Duplex Chillers have two refrigerant circuits that operate as their own independent circuits. These circuits are discussed as individual chiller refrigeration units in the following discussion. The sequence of operation of the two refrigeration circuits is discussed in a later section. 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.
General Information Figure 3. Pressure enthalpy curve (3 stage compressor) Figure 4.
General Information Figure 5. Pressure enthalpy curve (2 stage compressor) 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 CTV Duplex Sequence Of Operation This section will provide basic information on chiller operation for common events. With microelectronic controls, ladder diagrams cannot show today’s complex logic, as the control functions are much more involved than older pneumatic or solid state controls. Adaptive control algorithms can also complicate the exact sequence of operation. This section and its diagrams attempt to illustrate common control sequences.
General Information Figure 8. CDHE/F/G sequence of operation: auto to running This diagram shows the sequence of operations for a start of the first compressor on a duplex chiller. The ‘First’ compressor will be determined by the type of duplex start selected. Figure 9. CDHE, CDHF, and CDHG sequence of operation: running Staging Second Compressor On: This diagram shows the sequence of operations where the ‘First’ compressor is all ready running, and the ‘second’ compressor is staged on.
General Information Staging Second Compressor Off: This diagram shows the sequence of operations where there is no longer a need to run the ‘Second’ compressor, so it is staged off. The ‘First’ and ‘Second’ compressor will be determined by the type of duplex start selected Figure 10. CDHE/F/G sequence of operation: staging second compressor off Satisfied Setpoint: This diagram shows the sequence of operations where the setpoint has been satisfied, and the last compressor is staged off. Figure 11.
General Information Duplex Compressor Sequencing Four methods (Two fixed sequence methods, a balanced start and hour’s method, and a no staging method) are provided for order of a compressor sequencing on CTV Duplex chillers. The desired method is selectable at startup via the service tool. The application can decide to either balance the wear burden among the unit’s compressors, to start the most efficient compressor, or to simultaneously start and stop both compressors to minimize startup pull down time.
General Information Fixed Sequence – Compressor 2 / Compressor 1 If the chiller is in the Auto mode and all interlocks have been satisfied, compressor 2 will be started based on the leaving water temperature rising above the “Differential to Start” setting. Compressors 1 will stage on when the overall chiller average capacity exceeds Stage on Load point for 30 seconds. The stage on load point is adjustable up to 50%.
General Information Sequencing - Balanced Starts and Hours When desired to balance the wear between the compressors. This method will extend the time between maintenance on the lead compressor. When balanced starts and hours is selected, the compressor with the fewest starts will start. If that compressor is unavailable to start due to a circuit lockout (including restart inhibit) or a circuit diagnostic, then the other compressor will be started.
General Information Simultaneous Compressor Start/ Stop Both compressors will start in close succession to minimize the time it takes for the chiller to reach full load. Some process applications need the chiller to start and generate capacity as fast as possible. This method will start both compressors, slightly staggered to prevent doubling of the current inrush, but will generally control the chiller as if there were only one compressor.
General Information Compressor Load Balancing Duplex chillers with CH530 control will balance the compressor load by giving each compressor the same load command. The load command will be converted to IGV position that will be the same on each compressor. Balancing compressor load results in the best overall efficiency and with both circuits operating with nearly the same refrigerant pressures.
General Information Oil and Refrigerant Pump Compressor Lubrication System A schematic diagram of the compressor lubrication system is illustrated in Figure 16. (This can be applied to circuit 1 or 2.) 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 16.
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 17.
General Information Ice Machine Control UCP 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 from “Front Panel”, or if hardware is specified the UCP will accept either an isolated contact closure (1A19 Terminals J2-1 and J2-2 (Ground) ) or a remote communicated input (Tracer) to initiate the ice building mode where the unit runs fully loaded at all times.
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.
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 21. 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 22 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 23 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 34 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 – Limit Running – Limit Running – Limit Running – Limit Running – Limit Running – Limit Preparing To Shutdown Shutting Down Shutting Down Shutting Down CDHF-SVU01C-EN Sub Level Mode Motor Temperature Inhibit: Motor Temperature / Inhibit Temperature Restart Time Inhibit: MIN:SEC High Vacuum Inhibit
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. Main Screen Data Fields Table Description 1. Chiller Mode (>> submodes) 2. Circuit 1 Mode (>> submodes) 3. Circuit 2 Mode (>> submodes) 4. Evap Ent/Lvg Water Temp 5. Cond Ent/Lvg Water Temp 6.
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 To aid in comparing the status of both circuits, the heading on the Reports list screen has buttons as indicated in the table above (i.e., System, Ckt1, and Ckt2). The selected button is darkened, presented in reverse video, or some how changed to indicate it is the selected choice. Report Menu Description 1. Evaporator 2. Condenser 3. Compressor 4. Motor 5. Purge 6.
Operator Interface Report name: System Evaporator Description 1. Evap Entering Water Temp 2. Evap Leaving Water Temp 3. Evap Water Flow Switch Status 4. Evap Differential Wtr Press 5. Approx Evap Water Flow 6. Approx Chiller Capacity Resolution + or – XXX.X + or – XXX.X (Flow, No Flow) XXX.X XXXX XXXX Units Temperature Temperature Dependencies Diff Pressure Flow Tons If option installed If option installed If option installed Report name: Circuit Evaporator Description 1. Evap Sat Rfgt Temp 2.
Operator Interface Report name: System ASHRAE Chiller Log Description Resolution 1. Current Time/Date XX:XX mmm dd, yyyy 2. Chiller Mode: 3. Active Chilled Water Setpoint: XXX.X 4. Active Current Limit Setpoint: XXX 5. Refrigerant Type: 6. Refrigerant Monitor: XXX.X 7. Evap Entering Water Temp: XXX.X 8. Evap Leaving Water Temp: XXX.X 9. Evap Water Flow Switch Status: 10. Evap Differential Wtr Press: XXX.X 11. Approx Evap Water Flow: XXX.X 12. Approx Chiller Capacity: XXXX 13. Cond Entering Water Temp: XXX.
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 : To change chilled water setpoint, first select the settings tab screen. Chilled water setpoint to within the chiller sub-menu. (See next page for setpoint listing.) Upon selecting a Settings list (i.e. Chiller, Circuit 1 Purge, System Mode Override, etc.
Operator Interface Chiller Description 1. Front Panel Control Type 2. Front Panel Chilled Water Setpt Resolution or (Enumerations), Default (Chilled Water, Hot Water), Chilled Water (3) + or – XXX.X 3. Front Panel Hot Water Setpt (3) + or – XXX.X 4. Front Panel Current Limit Setpt XXX (4) 5. Front Panel Base Load Cmd On/Auto 6. Front Panel Base Load Setpt XXX 7. Front Panel Ice Build Cmd On/Auto 8. Front Panel Ice Termn Setpt XXX.X 9. Ice to Normal Cool Timer Setpt (0-10), 5 min 10.
Operator Interface System Mode Overrides Description 1. Compressor Control Signal Resolution or (Enumerations), Default XXX / (Auto,Manual [0-100] ), Auto Units Enum 2. Evap Water Pump (Auto, On), Auto Enum 3. Cond Water Pump (Auto, On), Auto Enum Circuit Mode Overrides Description 1. Oil Pump Resolution or (Enumerations), Default (Auto, On), Auto Units Enum 2. Clear Restart Inhibit Timer 3. Purge Exhaust Circuit Test 4. Purge Regen Cycle 5.
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. The analog setting subscreen is similar but offers an Auto/Manual radio button and value setting. An Auto/Manual selection is necessary to set the mode to override. Subsequently, when an arrow key is depressed that new value is assumed.
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.
Control System Components Figure 24.
Control System Components CDHF-SVU01C-EN 53
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 Temp Sensor Input 1F1 Controls Package Standard #1 (as required) #2 Standard Relay #1 Purpose Converts 24 vac to 24 vdc Conve
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 TRMM TRM4 (Tracer Comm 4 interface) 1A14 Optional TRM4 Communication or Interface Module LCI-C Tracer Communications CDRP (Condenser Refrigerant Pressure Output) 1A15 Optional Dual Analog CDRP Signal #2 Input/output Module Condenser Refrigerant Pressure output J2-1 COMM+, J2-2 COMM -J2-3, COMM +J2-4, COMM -, J2-4 Output #2, J2-6 Ground EPRO (Enhanced Protection) 4R22 EPRO Condenser Refrigerant Pressure Transducer 4R16 EPRO Compressor Discharge Refrigerant Temperature Sensor.
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, 4-20 mA 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/ output Module 1A16 Optional Dual GBAS Signal #1 Analog Input/ output Module 1A16 Optional Dual GBAS Signal #2 Analog Input/ output Module Percent RLA Compressor Output J2-1 Output #1, J2-3 Ground External Current limit Setpoint J2-2 Input #1, J2-3 Ground Chilled Water Reset input, or External Chiller Water Setpoint J2-5 Input #2, J2-6 Ground Percent RLA Output 2 to 10 Vdc corresponding
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 corresponds to a default 34°F to 65°F (-17.8 to 18.3°C) 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 System Components CDHF-SVU01C-EN 65
Control System Components 66 CDHF-SVU01C-EN
Control Sequence of Operation Electrical Sequence This section will acquaint the operator with the control logic governing CDHF/CDHG 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. Note: The typical wiring diagrams are representative of standard units and are provided only for general reference.
Control Sequence of Operation When less than 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) 4M4 (extended capacity) to satisfy chilled water setpoint. The chiller continues to run in its appropriate mode of operation: Normal, Softload, Limit Mode, etcetera. As explained in the General Information section.
Control Sequence of Operation Figure 24. Test and start timing sequence Steps A to F: Starter Integrity Test Steps G 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 circuit breaker 1Q5 reaches 2 normally open parallel sets of contacts: those of refrigerant and oil pump relay (1A7J2-5 to 1), and the 2K11 interlocking relay. Connected 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 Low Refrigerant Temperature Cutout The purpose of the low evaporator refrigerant temperature protection is to prevent water in the evaporator from freezing. When the Low Evaporator Refrigerant Temperature Cutout (LRTC) trip point is violated, a latching diagnostic indicating the condition is displayed. The Low Evaporator Refrigerant Temperature Diagnostic is active in both the Running and Stopped modes.
Machine Protection and Adaptive Control Figure 31. 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 Condenser Limit Condenser pressure is continuously monitored to provide a limit function that prevents High Pressure Cutout (HPC) trips. This protection is called Condenser Refrigerant Pressure Limit, or High Pressure Limit. A fully loaded compressor, operating at high Evaporator Leaving Water Temperature (ELWT) and high condenser temperatures causes high condenser pressures.
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 (10-30min, 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 above the High Oil Temperature Cutout setpoint this diagnostic will be issued - which will stop the compressor.
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 33. Reset function for return CWR Figure 34. 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 CDHF-SVU01C-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 35. Return CWR Figure 36.
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 both oil tank oil level(s); 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). 4. Note: Each 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! CONTROL POWER DISCONNECT SWITCH MUST REMAIN CLOSED TO ALLOW OIL SUMP HEATER OPERATION. Failure to do this will allow refrigerant to condense in the oil pump. 3.
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 EarthWise Purge unit are covered by PRGD-SVU01AEN or the latest revision which can be obtained at the nearest Trane office.
Periodic Maintenance WARNING Weekly Maintenance Hazardous Voltage w/Capacitors! Every 3 Months 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. container minimally and more often if the purge is operated excessively. [ ] Lubricate the vane control linkage bearings, ball joints, and pivot points; as needed a few drops of light machine oil (SAE-20) is sufficient. Also, apply one or two drops of oil on the vane operator shaft and spread it into a very light film; this will protect the shaft from moisture and rust.
Oil Maintenance Compressor Oil Change It is recommended to change the oil and oil filter: • After the first 1000 hours of chiller operation. For a chiller operated continuously this oil and oil filter change may be performed as soon as 1.5 months after first start-up, for a chiller operated intermittently it may be 4 or 6 months after first start-up. • Again at the first scheduled annual mainenance, preferably within 6 to 12 months of the first oil change. Note: Use only Trane OIL00022.
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 CDHF, CDHG units are provided with a 3/4inch vapor fitting with shutoff valve on the chiller suction and with a 3/4inch liquid connection with shutoff valve at the bottom of the evaporator shell.
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 Live Electrical Components! During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury. 6.
CDHF-SVU01C-EN
CDHF-SVU01C-EN 105
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CDHF-SVU01C-EN 107
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CDHF-SVU01C-EN 109
CDHF-SVU01C-EN
CDHF-SVU01C-EN 111
CDHF-SVU01C-EN
CDHF-SVU01C-EN 113
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CDHF-SVU01C-EN 115
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 CDHF-SVU01C-EN File Number SV-RF-CTV-CDHF-SVU01C-EN-405 Supersedes CDHF-SVU01B-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.
