Trane Water Dispenser CVHE SVU01E ENX39640712050 User Manual

Operation

Maintenance

Water Cooled CenTraVac^™

With CH530

X39640712050

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Contents

Warnings and Cautions

General Information

100

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

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General

Information

3. Product Coding Block

Unit Nameplate

Literature change

The CVHE, CVHF and CVHG models

are defined and built using the

product definition and selection

(PDS) system. This system describes

the product offerings in terms of a

product coding block which is made

up of feature categories and feature

codes. An example of a typical

product code block is given on this

page. The coding block precisely

identifies all characteristics of a unit.

Applicable to CVHE, CVHF, CVHG

The unit nameplate is located on the

left side of the unit control panel.

The following information is

About this manual

Operation and maintenance

provided on the unit nameplate.

information for models CVHE, CVHF

and CVHG are covered in this

manual. This includes both 50 and 60

Hz. CVHE, CVHF and CVHG

1. Serial Number

The unit serial number provides the

specific chiller identity. Always

provide this serial number when

calling for service or during parts

identification..

centrifugal chillers equipped with the

Tracer CH530 Chiller Controller

system. Please note that information

pertains to all three chiller types

unless differences exist in which

case the sections are broken down

by Chiller type as applicable and

discussed separately.

2. Service Model Number

4. Identifies unit electrical

The service model represents the unit requirements

as built for service purposes . It

5. Correct operating charges and type

identifies the selections of variable

unit features required when ordering

replacements parts or requesting

service.

of refrigerant

By carefully reviewing this

information and following the

instructions given, the owner or

operator can successfully operate

and maintain a CVHE, CVHF or CVHG

unit.

6. Unit Test Pressures and Maximum

Operating Pressures

7. Identifies unit Installation and

Operation and Maintenance manuals

Note: Unit-mounted starters are

identified by a separate number

found on the starter.

8. Drawing numbers for Unit Wiring

Diagrams

If mechanical problems do occur,

however, contact a qualified service

organization to ensure proper

diagnosis and repair of the unit.

Typical Product Description Block

MODL CVHE

HRTZ 60

DSEQ 2R

NTON 320

VOLT 575

CPIM 222

REF 123

TEST AIR

TYPE SNGL

EVTH 28

CPKW 142

EVSZ 032S

EVWT NMAR

CDTM IECU

CDWC STD

CDCO VICT

ECTY WEOR

SPKG DOM

GNSL NO

EVTM IECU

EVWC STD

EVCO VICT

CDSZ 032S

CDWT NMAR

CDTY STD

PURG PURE

HHOP NO

EVBS 280

EVPR 150

CDTH 28

Note: The CH530 controller was first

applied to CVHE with Design

Sequence “3K”, and to CVHF with

Design Sequence “1W”.

EVWP 2

EVWA LELE

CDBS 250

CDPR 150

TSTY STD

WCNM SNMP

GENR NO

HGBP WO

SRTY USTR

CDWP 2

CDWA LELE

ORSZ 230

OPTI CPDW

SOPT SPSH

AGLT CUL

PNCO TERM

ACCY ISLS

CNIF UCP

LUBE SNGL

SRRL 207

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An example of a typical model

number is:

C = (14^thdigit) Control Enclosure

S = Special

0 = (35^thdigit) Unit Option

1 = (36^thdigit) Control: Enhanced

protection

G = (37^thdigit) Control: Generic BAS

1 = (38^thdigit) Control: Extended

operation

4 = (39^thdigit) Tracer communication

interface

C = (40^thdigit) Control: Condenser

refrigerant pressure

1 = (41^stdigit) Control: Tracer IO

0 = (42^nddigit) Special Options

W = (43^nddigit) Control: Water flow

control

1 = (44^thdigit) Control: Chilled water

reset

A = (45^thdigit) Control: Heat Recovery

temperature sensors

0 = (46^thdigit) Gas Powered Chiller

3 = (47^thdigit) Compressor Motor

Frame Size

B = (48^thdigit) Volute Discharge

Angle

1 = (49^thdigit) Control: Operating

status

W = (50^thdigit) Industrial Chiller

Package (INDP)

C = Standard Control Enclosure

CVHF091NAL00ACU2758W7E8TB

C0000000K01G14C10W1A03B1

U = (15^thdigit) Compressor Motor

Power (kw)

275 = (16^th, 17^th, and 18^thdigit)

Compressor Imp Cutback

8 = (19^thdigit) Evaporator Shell Size

W = (20^thdigit) Evaporator Tube

Bundle

7 = (21^stdigit) Evaporator Tubes

E = (22^nddigit) Evaporator Waterbox

8 = (23^rddigit) Condenser Shell Size

T = (24^thdigit) Condenser Tube

Bundle

B = (25^thdigit) Condenser Tubes

C = (26^thdigit) Condenser

Waterboxes

0 = (27^thdigit) Heat Recovery

Condenser Shell Size

0 = (28^thdigit) Heat Recovery

Condenser Tube Bundle

0 = (29^thdigit) Heat Recovery

Condenser Tubes

0 = (30^thdigit) Heat Recovery

Condenser Waterboxes

0 = (31^stdigit) Auxiliary Condenser

Size and Waterboxes

0 = (32^nddigit) Auxiliary Condenser

Tubes

0 = (33^rddigit) Orifice Size

K = (34^thdigit) Orifice Size

Model Number Digit Identification

C = (1^stdigit) CenTraVac^®Hermetic

V = (2^nddigit) CenTraVac^®Hermetic

H = (3^rddigit) Direct Drive

F = (4^thdigit) Development sequence

091 = (5^th, 6^th, and 7^thdigit) Nominal

compressor tonnage

N = (8^thdigit) Unit Voltage

A = (9^thdigit) Unit Type

A = Cooling Condenser

B = Heat Recovery Condenser

C = Auxiliary Condenser

D = Free Cooling Option

S = Special

L0 = (10^thand 11^thdigit) Design

Sequence

0 = (12^thdigit) Hot Gas By-Pass

W = With HGB

0 = Without HGB

S = Special

A = (13^th) Starter type

A = Star-Delta Unit Mounted

C = Star Delta – Remote Mounted

E = X-Line Full Volt – Remote

Mounted

F = Autotransformer – Remote

Mounted

0 = Without INDP

W = With INDP

1 = (51^stdigit) Control Power

Transformer (CPTR)

0 = Without CPTR

1 = With CPTR

G = Primary Reactor – Remote

Mounted

H = X-Line Full Volt – Unit Mounted

J = Autotransformer – Unit

Mounted

S = Special

B = (52^nddigit) Motor and Terminal

Board Configuration

A = Six Lead Low Voltage

B = Three Lead Medium

Voltage

K = Primary Reactor – Unit

Mounted

L = Solid State – Unit Mounted

M = Solid State – Floor Mounted

N = Solid State – Wall Mounted

P = Adaptive Frequency Drive - Unit

Mounted

C = Six Lead Medium

Voltage

S = Special

R = Customer Supplied

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HGBP = Hot Gas Bypass

Control Optional Packages

Commonly Used Acronyms

For convenience, a number of

acronyms are used throughout this

manual. These acronyms are listed

alphabetically below, along with the

“translation” of each:

HVAC = Heating, Ventilating, and Air

Conditioning

OPST Operating Status Control

GBAS Generic Building Automation

Interface

IE = Internally-Enhanced Tubes

IPC = Interprocessor Communication

LBU = La Crosse Business Unit

LCD = Liquid Crystal Display

LED = Light Emitting Diode

EXOP Extended Operation

AFD = Adaptive Frequency Drive

CDRP Condenser Pressure

Transducer

ASME = American Society of

Mechanical Engineers

TRMM Tracer Communications

FRCL Free Cooling

ASHRAE = American Society of

Heating, Refrigerating and Air

Conditioning Engineers

MAR = Machine Shutdown Auto

Restart (Non-Latching where chiller

will restart when condition corrects

itself.)

HGBP Hot Gas Bypass

WPSR Water pressure sensing

EPRO Enhanced Protection

ACOS Auxillary Condenser sensors

CWR Chiller Water reset outdoor

BAS = Building Automation System

CABS = Auxiliary Condenser Tube-

Bundle S

MMR = Machine Shutdown Manual

Restart (Latching where chiller must

be manually reset.)

CDBS = Condenser Bundle Size

CDSZ = Condenser Shell Size

CH530 = Tracer CH530 Controller

DV = DynaView^™Clear Language

Display, also know as the Main

Processor (MP)

MP = Main Processor

PFCC = Power Factor Correction

Capacitor

PSID = Pounds-per-Square-Inch

(differential pressure)

PSIG = Pounds-per-Square-Inch

(gauge pressure)

CWR = Chilled Water Reset

CWR’ = Chilled Water Reset Prime

UCP = Unit Control Panel

DTFL = Design Delta-T at Full Load

(i.e., the difference between entering

and leaving chilled water

temperatures)

LLID = Low Level Intelligent Device

(Sensor, Pressure Transducer, or

Input/output UCP module)

RLA = Rated Load Amps

ELWT = Evaporator Leaving Water

Temperature

RTD = Resistive Temperature Device

Tracer CH530= Controls Platform

utilized on this Chiller

ENT = Entering Chilled Water

Temperature

TOD = Temperature Outdoor

FC = Free Cooling

GPM = Gallons-per-minute

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A heat-recovery or auxiliary

condenser can be factory-added to

the basic unit assembly to provide a

heat-recovery cycle.

— water-cooled condenser,

— related interconnecting piping.

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.

Figure 1. General CVHE and CVHG unit components

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Figure 1. General CVHE and CVHG unit components - continued

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Figure 2. Illustrates the general component layout of a typical CVHF chiller

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condenser. Baffles within the

condenser shell distribute the

compressed refrigerant gas evenly

across the condenser tube bundle.

Cooling tower water circulated

through the condenser tubes absorbs compressed, and then discharged

heat from the refrigerant, causing it to into the condenser.

condense. The liquid refrigerant then

Baffles within the condenser shell

passes through orifice plate ‘‘A’’ and

distribute the compressed refrigerant

into the economizer.

Compressed gas from the first-stage

impeller is discharged through the

second-stage variable guide vanes

and into the second-stage impeller.

Here, the refrigerant gas is again

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.

gas evenly across the condenser

The economizer reduces the energy

requirements of the refrigerant cycle

by eliminating the need to pass all

gaseous refrigerant through three

stages of compression. See Figure 3.

Notice that some of the liquid

refrigerant flashes to a gas because

of the pressure drop created by the

orifice plates, thus further cooling the

liquid refrigerant. This flash gas is

then drawn directly from the first

(Chamber A) and second (Chamber

B) stages of the economizer into the

third-and second-stage impellers of

the compressor, respectively.

tube bundle. Cooling tower water,

circulated through the condenser

tubes, absorbs heat from the

The gaseous refrigerant is then

drawn through the eliminators

(which remove droplets of liquid

refrigerant from the gas) and first-

stage variable inlet guide vanes, and

into the first stage impeller.

refrigerant, causing it to condense.

The liquid refrigerant then flows out

of the bottom of the condenser,

passing through an orifice plate and

into the economizer.

The economizer reduces the energy

requirements of the refrigerant cycle

by eliminating the need to pass all

gaseous refrigerant through both

stages of compression. See Figure 6.

Notice that some of the liquid

refrigerant flashes to a gas because

of the pressure drop created by the

orifice plate, thus further cooling the

liquid refrigerant. This flash gas is

then drawn directly from the

Note: Inlet guide vanes are designed

to modulate the flow of gaseous

refrigerant to meet system capacity

requirements; they also prerotate the

gas, allowing it to enter the impeller

at an optimal angle that maximizes

efficiency at all load conditions.

All remaining liquid refrigerant flows

through another orifice plate ‘‘C’’ to

the evaporator.

CVHE, CVHG Compressor

Compressed gas from the first-stage

impeller flows through the fixed,

second-stage inlet vanes and into the

second-stage impeller.

CVHF Compressor

economizer into the second-stage

impellers of the compressor.

Here, the refrigerant gas is again

compressed, and then discharged

through the third-stage variable guide

vanes and into the third stage

impeller.

All remaining liquid refrigerant flows

out of the economizer, passes

through another orifice plate and into

the evaporator.

Once the gas is compressed a third

time, it is discharged into the

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Figure 3. CVHE, CVHG pressure enthalpy curve

Figure 4. CVHE, CVHG 2-stage economizer

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Figure 5. CVHF pressure enthalpy curve

Figure 6. CVHF single stage economizer

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TechView^™Chiller Service Tool

— For the service technician or

advanced operator

DynaView^™Human Interface

Overview

Controls Operator Interface

Information is tailored to operators,

service technicians and owners

— For the operator

Day-to-day operational information is

presented at the panel. Up to seven

lines of data (English or SI units) are

simultaneously displayed on the ¼

VGA touch-sensitive screen.

Logically organized groups of

information — chiller modes of

operation, active diagnostics,

settings and reports put information

conveniently at your fingertips. See

Operator Interface Section for details.

All chiller status, machine

configuration settings, customizable

limits, and up to 60 active or historic

diagnostics are displayed through

the service tool interface. Without

changing any hardware, we give you

access to the latest and greatest

version of Tracer CH530! A new level

of serviceability using the innovative

TechView^™chiller service tool, a

technician can interact with an

individual device or a group of

devices for advanced

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.

By providing two different tools –

one for daily operation and one for

periodic service — everyone has

easy access to pertinent and

appropriate information.

troubleshooting. LED lights and their

respective TechView^™indicators

visually confirm the viability of each

device. Any PC that meets the system

requirements may download the

service interface software and Tracer

CH530 updates. For more information

on TechView^™visit your local Trane

Service company, or The Trane

Company’s website at

Figure 7. CVHE, CVHF, and CVHG sequence of operation overview

www.trane.com.

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Figure 8. CVHE, CVHF, and CVHG sequence of operation: power up to starting

Figure 9. CVHE, CVHF, and CVHG sequence of operation: running

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Figure 10. CVHE, CVHF, and CVHG sequence of operation: satisfied setpoint

Figure 11. CVHE, CVHF and CVHG sequence of operation: normal shutdown to stopped and run inhibit

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To ensure proper lubrication and

prevent refrigerant from condensing

in the oil tank, a 750-watt heater is

immersed in the oil tank and is used

to warm the oil while the unit is off.

When the unit starts, the oil heater is

de-energized. This heater energizes

as needed to maintain 140° to 145° F

(60-63°C) when the chiller is not

running.

A dual eductor system is used to

reclaim oil from the suction cover

and the evaporator, and deposit it

back into the oil tank. These eductors

use high pressure condenser gas to

draw the oil from the suction cover

and evaporator to the eductors and

then discharged into the oil tank. The

evaporator eductor line has a shut off

valve mounted by the evaporator and

ships closed. Open two turns if

necessary.

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 pressure-

regulating 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. From the

When the chiller is operating, the

temperature of the oil tank is typically

115° to 160°F (46-72°C). The oil return

lines from the thrust and journal

bearings, transport oil and some seal

leakage refrigerant. The oil return

lines are routed into a manifold

under the motor. Gas flow exits the

top of the manifold and is vented to

the Evaporator. A vent line solenoid

is not needed with the refrigerant

pump. Oil exits the bottom of the

manifold and returns to the tank.

Separation of the seal leakage gas in

the manifold keeps this gas out of the

tank.

Liquid refrigerant is used to cool the

oil supply to both the thrust bearing

and journal bearings. On refrigerant

pump units the oil cooler is located

inside the economizer and uses

refrigerant passing from the

condenser to evaporator to cool the

oil. Oil leaves the oil cooler and

flows to both the thrust and journal

bearings.

bearings, the oil drains back to the

manifold under the motor and then

on to the oil tank.

CAUTION

Surface Temperatures!

MAY EXCEED 150°F. Use caution

while working on certain areas of

the unit, failure to do so may result

in minor or moderate injury.

Motor Cooling System

Compressor motors are cooled with

liquid refrigerant, see Figure 12.

The refrigerant pump is located on

the front of the oil tank (motor inside

the oil tank). The refrigerant pump

inlet is connected to the well at the

bottom of the condenser. The

connection is on the side where a

weir assures a preferential supply of

liquid. Refrigerant is delivered to the

motor via the pump. Motor

refrigerant drain lines are routed to

the condenser.

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Figure 12. Oil refrigerant pump

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If the current exceeds the setpoint,

the current limit algorithm unloads.

The “Capacity Limited By High

Current” message normally

displayed while the current limit

routine is active is suppressed while

base loading.

input, an analog input, is at 1A17

terminals J2 – 1 and 3 (Ground)

which sets the external base loading

setpoint, and can be controlled by

either a 2-10Vdc or 4-20ma Signal. At

startup the input type is configured.

The graphs in Figure 13 show the

relationship between input and

percent RLA. While in base loading

the active current limit setpoint is set

to the Tracer or external base load

setpoint, providing that the base load

setpoint is not equal to 0 (or out of

range). If it is out of range, the front

panel current limit setpoint is used.

During base loading, all limits are

enforced with the exception of

current limit. The human interface

displays the message “Unit is

Running Base Loaded”. Hot Gas

Bypass is not run during base

loading. If base loading and ice

making are commanded

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. Industrial

process applications might use this

feature to impose a specific load on

the facility’s elecrical system.

Cogeneration plants might use this

feature to balance the system’s

heating, cooling and electrical

generation.

Base loading can occur via Tracer,

External signal, or front panel.

Tracer Base Loading:

Current Setpoint Range:

(20 - 100) percent RLA

Requires Tracer and Optional Tracer

Communications Module (LLID)

The Tracer commands the chiller to

enter the base load mode by sending

the base load mode request. If the

chiller is not running, it will start

regardless of the differential to start

(either chilled water or hot water). If

the chiller is already running, it will

continue to run regardless of the

differential to stop (either chilled

water or hot water), using the base

load control algorithm. While the unit

is running in base loading, it will

report that status back to the Tracer

by setting “Base Load Status = true”

in the Tracer Status Byte. When the

Tracer removes the base load mode

request (sets the bit to 0). The unit

will continue to run, using the

All chiller safeties and adaptive

control functions are in full effect

when Base Loading control is

enabled. If the chiller approaches full

current, the evaporator temperature

drops too low, or the condenser

pressure rises too high, Tracer CH530

Adaptive Control logic limits the

loading of the chiller to prevent the

chiller from shutting down on a

safety limit. These limits may prevent

the chiller from reaching the load

requested by the Base Loading

signal.

simultaneously, ice making takes

precedence.

An alternative and less radical

approach to Base Loading indirectly

controls chiller capacity. Artifically

load the chiller by setting the chilled

water setpoint lower than it is

capable of achieving. Then, modify

the chiller’s load by adjusting the

current limit setpoint. This method

provides greater safety and control

stability in the operation of the chiller

because it has the advantage of

leaving the chilled water temperature

control logic in effect. The chilled

water temperature control logic

responds quicker to dramatic system

changes, and can limit the chiller

loading prior to reaching an Adaptive

Control limit point.

normal chilled or hot water control

algorithm, and will turn off, only

when the differential to stop has been

satisfied.

Base Loading Control is basically a

variation of the current limit

algorithm. During base loading, the

leaving water control algorithm

provides a load command every 5

seconds. The current limit routine

may limit the loading when the

current is below setpoint. When the

current is within the deadband of the

setpoint the current limit algorithm

holds against this loading command.

External Base Loading:

Current Setpoint Range:

(20 - 100) percent RLA

The UCP accepts 2 inputs to work

with external base loading. The

binary input is at 1A18 Terminals J2-1

and J2-2 (Ground) which acts as a

switch closure input to enter the

base-loading mode. The second

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Figure 13. Base loading with external mA input and with external voltage input

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Ice Machine Control

Figure 14. CVHE, CVHF and CVHG sequence of operation: ice making: running

to ice making

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. Ice building will

be terminated either by opening the

contact or based on entering

evaporator fluid temperature. UCP

will not permit the Ice Building mode

to be entered again until the unit is

switched to the Non-ice building

mode and back into the ice building

mode. It is not acceptable to reset the

chilled water setpoint low to achieve

a fully loaded compressor. When

entering ice-building the compressor

will be loaded at its maximum rate

and when leaving ice building the

compressor will be unloaded at its

maximum rate. While loading and

unloading the compressor, all surge

detection will be ignored. While in

the ice building mode, current limit

setpoints less than the maximum will

be ignored. Ice Building can be

terminated by one of the following

means:

Figure 15. CVHE, CVHF and CVHG sequence of operation: ice making:

stopped to ice to ice building complete

1. Front Panel Disable, or

2. Opening the external Ice. Contacts/

Remote communicated input

(Tracer), or

3. Satisfying an evaporator entering

fluid temperature setpoint (Default

to 27°F).

4. Surging for 7 minutes at full open

IGV.

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When the chiller is changed over to

the free cooling mode, the

This compulsory refrigerant cycle is

sustained as long as a temperature

differential exists between condenser

and evaporator water. The actual

cooling capacity provided by the free

cooling cycle is determined by the

difference between these

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.

compressor will shut down if

running, the shutoff valves in the

liquid and gas lines open; unit

control logic prevents the

compressor from energizing during

free cooling. Liquid refrigerant then

drains (by gravity) from the storage

tank into the evaporator and floods

the tube bundle. Since the

temperature and pressure of the

refrigerant in the evaporator are

higher than in the condenser (i.e.,

because of the difference in water

temperature), the refrigerant in the

evaporator vaporizes and travels to

the condenser. Cooling tower water

causes the refrigerant to condense,

and it flows (again, by gravity) back

temperatures which, in turn,

determines the rate of refrigerant flow

between the evaporator and

condenser shells.

If condenser water is available at a

temperature lower than the required

leaving chilled water temperature, the

operator interface must remain in

“AUTO” and the operator starts the

free cooling cycle by enabling the

Free cooling mode in the

If the system load exceeds the

available free cooling capacity, the

operator must manually initiate

changeover to the mechanical

“DynaView^™Feature Settings” group

of the operator interface, or by means

of a Tracer request.

cooling mode by disabling the free

cooling mode of operation. The gas

and liquid line valves then close and

compressor operation begins. (See

Figure 8 beginning at “Auto” mode.)

Refrigerant gas is drawn out of the

evaporator by the compressor, where

Several components must be factory-

installed or field-installed to equip the to the evaporator.

unit for free cooling operation:

— a refrigerant gas line, and

electrically-actuated shutoff valve,

between the evaporator and

condenser;

— a valve liquid return line, and

electrically-actuated shutoff valve,

between the condenser sump and

the evaporator;

— a liquid refrigerant storage vessel

(larger economizer); and,

— additional refrigerant.

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General

Information

energized. To disable Free Cooling

and return to Powered Cooling, either

disable the Free Cooling Mode in the

DynaView^™settings menu if used to

enable Free Cooling or “OPEN” the

external binary input switch to the

1A20 Module if it was used to enable

Free Cooling. Once Free Cooling is

disabled, the Free Cooling relays

Relay Module 1A11 will de-energize

allowing the Free Cooling valves to

close. The Free Cooling valves end

switches must close within 3

minutes or an MMR diagnostic is

generated. Once the end switches

close the chiller will return to

“AUTO” and powered cooling will

resume if there is a call for cooling

based on the differential to start.

it is then compressed and

Free Cooling FRCL

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. Because the

pressure drop through the bleed line

is greater than that of the orifice flow

control device, the liquid refrigerant

flows normally from the condenser

through the orifice system and into

the economizer.

To enable Free Cooling Mode:

1. Free Cooling must first be installed

and commissioned.

2. Enable the Free Cooling mode in

the DynaView^™Settings Menu

3. Press “AUTO”, and if used, close

the external binary input switch

(connected to 1A20 J2- 1 to 2) while

the chiller is in “AUTO”.

Free Cooling cannot be entered if the

chiller is in “STOP”.

If the chiller is in “AUTO” and not

running, the condenser water pump

will start. After condenser water flow

is proven, Relay Module 1A11 will

energize operating the Free Cooling

Valves 4B12 and 4B13. The Free

Cooling Valves End Switches must

open within 3 minutes, or an MMR

diagnostic will be generated. Once

the Free Cooling Valves End

Switches open, the unit is in the Free

Cooling mode. If the chiller is in

“AUTO” and running powered

cooling, the chiller will do a friendly

shut down first, (Run: Unload, Post

Lube, and drive vanes closed). After

the vanes have been overdriven,

closed and condenser water proven,

the Free Cooling relays will be

Note: The manual control of the inlet

guide vanes is disabled while in the

Free Cooling Mode and the

compressor is prevented from

starting by the control logic.

Note: The relay at 1A11-J-2-4 to 6 is a

FC auxiliary relay and can be used as

required.

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General

Information

valve will be driven closed. After the

inlet guide vanes are fully closed the

chiller will shut down in the Friendly

mode. Chillers with HGBP have a

discharge temperature sensor (4R16)

monitoring the discharge gas

temperature from the compressor. If

this temperature exceeds 200°F, the

chiller will shut off on a MAR

After a chiller starts and is running

the inlet guide vanes will pass

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.

through the HGBP Cut-In-Vane

position as the chiller starts to load.

As the chiller catches the load and

starts to unload, the inlet guide vanes

will close to the HGBP Cut-In Vane

position. At this point the movement

of the inlet guide vanes is frozen and

further unloading of the chiller is

controlled by the opening of the

HGBP Valve 4M5 and module

modulates the HGBP valve at low

loads. When the control algorithm

determines the chiller to be shut

down, the inlet guide vanes will be

driven fully closed, and the HGBP

diagnostic. The chiller will reset

automatically when this temperature

drops 50°F below the trip-point.

HGBP is enabled in the Features

menu settings Group of the DV

Menus by enabling the option. The

setting the HGBP Cut-In Vane

Position is setup at unit

commissioning via the service tool.

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General

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The DynaView^™Main Processor

provides the hot water temperature

control mode as standard. The

leaving condenser water temperature

is controlled to a hot water setpoint

between 80 and 140°F (26.7 to 60°C)

The leaving evaporator water

temperature is left to drift to satisfy

the heating load of the condenser. In

this application the evaporator is

normally piped into a lake, well, or

other source of constant temperature

water for the purpose of extracting

heat.

An external binary input to select

external hot water control mode is on

the EXOP OPTIONAL module 1A18

terminals J2-3 to J2-4 (ground). Tracer

also has a binary input to select

chilled water control or hot water

temperature control.

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.

This type of operation requires an

endless source of evaporator load

(heat), such as well or lake water. The

chiller has only one condenser.

There is no additional leaving hot

water temperature cutout; the HPC

and condenser limit provide for high

temperature and pressure protection.

In hot water temperature control the

softloading pulldown rate limit

operates as a softloading pullup rate

limit. The setpoint for setting the

temperature rate limit is the same

setpoint for normal cooling as it is

for hot water temperature control.

In hot water temperature control

mode all the limit modes and

diagnostics operate as in normal

cooling with one exception; The

leaving condenser water temperature

sensor is an MMR diagnostic when

in hot water temperature control

mode. (It is an informational warning

in the normal cooling mode.)

Note: Hot water temperature control

mode does not convert the chiller to

a heat pump. Heat pump refers to the

capability to change from a cooling-

driven application to a heating-driven

application by changing the

refrigerant path on the chiller. This is

impractical for centrifugal chillers as

it would be much easier to switch

over the water side.

The hot water temperature control

feature is not designed to run with

HGBP, AFD, free cooling, or ice

making.

The factory set PID tuning values for

the leaving water temperature control

are the same settings for both normal

cooling and hot water temperature

control.

In the hot water temperature control

mode the differential-to-start and

differential-to-stop setpoints are used

with respect to the hot water setpoint

instead of with the chilled water

setpoint.

This is NOT heat recovery. Although

this feature could be used to recover

heat in some form, there is a second

heat exchanger on the condenser

side.

UCP provides a separate entry at the

DV to set the hot water setpoint.

Tracer is also able to set the hot

water setpoint. In the hot water mode

the external chilled water setpoint is

the external hot water setpoint; that

is, a single analog input is shared at

the 1A16 –J2-1 to J2-3 (ground)

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General

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To provide a heat recovery cycle, a

heat-recovery condenser is added to

the unit; see Figure 2. Though

Auxiliary Condensers

Heat Recovery Cycle

Unlike the heat-recovery condenser

(which is designed to satisfy comfort

heating requirements), the auxiliary

condenser serves a preheat function

only, and is used in those

‘‘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 high-

rise 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. (Keep in

mind that the heat recovery cycle is

only possible if a cooling load exists

to act as a heat source.)

physically identical to the standard

cooling condenser, the heat-recovery

condenser is piped into a heat circuit

rather than to the cooling tower.

During the heat recovery cycle, the

unit operates just as it does in the

‘‘cooling only’’ mode except that the

cooling load heat is rejected to the

heating water circuit rather than to

applications where hot water is

needed for use in kitchens,

lavatories, etc. While the operation of

the auxiliary condenser is physically

identical to that of the heat-recovery

condenser, it is comparatively

the cooling tower water circuit. When smaller in size, and its heating

hot water is required, the heating

water circuit pumps energize. Water

circulated through the heat-recovery

(or auxiliary) condenser tube bundle

by the pumps absorbs cooling-load

from the compressed refrigerant gas

discharge by the compressor. The

heated water is then used to satisfy

heating requirements.

capacity is not controlled.

Trane does not recommend

operating the auxiliary condenser

alone because of its small size.

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Unit Control

Panel (UCP)

The UCP houses several other

controls modules called panel

mounted LLID (Low Level Intelligent

Device), power supply, terminal

block, fuse, circuit breakers, and

transformer. The IPC (Interprocessor

communication) bus allows the

communications between LLID’s and

the main processor. Unit mounted

devices are called frame mounted

LLID’s and can be temperature

sensors or pressure transducers.

These and other functional switches

provide analog and binary inputs to

the control system.

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. (See Operators

interface section for detailed

information)

Figure 16. Control panel and approximate dimensions

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Unit Control

Panel (UCP)

conditions, Tracer CH530 reliably

accommodates variable evaporator

water flow and its effect on the

chilled water temperature. These

improvements keep chilled water

flowing at a temperature closer to its

setpoint.

current. Every five seconds then a

multiple objective algorithm

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.

compares each parameter to its

programmed limit. The chiller’s

Adaptive Control^™capabilities

maintain overall system performance

by keeping its peak efficiency.

Whenever the controller senses a

situation that might trigger a

protective shutdown, it focuses on

bringing the critical parameter back

into control. When the parameter is

no longer critical, the controller

switches its objective back to

controlling the chilled water

User-defined language support

DynaView^™is capable of displaying

English text or one of the two

alternate languages that are stored in

DynaView^™at one time. Switching

languages is simply accomplished

from a settings menu.

Similarly, TechView^™accommodates

a primary and a secondary language

from the same list of available

languages.

Tracer CH530’s Main Processor,

temperature, or to another more

critical parameter should it exist.

DynaView^™, is fast and keeps the

chiller online whenever possible.

Smart sensors collect three rounds of

data per second, 55 times the data

collection speed of its predecessor.

Each device (a sensor) has its own

microprocessor that simultaneously

converts and accurately calibrates its

own readings from analog to digital.

Variable water flow through the

evaporator

Chilled-water systems that vary water

flow through chiller evaporators have

caught the attention of engineers,

contractors, building owners, and

operators. Varying the water flow

reduces the energy consumed by

pumps, while requiring no extra

energy for the chiller. This strategy

can be a significant source of energy

savings, depending on the

Because all devices are

communicating digitally with the

DynaView^™main processor, there is

no need for the main processor to

convert each analog signal one at a

time. This distributed logic allows

the main processor to focus on

responding to changing conditions

— in the load, the machine, its

ancillary equipment, or its power

supply. Tracer CH530 constantly

receives information about key data

parameters, temperatures and

application. With its faster and more

intelligent response to changing

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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.) The “additional

info” icon will present a subscreen

that lists in further detail the

subsystem modes. (See Machine

Operating Modes.)

Main screen content can be viewed

by selecting the up or down arrow

icons. The Main screen is the default

screen and after an idle time of 30

minutes.

The DynaView^™(DV) Operator

The MP contains non-volatile

memory both checking for valid set

points and retaining them on any

power loss. System data from

modules (LLID) can be viewed at the

DynaView^™operator interface. Such

as evaporator and condenser water

temperatures, outdoor air

Interface contains the “Main

Processor (MP)” and is mounted on

the unit control panel front door

where it communicates commands

to other modules, collecting data,

status and diagnostic information

from the other modules over the IPC

(Inter Processor Communications)

link. The Main Processor (MP)

software controls water flows by

starting pumps and sensing flow

inputs, establishes a need to heat or

cool, performs pre-lube, performing

post-lube, starts the compressor(s),

performs water temperature control,

establishes limits, and pre-positions

the inlet guide-vanes.

temperature, evaporator and

condenser water pump control,

status and alarm relays, external

auto-stop, emergency stop,

evaporator and condenser water

pressure drops and evaporator and

condenser water flow switches.

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Operator

Interface

DynaView^™(DV) is the operator

Spin values (up or down) are a

graphical user interface model used

to allow a continuously variable

setpoint, such as leaving water

setpoint to be changed. The value

changes by touching the increment

or decrement arrows.

The main body of the screen is used

for description text, data, setpoints,

or keys (touch sensitive areas) The

double up arrows cause a page by

page scroll either up or down. The

single arrow causes a line by line

scroll to occur. At the end of the

screen, the appropriate scroll buttons

will disappear. Wrap around will not

occur.

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. This device is

capable of operating in 0 - 95 percent

relative humidity (non-condensing),

and is designed and tested with UV

considerations consistent with an

outdoor application in direct

Action buttons are buttons that

appear temporarily and provide the

operator with a choice such as Enter

or Cancel. The operator indicates his

choice by touching the button of

choice. The system then takes the

appropriate action and the button

typically disappears.

DynaView^™consists of various

screens, each meant to serve a

unique purpose of the machine being

served. Tabs are shown row across

the top of the display. The user

selects a screen of information by

touching the appropriate tab. The

folder that is selected will be brought

to the front so it’s contents are

visable

The bottom of the screen is the

persistent area. It is present in all

screens and performs the following

functions. The left circular area is

used to reduce the contrast and

viewing angle of the display. The

right circular area is used to increase

the contrast and viewing angle of the

display. The contrast control will be

limited to avoid complete “light” or

complete “dark”, which would

potentially confuse an unfamiliar

user to thinking the display was

malfunctioning.

sunlight. The enclosure includes a

weather tight connection means for

the RS232 service tool connection.

Touch screen key functions are

determined completely in the

software and change depending

upon the subject matter currently

being displayed. The user operates

the touch sensitive buttons by

touching the button of choice. The

selected button is darkened to

indicate it is the selected choice. The

advantage of touch sensitive buttons

is that the full range of possible

choices as well as the current choice

is always in view.

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Operator

Interface

selected key will be dark. The chiller

will stop when the Stop key is

touched, entering the stop sequence.

Pressing the “Immediate Stop”

button will cause the chiller to stop

right away.

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).

How It Works

This new feature will be activated

after the service tech sets a variable

shut down timer in TechView to be

greater that 0 seconds and up to 20

seconds (i.e. 0 < Timer 20). Then,

when the user presses the ‘STOP’

button on the DynaView display and

initiates a chiller shutdown, a

window will now appear that

displays the “Unit Stop Information

Screen” as shown below.

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.

The AUTO and STOP, take

precedence over the ENTER and

CANCEL keys. (While a setting is

being changed, AUTO and STOP

keys are recognized even if ENTER or

CANCEL has not been pressed.

Selecting the Auto key will enable the

chiller for active cooling ( if no

diagnostic is present.)

Pressing on the Alarms button takes

you to the corresponding screen.

TechView service tool is utilized to

enable this feature.

Persistent keys, horizontal at the

bottom of the display, are those keys

that must be available for operation

regardless of the screen currently

being displayed. These keys are

critical for machine operation. The

Auto and Stop keys will be

Chiller Stop Prevention/Inhibit

Feature

A new chiller “Stop prevention/

inhibit” feature allows a user to

prevent an inadvertent chiller stop

from the DynaView screen for those

chillers which are solely controlled

by the CH530.

presented as radio buttons within the

persistent key display area. The

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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. Additional information (if

it exists) regarding the machine

operating state will be available to

the user by selecting the “additional

information” button (double right

arrow) next to the top-level operating

mode. These sub-level modes are

shown in the table at left.

The TOP LEVEL MODE is the text

seen on the single top level chiller

system operating mode line. The

SUB LEVEL MODE is the text seen on

the operating mode sub-menu. The

operating mode sub-menu may have

up to six (6) lines of text displayed.

The BAS CODE is the code that will

be sent via COMM4 to the Tracer

Summit system as the chiller system

mode. Note that each top level mode

may contain multiple sub level

A general description of the top level modes is show in the following table.

Top Level Mode

Stopped

Description

Unit inhibited from running and will require

modes. In general, the BAS CODE

will reflect the top level mode and not

the sub level mode.

user action to go to Auto.

Run Inhibit

Unit inhibited from running by Tracer,

External BAS, or an Auto Reset diagnostic.

Unit determining if there is a need to run.

Unit waiting for tasks required prior to

compressor start to be completed.

Auto

Waiting To Start

Starting Compressor

Running

Unit is starting compressor.

Compressor is running with no limits in

effect.

Running – Limit

Preparing To Shutdown

Compressor is running with limit in effect.

Unit is closing inlet guide vanes prior to

compressor shutdown.

Shutting Down

Free Cooling

Compressor has been stopped and unit is

performing shutdown tasks.

Unit is in Free Cooling mode and will not

run the compressor.

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Operator

Interface

Figure 19

Reference

BAS Code

Top Level Mode

SYSTEM RESET

Sub Level Mode

Boot & Application software part number, self-test, and

configuration validity screens will be present.

Local Stop

Panic Stop

Diagnostic Shutdown – Manual Reset

Ice Building Is Complete

Tracer Inhibit

Stopped

Run Inhibit

Auto

100

External Source Inhibit

Diagnostic Shutdown – Auto Reset

Waiting For Evaporator Water Flow

Waiting For A Need To Cool

Waiting For A Need To Heat

Auto

Power Up Delay Inhibit:

MIN:SEC

Waiting To Start

Waiting For Condenser Water Flow

Establishing Oil Pressure

Pre-Lubrication Time:

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Operator

Interface

Reference

BAS Code

Top Level Mode

Waiting To Start

Sub Level Mode

Motor Temperature Inhibit: Motor Temperature / Inhibit Temperature

Restart Time Inhibit:

MIN:SEC

High Vacuum Inhibit: Oil Sump Press / Inhibit Press

Low Oil Temperature Inhibit: Oil Temperature / Inhibit Temperature

Waiting For Starter To Start:

MIN:SEC

Starting Compressor There is no sub mode displayed

Running

There is no sub mode displayed

Hot Water Control

Running

Surge

Running

Base Loaded

Running

Hot Gas Bypass

Running

Ice Building

Running

Ice To Normal Transition

Current Control Soft Loading

Capacity Control Soft Loading

Current Limit

Running

Running – Limit

Free Cooling

Preparing To

Shutdown

Phase Unbalance Limit

Condenser Pressure Limit

Evaporator Temperature Limit

Minimum Capacity Limit

Maximum Capacity Limit

Opening Free Cooling Valves

Closing Free Cooling Valves

Closing IGV:

IGV Position %

MIN:SEC

Shutting Down

Post-Lubrication Time:

Evaporator Pump Off Delay:

Condenser Pump Off Delay:

MIN:SEC

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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.

Description

Chiller Operating Mode (>>sub modes)

Evaporator Entering and Leaving Water Temperature

Condenser Entering and Leaving Water Temperature

Active Chilled Water Setpoint (>>source)

Active Hot Water Setpoint (>>source)

Active Current Limit Setpoint (>>source), If enabled

Active Base Loading Setpoint (>>source), If enabled

Purge Operating Mode

Purge Status

Average Line Current

Approximate Chiller Capacity, If option installed

Active Ice Termination Setpoint (>>source), If option installed

Software Version

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Operator

Interface

The reason for all diagnostic must be

determined and corrected. Do not

reset and restart the chiller as this

can cause a repeat failure. Contact

local Trane Service for assistance as

necessary.

A Manual Override indicator (shares

space with the Alarms key) alerts the

operator to the presence of a manual

override. An Alarm will take

precedence of the Manual, until the

reset of active alarms, at which point

the Manual indicator would reappear

if such an override exists.

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.

After corrective action, the chiller can

be reset and/or restarted. In the case

of “Unit Shutdown - Reset Required”

diagnostic types, the chiller will have

to be manually reset through the

Diagnostics alarm menu.

Temperature settings can be

expressed in F or C, depending on

Display Units settings.

Machine shutdowns can be of two

types:

Dashes (“- - - -”) appearing in a

temperature or pressure report,

indicates that the value is invalid or

not applicable.

Latching - Machine Shutdown

Manual Reset Required (MMR)

When reset they become historic and

viewable via the service tool

TechView.

The languages for DynaView^™will

reside in the main processor. The

main processor will hold three

languages, English, and two alternate

languages. The service tool

Performing a Reset All Active

Diagnostics will reset all active

diagnostics regardless of type,

machine or refrigerant circuit.

Non-Latching - Machine Shutdown

Auto Reset (MAR)

Latching (MMR) require corrective

action and manual reset.

(TechView^™) will load the main

processor with user selected

Non-Latching (MAR) will restart

automatically when condition

corrects itself.

languages from a list of available

translations. Whenever possible,

complete words will be used on the

persistent keys as described.

There are over 200 potential

messages, too numerous to

incorporate in this manual.

Up to ten active diagnostics can be

displayed if required.

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Operator

Interface

The chilled water reset status area in

the right most column will display

one of the following messages:

Return, Constant Return, Outdoor,

None

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

The left column text “Front Panel”,

“BAS”, “External”, Chilled Water

Reset, and “Active Chilled Water

Setpoint” will always be present

regardless of installation or enabling

those optional items. In the second

column “- - - -” will be shown if that

option is Not Installed, otherwise the

current setpoint from that source will

be shown.

setpoint arbitration sub-screen.

The Active Chilled Water Setpoint

the result of arbitration between the

front panel, BAS, and external

setpoints,

The “Back” button provides

navigation back to the chiller screen.

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Operator

Interface

The left column text “Front Panel”,

“BAS”, “External”, and “Active

Current Limit Setpoint” will always

be present regardless of installation

or enabling those optional items. In

the second column “- - - -” will be

shown if that option is Not Installed,

otherwise the current setpoint from

that source will be shown. The

“Back” button provides navigation

back to the chiller screen.

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 sub-

screen. 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.

Note: This is the same for other

setpoints in the “Main” menu.

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Operator

Interface

Reports

Evaporator Report items

Evaporator Entering Water Temperature

Evaporator Leaving Water Temperature

Evaporator Saturated Refrigerant Temperature

Evaporator Refrigerant Pressure

Evaporator Approach

Units

°C or °F

Psia or kPa

°C or °F

Evaporator Water Flow Switch Status

Evaporator Differential Water Pressure, If installed

Approximately Evaporator Water Flow, If installed

Approximate Chiller Capacity, If installed

Flow or No Flow

Psid

Gpm or LPM

Tons or kW

Condenser Report Items

Units

Condenser Entering Water Temperature

°C or °F

Condenser Leaving Water Temperature

°C or °F

Condenser Saturated Refrigerant Temperature

Evaporator Refrigerant Pressure Temperature

Condenser Refrigerant Pressure

°C or °F

Psia or kPa

°C or °F

Condenser Approach Temperature

Condenser Water Flow Switch Status

Condenser Differential Water Pressure, If installed

Approximate Condenser Water Flow, If installed

Auxiliary Condenser or Heat Recovery Entering Water Temperature, If installed

Auxiliary Condenser or Recovery Leaving Water Temperature, If installed

Outdoor Air Temperature, If installed

Open or closed

Psid or kPa

Gpm or LPM

°C or °F

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Operator

Interface

Compressor Report Items

Compressor Starts:

Units

###

Compressor Running Time:

Hour and minute

°C or °F

Compressor Discharge Temperature; If installed

Oil Tank Pressure

Oil Discharge Pressure

Oil Differential Pressure

Oil Tank Temperature

°C or °F

Inboard Bearing Temperature, If installed

Outboard Bearing Temperature, If installed

Vanes Position

°C or °F

Percent open

Steps

Vanes Position Steps

Hot Gas Bypass Time, If installed

Hour and minute

Motor Report Items

Units

Percent RLA L1 L2 L3

Percent RLA

Amps

Vac

Amps L1 L2 L3

Volts AB, BC, CA

Power Consumption, If installed

Load Power Factory, If installed

Winding Temperature A

xxx kW

°C or °F

Winding Temperature B

Winding Temperature C

Adaptive Frequency Drive Speed, If installed

Adaptive Frequence Drive Speed, If installed

Adaptive Frequency Drive Heat Sink Temperature, If installed

RPM

°C or °F

Purge Report Items

Units

Time Until Next Purge Run

Daily Pumpout – 24 Hours

Average Daily Pumpout – 7 Days

Daily Pumpout Limit and Alarm

Chiller On – 7 Days

Pumpout Chiller On – 7 Days

Pumpout Chiller Off – 7 Days

Pumpout - Life

Minute

Percent

Minute

°C or °F

Purge Refrigerant Compressor Suction Temperature

Purge Liquid Temperature

Carbon Tank Temperature

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Operator

Interface

ASHRAE Chiller Log

1. Current Time and Date Monitor

2. Operating Mode

Units

HH:MM xm

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:

°C or °F

% RLA

PPM

Minute

Enum

Hours:Minutes

°C or °F

14. Compressor Discharge Temperature; If option installed

15. Discharge Oil Pressure;

Psia or kPa

Psid or kPa

°C or °F

16. Oil Tank Pressure:

17. Differential Oil Pressure:

18. Oil Tank Temperature:

19. Inboard Bearing Temperature, If option installed

20. Outboard Bearing Temperature, If option installed

21. Evaporator Entering Water Temperature

22. Evaporator Leaving Water Temperature

23. Evaporator Saturated Refrigerant Temperature

24. Evaporator Refrigerant Press

°C or °F

Psia or kPa

°C or °F

25. Evaporator Approach

26. Evaporator Water Flow Switch Status:

27. Evaporator Differential Water Pressure, If installed

28. Approximately Evaporator Water Flow, If installed

29. Approximate Chiller Capacity, If installed

30. Condenser Entering Water Temperature

31. Condenser Leaving Water Temperature

32. Saturated Condenser Refrigerant Temperature

33. Condenser Refrigerant Pressure

Flow/No flow

Psid or kPa

GPM or LPM

Tons or kW

°C or °F

Psia or kPa

°C or °F

34. Condenser Approach

35. Condenser Water Flow Switch Status

36. Condenser Differential Water Pressure

37. Approximate Condenser Water Flow, If installed

38. Second Condensor Entering Water Temperature, If installed

39. Second Condensor Leaving Water Temperature, If installed

Flow or No Flow

Psia or kPa

GPM or LPM

°C or °F

Historic Diagnostics Log

1 to 20 Historic Diagnostics (main processor software 6.0 and later)

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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.)

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Operator

Interface

Chiller

Description

Units

notes

1. Front Panel Control Type

2. Front Panel Chilled Water Setpoint

3. Front Panel Hot Water Setpoint

4. Front Panel Current Limit Setpoint

5. Front Panel Base Load Command

6. Front Panel Base Load Setpoint

7. Front Panel Free Cool Command

8. Front Panel Ice Building Command

9. Front Panel Ice Termination Setpoint

10. Ice to Normal Cooling Timer

11. Differential to Start

(Chilled Water, Hot Water), Chilled Water default

Temperature

Percent

On or Auto

Percent

On or Auto

Temperature

(0-10), 5 Minutes default

Temperature

12. Differential to Stop

13. Setpoint Source

Temperature

*(BAS/EXT/FP, EXT/FP, FP), none default

*Follows hierarchy of selection from left to right (except ice build which is “OR” logic).

Feature Settings

Description

Units

1. Chilled Water Reset

(Constant, Outdoor, Return, Disable), Disable

Percent

2. Return Reset Ratio

3. Return Start Reset

4. Return Maximum Reset

5. Outdoor Reset Ratio

6. Outdoor Start Reset

7. Outdoor Maximum Reset

8. External Chilled Water Setpoint

9. External Current Limit Setpoint

10. Ice Building Feature Enable

11. External Base Loading Setpoint

Temperature

Percent

Temperature

(Enable, Disable), Disable

Mode Overrides

Description

1. Compressor Control Signal

Units

Default

Monitor Value

Notes

(Auto, Manual [0-100] ), Auto

Percent Vane Position

Evaporator Leaving Water

Temperature, AFD Frequency, if installed

1) Evaporator Flow status

2. Evaporator Water Pump

3. Condenser Water Pump

4. Oil Pump

(Auto, On),

Auto

2) Override Time Remaining

1) Condenser Flow status

2) Override Time Remaining

1) Differential pressure

2) Override Time Remaining

5. Purge Exhaust Circuit Test

6. Purge Regeneration Cycle

(Off, On),

Off

Carbon Temperature

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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

Units

Default

(Auto, On, Adaptive, Stop), Adaptive

Minutes

Hours

(Enable, Disable),

Temperature

Enable

Display Settings

Description

1. Date Format

2. Date

Units

notes

(“mmm dd, yyy”, “dd-mmm-yyyy”), “mmm dd, yyy”

3. Time Format

4. Time of Day

5. Keypad and Display Lockout

6. Display Units

7. Language

(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

(12-hour, 24-hour), 12-hour

(Enable, Disable), Disable

(SI, English), English

(English, Selection 2, Selection 3), English

(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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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. Binary setpoints are considered to be simple two state

enumeration and will use buttons. Analog setpoints are displayed as spin

buttons. The lower half of the screen is reserved for help screens. To change

the setpoint the ENTER key must be touched, otherwise the new setting is

cancelled.

Note: Spin buttons used to change

setpoint value.

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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.

Mode Override for Enumerated Settings is shown below:

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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.

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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.

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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. The password “159” is not programmable from either DynaView^™

or TechView^™.

If the Display and Touch Screen Lock feature is Disabled, the following screen

will be automatically shown if the MP temperature is below 32°F (0°C) and it

has been 30 minutes after the last key stroke. Note: the main processor is

equipped with an on-board temperature sensor which enables the ice

protection feature.

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Interprocessor

Communication

Node Zero:

Inter Processor

Node number zero is is a special

node assignment that is reserved for

devices that are service selected. A

LLID communicating on node

address zero will also communicate

on an assigned node address. A LLID

will only communicate on node

address zero if it is service selected.

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. A typical CVHE

control network will have less than

50 devices. IPC3 allows for a

Binding:

Binding is the process of assigning a

node number and functional IDs to a

LLID. Binding is a simple process:

1. Service selecting the LLID with a

magnet.

2. Assigning functional IDs to that

LLID with TechView^™.

maximum of 255 devices per

network.

Functional Identification:

When each LLID on the bus is bound,

its inputs and outputs are given a

functional ID. The Frame LLIDS have

only one functional ID, but most

Panel LLIDs have more than one

functional ID. A dual high voltage

binary input will have two functional

IDs, a quad relay output has four

functional IDs.

IPC3 Definitions:

Bus Management:

The DynaView^™provides the bus

management having the task of

restarting the link, or filling in for

missing nodes when the normal

communication has been degraded.

This involves reassigning node

addresses and filling in for nodes

that are off-line. The DynaView^™

always has a node number of 01.

The DynaView^™Main Processor with

its IPC3 Bus communicates to the

control panel devices, unit mounted

devices, and any remote devices on

the IPC3 bus network. The various

devices are discussed in the

Node Assignment:

When a unit is factory

commissioned, the LLIDS must have

their node addresses assigned to

them for storage in non-volatile

memory. The node addresses are

normally assigned sequentially

during factory commissioning.

upcoming sections.

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Control System

Components

communications, WPSR Water Flow

Pressure sensing, FRCL Free

Cooling, HGBP Hot Gas Bypass , and

EPRO Enhanced Protection

the same device designators (see

right hand column). Optional

controls are present when a specific

optional controls package is

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

specified, as listed in the second

column. Optional controls packages

are; OPST Operating Status, GBAS

Generic Building Systems, EXOP

Extended operation, CDRP

Figure 20 illustrates the Control Panel

Components Layout.

Modules 1A1, 1A3, 1A4, 1A5, 1A6,

1A7, and 1A13 are standard and

present in all configurations. Other

Modules vary depending on machine

optional devices.

Condenser Pressure, TRMM Tracer

Figure 20. Control panel components layout and approximate dimensions

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Control System

Components

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Control System

Components

Control Panel Devices

Standard Devices

Controls

Field Connection

Point Terminals

not for field use

Description

Package

Purpose

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*

Standard

(as required) #2

Converts 24 vac to 24 vdc

Oil Heater Relay

Standard

Relay #1

High Pressure Cutout

not for field use

Relay #1

Relay #2

Input 1

Input 2

Chilled water pump

(Relay #1)

Condenser water pump control

(relay #2)

J2-4 NO, J2-5 NC,

J2-6 common

J2-1 NO, J2-2 NC,

J2-3 common

J2-2 Condenser water

flow switch

J3-2 Chilled water

flow switch

Condenser Flow Input

Evaporator Flow Input

Oil Pump and

Refrigerant Pump

External Auto Stop,

Emergency stop

not for field use

Signal #1

Signal #2

J2-1 Binary Input Signal #1,

J2-2 Ground

J2-3 Binary Input Signal #2,

J2-4 Ground

Compressor Motor

Winding Temp Sensor

LLID Power Supply Transformer

Primary Circuit protection

not for field use

1F1

1T1

1Q1

not for field use

Control Panel Power

Transformer ; 120:24Vac

Circuit Breaker - Compressor

Motor Controller Control Power

Branch Circuit

1Q2

1Q3

Standard

Circuit Breaker -

not for field use

Purge System Branch Circuit

Circuit Breaker –

Module [- LLID]

Power Supply Branch Circuit

1Q4

Standard

Circuit Breaker -

Oil System Control

Branch Circuit

Oil Pump Motor Branch

Circuit protection

not for field use

1Q5

Standard

1X1 Terminal Block

Control Panel Terminal Block,

Flow switch connections

1X1-5 Chilled water flow

flow switch input

1X1-6 Condenser water flow

switch input

*previously was located in Purge Control Panel

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Control System

Components

auxiliary contacts 5K1 on terminals

1X1-5 and 1A6-J3-2. Proof of

flow switch 5S2 and the closure of

auxiliary contacts 5K2 on terminals

1X1-6 and 1A6-J2-2.

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

condenser water flow for the

condenser is made by the closure of

OPST Operation Status Option

Relay output modules 1A8 and 1A9 provide relay outs as shown:

1A8 Optional Quad Relay

OPST

Relay #1

Relay #2

Relay #3

Relay #4

Relay #2

Relay #3

Relay #4

Compressor running relay,

J2-10 NO, J2-11 NC,

J2-12 common

J2-7 NO, J2-8 NC,

J2-9 common

J2-4 NO, J2-5 NC,

J2-6 common

J2-1 NO, J2-2 NC,

J2-3 common

J2-7 NO, J2-8 NC,

J2-9 common

J2-4 NO, J2-5 NC

to J2-6 common

J2-1 NO, J2-2 NC,

to J2-3 common

Output Status

1A8 Optional Quad Relay

Output Status

1A8 Optional Quad Relay

Output Status

1A8 Optional Quad Relay

Output Status

1A9 Optional Quad Relay

Output Status

1A9 Optional Quad Relay

Output Status

1A9 Optional Quad Relay

Output Status

MMR Alarm Relay,

(Latching)

Limit Warning Relay,

MAR Alarm Relay

(Non-Latching)

Purge Alarm Relay

Head Relief Request Relay

Maximum Capacity Relay

Head Relief Request Output

Maximum Capacity Relay

(TechView adjustable)

without the head relief request relay,

by limiting inlet guide vane stroke

and chiller capacity.

When the chiller is running in

Condenser Limit Mode or in Surge

Mode, the head relief request relay

(1 minute default) on the 1A9–J2-6 to

J2-4 will be energized and can be

used to control or signal for a

reduction in the entering condenser

water temperature. Designed to

prevent high refrigerant pressure trip-

outs during critical periods of chiller

operation.

When the chiller has been operating

at maximum capacity for 10 minutes

(TechView adjustable 1 to 60 min.)

this relay will activate. Also upon

being less than maximum capacity

for 10 minutes this relay will

deactivate.

Keep in mind that Condenser Limit

Control supplements the protection

provided by the condenser pressure

high pressure cutout switch 3S1.

Compressor Motor Winding

Temp Sensor Module

Compressor Running Relay

Relay activates while compressor is

running.

The motor temperature module 1A26

connects via unit wiring to the three

motor winding temperature sensors.

If the unit is not equipped with the

CDPR Enhanced Condenser Limit

Option the unit will use the

condenser refrigerant temperature

sensor (input converted to saturated

refrigerant pressure) to perform the

Standard Condenser Limit function,

Machine Shutdown Manual

Reset (MMR)

Limit warning machine shutdown

auto reset relays will activate with

such conditions for remote status

indication.

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Control System

Components

EXOP Extended Operation Option

The 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 modules*

J2-12 common

1A17 Optional Dual Analog

Input/Output Module

1A17 Optional Dual Analog

Input/Output Module

1A18 Optional Dual LV

Binary input module

1A18 Optional Dual LV

Binary input module

1A19 Optional Dual LV

Binary input module

*previously was 1A10

Signal #1

Signal #2

Signal #1

Signal #2

Signal #1

External Base Loading

Setpoint input

Refrigerant monitor inputs

J2-1 Output #1,

J2-3 Ground

J2-4 Output #2,

J2-6 Ground

External Base Loading

Enable or Disable input, points J2-2 Ground

External Hot Water Control

Enable or Disable input

Ice Building Control

Enable or Disable input point

J2-1 Binary Input Signal #1,

J2-3 Binary Input Signal #2,

J2-4 Ground

J2-1 Binary Input Signal #1,

J2-2 Ground

Refrigerant Monitor Input 1A17

Analog type input 4-20ma input signal to the 1A17 J2-4 to J2-6 (ground). This represents 0-100 ppm.

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Control System

Components

FRCL (Free Cooling Option)

1A11 Optional Quad

FRCL

Relay #1

Signal #1

Free Cooling Relay 1,

J2- 4 NO to J2-6 common

Relay Output Status

1A20 Optional Dual LV FRCL

Binary input module

1A20 Optional Dual LV

Binary input module

External Free Cooling Switch,

Free Cooling Valves closed

J2-1 Binary Input Signal #1,

J2-2 Ground

Not for field use

FRCL Signal #2

HGBP (Hot Gas Bypass Option)

1A7 Dual High Voltage

HGBP #1

Hot Gas Bypass input

Auxiliary relays

Not for field use

Binary input

1A12 Optional Quad

Relay Output Status

HGBP Relay #1

TRMM TRM4 (Tracer Comm 4 interface)

1A14 Optional

Communication

Interface Module

TRM4

Tracer Communications

J2-1 COMM+, J2-2 COMM -J2-3,

COMM +J2-4, COMM -,

LCI-C

CDRP (Condenser Refrigerant Pressure Output)*

1A15 Optional Dual Analog

Input/output Module

CDRP

or GBAS

Signal #2

Condenser Refrigerant

Pressure output

J2-4 Output #2, J2-6 Ground

EPRO (Enhanced Protection)

4R22 EPRO

4R16 EPRO

Condenser Refrigerant Pressure Transducer

Compressor Discharge Refrigerant Temperature Sensor. (This is also included with H6BP).

Inboard Bearing Temperature Sensor

4R1

4R2

EPRO

Outboard Bearing Temperature Sensor

*See CTV-PRB006-EN for “Condenser Water Temperature Control”.

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Control System

Components

Pressure based

Temperature based

CDRP Refrigerant Pressure

Output Option 1A15:

With the Enhanced Protection EPRO

option, a condenser pressure

transducer is installed and the

pressure is measured.

On standard machines the Percent

Condenser Pressure Indication

Output is based on the Saturated

Condenser Refrigerant and a

temperature to pressure conversion

is made.

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.

If the Condenser Pressure sensor

goes out of range due to either an

open or short, a pressure sensor

diagnostic will be called and the

output will go to end of range low.

That is, for an out of range low on the

sensor, the output will be limited to

2.0 VDC. For an out of range high on

the sensor, the output will be limited

to 2.0 VDC.

If the Condenser Saturated

Temperature goes out of range due to

an open or short, a pressure sensor

diagnostic will be called and the

output will also go to the respective

out of range value. That is, for an out

of range low on the sensor, the

output will be limited to 2.0 VDC. For

an out of range high on the sensor,

the output will be limited to 10.0

VDC.

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-

20mA is not supported.

A) Condenser Pressure Output.

2 to 10 Vdc corresponds to 0 Psia to

the HPC (in Psia) setting.

Note: Controls allow Delta Pressure

or condenser pressure output, but

not both.

Figure 21. Condenser pressure based output

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Control System

Components

The “Minimum Delta Pressure “ is

typically set to 0 psi and will then

correspond to 2 vdc. The “Maximum

Delta Pressure “ is typically set to 30

psi and corresponds to 10 vdc.

increments of 1 psid (1kPa). The

condenser refrigerant pressure is

based on the Condenser Refrigerant

Temperature sensor if the Condenser

Pressure Option is selected as “Not

Installed” at the display.

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

Calibration setting has a range of 0-

400 psid (0-2758 kPa) in increments of based on the Saturated Evaporator

1 psid (1kPa). The Maximum Delta

Pressure Calibration setting has a

range of 1-400 psid (7-2758 kPa) in

The evaporator refrigerant pressure is

Refrigerant Temperature Sensor.

See CTV-PRB006-EN for additional

information about condenser water

temperature control.

Figure 22. Delta pressure setting - differential pressure based output

(Defaults shown)

In this example, 2 vdc corresponds to 0 psi differential and 10 vdc

corresponds to 30 psi differential. The min value of 0 psi, and the max value of

30 psi are individually adjustable via the service tool.

Note: Typical settings for CVHE, F, G with refrigerant pumps are as follows.

• Min pressure 0 psid (= 2 vdc)

• Max pressure 6 psid (= 10 vdc)

• Target tower control at 4 psid

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Control System

Components

GBAS (Generic Building Automation System)

1A15 Optional Dual

GBAS

Signal #1

Signal #2

Percent RLA Compressor Output

External Current limit Setpoint

J2-1 Output #1, J2-3 Ground

J2-2 Input #1, J2-3 Ground

J2-5 Input #2, J2-6 Ground

Analog Input/

output Module

1A16 Optional Dual

Analog Input/

output Module

1A16 Optional Dual

Analog Input/

CDRP

GBAS

Chilled Water Reset input,

or External Chiller Water Setpoint

output Module

Percent RLA Output

Notes: 0% RLA = 2 vdc

120% RLA = 10 vdc

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.

Example: If RLA is 500 amps then

10 vdc = 600 amps.

The following graph illustrates the

output:

Figure 23. Voltage versus percent RLA

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Control System

Components

The ECWS or ECLS LLID will report

either a very low or very high value

when there is either an open or short

in the system.

External Chilled Water

External Current Limit Setpoint

The External Current Limit is an

option that allows the current limit

setpoint to be changed from a remote

location. The External Limit Setpoint

is found on 1A16 J2-2 to J2-3

(ground), 2-10 vdc and 4-20 ma each

correspond to a 40 to 100 percent

RLA range. UCP limits the maximum

ECLS to 100 percent. Default 40 to

100%, adjustable via service tool.

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.

When an open or short is detected

(or the signal is severely beyond the

valid range) on the 2-10 VDC or 4-

20mA ECLS input and when the

ECLS option is installed, an

informational diagnostic shall be

generated. The active current limit set

point will default to the panel (or next

priority) current limit set point. Open

and short criteria will be set as close

to the end of the range values as

possible and still reliably detect an

open and short.

Note: To use external inputs, the

setpoint source setting on DynaView

must be set to “Ext/FP.”

WPSR (WFC Water Pressure Sensing Option)

1A21 Optional Dual

Analog Input or output

Module

1A21 Optional Dual

Analog Input or output

Module

WPSR = WFC Signal #1

Evaporator Differential

Water Pressure

Not for field use

WPSR = WFC Signal #2

Condenser Differential

Water Pressure

Module Characteristics

1A1, 1A2 Power Supply :

Unit Control Power Supply Module

Converts 27 vac to 24 vdc.

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 with a

maximum of two 14 AWG.

Power, 24 +/- 10 percent VDC, 20 mA

maximum. Trane IPC3 protocol. J1-1

+24VDC, J1-2 Ground, J1-3 COMM +,

J1-4 COMM -

1A7 High Power Relay

Power Input Voltage: 23VRMS

minimum, 27VRMS Nominal,

30VRMS maximum

Power, 24 +/- 10 percent VDC, 60 mA

maximum, Trane IPC3 protocol. J1-1

+24VDC, J1-2 Ground, J1-3 COMM +

J1-4 COMM -

Relay output contacts at 120 VAC:

16.0 Amps resistive, 6.4 Amps pilot

duty, 1 HP, 16.0 FLA

Frequency: 50-60 Hz

J2 14-26 AWG with a maximum of

two 14 AWG J2-1 NO, J2-2 NO, J2-3

NC, J2-4 COM, J2-5 COM.

Current: Full load 27 VAC – 4.30 A

(RMS)

1A4, 1A6 Dual High Voltage Binary

input module:

Binary Input Signal #1 J2-1 to 2

Inrush 27 VAC (RMS) ~ 30A (RMS)

Power, 24 +/- 10% VDC, 60 mA max.

Communications, RS485 Physical

layer, 19.2 Kbaud, Trane IPC3

protocol.

Binary Input Signal #2 J3-1 to 2

Power Output: Class II Voltage 24

VDC, Rated Current 2.44 Amps.

Fused @ 3 amps. (FUS01513)

High Voltage Binary Input: Off

Voltage: 0 to 40 VAC RMS , On

Voltage: 70 to 276 VAC RMS

J1: J1-1 +24 VDC, J1-2 GND, J1-3

COMM +, J1-4 COMM -

J11: J11-1 +24 VDC, J11-2 GND, J11-3

COMM +, J11-4 COMM -

1A3, 1A5, 1A10 Dual Relay Output

modules :

Relay #1 J2-1 NO, J2-2 NC, J2-3

common

Input is not polarity sensitive (Hot

and neutral can be switched), Input

impedance 130K to 280K ohms

Relay #2 J2 4 NO, J2-5 NC, J2-6

common

14 - 26 AWG with a maximum of two

14 AWG

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Control System

Components

1A8, 1A9, 1A11, 1A12 Quad Relay

Output Status:

Relay #1 J2-1 NO, J2-2 NC, J2-

common

1A13, 1A18, 1A19, 1A20 Dual Binary

input module:

J2-1 Binary Input Signal #1, J2-2

Ground, J2-3 Binary Input Signal #2,

J2-4 Ground

Relay #2 J2-4 NO, J2-5 NC, J2-6

common

Binary Input: Looks for a dry contact

closure. Low Voltage 24V 12 mA.

Relay #3 J2-7 NO, J2-8 NC, J2-9

common

14 - 26 AWG with a maximum of two

14 AWG

Relay #4 J2-10 NO, J2-11 NC, J2-12

common

Power, 24 +/- 10 percent VDC, 40 mA

maximum Trane IPC3 protocol.

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.

1A14 Communication interface

Module

Power, 24 +/- 10 percent VDC, 50 mA

maximum. Trane IPC3 protocol.

J1-1 +24 VDC

J2-1 COMM +.

J2-2 COMM -

J2-3 COMM +

J2-4 COMM -

J11-1+24 VDC

J11-2 Ground

J11-3 COMM +

J11-4 COMM -

J1-2

J1-3

J1-4

Ground

COMM +

COMM -

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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

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: 14 - 26 AWG with a maximum of

two 14 AWG

J2-1 Output #1 to J2-3 (Ground), J2-4

Output #2 to J2-6 (Ground).

Recommended Length to Run external Output signals

Gauge

Ohms per Feet

0.00 2823

0.004489

0.007138

0.01135

Length (Feet)

1062.7

668.3

Maximum Length (Meters)

324

203.8

128.1

80.6

50.7

31.9

420.3

264.3

0.01805

166.3

0.0287

104.5

0.04563

65.7

0.07255

41.4

12.6

Note: the above table is for copper conductors only.

Analog Input:

The analog input can be software

switched between a voltage input or

a current input. When used as a

current input a 200 Ohm load resistor

is switched in.

2-12 Vdc or 4 to 20 mA Analog Inputs

UCP accepts either a 2-10 Vdc or 4-20

analog input suitable for customer

external control. The type is

determined at unit commissioning

during feature installation.

J2: 14 - 26 AWG with a maximum of

two 14 AWG

J2-2 Input #1 to

J2-3 (Ground).

J2-5 Input #2 to

J2-6 (Ground).

Power, 24 +/- 10 percent VDC, 60 mA

maximum, Trane IPC3 protocol.

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Control System

Components

Probe Operating Temperature Range - EarthWise^™Purge

Unit mounted devices

Vane Actuator Control

40 to 250°F (-40 to 121^oC)

Trane has also revolutionized its

Accuracy +/- 0.25^oC over the range -4

to 122°F (-20 to 50^oC), +/- 0.50^oC over

the range -40 to 250°F (-40 to 121^oC)

Power and Communications and

Terminations Power 24 +/- 10% VDC,

20 mA maximum.

controller-integrated purge, which

features an automatic regeneration

system for high-efficiency,

maintenance-free refrigerant

containment. Air and

noncondensables are pumped out

faster, and the lower temperature

refrigeration system enhances the

base purge efficiency. See EarthWise

purge operation and maintenance

manual for details.

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^™. Compressor Control

Signal allow the operator to manually

increase or decrease the compressor

load by adjusting the compressor

control signal.

Trane IPC3 protocol

Communications.

Pressure sensors

Oil tank sump 4R4 and oil pump

discharge 4R3, evaporator and

condenser refrigerant pressure 4R22,

Unit-mounted medium - voltage

Working Pressure Range: 0 to 50 Psia starter

Accuracy: 0.3% of full scale output

at 68°F (20°C)

Power and Communications and

Terminations

Power 24 +/- 10% VDC, 20 mA

maximum.

Communications, RS485 Physical

Layer, 19.2 Kbaud, Trane IPC3

protocol.

Take advantage of Tracer CH530’s

new starter and save space in your

equipment room. There is no need

for a remote or floor-mounted starter

with our new, exclusive unit-

Note: If the chiller is operating in a

limit mode (current limit, condenser

limit, evaporator limit, etcetera.) The

limit operation has priority over all

DynaView^™manual modes of

operation.

mounted medium - voltage starter

from Cutler-Hammer.

Adaptive Frequency^™motor drive

Tracer CH530 complements Trane’s

Adaptive Frequency motor drive

(AFD) system for chillers better than

ever before. Brand new control logic

allows safe, more efficient inlet vane

and motor speed control operation to

maximize part-load performance and,

when necessary, limit the starting

current.

On each UCP power-up, the inlet

guide vanes are driven full closed to

recalibrate the zero position (Steps)

of the Stepper motor vane actuator.

Starter Module

In the hierarchy of modules the

Starter module 2A1 (1A23 when

customer supplied starter specified)

is second only to the DynaView^™.

The starter module is present in all

starter selections (except AFD) .This

includes Wye Delta, Across the Line,

Solid State whether remote unit

mounted or supplied by others. The

starter module provides the logic to

provide the motor protection for

Current overload, phase reversal,

phase loss, phase imbalance, and

momentary power loss. These

functions are discussed in the motor

protection section of this manual.

Temperature sensors,

Evaporator sensors 4R6 and 4R7, and

condenser sensors 4R8, 4R9 entering

and leaving, bearing temperature

sensors 4R1, 4R2, oil temperature

sensor 4R5, outdoor air temperature

4R13, and evaporator 4R10 and

condenser 4R11 saturated refrigerant

temperature sensors.

When equipped with the Trane

Adjustable Frequency Drive (AFD) the

Unit Control Panels DynaView^™also

provides the Operator interface to the

AFD control. The Service Tool,

TechView^™is also utilized for setting

service items. See the Adjustable

Frequency drive operation

maintenance manual that ships with

the chiller for details .

Relay outputs @ 120 vac: 7.2 amps

resistive 2.88 amps Pilot Duty 1/3 hp,

7.2 FLA.

Relay outputs @ 240 vac: 5 amps 6

general purpose.

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Control Sequence

of Operation

1. Circuit Breaker 1Q1 which

provides power to the starter

module (2A1) relay outputs and the

High Pressure Cutout switch (3S1).

2. Circuit Breaker 1Q2 which

provides power to the Purge

circuitry.

3. Circuit Breaker 1Q3 which

provides power to Transformer

(1T1) which steps down the 115

Vac to 24 Vac. This 24 Vac then

powers the 24 Vdc power supply

1A1, and 1A2 if present. The 24 vdc

is then connected to all modules

via the Interprocessor

UCP and Wye-Delta Starter

Control Circuits

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.

Logic Circuits within the various

modules will determine the starting,

running, and stopping operation of

the chiller. When operation of the

chiller is required the chiller mode is

set at ‘‘Auto’’. Using customer

supplied power, the chilled water

pump relay (5K1) is energized by the

1A5 Module output at 1A5-J2-4, and

chilled water flow must be verified

within 4 minutes 15 seconds by the

1A6 Module. The main processors

logic decides to start the chiller

based on the differential to start

setpoint. With the differential to start

criteria met module 1A5 then

Note: The typical wiring diagrams

are representative of standard units

and are provided only for general

reference. They may not reflect the

actual wiring of your unit. For

specific electrical schematic and

connection information, always refer

to the wiring diagrams that shipped

with the chiller.

communications Bus providing

module power.

1Q3 also provides power to the

external chiller water proof of flow

device connected between terminal

block 1X1-5 to 1A6-J3-2, and

condenser water proof of flow

device connected at 1X1-6 to 1A6-

J2-2.

energizes condenser water pump

relay (5K2) via customer supplied

power at 1A5 J2-1.

Based on the restart inhibit function

and the differential to start setpoint,

oil and refrigerant pump (4M3) will

be energized by 1A7 Module (1A7-J1).

The oil pressure must be at least 9

Psid for 60 continuous seconds and

condenser water flow verified within

4 minutes 15 seconds minutes for the

compressor start sequence to be

initiated.

With the supply power disconnect

switch or circuit breaker (2Q1 or 2K3)

closed, 115-volt control power

transformer 2T5 and a 40-amp starter

panel fuse (2F4 ) to terminal (2X1-1)

starter panel to terminal 1X1-1 in the

control panel. From this point,

control voltage flows to:

4. Circuit Breaker 1Q4 which

provides power to the Oil Heater

4HR1 circuit and to Circuit Breaker

1Q5 oil and refrigerant pump

circuits.

5. The DynaView^™display module

1A22, receives 24 vdc power from

the IPC bus.

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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.

G. If no diagnostics are generated in

the above tests, the Stop Relay (2A1-

J10) is closed for 2 seconds and the

Start Relay (2A1-J8) is closed to

energize the start contactor (2K1). The

shorting contactor (2K3) has already

been energized from (F) above. The

compressor motor (4M1) starts in the

‘‘Wye’’ configuration, an auxiliary

contact (2K1-AUX) locks in the start

contactor (2K1) coil.

L. The run contactor (2K2) is closed

through auxillary contacts on the

shorting contactor (2K3), shorting out

the transition resistors. This places

the compressor motor in the ‘‘Delta’’

configuration and the starter module

waits to look for this transition for

about 2.3 seconds through the

closure of the transition complete

contacts 2K2-Aux at module 2A1-J12

input)

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.

H. After the compressor motor has

accelerated and the maximum phase

current has dropped below 85

percent of the chiller nameplate RLA

for 1.5 seconds, the starter transition

to the ‘‘Delta’’ configuration is

initiated.

M. The starter module must now

confirm closure of the transition

complete contact (2K2-AUX) within

2.5 seconds after the shorting relay

(2A1-J4) is opened. Finally, the

transition relay (2A1-J2) is opened de-

energizing the transition contactor

(2K4) and the compressor motor

starting sequence is complete. An

MMR diagnostic will be generated if

the transition complete contacts (2K2-

AUX) do not close. A diagram of this

test or start sequence is shown in

Figure 24.

B. Delay time - 20 msec.

C. Close start contactor (2K1) and

check for no current - 500 msec. If

currents are detected, the MMR

diagnostic ‘‘Starter Fault Type I’’ is

generated.

J. The transition contactor (2K4) is

closed through relay 2A1-J2, placing

the transition resistors (2R1, 2R2, and

2R3) in parallel with the compressor

motor windings. The run relay (2A1-

J6-3 to 1) is closed.

D. Stop relay (2A1-J10-3 to 1) closes

for one second for test “C” above.

E. Delay time - 200 msec. (Opens

2K1).

F. Close shorting contactor, (2K3) and

check for no current - one second. If

currents are detected the MMR

diagnostic ‘‘Starter Fault Type II’’ is

generated. (Starter Integrity test)

K. The shorting contactor (2K3) is

opened through the opening of relay

2A1-J4 100 msec after the closure of

the transition relay 2A1-J2, and the

run relay 2A1-J6.

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Control Sequence

of Operation

If the STOP key is pressed on the

operator interface, the chiller will

follow the same stop sequence as

above except the chilled water pump

relay (1A5-J2) will also open and stop

the chilled water pump after the

chilled water pump delay timer has

timed out after compressor shut

down.

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.

1. The inlet guide vanes are driven

closed up to 50 seconds.

2. After the inlet guide vanes are

closed, the stop relay (2A1-J10) and

the condenser water pump relays

(1A5-J2) open to turn off. The oil

and refrigerant pump motor (4B3)

will continue to run for 3 minutes

post lube while the compressor

coasts to a stop. The chilled water

pump will continue to run while

the Main processor module (1A22)

monitors leaving chilled water

temperature preparing for the next

compressor motor start based on

the ‘‘differential to start’’ setpoint.

If the “Immediate Stop” is initiated, a

panic stop occurs which follows the

same stop sequence as pressing the

STOP key once except the inlet guide

vanes are not sequence closed and

the compressor motor is immediately

turned off.

If the chilled water temperature drops

below the chilled water set point by

an amount set as the ‘‘differential to

stop’’ setpoint, a normal chiller stop

sequence is initiated as follows:

(Refer to Figure 10.)

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Control Sequence

of Operation

Figure 24. Test and start timing sequence

Timing requirements to operate the

“Stop”, “Start”, “Short”,

“Transition”, and “Run” contact

closure outputs are shown below.

Prior to closing the “Short” contact,

the transition complete input shall be

verified to be open, otherwise an

MMR diagnostic shall be generated.

Steps A to F: Starter Integrity Test.

Steps F to N: Starter Timing

Interval

Minimum

Maximum

Units

Actual Design

A. (Test for transition complete

input open)

B. (Just delay time)

C. (Close 1M (2K1) Contactor and test

for no current.) (Starter integrity test)

160 to 240 milliseconds

20 milliseconds

500 milliseconds

D. (Hold 1M (2K1) Contactor and test

for no current.) (Starter integrity test)

1 second

E. (Open 1M (2K1) Delay time

200 milliseconds

F. (Close Shorting Contactor (2K3) and

and test for no current, then wait for

Start command.) (Starter integrity test)

100

2.0

milliseconds

second

1 second (Minimum)

2 second

G. (Close 1M (2K1)

H. (Wait 1.5 seconds after phase currents

drop to 85 percent)

second

1.5 second

J. (Begin Transition sequence)

K. (Open S (Shorting) Contactor)

L. (Close 2M (2K2) Contactor

M. (Wait to look for Transition complete)

N. (Filtering time on Transition

complete input)

250

100

300

milliseconds

100 milliseconds

260 milliseconds

140 milliseconds

2.32 to 2.38 second

milliseconds

160 to 240 milliseconds

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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.

to the start windings of the refrigerant

pump. When motor 4M3 first starts,

current draw is high: This causes

current sensing relay 4K8 to close its

normally open contacts and pull in

pump Capacitor 4C1. Increasing

motor speed and related decreasing

current through the main winding

and relay coil reduce the magnetic

force and the armature “Drops out”

to open the start contacts and

disconnect the start windings and

capacitor. Current now flows only to

the Run windings of the oil pump

motor or refrigerant and oil pump

motor.

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^™.

Closure of the (1A7-J2-5 to 1), or 2K1

auxiliary contacts also allows current

to pass through the coil of the

refrigerant pump starter relay (4K8),

Maximum Acceleration

Timer Setting

by Starter Type

Wye-Delta

27 Seconds

Auto-Transformer

Primary Reactor

Across the Line

Solid State

AFD

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Machine Protection

and Adaptive

Control

momentary power losses. Tests have

shown that these short-term power

interruptions can be damaging to the

motor and compressor if the chiller

is reconnected to the line while the

motor and line phases do not match.

The chiller will be shut down when a

MPL is detected and will display a

non-latching diagnostic indicating

the failure. The oil pump will be run

for the post-lube time period when

power returns. The compressor and

compressor motor are protected from

damage from large torques and

to the power source following a

momentary loss of power.

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.

MPL’s greater than 2 or 3 cycles are

detected resulting in unit shut down.

Disconnection from the line is

initiated within 6 line cycles of the

power loss. MPL protection is active

anytime the compressor is in the

running mode. (The transition

complete input has been satisfied).

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. Power interruptions of less

than 30 line-cycles are defined as

MPL is enabled however can be

disabled, if required via the service

tool.

inrush currents resulting from

reconnecting the compressor motor

Figure 25. CVHE, CVHF, and CVHG sequence of operation: momentary power loss, (DynaView^™and Starter module

remain powered)

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Machine Protection

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Control

the compressor when the current

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.

The overload protection will

ultimately shut the unit down

anytime the highest of the three

phase currents exceeds the time-trip

curve. A manual reset diagnostic

describing the failure will be

displayed.

Overload protection for the motor

starts based on the Maximum Time

to Transition permitted for a

particular motor .

exceeds the specified time-trip curve.

The compressor overload time trip

curve is expressed as a percent of the

Rated Load Amps of the compressor

and is not adjustable:

Running Over Current Protection

In the run mode, a “time-to-trip”

curve is looked at to determine if a

diagnostic should be called. The

UCP continuously monitors

Overload Must Hold = 102 Percent

RLA.

Overload Must Trip in 20 (+0 -3)

seconds = 112 Percent RLA

(Note the above gives a nominal 20

second must trip point of 107 Percent

RLA.)

compressor line currents to provide

running over current and locked rotor

protection. Over current protection is

based on the line with the highest

current. It triggers a manually

Overload Must Trip in 1.5 seconds =

140 Percent RLA (Nominal)

resettable diagnostic shutting down

The linear time-trip curve is as

follows:

Figure 26. Overload trip time versus percent RLA

The Maximum Acceleration Time

Setting and Current Transformer

Setting are factory set however can

be set with the service tool;

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Machine Protection

and Adaptive

Control

The Current Limit Setpoint (CLS) can

be changed from: Front Panel,

Phase Imbalance Protection

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.

CH530 provides phase imbalance

protection based on the average

three-phase current. The three phase

currents supplied to the motor are

monitored for unequal amperage

draw. Motor overload is not

External Analog input (with GBAS

option), or Tracer (Tracer option).

However, If present Tracer current

setpoint has the highest priority,

unless disabled in the DynaView^™

Setpoint source override menu. The

External CLS has second priority, and

will be used if Tracer is disabled or

not installed. The Front Panel

considered to be a problem since

each phase of the motor is monitored

for overcurrent. In addition, since

each phase is monitored for loss of

current, the motor will be protected

against single phasing.

The current limit control logic

Setpoint has the lowest priority, and

will be used if Tracer and the External

CLS are both disabled.

attempts to prevent the motor from

shutting down on a diagnostic trip by

limiting compressor current draw

relative to an adjustable current limit

DynaView^™Current Limit Setpoint.

This setpoint can also be lowered to

provide electrical demand limiting on

the unit as required. This could also

be set to allow the Chiller to continue

to run at a lower load to avoid

Under and Over Voltage Protection

Under/over voltage protection can be

enabled (default) or disabled via

TechView.

Phase Loss Protection

Loss of phase detection protects the

chiller motor from damage due to a

single-phasing condition. The

controls will shut down the chiller if

any of the three phase currents

feeding the motor are lost. The

shutdown will result in a latching

diagnostic indicating the failure. The

motor is protected from over-current

during a single-phase condition by

the Current Overload Protection

feature. Phase Loss Protection

provides redundant protection and a

diagnostic that more accurately

describes the fault.

If Disabled : No effect.

If Enabled :

and an Overvoltage condition occurs:

tripping off via a diagnostic.

-Diagnostic called when the average

of the three line voltages is greater

than 112.5% of the unit line voltage

set point for 60 seconds.

The Current Limit function uses a PID

algorithm (Similar to the Leaving

Water Temperature control) that

allows the chiller to run at the

Current Limit Setpoint. At machine

startup, or with any setpoint change

the new current limit setpoint

reached after the is filtered setpoint

time elapses. The minimum current

limit setpoint is default set to 40

percent RLA (20-100 percent). The

filtering time is default set to 10

minutes (0-120 minutes), however

these can be altered via the service

tool. This filtered setpoint allows for

stable control if the Current Limit

setpoint is adjusted during a run.

-Diagnostic cleared when the average

of the three line voltages is 110% or

less of the unit line voltage set point.

and an Undervoltage condition

occurs:

Reverse Rotation Protection

This function protects the

-Diagnostic called when the average

of the three line voltages is less than

87.5% of the unit line voltage set

point for 60 seconds.

compressor from being driven in the

reverse direction. Incorrect phase

rotation detection results in a

manually resettable diagnostic.

Phase Reversal protection is default

to Enable, however can be disabled

via the service tool.

-Diagnostic cleared when the average

of the three line voltages is 90% or

greater of the unit line voltage set

point.

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Machine Protection

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Control

drop below setpoint and may even

cause the chiller to cycle off. Soft

loading prevents the chiller from

going to full capacity during the

pulldown period. After the

Softloading is not active during Ice

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.)

Making or during the Ice To normal

Transition. Softloading will be

enabled after the Ice to normal

Transition timer has expired.

compressor has been started, the

starting point of the filtered setpoint

is initialized to the value of the

Evaporator Leaving Water

Softloading is not active during Free

Cooling, The softloading is active

during the transition from Free

Cooling to Powered operation.

temperature and the percent RLA.

Softloading times can be active

during Hot Gas Bypass Control

There are three independent Softload

setpoints:

• Capacity Control Softload Time

(default to 10 minutes, 0-120

minutes) This setting controls the

time constant of the Filtered Chilled

Water Setpoint.

• Current Limit Control Softload Time

(default 10 minutes; 0-120 minutes)

This Setting controls the time

constant of the Filtered Current

Limit Setpoint.

• Current Limit Softload Starting

Percent (default is 40 percent RLA;

20-100 percent): This setting

controls the Starting point of the

Filtered Current Limit Setpoint

Minimum and Maximum Capacity

Limit

SoftLoading

A Minimum Capacity can be set to

limit the unloading ability of the

compressor thus forcing differential

to stop to be reached cycling the

chillers. Minimum capacity limit will

be displayed when in this limit

mode. This indicates when the chiller

is running fully unloaded.

Softloading stabilizes the startup

control during the initial chiller

pulldown. Soft loading is used to

bring the building loop temperature

from its start value to the Chilled

Water or Hot Water Setpoint in a

controlled manner. Without soft

loading, the chiller controls will load

the chiller rapidly and use the full

chiller capacity to bring the loop

temperature to setpoint. Although the

start temperature of loop may have

been high, the actual system load

may be low. Thus, when the setpoint

is met the chiller must unload

Similarly a maximum capacity can be

set to limit normal chilled water

temperature control, the maximum

capacity relay is energized which is a

signal used by generic BAS systems

to start another chiller.

Service tool provides access to these

three setpoints, if it is determined

necessary to change from the

defaults.

The minimum (default at 0 percent)

and maximum (default at 100 percent)

capacity are adjustable via the service

tool.

quickly to the system load value. If it

is not able to unload quickly enough,

the supply water temperature will

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Machine Protection

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Control

Evaporator Limit uses the Evaporator

Refrigerant Temperature sensor in a

PID algorithm (Similar to the Leaving

Water Temperature control) that

Cutout results in an automatically

Evaporator Limit

resettable diagnostic (MAR). The

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).

DynaView^™Operating Mode

indicates when the “Leaving Water

allows the chiller to run at the LRTC + Temperature Cutout Setpoint”

2 degree F.

conflicts with the chilled water

temperature setpoint by a message

on the display. The “Leaving Water

Temperature Cutout Setpoint” and

chilled water setpoint, both active

and front panel, are separated by a

minimum of 1.7°F. See Cutout

Strategy, Figure 27. When either

difference is violated, the UCP does

not permit the above differences to

be violated and the display exhibits a

message to that effect and remains at

the last valid setpoint. After violation

of the “Leaving Water Temperature

Cutout Setpoint” for 30°F seconds the

chiller will shutdown and indicate a

diagnostic.

When actively limiting machine

control “Evaporator Temperature

Limit” will be displayed as a sub-

operating mode.

Evaporator limit could occur with an

initial pull down of a loop where the

Condenser is colder than the

Leaving Water Temperature

Cutout

Evaporator (Inverted Start), the

Leaving water temperature cutout is a

safety control that protects the chiller

from damage caused by water

freezing in the evaporator. The cutout

setpoint is factory set however is

adjustable with the Service tool.

Evaporator refrigerant temperature

may drop below the Low Refrigerant

Temperature Cutout (LRTC). This limit

prevents the unit from shutting down

on a diagnostic during this type of

pulldown. Another example is a

Chiller that is low on refrigerant

charge will run with low Evaporator

refrigerant temperatures. This limit

allows the chiller to continue to run

at a reduced load.

The “Leaving Water Temperature

Cutout Setpoint” is independently

adjustable from the chilled water

setpoint and factory set. Shutdown of

the compressor due to violation of

the Leaving Water Temperature

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Machine Protection

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Control

setpoint that should be based on the

Low Refrigerant Temperature

Cutout

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.

The High Evaporator Water

percentage of antifreeze used in the

customer’s water loop. The Service

tool will display a warning message

such as “Warning: Adequate

Antifreeze required” for any

Evaporator Refrigerant Temperature

Cutout below 28°F and any Leaving

Water Temperature Cutout below

35°F.

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.

The percent of antifreeze required is a

function of the leaving water

temperature setpoint and the worse

case (lowest permitted water flow)

approach temperatures of the

chiller’s evaporator design.

The Low Evaporator Refrigerant

Cutout Setpoint is factory set to 36°F.

This can be altered via the service

tool. A Service Tool adjustable

Temperature diagnostic is an

immediate shutdown and is

Head Relief Relay

(See page 53 also)

nonlatching. The diagnostic will auto

reset and the pump will return to

normal control when the temperature

falls 5°F below the cutout setting.

High Evaporator Water Temperature

Cutout is a setpoint that is adjustable

in TechView from 80°F and 150°F. The

default is 105°F.

Surge, condenser limit, and certain

conditions on ice mode will energize

the head relief relay. Note: There is a

TechView programmable head relief

relay filter times setpoint. The default

is one minute.

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Machine Protection

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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.

Figure 27 illustrates these functions

as follows:

• chilled water setpoint

• evap leaving water temp cutout

• evap rfgt temp output

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Machine Protection

and Adaptive

Control

The Condenser Limit will be based

Condenser Limit

Evaporator Variable Flow

Compensation

from a pressure conversion from the

Condenser Refrigerant Temperature

sensor, unless there is a Condenser

Refrigerant Pressure sensor installed

(CDRP option). If the Condenser

Refrigerant Pressure Sensor is

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

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.

installed, then the limit will be based

from the Pressure sensor.

The following data will be shown at

the DynaView and TechView displays

and at Tracer Summit.

• Evaporator and condenser

differential water pressures (psid)

• Evaporator and condenser gpm

• Evaporator tons

Temperature (ELWT) and high

When limited by this action,

“Condenser Pressure Limit” will be

displayed as a sub-operating mode.

The Condenser Limit Setpoint is

factory set (93 percent of HPC),

however can be altered via the

service tool.

condenser temperatures causes high

condenser pressures. The purpose of

this limit is to avoid High Pressure

Cutout (HPC) trips by allowing the

Chiller to continue to run at a lower

load instead of tripping off via HPC.

How It Works

The Tracer chiller controller uses a

patented, variable, water-flow

compensation algorithm to maintain

stable, precise capacity control.

Variable flow compensation is a new

optional control feature for CTV

chillers.

It will automatically adjust capacity

control to:

• Maintain control stability at low

flow.

• Reject variable-flow disturbance.

If the water-pressure transducer fails

and the flow switch continues to

prove flow, water-flow compensation

will be disabled and the design delta

T will be used.

For applications designed to operate

with variable-primary (VPF) water-

flow, variable flow compensation

allows the chiller to respond quickly

to accelerating or decelerating water.

By automatically adjusting the

control gain, large changes in the

water-flow rate can be tolerated.

For details, refer to CTV-PRC007-EN.

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Machine Protection

and Adaptive

Control

During the time the start is inhibited

Restart Inhibit.

Restart Inhibit Start to Start

Time Setting

due to the start-to-start timer, the

DynaView shall display the mode

‘Restart Inhibit’ and the also display

the time remaining in the 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.

This setting defines the shortest

chiller cycle period possible after the

free starts have been used. If the

number of free starts is programmed

to “1”, and the Start to Start Time

Setting is programmed to 10

A “Restart Inhibit Invoked” warning

diagnostic will exist when the

attempted restart of a compressor is

inhibited.

minutes, then the compressor will be

allowed one start every 10 minutes.

The start-to-start time is the time from

when the motor was commanded to

energize to when the next command

to enter prestart is given.

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). These settings are

If all three motor winding

temperatures are less than the

“Restart Inhibit Temperature”

Setpoint (default 165°F/74°C) then

restart is allowed.

adjustable via the service tool.

Clear Restart Inhibit

A Clear Restart Inhibit “button” is

provided within Settings; Manual

Override on the DynaView display.

This provides a way for an operator

to allow a compressor start when

there is a currently active Restart

Inhibit that is prohibiting such a start.

The “button” press will have no

other function than to remove the

restart inhibit if there is one active. It

does not change the count of any

internal restart inhibit timers or

accumulators. command, but is

inhibited, pending the expiration of

the timer.

Restart Inhibit Free Starts

Restart inhibit mode exist when at

least one of the three motor winding

temperatures is greater than or equal

to the “Restart Inhibit Temperature”

Setpoint but less than 265°F/129.4°C.

Restart inhibit mode is entered until

all three motor winding temperatures

are less than the ‘Restart Inhibit

Temperature’ Setpoint

This setting will allow a number of

rapid restarts equal to its value. If the

number of free starts is set to “1”,

this will allow only one start within

the time period set by the Start to

Start Time Setting. The next start will

be allowed only after the start to start

timer has expired. If the number of

free starts is programmed to “3”, the

control will allow three starts in rapid

succession, but thereafter, it would

hold off on a compressor start until

the Start to Start timer expired. i.e.

with 3 free starts and 20 min. restart

inhibit settings, it will take 60

Note: When one of the three motor

winding temperatures is 265°F/

129.4°C or greater, a High Motor

Winding Temperature diagnostic

shall be called.

The restart inhibit function, setpoints

and clear features exist for each

compressor and operate

independently of other compressors

on that chiller.

Note: When the start is inhibited by

the restart inhibit function, the time

remaining will be displayed along

with the restart inhibit mode.

minutes of run time to restore the

total of 3 free starts.

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Machine Protection

and Adaptive

Control

High Vacuum Lockout

If the oil temperature is at or below a

given Low Oil Temperature Inhibit

setting (default 95°F/35°C) the

compressor cannot be started. This

is an inhibit mode and will be

reported to the operator interface. The

oil heater is energized in an attempt

to raise the oil temperature over this

inhibit temperature setpoint. The

compressor is inhibited from starting

until the oil temperature is raised 5 or

more degrees above this setpoint.

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. Oil

temperature is used to estimate this

dilution since the oil temperature

directly corresponds to amount of

refrigeration dilution in the oil. It is

required that oil contains minimal

refrigerant in it. This is accomplished

by boiling the refrigerant out of the

oil by maintaining a high enough oil

temperature.

The Low Oil Temperature Start Inhibit

is tested on every start unless a quick

restart is being performed during

post lube.

If the Enhanced Oil Temperature

Protection setting is enabled, the Low

Oil Temperature Start Inhibit value is

the greater of 100°F/37.8°C or the

Saturated Evaporator Refrigerant

Temperature + 30°F/16.7°C.

If the Enhanced Oil Temperature

Protection setting is not enabled, the

Low Oil Temperature Start Inhibit

value is settable with the Low Oil

Temperature Start Inhibit Setpoint via

the service tool.

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Machine Protection

and Adaptive

Control

If the oil temperature is at or above

Oil Temperature Control

the High Oil Temperature Cutout

setpoint this diagnostic will be

issued - which will stop the

compressor.

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 Oil Temperature violates this

temperature cutout for more than 120

seconds this diagnostic is issued.

If the oil temperature is at or below

the Low Oil Temperature Cutout

setpoint, this diagnostic will be

issued and stops the compressor.

Manual Oil Pump Control

The oil pump control accepts

commands to turn on the oil pump.

The manual oil pump choices will be

“Auto” or “On”. When the oil pump

is commanded “On”, it will revert to

“Auto” in 15 minutes.

This diagnostic is ignored for the first

10 minutes of compressor run. After

that, if the oil temperature falls below

this cutout temperature for more than

60 consecutive seconds this

diagnostic is issued.

High Oil Temperature Cutout

Name: High Oil Temperature Cutout

Type of Diagnostic: Latching, results

in Immediate Shutdown.

Default Setpoint value: 180°F (82.2°C)

Implemented to avoid overheating of

the oil and the bearings.

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Machine Protection

and Adaptive

Control

The following equations and

parameters apply for CWR.

MAXIMUM RESET is a user

Controls Chilled Water Reset

(CWR)

adjustable limit providing the

maximum amount of reset. For all

types of reset, CWS - CWS < or =

Maximum Reset.

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

CWS’ = CWS + RATIO (START

RESET - TWE - TWL) and CWS’ > or

= CWS and CWS’ - CWS < or =

Maximum Reset.

Both Return and Outdoor Reset do

not apply to Heating Mode where the

UCP is controlling the Leaving

Outdoor Air Temperature

Condensing Hot Water Temperature.

CWS = CWS + RATIO (START RESET

- TOD) and CWS’ > or = CWS and

CWS - CWS < or = Maximum Reset.

When the CWR function is based on

return water temperature, the CWR

feature is standard.

Constant Return Reset will reset the

leaving water temperature setpoint so

as to provide a constant entering

water temperature. The Constant

Return Reset equation is the same as

the Return Reset equation except on

selection of Constant Return Reset,

the UCP shall automatically set

RATIO, START RESET, and

Where

When the CWR function is based on

outdoor air temperature, the CWR

feature is an option requiring an

outdoor temperature sensor module

installed in the UCP panel, and

sensor installed outdoors.

CWS’ is the new chilled water

setpoint.

CWS is the active chilled water

setpoint before any reset has

occurred.

MAXIMUM RESET to the following:

RESET RATIO is a user adjustable

gain.

The type of CWR is selected in the

Operator Interface settings Menu

along with the Reset Ratio, Start

Reset Setpoint, and the Maximum

Reset Setpoint.

The RATIO = 100 percent

The START RESET = Design Delta

Temperature

The MAXIMUM RESET = Design

Delta Temperature

START RESET is a user adjustable

reference.

TOD is the Temperature Outdoor

Sensor.

The equation for Constant Return is

as follows:

TWE is entering evaporator water

temperature.

TWL is the Leaving Evaporator

Temperature.

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Machine Protection

and Adaptive

Control

Table 3. Values for start reset types

The values for “RESET TYPE” are:

Constant Return

CWS’ = CWS + 100 percent

(Design Delta Temperature) - (TWE-

TWL) and CWS’ > or = CWS and

CWS’ -CWS < or = Maximum Reset

Reset

Type:

Outdoor

Air Reset

Return

Reset

Const Return

Reset

Disable

The values for “RESET RATIO” for each of the reset types are:

Notice that Constant Return is

nothing more than a specific case of

Return Reset offered for operator

convenience.

Reset

Type

Reset

Ratio

Range

Increment

English

Units

Increment

SI Units

Factory

Default

Value

50 percent

10 percent

Return 10 to 120 percent

Outdoor -80 to 80 percent

1 percent

When any type of CWR is enabled,

the UCP will step the CWS toward

the desired CWS (based on the above

equations and setup parameters) at a

rate of 1°F every 5 minutes until the

Active CWS equals the desired

CWS’. This applies when the chiller

is running only.

The values for “START RESET “ for each of the reset types are:

Reset

Type

Start

Reset

Range

Increment

English

Units

Increment

SI Units

Factory

Default

Value

Return 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

(10 to 54.44°C)

0.1°F

90°F

(32.22°C)

Using the Equation for calculating

CWR for Outdoor Air Temperature

The values for “MAXIMUM RESET” for each of the reset types are:

Equation:

Degrees of Reset = Reset Ratio*(Start

Reset - TOD)

Reset

Maximum

Increment

English

Units

Increment

SI Units

Factory

Default

Value

5°F

(2.78°C)

Reset

Range

The chiller will start at the Differential

to Start value above a fully reset CWS

or CWS for both Return and Outdoor

Reset.

Return 0 to 20°F

(0.0 to 11.11°C)

Outdoor 0 to 20°F

(0.2 to 11.11°C)

0.1°F

0.1°C

0.1°F

5°F

(2.78°C)

The graph on the next page, shows

the reset function for Outdoor Air

Temperature: Note: This graph

assumes that Maximum Reset is set

to 20 degrees.

Degrees of Reset:

Degrees of Reset = Active CWS -

Front Panel CWS

Degrees of Reset = CWS’ - CWS

To obtain Active CWS from Degrees

of Reset: Active CWS = Degrees of

Reset + Front Panel CWS

(* = multiply)

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Machine Protection

and Adaptive

Control

Start Reset = Outdoor Air Start Reset

If:

Reset Ratio:

Reset Ratio = -70 percent

Start Reset = 90

TOD = 100

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:

If:

Maximum Reset = 17

Reset Ratio = 35 percent

Start Reset = 80

TOD = 65

How many Degrees of Reset will

there be?

Reset Ratio percent /100 = Reset

Ratio decimal

Maximum Reset = 10.5

Degrees of Reset = Reset Ratio* (Start

Reset - TOD)

Degrees of Reset = -7* (90-100)

Degrees of Reset = 7

Example of converting Reset Ratio:

How many Degrees of Reset will

there be?

If the Reset Ratio displayed on the

CLD is 50 percent then use (50/100)=

.5 in the equation

Degrees of Reset = Reset Ratio*(Start

Reset - TOD)

Degrees of Reset = .35*(80-65)

Degrees of Reset = 5.25

(* = multiply)

TOD = Outdoor Air Temperature

Figure 28. Outdoor air temperature versus degrees of reset

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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.

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Machine Protection

and Adaptive

Control

How many Degrees of Reset will

there be?

Example of Calculating Return Reset:

How many Degrees of Reset will

there be?

If:

Degrees of Reset = Reset Ratio*(Start

Reset - (TWE-TWL))

Degrees of Reset = .7*(20-(60-53))

Degrees of Reset = 9.1

Reset Ratio = 50%

Start Reset = 25

TWE = 65

Degrees of Reset = Reset Ratio*(Start

Reset - (TWE-TWL))

Degrees of Reset = .5*(25-(65-45))

Degrees of Reset = 2.5

TWL = 45

Maximum Reset = 8

If:

Reset Ratio = 70%

Start Reset = 20

TWE = 60

TWL = 53

Maximum Reset = 14

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Machine Protection

and Adaptive

Control

Figure 31. Return CWR

Figure 32. Constant CWR

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Unit Startup

The UCP also checks compressor

motor winding temperature, and a

start is initiated if the winding

temperature is less than 265°F. The

chilled water pump relay is energized

and evaporator water flow is proven.

When less than 5 seconds remain on

the restart inhibit, the pre-start starter

test is conducted on Y-Delta starters.

If faults are detected, the unit’s

compressor will not start, and a

MMR Diagnostic will be generated.

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”.

Next, the UCP checks the leaving

evaporator water temperature and

compares it to the chilled water

setpoint. If the difference between

these values is less than the start

differential setpoint, cooling is not

needed.

If the compressor motor starts and

accelerates successfully, “Unit is

Running” appears on the display. At

this time the purge unit will start

operating on “Automatic” and will

continue to operate as long as chiller

compressor is running.

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).

If the UCP determines that the

difference between the evaporator

leaving water temperature and chilled start-up, unit operation is locked out,

water setpoint exceeds the start

differential setpoint, the unit enters

the initiate Start Mode and the oil

pump and Refrigerant pump and the

condenser water pump are started. If

condenser water flow is not proven

(flow switch 5S3 does not close)

within 4-minutes 15 seconds, the unit

is locked out on a MMR Diagnostic.

Note: Whenever the UCP detects a

MMR diagnostic condition during

Note: The oil heater is energized

during the compressor off cycle.

During unit operation, the oil tank

heater is de-energized.

and manual reset is required before

the start-up sequence can begin

again. If the fault condition has not

cleared, the UCP will not permit

restart.

4. If the chiller is equipped with the

free cooling option, ensure that the

free cooling option is disabled in

the Chiller Settings menu.

5. Check the chilled water setpoint

and readjust it, if necessary, in the

Chiller Settings menu.

Oil pressure must be verified within 3

minutes or a MMR diagnostic is

generated.

6. If necessary, readjust the current

limit setpoint in the Chiller

Setpoints menu.

7. Press “AUTO”.

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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 3-

minute 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.

ƽ WARNING

5. If the evaporator was previously

drained, vent and fill the evaporator

and chilled water circuit. When all

air is removed from the system

(Including each pass), close the

vent valves in the evaporator water

boxes.

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. Lubricate the external vane control

linkage as needed.

7. Check the adjustment and

operation of each safety and

operating control.

Once the post-lube cycle is done, the

unit returns to auto mode.

Seasonal Unit Start-Up

8. Close all disconnect switches.

1. Close all drain valves, and re-

install the drain plugs in the

evaporator and condenser

headers.

9. Perform instructions listed in

“Daily Unit Start-up” section.

ƽ WARNING

2. Service the auxiliary equipment

according to the start-up and

maintenance instructions provided

by the respective equipment

manufacturers.

Toxic Hazards!

• Do not run evaporator water pump

longer than 30 minutes after the

chiller is shutdown.

3. Vent and fill the cooling tower, if

used, as well as the condenser

and piping. At this point, all air

must be removed from the system

(including each pass). Then close

the vents in the condenser water

boxes.

• Ensure that the evaporator is

isolated from the hot water loop

before changeover to heating

mode.

Do not allow the chiller to increase

above 110°F in temperature while

unit is off. Failure to prevent high

chiller temperature will cause the

inside pressure to rise. The rupture

disk is designed to relieve and

discharge the refrigerant from the

unit if the pressure in the evaporator

exceeds 15 PSIG (103.4 Kpa). A

significant release of refrigerant into

a confined space due to a rupture

disk failure could displace available

oxygen to breathe and cause

possible asphyxiation. Should a

rupture disk fail, evacuate the area

immediately and contact the

appropriate rescue or response

authority. Failure to take appropriate

precautions or react properly to a

potential hazard could result in

death or serious injury.

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Unit Shutdown

Unit Shutdown Procedures

Daily Unit Shutdown

manual should be performed by

qualified Trane service technicians.

Note: During extended shutdown, be

sure to operate the purge unit for a 2-

hour period every two weeks. This

will prevent the accumulation of air

and noncompensable in the

Note: Refer to Start-Run Shutdown

sequence in General Information

Overview Sequence of Operation.

1. Press STOP.

machine. To start the purge, change

the purge mode to ON in the

2. After compressor and water

pumps shutdown turn Pump

Contactors to OFF or open pump

disconnects.

DynaView^™Settings Purge Menu.

Remember to turn the purge mode to

Adaptive after the 2-hour run time.

Seasonal Unit Shutdown

Trouble Analysis

If the ALARM indicator on the control

panel is flashing, an MMR diagnostic

has occurred. Refer to Diagnostic

section for trouble shooting

information. (page 35)

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. Open all disconnect switches

except the control power

disconnect switch.

4. Drain the condenser piping and

cooling tower, if used. Rinse with

clean water.

5. Remove the drain and vent plugs

from the condenser headers to

drain the condenser. Air dry bundle

of residual water.

6. Once the unit is secured for winter,

the maintenance procedures

described under “Annual

Maintenance” in the Periodic

Maintenance section of this

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Periodic

Maintenance

for Water Cooled CenTraVacs with

UCP Control Panels’’ and ‘‘UCP

‘‘Settings Group’’ Menu Record’’.

When filled out accurately by the

machine operator, the completed

logs can be reviewed to identify any

developing trends in the chiller’s

operating conditions.

Overview

CAUTION

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.

Moisture Contamination!

IF FREQUENT PURGING IS

REQUIRED, MONITOR PURGE

PUMPOUT RATE, IDENTIFY AND

CORRECT SOURCE OF AIR OR

WATER LEAK AS SOON AS

POSSIBLE. Failure to do so can

shorten chiller life expectancy, due to

moisture contamination caused by

leakage.

For example, if the machine operator

notices a gradual increase in

condensing pressure during a

month’s time, he can systematically

check, then correct the possible

cause(s) of this condition (fouled

condenser tubes, noncondensable in

the system, etcetera)

Recommended purge maintenance

procedures for the Purifier Purge unit

are covered by PRGD-SVU01A-EN or

the latest revision which can be

[ ] Check the oil level in the chiller oil

sump using the two sight glasses

provided in the oil sump head. When

the unit is operating, the oil level

should be visible in the lower sight

glass.

obtained at the nearest Trane office.

Record Keeping Forms

Daily Maintenance and Checks

[ ] Check the chiller’s evaporator and

condenser pressures, oil tank

An important aspect of the chiller

maintenance program is the regular

completion of records. Provided at

the end of this manual are copies of

the “Annual Inspection Check List

and Report”, “CenTraVac with UCP

Commissioning Checklist and ‘‘Start-

Up Test Log’’, a ‘‘Start-Up Test Log

pressure, differential oil pressure and

discharge oil pressure. Compare the

readings with the values provided in

the Normal Chiller Operating

Characteristics table.

IMPORTANT: IT IS HIGHLY

RECOMMENDED THAT THE

OPERATING LOG BE COMPLETED

ON A DAILY BASIS.

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Periodic

Maintenance

Note: For additional information

regarding the safe discharge of

capacitors, see PROD-SVB06A-EN or

PROD-SVB06A-FR

ƽ ^WARNING

Hazardous Voltage w/

Capacitors!

Weekly Maintenance

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. Failure

to disconnect power and discharge

capacitors before servicing could

result in death or serious injury.

[ ] Complete all recommended daily

maintenance procedures and checks.

Complete logs on a daily basis.

Every 3 Months

[ ] Complete all recommended

weekly maintenance procedures.

Refer to the previous sections for

details.

[ ] Clean all water strainers in the

CenTraVac water piping system.

Every 6 Months

Normal Chiller Operating Characteristics

Operating Characteristic

Approx. Evaporator Pressure

Approx. Condenser Pressure

Normal Reading

(6 to 9 PSIA) (-9 to -6 PSIG)

(17 TO 27 PSIA) 2 to 12 PSIG

(Standard Condensers)

Oil Sump Temperature:

Unit Not Running

140°F to 145°F

(60°C to 63°C)

80°F to 162°F

(26.6°C to 72°C)

18 to 22 psid

Unit Running

Differential Oil Pressure

Notes:

1. Condenser pressure is dependent on condenser water temperature, and

should equal the saturation pressure of HCFC-123 at a temperature above

that of leaving condenser water at full load.

2. Normal pressure readings for ASME condensers exceed 12 PSIG.

3. Oil Tank Pressure 12” to 18” HG Discharge Oil Pressure 7 to 15 PSIG.

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Periodic

Maintenance

spread it into a very light film; this

will protect the shaft from moisture

and rust.

[ ] Complete all recommended

Inspection Checklist and Report’’

illustrated in this manual.

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.

[ ] Perform the annual maintenance

procedures referred to in the

Maintenance Section of the purge

manual.

Off-Season Maintenance

During those periods of time when

the chiller is not operated, be sure

the control panel is energized. This is

to keep the purge operational, the oil

heater warm and will also keep air

out of the machine.

[ ] Lubricate vane operator tang

o-rings as described in the

maintenance section.

[ ] Use an ice water bath to verify that

the accuracy of the evaporator

refrigerant temperature sensor (4R10)

is still within tolerance (+ or - 2.0° at

32°F (1° at 0°C)). If the evaporator

refrigerant temperature displayed on

the UCP’s read-out is outside this 4-

degree tolerance range, replace the

sensor.

[ ] Lubricate the oil filter shutoff valve

o-rings by removing the pipe plug

and adding several drops of Trane

OIL00022. Replace plug.

Annual Maintenance

Shut down the chiller once each year

to check the items listed ; a more

detailed inspection checklist is

provided on the ‘‘Model CVHE, CVHF

and CVHG CenTraVac Annual

[ ] Drain the contents of the rupture

disc and purge discharge ventline

drip-leg, into an evacuated waste

container minimally and more often if

the purge is operated excessively.

Note: If the sensor is exposed to

temperature extremes outside its

normal operating range (0°F to 90°F) (-

18°C to 32°C), check its accuracy at

six-month intervals.

Also, apply one or two drops of oil

on the vane operator shaft and

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Oil Maintenance

[ ] Pump the oil from the chiller

costs and maximize it’s operating life.

A drain fitting is installed in the oil

filter top, after the oil filter, for

obtaining oil samples.

Compressor Oil Change on

CVHE, CVHF, CVHG

through the oil charging valve into an

airtight resealable container, using a

magnetically-driven auxiliary pump.

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. The oil analysis should

be performed by a qualified

Forcing the oil from the oil sump by

pressurizing the chiller (by raising

chiller temperature or adding

Note: Use only Trane OIL00022. A full

oil change is 9 gallons of OIL00022.

Oil Change Procedure

When oil analysis indicates the need

to change compressor oil, use the

following procedure for removing

oil.

nitrogen) is not recommended.

Refrigerant dissolved in the oil can

be removed and returned to the

chiller by using an appropriate deep-

vacuum recovery unit and heating

and agitating the oil container. Follow

all Federal, State and Local

CAUTION

laboratory that is experienced in

refrigerant and oil chemistry and in

the servicing of Trane centrifugal

chillers.

regulations with regard to disposal of

waste oil.

Heater Damage!

The oil sump heater must be

deenergized before draining the

sump. Failure to do so could

possibly burn out the oil sump

heater.

In conjunction with other diagnostics

performed by a qualified service

technician, oil analyses can provide

valuable information on the

performance of the chiller to help

minimize operating and maintenance

[ ] Draw the oil from the chiller

through the oil charging valve on the

chiller oil sump into an approved,

evacuated tank; or,

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Oil Maintenance

4. Allow at least 15 minutes for the oil

to drain from the filter back into

the oil sump.

Replacing Oil Filter

Replace oil filter: (1) annually, (2) at

each oil change, (3) or if erratic oil

pressure is experienced during

chiller operation.

5. Pull the “D” handle to unlock the

pin and rotate the valve to the

“Change Filter” position. This

isolates the filter from the unit. The

locking pin should drop into a

detent in this position.

Oil Filter Replacement

Use the following procedure to

service the oil filter. Refer to Figure

34.

6. Remove and replace the filter as

quickly as possible. Tighten filter

2/3 to 3/4 turn per instructions

written on the filter. Place the used

filter in a reusable container.

Follow all local, state and federal

regulations to dispose of the filter.

Pull the “D” handle to unlock the

pin and rotate the valve to the

“RUN” position. The locking pin

should drop into a detent in this

position. The chiller is now ready

for operation.

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. Pull the “D” handle on the rotary

valve locking pin out of its detent

and rotate the valve to the

“DRAIN” position. An offset

pointer is located on top of the

valve with wrench flats to allow

turning. The spring force on the

locking pin should allow the pin to

drop into a detent at this position.

7. Purge unit.

8. Check oil pressure 18-27 psi.

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Maintenance

[ ] Measure the compressor motor

winding resistance to ground; a

qualified service technician should

conduct this check to ensure that the

findings are properly interpreted.

Lubricate the vane linkage shaft

bearings and rod end bearings as

needed with a few drops of light-

weight machine oil.

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.

The CenTraVac inlet guide vane tang

operators should be serviced

annually with R123 compatible

grease. Use only Rheolube 734A,

available from Trane as LUB00033

(16oz. standard grease gun cartridge)

or LUB00063 (3oz. mini grease gun

cartridge)

Contact a qualified service

organization to leak-test the chiller;

this procedure is especially

important if the system requires

frequent purging.

CAUTION

[ ] Use a nondestructive tube test to

inspect the condenser and evaporator

tubes at 3-year intervals.

To service the 1st stage tang

operator of all units except CVHF

extended capacity chillers with 1470

or 1720 compressors.

Oil Supply System

Problems!

Note: It may be desirable to perform

tube tests on these components at

more frequent intervals, depending

upon chiller application. This is

especially true of critical process

equipment.

Plugging of oil supply system could

lead to bearing failure. Failure to use

care could result in Loctite getting

into the chiller which may cause

problems with the Oil supply

1. The chiller must be off.

2. Carefully remove any insulation

that may have been placed over the

two lubrication ports of the tang

operator base. This insulation will

need to be replaced after the

service is complete.

[ ] Depending on chiller duty, contact

a qualified service organization to

determine when to conduct a

complete examination of the unit to

discern the condition of the

compressor and internal

system and eductor system.

[ ] Inspect the condenser tubes for

fouling; clean if necessary.

3. Note the position of the tang

operator arm, note the placement

of spacing washers etc., then

disconnect the linkage rod from

the tang operator arm. Manually

move the tang operator arm and

note the amount of effort required

to operate the assembly.

4. Loosen but DO NOT REMOVE the

1/16" NPT lubrication port plug that

is highest on the assembly.

5. Loosen and remove the remaining

lower 1/16" NPT plug.

6. Using a grease gun with an

appropriate fitting, insert ONLY

Rheolube grease into the open port

until clean grease is seen to appear

around the threads of the plug in

the opposite port.

ƽ WARNING

components.

Note: (a) Chronic air leaks, which can

cause acidic conditions in the

compressor oil and result in

premature bearing wear; and, (b)

Evaporator or condenser water tube

leaks. Water mixed with the

compressor oil can result in bearing

pitting, corrosion, or excessive wear.

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. Failure

to disconnect power and discharge

capacitors before servicing could

result in death or serious injury.

Note: For additional information

regarding the safe discharge of

capacitors, see PROD-SVB06A-EN or

PROD-SVB06A-FR

[ ] Submit a sample of the

compressor oil to a Trane qualified

laboratory for comprehensive

analysis on an annual basis; this

analysis determines system moisture

content, acid level and wear metal

content of the oil, and can be used as

a diagnostic tool.

7. Tighten the plug that was loosened

in step 4. Tighten the plug to hand

tight plus 1/4 to 1/2 turn.

Lubrication

8. Remove the grease fitting, if used.

The only CVHE, CVHF and CVHG

chiller component that requires

periodic lubrication is the external

vane linkage assembly and Rotary oil

valve.

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Maintenance

DO NOT LEAVE GREASE FITTINGS

INSTALLED.

and the other on the bottom of the

operator base. Use the same

procedure as described above,

except that it will be necessary to

temporarily disconnect the vane

actuators from the tang operator

arms in order to test for a

The oil valve block rotary valve uses

dual O-Rings to seal to atmosphere.

These should be manually lubricated

by removing the pipe plug at the

valve lubrication port and placing a

few drops of Trane OIL00022 in the

cavity. Be sure to reinstall the pipe

plug when lubrication is completed.

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.

“hydraulically locked” condition.

9. Using a clean wooden dowel or

other similar tool, remove excess

grease from the remaining open

lubrication port.

Figure 33. Rotary valve in drain position

10. Clean and then lightly coat the

threads of the plug with Rheolube

grease and re-install it into the

lubrication port. Tighten the plug

to hand tight plus 1/4 to 1/2 turn.

11. Before reconnecting the vane

linkage, grasp the tang operator

arm and manually operate the

vane assembly. If it is now

difficult to move, then the tang

operator may have become

“hydraulically locked” because of

excess grease in the assembly.

This situation could cause

damage to the o-rings of the

assembly. If this occurs then

remove one of the lubrication

plugs, remove some of the

grease, then re-install the plug.

12. Reconnect the linkage to the tang

operator arm. Ensure the spacer

washers between the linkage and

the arm are properly placed and

that the assembly does not bind.

Re-install any insulation that was

cut or removed. The unit may be

restarted.

Front View with Refrigerant Pump

To service the 1st and 2nd stage tang

operators on CVHF and CDHF

extended capacity chillers with 1470

or 1720 compressors.

The 1st and 2nd stage rotary inlet

guide vane tang operators of the

extended capacity chillers also

require periodic lubrication, at least

annually, with R123 compatible

Rheolube grease. These actuators

have two 1/8" NPT plugs located 180

degrees apart, with one on the top

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Maintenance

3. Transfer the refrigerant using one

of the following (listed in order of

preference):

Refrigerant Charge

Depending on the chiller duty,

contact a qualified service

organization to determine when to

conduct a complete examination of

the unit to discern the condition of

the compressor and internal

components.

ƽ WARNING

a. An approved Trane low-

pressure refrigerant recovery

and recycle unit.

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.

b. The available pressure

differential.

Note: If your chiller is covered by a

Trane extended warranty, the terms of

that warranty may require that the

procedures listed in the Periodic

Maintenance section of this manual

be followed for your extended

warranty to remain in force. The

terms may also require that the chiller

be inspected by a Trane authorized

warranty agent every

c. Gravity. (Use a return vent line

to refrigerant drums to equalize

pressure.)

5. Do not use dry nitrogen to push

refrigerant into the chiller as was

common practice in the past. This

will contaminate the charge and

require excessive purging, which

will result in unnecessary release

of refrigerant.

Failure to follow proper procedures

or the use of non-approved

refrigerants, refrigerant substitutes,

or refrigerant additives could result

in death or serious injury or

equipment damage.

4-years or 40,000 operating hours,

whichever occurs first. This

inspection will include, at a

6. Weigh in the proper charge.

minimum, a review of the annual

inspection checklists and the daily

operating logs, as well as

performance of a leak test and a

general inspection of the chiller. The

owner is then required to follow the

recommendations made as a result of

this inspection at the owners

expense.

7. Use recovery and recyle unit or

vacuum pump to evacuate hoses;

discharge outdoors.

The refrigerant charging procedure

for Trane centrifugal chillers is:

1. If water is present in the tubes,

break machine vacuum with

refrigerant vapor, or circulate

water, to avoid tube damage.

8. If refrigerant is supplied in new

returnable cylinders, be sure and

refer to General Service Bulletin

CVHE-SB-48B for information on

returning cylinders. This service

bulletin is available at the nearest

Trane office.

2. Always use refrigerant compatible

hoses or copper-tubing with self-

sealing connections or shut-off

valves.

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Maintenance

Recovery and Recycle

Cleaning the Condenser

CAUTION

Connections

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.)

Proper Water Treatment!

The use of untreated or improperly

treated water in a CenTraVac may

result in scaling, erosion, corrosion,

algae or slime. It is recommended

that the services of a qualified water

treatment specialist be engaged to

determine what water treatment, if

any, is required. Trane assumes no

responsibility for equipment failures

which result from untreated or

improperly treated water, or saline or

brackish water.

Leak Testing

To leak-test a chiller containing full

refrigerant charge, raise chiller

pressure using a controlled hot water

or electric-resistance system to a

maximum of 8 psig. Do not use

nitrogen, which will cause excessive

refrigerant discharge by the purge

system.

See Figure 34 which shows a Typical

Chemical Cleaning Setup.

Figure 34 - Typical Chemical Cleaning Setup

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Maintenance

Condenser tube fouling is indicated

when the approach temperature (the

difference between the condensing

refrigerant temperature and the

leaving condenser water

Cleaning the Evaporator

Since the evaporator is typically part

of a closed circuit, it does not

accumulate appreciable amounts of

scale or sludge. Normally, cleaning

every 3 years is sufficient. However,

on open CVHE, CVHF and CVHG

systems, such as air washers,

periodic inspection and cleaning is

recommended.

CAUTION

Unit Corrosion Damage!

Proper procedures must be followed

when using corrosive chemicals to

clean water side of unit. It is

recommended that the services of a

qualified chemical cleaning firm be

used. Proper personal protective

equipment as recommended by the

chemical manufacturer should be

used. Refer to the chemicals MSDS

sheet for proper safety procedures.

Failure to follow proper procedures

could result in corrosion damage to

the unit and tubes.

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

Control Settings and

Adjustments

contaminants.

Time delays and safety control cutout

settings need to be checked annually.

For control calibration and check-out,

contact a Trane qualified service

organization.

Use the mechanical cleaning method

to remove sludge and loose material

from smooth-bore tubes.

To clean other types of tubes

including internally-enhanced types,

consult a qualified service

IMPORTANT: ALL OF THE

MATERIALS USED IN THE

organization for recommendations.

EXTERNAL CIRCULATION SYSTEM,

THE QUANTITY OF THE SOLUTION,

THE DURATION OF THE CLEANING

PERIOD, AND ANY REQUIRED

SAFETY PRECAUTIONS SHOULD BE

APPROVED BY THE COMPANY

FURNISHING THE MATERIALS OR

PERFORMING THE CLEANING.

1. Remove the retaining nuts and

bolts from the water box covers at

each end of the condenser. Use a

hoist to lift the covers off the water

box. (A threaded connection is

provided on each water box cover

to allow insertion of an eyebolt).

2. Work a round nylon or brass

bristled brush (attached to a rod) in

and out of each of the condenser

water tubes to loosen the sludge.

REMEMBER, HOWEVER, THAT

WHENEVER THE CHEMICAL TUBE

CLEANING METHOD IS USED, IT

MUST BE FOLLOWED UP WITH

MECHANICAL TUBE CLEANING,

FLUSHING AND INSPECTION.

3. Thoroughly flush the condenser

water tubes with clean water.

Scale deposits may be best removed

by chemical means. Be sure to

consult a qualified chemical house in

the area (one familiar with the local

water supply’s chemical mineral

content) for a recommended cleaning

solution suitable for the job.

Remember, a standard condenser

water circuit is composed solely of

copper, cast iron and steel.

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Maintenance

3. After all traces of refrigerant are out

of the unit, a positive nitrogen

charge should be put into the unit

(6 to 8 psig). This positive pressure

must be checked monthly to

Unit Preparation

Purge System

The following steps are necessary in

order to properly prepare a unit for

storage.

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

1. Remove all liquid refrigerant if the

unit is charged.

insure no noncondensables get

into the unit. Use a pressure gage

on the evaporator shell to verify

that the 6 to 8 psig dry nitrogen

holding charge is still in the

chiller. If this charge has escaped,

contact a qualified service

ƽ ^WARNING

compressor power requirements,

and reduces the chiller’s efficiency

and cooling capacity.

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.

organization and the Trane sales

engineer that handled the order.

The Trane EarthWise Purge is the

only purge system available for the

CVHE, CVHF and CVHG chiller. The

purge is designed to remove

noncondensable gases and water

from the refrigeration system.

EarthWise Purge unit operation,

maintenance and trouble shooting is

covered by a separate operation and

maintenance manual, which may be

obtained from the nearest Trane

office.

4. The refrigerant charge should be

stored in proper refrigerant

containers. Due to possible

leakage, do not store in used

drums.

5. Maintain control power to the

control panel. This will maintain

oil temperature in the oil sump

and the capability of the control

panel to present report

Failure to follow proper procedures

or the use of non-approved

refrigerants, refrigerant substitutes,

or refrigerant additives could result

in death or serious injury or

equipment damage.

information. The Chiller Reports

should be viewed once a week for

normal readings. Any abnormal

observation must be reported to

the Trane Sales Engineer that

handled the order.

Overview

This section describes extended

storage requirements for UCP

installed CVHE, CVHF and CVHG

chillers to be removed from service

for an undetermined length of time.

2. After the liquid refrigerant is

removed, using a recovery or

recycle unit or vacuum pump, pull

a vacuum to remove remaining

refrigerant vapor from the unit.

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Maintenance

8. The oil can be left in the unit.

a qualified service organization to

perform this task. If the

compressor motor cannot be

bump started, then the shaft must

be rotated manually by a qualified

service organization.

ƽ WARNING

9. The water side should not cause a

problem if shut down and

Hazardous Voltage w/

Capacitors!

drained. There may be slight

scaling inside the tubes, but not

enough to cause a problem. The

customer should inspect and

clean tubes before the unit is

returned to service.

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. Failure

to disconnect power and discharge

capacitors before servicing could

result in death or serious injury.

11. Obtain an oil analysis initially

after six months of storage, and

once each succeeding year. If no

oil breakdown is evident do not

change the oil. If breakdown is

evident, the oil must be replaced.

IMPORTANT: DO NOT USE

UNTREATED OR IMPROPERLY

TREATED WATER, OR EQUIPMENT

DAMAGE MAY OCCUR.

12. If the unit is stored for more than

five years, and the storage is

expected to be indefinite, the unit

should be examined for leaks

every five years from the initial

storage date.

IMPORTANT: SCALE DEPOSITS ARE

BEST REMOVED BY CHEMICAL

MEANS. BE SURE TO CONSULT

ANY QUALIFIED CHEMICAL HOUSE

IN THE AREA (ONE FAMILIAR WITH

THE LOCAL WATER SUPPLY’S

CHEMICAL MINERAL CONTENT)

FOR A RECOMMENDED CLEANING

SOLUTION SUITABLE FOR THE

JOB.

13. When the unit is to be returned to

service, the services of a qualified

service organization should be

obtained to conduct all activities

associated with the startup of a

new chiller.

Note: For additional information

regarding the safe discharge of

capacitors, see PROD-SVB06A-EN or

PROD-SVB06A-FR

10. Motor bearings: If the motor sits

for a long time the bearings

could take a set and cause

6. Remove the factory installed

jumper or the field installed wiring

on terminals in the unit control

panel. This will prevent unwanted

chiller operation.

bearing problems or replacement

later. Once every six months the

chiller oil pump must be started

and the compressor motor bump

started to rotate the shaft. Contact

7. Set the purge operating mode to

OFF on UCP chillers.

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CVHE-SVU01E-EN

Literature Order Number

File Number

SL-RF-CTV-CVHE-SVU01E-EN-0405

CVHE-SVU01D-EN 604

La Crosse

Supersedes

Stocking Location

Trane

Trane has a policy of continuous product and product data improvement and reserves the right to change design

and specifications without notice.

A business of American Standard Companies

www.trane.com

For more information contact your local district office

or e-mail us at [email protected]

Only qualified technicians should perform the installation and servicing of equipment referred to in this

publication.

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