American Standard CH530 User Manual

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Operation Maintenance

Duplex CDHF, CDHG Water Cooled CenTraVac With CH530

™

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Warnings and Cautions

Notice that warnings and cautions appear at appropriate intervals throughout this manual. Warnings are provided to alert installing contractors to potential hazards that could result in personal injury or

death, while cautions are designed to alert personnel to conditions that could result in equipment damage.

Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

NOTICE:

Warnings and Cautions appear at appropriate sections throughout this manual.

Read these carefully.



 WARNING – Indicates a potentially hazardous situation which, if not avoided, could result in

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death or serious injury.

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CAUTION – Indicates a potentially hazardous situation which, if not avoided, may result in





minor or moderate injury. It may also be used to alert against unsafe practices.

CAUTION – Indicates a situation that may result in equipment or property-damage-only accidents.

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Warnings and Cautions

General Information

Unit Control Panel (UCP)

Operator Interface

Chilled Water Setpoint

Inter Processor Communication (IPC)

Control System Components

Controls Sequence of Operation

Machine Protection and Adaptive Control

Unit Startup

Unit Shutdown

Periodic Maintenance

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Oil Maintenance

Maintenance

Forms

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General Information

Literature change

Applicable to CDHF, CDHG

About this manual

Operation and maintenance information for models CDHF, CDHG are covered in this manual. This includes both 50 and 60 Hz. CDHF and CDHG centrifugal chillers equipped with the Tracer CH530 Chiller Controller system. 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.

By carefully reviewing this information and following the instructions given, the owner or operator can successfully operate and maintain a CDHF, or CDHG unit.

If mechanical problems do occur, however, contact a qualified service organization to ensure proper diagnosis and repair of the unit.

Unit Nameplate

The unit nameplate is located on the left side of the unit control panel.

The following information is provided on the unit nameplate.

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..

2. Service Model Number

The service model represents the unit as built for service purposes . It identifies the selections of variable unit features required when ordering replacements parts or requesting service.

Note: Unit-mounted starters are identified by a separate number found on the starter.

3. Product Coding Block

The CDHF and CDHG 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.

4. Identifies unit electrical requirements

5. Correct operating charges and type of refrigerant

6. Unit Test Pressures and Maximum Operating Pressures

7. Identifies unit Installation and Operation and Maintenance manuals

8. Drawing numbers for Unit Wiring Diagrams

Typical Product Description Block

MODL CDHF DSEQ 2R NTON 2500 VOLT 575 REF 123 HRTZ 60 TYPE SNGL CPKW 142 CPIM 222 TEST AIR EVTM IECU EVTH 28 EVSZ 032S EVBS 280 EVWC STD EVWP 2 EVWT NMAR EVPR 150 EVCO VICT EVWA LELE CDTM IECU CDTH 28 CDSZ 032S CDBS 250 CDWC STD CDWP 2 CDWT NMAR CDPR 150 CDCO VICT CDWA LELE CDTY STD TSTY STD ECTY WEOR ORSZ 230 PURG PURE WCNM SNMP SPKG DOM OPTI CPDW HHOP NO GENR NO GNSL NO SOPT SPSH ACCY ISLS HGBP WO LUBE SNGL AGLT CUL CNIF UCP SRTY USTR SRRL 207 PNCO TERM

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General Information

Model Number - An example of a typical duplex centrifugal chiller model number is:

CDHF2100AA0BC2552613C0B203B0 B20KJAC1GW40C111340A010

Digit: Description

st-2nd

CD = CenTraVac® Duplex - 2

compressors

H =Direct Drive

F = Development Sequence

4 (F - 2 Stage) (G - 3 Stage)

th-8th

2100 = Nominal total

compressor tonnage

A = Unit Voltage A = 380V-60Hz-3Ph B = 440V-60Hz-3Ph C = 460V-60Hz-3Ph D = 480V-60Hz-3Ph E = 575V-60Hz-3Ph F = 600V-60Hz-3Ph G = 2300V-60Hz-3Ph H = 2400V-60Hz 3Ph J = 3300V-60Hz-3Ph K = 4160V-60Hz-3Ph L = 6600V-60Hz-3Ph M = 380V-50Hz-3Ph N = 400V-50Hz-3Ph P = 415V-50Hz-3Ph R = 3300V-50Hz-3Ph T = 6000V-50Hz-3Ph U = 6600V-50Hz-3Ph

-11th A0 = Design Sequence

B = Compressor Motor

Power, LH Circuit

C = Compressor Motor Power, RH Circuit. Compressor Motor codes: A = 588 KW B = 653 KW C = 745 KW D = 856 KW E = 957 KW F = 1062 KW G = 1228 KW H = 433 KW J = 489 KW K = 548 KW L = 621 KW

M = 716 KW N = 799 KW P = 892 KW R = 403 KW S = 453 KW T = 512 KW U = 301 KW V = 337 KW W = 379 KW X = 1340 KW

-16th 255 = Compressor Impeller

Diameter LH Circuit

-19th 261 = Compressor Impeller

Diameter RH Circuit

3 = Evaporator Tube Bundle Size 1 = 2100 nominal ton evaporator 2 = 2300 nominal ton evaporator 3 = 2500 nominal ton evaporator 4 = 1610 nominal ton evaporator 5 = 1850 nominal ton evaporator

C = Evaporator Tubes A = I/E copper, 0.028” wall, 0.75” O.D. B = I/E copper, 0.035” wall, 0.75” O.D. C = S/B copper, 0.028” wall, 0.75” O.D. D = S/B copper, 0.035” wall, 0.75” O.D. E = I/E copper, 0.028” wall, 1.0” O.D. F = I/E copper, 0.035” wall, 1.0” O.D.

0 = Not Assigned

B - Evaporator Waterbox

23 A = 150 psig 1 pass marine B = 300 psig 1 pass marine C = 150 psig 1 pass non-marine D = 300 psig 1 pass non-marine

2 = Evaporator Waterbox Connection; 1 = Victaulic 2 = Flanged

0 = Not Assigned

3 = Condenser Tube Bundle Size

26 1 = 2100 nominal ton condenser 2 = 2300 nominal ton condenser 3 = 2500 nominal ton condenser 4 = 1610 nominal ton condenser 5 = 1760 nominal ton condenser 6 = 1900 nominal ton condenser

B = Condenser Tubes A = I/E copper, 0.028” wall, 0.75” O.D. B = I/E copper, 0.035” wall, 0.75” O.D. C = S/B copper, 0.028” wall, 0.75” O.D. D = S/B copper, 0.035” wall, 0.75” O.D. E = I/E copper, 0.028” wall, 1.0” O.D. F = I/E copper, 0.035” wall, 1.0” O.D. G = I/E 90/10 CU/NI, 0.035” wall,

0.75” O.D.

0 = Not Assigned

B = Condenser Waterboxes A = 150 psig 1 pass marine B = 300 psig 1 pass marine C = 150 psig 1 pass non-marine D = 300 psig 1 pass non-marine

2 = Condenser Waterbox Connection; 1 = Victaulic 2 = Flanged

0 = Not Assigned

K = Orifice Size, LH Circuit,

J = Orifice Size, RH Circuit,

33 Orifice Nominal Tons: A = 710 B = 790 C = 880 D = 990 E = 1100 F = 1265 G = 1400 H = 1540 K = 1810 J = 1660 L = 1970 M = 2150 N = 1045 P = 1185 R = 1335 T = 1605 U = 1735

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V = 1890 W = 2060 X = 1475 Z = 560 - 3 stage 935 - 2 stage Y = 500 - 3 stage 835 - 2 stage 1 = 630 - 3 stage 2245 - 2 stage 2 = 800 - 3 stage 2345 - 2 stage 3 = 900 - 3 stage 2450 - 2 stage 4 = 1000 - 3 stage 2560 - 2 stage 5 = 1120 - 3 stage 2675 - 2 stage 6 = 1250 7 = 1600 8 = 1800 9 = 750

A = Starter Type A = Star-Delta Unit Mounted C = Star Delta Remote Mounted E = X-Line Full Volt Remote Mounted F = Autotransformer Remote Mounted G = Primary Reactor Remote Mounted H = X-Line Full Volt Unit Mounted J = Autotransformer Unit Mounted K = Primary Reactor Unit Mounted L = Solid State Unit Mounted M = Solid State Floor Mounted N = Solid State Wall Mounted P = Adaptive Freq. Drive-Unit Mounted R = Customer Supplied

C = Control Enclosure; C = Standard S = Special

1 = Control: Enhanced Protection; 0 = None 1 = Enhanced protection

G = Control: Generic BAS; 0 = None G = Generic BAS

W = Water Flow Control; 0 = None W = Water flow control

4 = Tracer® Comm. Interface 0 = None, 4 = COMM 4, 5 = COMM 5, S = Special

C = Control: Condenser Refrigerant Pressure; 0 = None, C = with

1 = Control: Extended Operation; 0 = None 1 = Extended operation

1 = Chilled Water Reset Outdoor Air Temperature Sensor 0 = None, 1 = Chilled water reset – with outdoor air temperature sensor, S = Special

1 = Control: Operating Status, 0 = None, 1 = Operating Status

1 = Gas Powered Chiller; 0 = No 1 = Yes

3 = Compressor Motor Frame Size LH Circuit

4 = Compressor Motor Frame Size RH Circuit FRAME SIZE CODES: 3 = 440E, 4 = 5000, 5 = 5800, 6 = 5800L, S = Special

0 = Unit Insulation; 0 = None 1 = Insulation package

A = Spring Isolators 0 = No A = Yes

0 = Not Assigned 0 = Not assigned

1 = Evaporator & Condenser Size 1 = 210D - 2100, 2 = 250D – 2500, 3 = 250X - 2500 , 4 = 250M - 2500

0 = Special Options 0 = None S = Special Option

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General Information

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:

AFD = Adaptive Frequency Drive

ASME = American Society of Mechanical Engineers

ASHRAE = American Society of Heating, Refrigerating and Air Conditioning Engineers

BAS = Building Automation System

CABS = Auxiliary Condenser TubeBundle S

CDBS = Condenser Bundle Size

CDSZ = Condenser Shell Size

CH530 = Tracer CH530 Controller

DV = DynaView Display, also know as the Main Processor (MP)

CWR = Chilled Water Reset

CWR’ = Chilled Water Reset Prime

DTFL = Design Delta-T at Full Load (i.e., the difference between entering and leaving chilled water temperatures)

ELWT = Evaporator Leaving Water Temperature

ENT = Entering Chilled Water Temperature

GPM = Gallons-per-minute

HGBP = Hot Gas Bypass

™

Clear Language

HVAC = Heating, Ventilating, and Air Conditioning

IE = Internally-Enhanced Tubes

IPC = Interprocessor Communication

LBU = La Crosse Business Unit

LCD = Liquid Crystal Display

LED = Light Emitting Diode

MAR = Machine Shutdown Auto Restart (Non-Latching where chiller will restart when condition corrects itself.)

MMR = Machine Shutdown Manual Restart (Latching where chiller must be manually reset.)

MP = Main Processor

PFCC = Power Factor Correction Capacitor

PSID = Pounds-per-Square-Inch (differential pressure) PSIG = Pounds-per-Square-Inch (gauge pressure)

UCP = Unit Control Panel

LLID = Low Level Intelligent Device (Sensor, Pressure Transducer, or Input/output UCP module)

RLA = Rated Load Amps

RTD = Resistive Temperature Device

Tracer CH530 = Tracer CH530 controller

TOD = Temperature Outdoor

Control Optional Packages

OPST Operating Status Control

GBAS Generic Building Automation

Interface

EXOP Extended Operation

CDRP Condenser Pressure

Transducer

TRMM Tracer Communications

WPSR Water pressure sensing

EPRO Enhanced Protection

CWR Chiller Water reset outdoor

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General Information

Overview

CDHF - CDHG

See Figure 1 for General Unit components. Each Chiller unit is composed of the following components as viewed when facing the control panel front side:

• Common Evaporator and Common Condenser

Figure 1. General Duplex unit components - front view

• Compressors and Motor 1 (Left hand), and 2 (Right hand)

• Economizers 1(LH), and 2 (RH),

• Purge 1(LH), and 2 (RH),

• Oil Tank/ Refrig. Pump 1 (LH), and 2 (RH),

• Control Panel 1 (LH), and 2 (RH)

• And when specified Unit mounted Starters 1 (LH) and 2 (RH) (not shown).

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Figure 2. General Duplex unit components (2 stage compressor)

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General Information

Cooling Cycle

Duplex Chillers have two refrigerant circuits that operate as their own independent circuits. These circuits are discussed as individual chiller refrigeration units in the following discussion. The sequence of operation of the two refrigeration circuits is discussed in a later section.

When in the cooling mode, liquid refrigerant is distributed along the length of the evaporator and sprayed through small holes in a distributor (i.e., 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.

The gaseous refrigerant is then drawn through the eliminators (which remove droplets of liquid refrigerant from the gas) and firststage variable inlet guide vanes, and into the first stage impeller.

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.

Compressor 1 or 2 (3 Stage)

Compressed gas from the first-stage impeller flows through the fixed, second-stage inlet vanes and into the second-stage impeller.

Here, the refrigerant gas is again compressed, and then discharged through the third-stage variable guide vanes and into the third stage impeller.

Once the gas is compressed a third time, it is discharged into the 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 heat from the refrigerant, causing it to condense. The liquid refrigerant then passes through orifice plate ‘‘A’’ and into the economizer.

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.

All remaining liquid refrigerant flows through another orifice plate ‘‘C’’ to the evaporator.

Compressor 1 or 2 (2 Stage)

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 compressed, and then discharged into the 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 heat from the 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 economizer into the second-stage impellers of the compressor.

All remaining liquid refrigerant flows out of the economizer, passes through another orifice plate and into the evaporator.

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Figure 3. Pressure enthalpy curve (3 stage compressor)

Figure 4. 2-stage economizer (3 stage compressor)

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Figure 5. Pressure enthalpy curve (2 stage compressor)

Figure 6. Single stage economizer (2 stage compressor)

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Overview

Controls Operator Interface

Information is tailored to operators, service technicians and owners.

When operating a chiller, there is specific information you need on a day-to-day basis — setpoints, limits, diagnostic information, and reports.

When servicing a chiller, you need different information and a lot more of it — historic and active diagnostics, configuration settings, and customizable control algorithms, as well as operation settings.

By providing two different tools – one for daily operation and one for periodic service — everyone has easy access to pertinent and appropriate information.

DynaView™ Human Interface

— 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.

TechView

— For the service technician or advanced operator 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 technician can interact with an individual device or a group of devices for advanced troubleshooting. LED lights and their respective TechView 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 Service company, or The Trane Company’s website at www.trane.com.

™

Chiller Service Tool

™

chiller service tool. A

™

indicators

™

visit your local Trane

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General Information

CTV Duplex Sequence Of Operation

This section will provide basic information on chiller operation for common events. With microelectronic controls, ladder diagrams cannot show today’s complex logic, as the control functions are much more involved than older pneumatic or solid state controls. Adaptive control algorithms can also complicate the exact sequence of operation. This section and its diagrams attempt to illustrate common control sequences.

The Sequence of Events diagrams use the following KEY:

Software States: (Figure 7)

There are five generic states that the software can be in:

1. Power Up, Stopped, Starting, Running, Stopping

Timeline Text: (Figures 8-11)

Figure 7. Sequence of operation overview.

The large timeline cylinder indicates the upper level operating mode, as it would be viewed on DynaView. Text in Parentheses indicates sub-mode text as viewed on DynaView. Text above the timeline cylinder is used to illustrate inputs to the Main Processor. This may include User input to the DynaView Touch pad, Control inputs from sensors, or Control Inputs from a Generic BAS. Boxes indicate Control actions such as Turning on Relays, or moving the Inlet Guide Vanes. Smaller cylinders indicate diagnostic checks, Text indicates time based functions, Solid double arrows indicate fixed timers, Dashed double arrows indicate variable timers

Power Up Diagram:

The Power up chart shows the respective DynaView screens during a power up of the main processor. This process takes from 30 to 50 seconds depending on the number of installed Options. On all power ups, the software model always will transition through the ‘Stopped’ Software state independent of the last mode. If the last mode before power down was ‘Auto’, the transition from ‘Stopped’ to ‘Starting’ occurs, but it is not apparent to the user.

Software Operation Overview Diagram:

The Software Operation Overview is a diagram of the five possible software states. This diagram can be thought of as a State Chart, with the arrows, and arrow text, depicting the transitions between states.

The text in the circles are the internal software designations for each State. The first line of text in the Circles are the visible top level operating modes that can be displayed on Dyna View. The shading of each software state circle corresponds to the shading on the timelines that show the state that the chiller is in.

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Figure 8. CDHE/F/G sequence of operation: auto to running

This diagram shows the sequence of operations for a start of the first compressor on a duplex chiller. The ‘First’ compressor will be determined by the type of duplex start selected.

Staging Second Compressor On:

This diagram shows the sequence of operations where the ‘First’ compressor is all ready running, and the ‘second’ compressor is staged on. The ‘First’ and ‘Second’ compressor will be determined by the type of duplex start selected

Figure 9. CDHE, CDHF, and CDHG sequence of operation: running

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Staging Second Compressor Off:

This diagram shows the sequence of operations where there is no longer a need to run the ‘Second’ compressor, so it is staged off. The ‘First’ and ‘Second’ compressor will be determined by the type of duplex start selected

Figure 10. CDHE/F/G sequence of operation: staging second compressor off

Satisfied Setpoint:

This diagram shows the sequence of operations where the setpoint has been satisfied, and the last compressor is staged off.

Figure 11. CDHE, CDHF and CDHG sequence of operation: normal shutdown to stopped and run inhibit

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General Information

Duplex Compressor Sequencing

Four methods (Two fixed sequence methods, a balanced start and hour’s method, and a no staging method) are provided for order of a compressor sequencing on CTV Duplex chillers. The desired method is selectable at startup via the service tool. The application can decide to either balance the wear burden among the unit’s compressors, to start the most efficient compressor, or to simultaneously start and stop both compressors to minimize startup pull down time. Each method has specific applications were it can be used advantageously.

If one compressor is locked out, in restart inhibit, or generally not ready to start, the available compressor will be started.

Note: The following description assumes compressor 1 is the down stream compressor.

Fixed Sequence – Compressor 1/ Compressor 2 (Default mode)

If the chiller is in the Auto mode and all interlocks have been satisfied, compressor 1 will be started based on the leaving water temperature rising above the “Differential to Start” setting. Compressors 2 will stage on when the overall chiller average capacity exceeds Stage ON Load point for 30 seconds. The stage on load point is adjustable (via service tool) up to 50%. The default is 40% which means that a single compressor would have to load to 80% (the average would be 40%) before the second compressor starts. Both compressors will run until chiller average capacity drops below Stage off Load point for 30 seconds. The Stage OFF load point is also

Figure 12. CDHF/G sequence of operation: lead 1/lag 2

adjustable (via service tool) (default = 30%, range from 0 to 50%). Compressor 2 will be shut down and compressor 1 will run until water temperature drops below the differential to stop. Before shutting down, compressor 2 will be unloaded and compressor 1 will be loaded to maintain the same average capacity command.

When running chilled water temperature at selected conditions, the downstream compressor usually will be the most efficient compressor to operate at part load because compressors on Duplex chillers are not sized exactly the same.

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General Information

Fixed Sequence – Compressor 2 / Compressor 1

If the chiller is in the Auto mode and all interlocks have been satisfied, compressor 2 will be started based on the leaving water temperature rising above the “Differential to Start” setting. Compressors 1 will stage on when the overall chiller average capacity exceeds Stage on Load point for 30 seconds. The stage on load point is adjustable up to 50%. The default is 40% which means that a single compressor would have to load to 80% (the average would be 40%) before the second compressor

starts. Both compressors will run until chiller average capacity drops below Stage off Load point for 30 seconds. The stage off load point is also adjustable. Compressor 1 will be shut down and compressor 2 will run until water temperature drops below the differential to stop. Before shutting down, compressor 1 will be unloaded and compressor 2 will be loaded to maintain the same average capacity command.

Figure 13. CDHE/F/G sequence of operation: lead 2 lag 1

If chilled water reset is used, the upstream compressor usually will be the most efficient compressor to operate at part load. If the leaving water temperature is reset and the chiller only needs one compressor, then the upstream compressor would be running closer to its selection point and will be the most efficient compressor to operate.

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General Information

Sequencing - Balanced Starts and Hours

When desired to balance the wear between the compressors. This method will extend the time between maintenance on the lead compressor. When balanced starts and hours is selected, the compressor with the fewest starts will start. If that compressor is unavailable to start due to a circuit lockout (including

Figure 14. CDHF/G sequence of operation: equalize starts and hours

restart inhibit) or a circuit diagnostic, then the other compressor will be started. The second compressor will stage on when chiller capacity exceeds the Stage on Load point for 30 seconds. When chiller capacity falls below Stage off Load point for 30 seconds, the compressor with the most hours will be shut off.

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General Information

Simultaneous Compressor Start/ Stop

Both compressors will start in close succession to minimize the time it takes for the chiller to reach full load. Some process applications need the chiller to start and generate capacity as fast as possible. This method will start both compressors, slightly staggered to prevent doubling of the current inrush, but will generally control the chiller as if there were only one compressor.

Figure 15. CDHF/G sequence of operation: combined start

If the chiller is in the Auto mode and all interlocks have been satisfied, compressor 1 will be started based on the leaving water temperature rising above the “Differential to Start” setting. When compressor 1 is at speed, compressor 2 will start. Both compressors will run until water temperature falls below the differential to stop, at that time both compressors will be shut down.

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Compressor Load Balancing

Duplex chillers with CH530 control will balance the compressor load by giving each compressor the same load command. The load command will be converted to IGV position that will be the same on each compressor.

Balancing compressor load results in the best overall efficiency and with both circuits operating with nearly the same refrigerant pressures.

When both compressors are running the overall chiller load command will be split evenly between the two compressors unless limit control overrides balancing. When transitioning between one compressor operation and twocompressor operation, the load commands will be actively balanced at a rate slow enough to minimize capacity control disturbances

Restart Inhibit

The purpose of restart inhibit feature is to provide short cycling protection for the motor and starter.

The operation of the restart inhibit function is dependent upon two setpoints. The Restart Inhibit Free Starts (1-5, 3 default), and the Restart Inhibit Start to Start Timer (10-30min, 20 default). These settings are adjustable via the service tool.

Restart Inhibit Free Starts

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.

Restart Inhibit Start to Start Time Setting

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 20 minutes, then the compressor will be allowed one start every 20 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.

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.

The restart inhibit function, setpoints and clear features exist for each compressor and operate independently of other compressors on that chiller.

During the time the start is inhibited 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.

A “Restart Inhibit Invoked” warning diagnostic will exist when the attempted restart of a compressor is inhibited.

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General Information

Oil and Refrigerant Pump

Compressor Lubrication System -

A schematic diagram of the compressor lubrication system is illustrated in Figure 16. (This can be applied to circuit 1 or 2.)

Oil is pumped from the oil tank (by a pump and motor located within the tank) through an oil pressureregulating valve designed to maintain a net oil pressure of 18 to 22 psid. It is then filtered and sent to the oil cooler located in the economizer and on to the bearings. From the bearings, the oil drains back to the manifold under the motor and then on to the oil tank.

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WARNING

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

Surface Temperatures!

MAY EXCEED 150°F. Use caution while working on certain areas of the unit, failure to do so may result in death or personal injury.

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.

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.

Note: 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.

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.

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.

Motor Cooling System

Compressor motors are cooled with liquid refrigerant, see Figure 16.

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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General Information

Figure 16. Oil refrigerant pump - circuit 1 or 2

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General Information

Base Loading Control Algorithm:

This feature allows an external controller to directly modulate the capacity of the chiller. It is typically used in applications where virtually infinite sources of evaporator load and condenser capacity are available and it is desirable to control the loading of the chiller. Two examples are industrial process applications and cogeneration plants. 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.

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.

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.

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.

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 normal chilled or hot water control algorithm, and will turn off, only when the differential to stop has been satisfied.

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

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 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.

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General Information

Figure 17. Base loading with external mA input and with external voltage input

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General Information

Ice Machine Control

UCP provides a service level “Enable or Disable” menu entry for the Ice Building feature when the Ice Building option is installed. Ice Building can be entered from “Front Panel”, or if hardware is specified the UCP will accept either an isolated contact closure (1A19 Terminals J2-1 and J2-2 (Ground) ) or a remote communicated input (Tracer) to initiate the ice building mode where the unit runs fully loaded at all times. 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 icebuilding 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:

1. Front panel disable.

2. Opening the external Ice. Contacts/ Remote communicated input (Tracer).

3. Satisfying an evaporator entering fluid temperature setpoint. (Default is 27°F)

4. Surging for 7 minutes at full open IGV.

Figure 18. Sequence of operation: ice making: running to ice making

Figure 19. Sequence of operation: ice making: stopped to ice to ice building complete

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General Information

Hot Water control

Occasionally CTV chillers are selected to provide heating as a primary mission. With hot water temperature control, the chiller can be used as a heating source or cooling source. This feature provides greater application flexibility. In this case the operator selects a hot water temperature and the chiller capacity is modulated to maintain the hot water setpoint. Heating is the primary mission and cooling is a waste product or is a secondary mission. This type of operation requires an endless source of evaporator load (heat), such as well or lake water. The chiller has only one condenser.

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 coolingdriven 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.

This is NOT heat recovery. Although this feature could be used to recover heat in some form, there’s not a second heat exchanger on the condenser side.

The DynaView 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.

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.)

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.

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

™

Main Processor

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)

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.

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.

The hot water temperature control feature is not designed to run with HGBP, AFD, 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.

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Unit Control Panel (UCP)

Control Panel Devices and Unit Mounted Devices

Unit Control Panel (UCP)

Safety and operating controls are housed in the unit control panel, the starter panel and the purge control panel. The UCP ‘s operator interface and main processor is called the DynaView the UCP door. (See Operators interface section for detailed information)

Figure 20. Left control panel

™

(DV) and is located on

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 provides communication between LLID’s and the main processor. Unit mounted devices are called frame mounted LLID’s and can be temperature sensors or pressure transducers, vane actuator. These and other functional switches provide analog and binary inputs to the control system.

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Unit Control Panel (UCP)

Tracer CH530 Chiller Controller

Revolutionary control of the chiller, chilled water system, and your entire building with unprecedented accuracy, reliability, efficiency, and support for maintenance using the chiller’s PC-based service tool. Chiller reliability is all about producing chilled water and keeping it flowing, even when facing conditions that ordinarily would shut down the chiller — conditions that often happen when you need cooling the most.

Tracer CH530’s Main Processor, DynaView 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.

Because all devices are communicating digitally with the DynaView 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

™

, is fast and keeps the

™

main processor, there is

current. Every five seconds then a multiple objective algorithm 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 temperature, or to another more critical parameter should it exist.

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 application. With its faster and more intelligent response to changing

conditions, Tracer CH530 water flow sensing option 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.

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.

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Operator Interface

Figure 21. DynaView™ main processor

DynaView 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 information” icon (arrow) 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.

™

presents three menu

The DynaView™ (DV) Operator 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.

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 as evaporator and condenser water temperatures, outdoor air 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.

™

operator interface. Such

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Operator Interface

DynaView™ (DV) is the operator interface of the Tracer CH530 control

system utilized on the CTV machine. The DynaView wide, 8” high and 1.6” deep. The DynaView 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 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.

™

enclosure is 9.75"

™

display is approximately

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.

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 screens, each meant to serve a unique purpose of the machine being served. Tabs are shown 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

™

consists of various

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.

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.

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Operator Interface

The Auto and Stop keys are used to put the unit into the auto or stop modes. Key selection is indicated by being darkened (reverse video).

The Alarms button is to the right of the Stop key. The Alarms button appears only when alarm information is present. The alarm blinks to draw attention to the shutdown diagnostic condition. Blinking is defined as normal versus reverse video. Pressing on the Alarms button takes you to the corresponding screen.

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 presented as radio buttons within the persistent key display area. The

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 immediately.

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.)

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.

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.

TechView service tool is utilized to enable this feature.

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Operator Interface

Figure 22

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

Top Level Mode Description

Stopped Unit inhibited from running and will require

user action to go to Auto.

Run Inhibit Unit inhibited from running by Tracer,

External BAS, or an Auto Reset diagnostic. Auto Unit determining if there is a need to run. Waiting To Start Unit waiting for tasks required prior to

compressor start to be completed. Starting Compressor Unit is starting compressor. Running Compressor is running with no limits in

effect. Running – Limit Compressor is running with limit in effect.

Preparing To Shutdown Unit is closing inlet guide vanes prior to

compressor shutdown. Shutting Down Compressor has been stopped and unit is

performing shutdown tasks.

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 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 modes. In general, the BAS CODE will reflect the top level mode and not the sub level mode.

™

, the user will be

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Figure 23

Operator Interface

Reference

Top Level Mode Sub Level Mode BAS Code SYSTEM RESET Boot & Application software part number, self-test, and

configuration validity screens will be present. NA

Stopped Local Stop 00 Stopped Panic Stop 00 Stopped Diagnostic Shutdown – Manual Reset 00 Run Inhibit Ice Building Is Complete 100 Run Inhibit Tracer Inhibit 100 Run Inhibit External Source Inhibit 100 Run Inhibit Diagnostic Shutdown – Auto Reset 100 Auto Waiting For Evaporator Water Flow 58 Auto Waiting For A Need To Cool 58 Auto Waiting For A Need To Heat 58 Auto Power Up Delay Inhibit: MIN:SEC 58 Waiting To Start Waiting For Condenser Water Flow 70 Waiting To Start Establishing Oil Pressure 70 Waiting To Start Pre-Lubrication Time: MIN:SEC 70

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Operator Interface

Reference

Top Level Mode Sub Level Mode BAS Code Waiting To Start Motor Temperature Inhibit: Motor Temperature / Inhibit Temperature 70

Waiting To Start Restart Time Inhibit: MIN:SEC 70 Waiting To Start High Vacuum Inhibit: Oil Sump Press / Inhibit Press 70 Waiting To Start Low Oil Temperature Inhibit: Oil Temperature / Inhibit Temperature 70 Waiting To Start Waiting For Starter To Start: MIN:SEC 70 Starting Compressor There is no sub mode displayed 72 Running There is no sub mode displayed 74 Running Hot Water Control 74 Running Surge 74 Running Base Loaded 74 Running Ice Building 74 Running Ice To Normal Transition 74 Running Current Control Soft Loading 74 Running Capacity Control Soft Loading 74 Running – Limit Current Limit 75 Running – Limit Phase Unbalance Limit 75 Running – Limit Condenser Pressure Limit 75 Running – Limit Evaporator Temperature Limit 75 Running – Limit Minimum Capacity Limit 75 Running – Limit Maximum Capacity Limit 75 Preparing To Shutdown Closing IGV: IGV Position % 7E

Shutting Down Post-Lubrication Time: MIN:SEC 7E Shutting Down Evaporator Pump Off Delay: MIN:SEC 7E Shutting Down Condenser Pump Off Delay: MIN:SEC 7E

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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.

Main Screen Data Fields Table

Description Units Resolution Dependencies

1. Chiller Mode (>> submodes)

2. Circuit 1 Mode (>> submodes)

3. Circuit 2 Mode (>> submodes)

4. Evap Ent/Lvg Water Temp F / C 0.1

5. Cond Ent/Lvg Water Temp F / C 0.1

6. Active Chilled Water Setpoint (>>source) F / C 0.1

7. Active Hot Wtr Setpoint (>>source) F / C 0.1 If in heat installed

8. Active Current Limit Setpoint (>>source) % RLA 1

9. Active Base Loading Setpoint (>>source) % 1 If enabled

10. Circuit 1 Purge Mode (status, i.e. on, off, See modes in Emum adaptive, auto)) purge manual

11. Circuit 2 Purge Mode (status, i.e. on, off, See modes in Enum adaptive, auto)) purge manual

12. Approx Chiller Capacity Tons / kW XXX If option installed

13. Active Ice Termination Setpoint (>>source) F / C 0.1 If option installed

14. Software Version 0.XX

Chiller Operating Mode

The machine-operating mode indicates the operational status of the chiller. A subscreen with additional mode summary information will be provided by selection of an additional information icon (>>). The operating mode lines will remain stationary while the remaining status items scroll with the up/down arrow keys.

Circuit Operating Mode

The circuit-operating modes indicate the operational status of the circuits. A subscreen with additional mode summary information will be provided by selection of an additional information icon (>>). The operating mode lines will remain stationary while the remaining status items scroll with the up/down arrow keys.

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Operator Interface

Diagnostic Screen

The diagnostic screen is accessible by touching the Alarms enunciator.

When an alarm is present, the alarm enunciator is present next to the Stop key. A flashing “alarm” indicates a machine shutdown and a non flashing “alarm” indicates an informational message.

Machine shutdowns can be of two types:

Latching - Machine Shutdown Manual Reset Required (MMR)

Non-Latching - Machine Shutdown Auto Reset (MAR)

Latching (MMR) require corrective action and manual reset.

Non-Latching (MAR) will restart automatically when condition corrects itself.

There are over 200 potential messages, too numerous to incorporate in this manual.

Up to ten active diagnostics can be displayed if required.

The reason for all diagnostics 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.

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.

When reset they become historic and viewable via the service tool TechView.

Performing a Reset All Active Diagnostics will reset all active diagnostics regardless of type, machine or refrigerant circuit.

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 over any manual override, until the reset of active alarms, at which point the Manual indicator would reappear if such an override exists.

Temperature settings can be expressed in F or C, depending on Display Units settings.

Dashes (“- - - -”) appearing in a temperature or pressure report, indicates that the value is invalid or not applicable.

The languages for DynaView reside in the main processor. The main processor will hold three languages, English, and two alternate languages. The service tool (TechView processor with user selected languages from a list of available translations. Whenever possible, complete words will be used on the persistent keys as described.

™

) will load the main

™

will

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Operator Interface

The active chilled water setpoint is the setpoint that is currently in use. It will be displayed to 0.1 degrees Fahrenheit or Celsius. Touching the double arrow to the left of the Active Chilled Water Setpoint will take the user to the active chilled water setpoint arbitration sub-screen.

The Active Chilled Water Setpoint

the result of arbitration between the front panel, BAS, and external setpoints,

The chilled water reset status area in the right most column will display one of the following messages: Return, Constant Return, Outdoor, None

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.

The “Back” button provides navigation back to the chiller screen.

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Operator Interface

The active current limit setpoint is the current limit setpoint that is currently in use. It will be displayed in percent RLA. Touching the double arrow to the left of the Active Current Limit Setpoint will take the user to the active current limit setpoint subscreen. The active current limit setpoint is that setpoint to which the unit is currently controlling. It is the result of arbitration between the front panel, BAS, and external setpoints.

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.

Note: This is the same for other setpoints in the “Main” menu.

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Operator Interface

Reports

To aid in comparing the status of both circuits, the heading on the Reports list screen has buttons as indicated in the table above (i.e., System, Ckt1, and Ckt2). The selected button is darkened, presented in reverse video, or some how changed to indicate it is the selected choice.

Report Menu

Description Heading Buttons

1. Evaporator System, Ckt 1, Ckt 2

2. Condenser System, Ckt 1, Ckt 2

3. Compressor Ckt 1, Ckt 2

4. Motor Ckt 1, Ckt 2

5. Purge Ckt 1, Ckt 2

6. ASHRAE Chiller Log System, Ckt 1, Ckt 2

When a report screen is selected, the appropriate circuit is displayed in the screen heading as shown in the sample evaporator screen below:

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Operator Interface

Report name: System Evaporator

Description Resolution Units Dependencies

1. Evap Entering Water Temp + or – XXX.X Temperature

2. Evap Leaving Water Temp + or – XXX.X Temperature

3. Evap Water Flow Switch Status (Flow, No Flow)

4. Evap Differential Wtr Press XXX.X Diff Pressure If option installed

5. Approx Evap Water Flow XXXX Fl ow If option installed

6. Approx Chiller Capacity XXXX Tons If option installed

Report name: Circuit Evaporator

Description Resolution Units Dependencies

1. Evap Sat Rfgt Temp + or – XXX.X Temperature

2. Evap Rfgt Pressure XXX.X Pressure

3. Evap Approach Temp + or – XXX.X Temperature

Report name: System Condenser

Description Resolution Units Dependencies

1. Cond Entering Water Temp + or – XXX.X Temperature

2. Cond Leaving Water Temp + or – XXX.X Temperature

3. Cond Water Flow Switch Status (Flow, No Flow)

4. Cond Differential Wtr Press XXX.X Diff Pressure If option installed

5. Approx Cond Water Flow XXXX Flow If option installed

6. Outdoor Air Temperature + or – XXX.X Temperature If option installed

Report name: Circuit Condenser

Description Resolution Units Dependencies

1. Cond Sat Rfgt Temp + or – XXX.X Temperature

2. Cond Rfgt Pressure XXX.X Pressure

3. Cond Approach Temp + or – XXX.X Temperature

Note: Approach temperatures shown are the mathematical difference between the chiller leaving water temperature and the corresponding saturated refrigerant temperature of same circuit. When one compressor is operational the approach value will be similar to those values found on single compressor models. However when both compressors are operating, the upstream compressor circuits approach will be the mathematical difference of the upstream chillers refrigerant temperature and the leaving water temperature after the down stream chillers circuit. Therefore the approach of the upstream circuit

CDHF-SVU01C-EN

will be a negative number in many instances, when both compressors are operating.

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Operator Interface

Report name: System ASHRAE Chiller Log

Description Resolution Units Dependencies

1. Current Time/Date XX:XX mmm dd, yyyy Date / Time

2. Chiller Mode: Enum

3. Active Chilled Water Setpoint: XXX.X Temperature

4. Active Current Limit Setpoint: XXX % RLA

5. Refrigerant Type: Enum

6. Refrigerant Monitor: XXX.X PPM If option installed

7. Evap Entering Water Temp: XXX.X Temperature

8. Evap Leaving Water Temp: XXX.X Temperature

9. Evap Water Flow Switch Status: Enum If option not installed

10. Evap Differential Wtr Press: XXX.X Diff Pressure If option installed

11. Approx Evap Water Flow: XXX.X GPM/LPM If option installed

12. Approx Chiller Capacity: XXXX Capacity If option installed

13. Cond Entering Water Temp: XXX.X Temperature

14. Cond Leaving Water Temp: XXX.X Temperature

15. Cond Water Flow Switch Status: Enum If option not installed

16. Cond Differential Wtr Press: XXX.X Pressure

17. Approx. Cond Water Flow: XXXX Flo w If option installed

Report name: Circuit ASHRAE Chiller Log

Description Resolution Units Dependencies

1. Circuit Operating Mode: Enum

2. Amps L1 L2 L3 XXXX Amps XXX.X if less than 1000 Amps

3. Volts AB BC CA XXXX Volts

4. Purge Daily Pumpout –24 Hrs: XXX.X Min

5. Purge Daily Pumpout Limit/Alarm XXX.X Min

6. Purge Pumpout - Life XXXXXX.X Min

7. Purge Operating Mode: Enum

8. Purge Status: Enum

9. Compressor Starts: XXXX Integer

10. Compressor Running Time: XX:XX Hours:Minute

11. Compressor Rfgt Discharge Temp: XXX.X Temperature If option installed

12. Oil Pump Discharge Pressure: XXX.X Pressure

13. Oil Tank Pressure: XXX.X Pressure

14. Differential Oil Pressure: XXX.X Diff Pressure

15. Oil Tank Temp: XXX.X Temperature

16. Inboard Bearing Temp: XXX.X Temperature If option installed

17. Outboard Bearing Temp: XXX.X Temperature If option installed

18. Evap Sat Refrigerant Temp: XXX.X Temperature

19. Evap Rfgt Pressure: XXX.X Pressure

20. Evap Approach Temp: XXX.X Temperature

21. Cond Sat Rfgt Temp: XXX.X Temperature

22. Cond Rfgt Pressure: XXX.X Pressure

23. Condenser Approach Temp: XXX.X Temperature

Historic Diagnostics Log

1 to 20 Historic Diagnostics (main processor 2.0 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.

To change chilled water setpoint, first select the settings tab screen. Chilled water setpoint to within the chiller sub-menu. (See next page for setpoint listing.)

Upon selecting a Settings list (i.e. Chiller, Circuit 1 Purge, System Mode Override, etc.) a listing of all setpoints available to change along with their current value will appear. The operator selects a setpoint to change by touching either the verbal description or setpoint value. Doing this causes the screen to switch to either the Analog Settings Subscreen or the Enumerated Settings Subscreen.

Header Screen

To aid in comparing circuit level setpoints, the heading on the Settings list have buttons as indicated in the table above (i.e., Ckt1 and Ckt2). The selected button is darkened, presented in reverse video, to indicate it is the selected choice.

Settings screen for standard CTV :

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Operator Interface

Chiller

Description Resolution or (Enumerations), Default Units

1. Front Panel Control Type (Chilled Water, Hot Water), Chilled Water Enum

2. Front Panel Chilled Water Setpt (3)

+ or – XXX.X Temperature

3. Front Panel Hot Water Setpt (3)

+ or – XXX.X Temperature

4. Front Panel Current Limit Setpt XXX (4) Percent RLA

5. Front Panel Base Load Cmd On/Auto enum

6. Front Panel Base Load Setpt XXX Percent

7. Front Panel Ice Build Cmd On/Auto Enum

8. Front Panel Ice Termn Setpt XXX.X Temperature

9. Ice to Normal Cool Timer Setpt (0-10), 5 min Minutes

10. Differential to Start XXX.X Temperature

11. Differential to Stop XXX.X Temperature

12. Setpoint Source *(BAS/Ext/FP, Ext/ Front Panel, Front Panel),

BAS/Ext/FP Default Enum

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

Feature Settings

Description Resolution or (Enumerations), Default Units

1. Chilled Water Reset (Constant, Outdoor, Return, Disable), Disable Enum

2. Return Reset Ratio XXX Percent

3. Return Start Reset XXX.X Temperature

4. Return Maximum Reset XXX.X Temperature

5. Outdoor Reset Ratio XXX Percent

6. Outdoor Start Reset XXX.X Temperature

7. Outdoor Maximum Reset XXX.X Temperature

8. Ext Chilled Water Setpoint (Enable, Disable), Disable Enum

9. Ext Current Limit Setpoint (Enable, Disable), Disable Enum

10. Ice Building Feature Enable (Enable, Disable), Disable Enum

11. Ext Base Loading Setpoint (Enable, Disable), Disable Enum

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Operator Interface

System Mode Overrides

Description Resolution or (Enumerations), Default Units Monitor Value

1. Compressor XXX / (Auto,Manual [0-100] ), Auto Enum IGV % Open Control Signal Evap. LWT

AFD Freq.

2. Evap Water Pump (Auto, On), Auto Enum 1) Evap Flow status

2) Override Tim e Remaining

3. Cond Water Pump (Auto, On), Auto Enum 1) Cond Flow status

2) Override Time Remaining

Circuit Mode Overrides

Description Resolution or (Enumerations), Default Units Monitor Value

1. Oil Pump (Auto, On), Auto Enum 1) Diff press

2) Override Time Remaining

2. Clear Restart Inhibit Timer

3. Purge Exhaust Circuit Test (Off, On), Off Enum none

4. Purge Regen Cycle (Off, On), Off Enum Carbon Temp

5. Front Panel Ckt Lockout (Not Locked Out, Locked Out), Not Locked Out Enum

Purge

Description Resolution or (Enumerations), Default Units

1. Purge Operating Mode (Auto, On, Adaptive, Stop), Adaptive Enum

2. Daily Pumpout Limit XXX Minutes

3. Disable Daily Pumpout Limit

(0 to disable)

0, XX Hours

4. Purge Liquid Temp Inhibit (Enable, Disable), Enable Enum

5. Purge Liquid Temp Limit XXX.X Temperature

Display Settings

Description Resolution or (Enumerations), Default Units

1. Date Format (“mmm dd, yyy”, “dd-mmm-yyyy”), “mmm dd, yyy” Enum

2. Date

3. Time Format (12-hour, 24-hour), 12-hour Enum

4. Time of Day

5. Keypad/Display Lockout (Enable, Disable), Disable Enum

6. Display Units (SI, English), English Enum

7. Pressure Units (Gauge, Absolute), Absolute Enum

8. Language (English, Selection 2, Selection 3), English (2) Enum

(1) Temperatures will be adjustable to 0.1 degree F or C. The Main Processor provides the minimum and maximum allowable value. (2) Adjustable to the nearest whole number percent. The Main Processor provides the minimum and maximum allowable value. (3) Terminates with 10 minutes if inactivity (4) The Date and Time setup screen formats deviate slightly from the standard screens defined above. See the time and date section for further details. (5) Enables a DynaView

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.

™

Lockout screen. All other screens timeout in 30 minutes to this screen when enabled. The DynaView™ Lockout Screen displays a 0-9 keypad to

™

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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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Page 47

Note: Radio 1 and Radio 2 refer to “touch sensitive buttons.” The labels depend upon the setting being controlled.

Operator Interface

Settings with buttons only [screen has no cancel or enter key] do accept the new selection immediately.

The analog setting subscreen is similar but offers an Auto/Manual radio button and value setting. An Auto/Manual selection is necessary to set the mode to override. Subsequently, when an arrow key is depressed that new value is assumed.

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.

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

Note: the main processor is

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Interprocessor Communication

Inter Processor Communications IPC3

When using Tracer CH530, you will not be required to know all the details about the structure of the IPC3 bus. However this page gives detailed information about the system for those of you that are really interested in how it works. The IPC3 protocol is based on RS485 signal technology. IPC3 was designed to be very efficient. It communicates at 19.2 Kbaud.

IPC3 Definitions: Bus Management:

The DynaView 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.

Node Assignment:

When a unit is factory commissioned, the Low Level Intelligent Device (LLID), or module, must have their node addresses assigned to them for storage in nonvolatile memory. The node addresses are normally assigned sequentially during factory commissioning.

Node Zero:

™

provides the bus

™

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.

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

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.

The DynaView 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 upcoming sections.

™

Main Processor with

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 24 illustrated below, identifies these devices. The Control Panel Devices table corresponds to the same device designators (see right hand column). Optional controls are present when a specific optional controls package is specified, as listed in the second column. Optional controls packages are; OPST Operating Status, GBAS Generic Building Systems, EXOP Extended operation, CDRP Condenser Pressure, TRMM Tracer communications, WPSR Water Flow Pressure sensing, FRCL Free Cooling, HGBP Hot Gas Bypass , and EPRO Enhanced Protection

Figure 24 illustrates the Control Panel Components Layout.

LLID Modules 1A1, 1A3, 1A4, 1A5, 1A6, 1A7, and 1A13 are standard and present in all configurations. Other Modules vary depending on machine optional devices.

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Control System Components

Figure 24. Control panel components layout

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Control System Components

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Control System Components

Control Panel Devices

Standard Devices

Controls Field Connection

Description Package Purpose Point Terminals

1A1 Power Supply Standard #1 Converts 24 vac to 24 vdc not for field use 1A2 Power Supply (as required) #2 Converts 24 vac to 24 vdc not for field use 1A3 Dual Relay Standard Relay #1 Oil Heater Relay not for field use Output modules 1A4 Dual High Standard High Pressure Cutout not for field use Voltage Input

1A5 Quad Relay Standard Relay #1 Chilled water pump J2-4 NO, J2-5 NC, Output modules (Relay #1) J2-6 common

1A5 Quad Relay Standard Relay #2 Condenser water pump control J2-1 NO, J2-2 NC, Output modules (relay #2) J2-3 common

1A6 Dual High Standard Input 1 Condenser Flow Input J2-2 Condenser water Voltage Input flow switch

1A6 Dual High Standard Input 2 Evaporator Flow Input J3-2 Chilled water Voltage Input flow switch

1A7 High Power Standard Oil Pump and not for field use Output Relay Refrigerant Pump

1A13 Dual LV Binary Standard Signal #1 External Auto Stop, J2-1 Binary Input Signal #1, input module J2-2 Ground

1A13 Dual LV Binary Standard Signal #2 Emergency stop J2-3 Binary Input Signal #2, input module J2-4 Ground

1A26 Temp Sensor Standard Compressor Motor not for field use Input

1F1 Standard LLID Power Supply Transformer not for field use

Primary Circuit protection

1T1 Standard Control Panel Power not for field use

Transformer ; 120:24Vac

1Q1 Standard Circuit Breaker Compressor not for field use

Motor Controller Control Power Branch Circuit

1Q2 Standard Circuit Breaker - not for field use

Purge System Branch Circuit

1Q3 Standard Circuit Breaker – not for field use

Module [- LLID] Power Supply Branch Circuit

1Q4 Standard Circuit Breaker - not for field use

Oil System Control Branch Circuit

1Q5 Standard Oil Pump Motor Branch not for field use

Circuit protection

1X1 Terminal Block Standard Control Panel Terminal Block, 1X1-5 Chilled water flow

Flow switch connections flow switch input

1X1-6 Condenser water flow switch input

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Control System Components

Chilled and Condenser Water Flow Interlock Circuits

Proof of chilled water flow for the evaporator is made by the closure of flow switch 5S1 and the closure of

OPST Operation Status Option Relay output modules 1A8 and 1A9 provide relay defaults shown (For other selections, see Installation Manual):

1A8 Optional Quad Relay OPST Relay #1 Chiller Non-Latching Alarm J2-1 NO, J2-2 NC, Output Status J2-3 common

1A8 Optional Quad Relay OPST Relay #2 Chiller Limit J2-4 NO, J2-5 NC, Output Status Mode Indicator J2-6 common

1A8 Optional Quad Relay OPST Relay #3 Chiller Latching J2-7 NO, J2-8 NC, Output Status Alarm Indicator J2-9 common

1A8 Optional Quad Relay OPST Relay #4 Chiller Running Indicator J2-10 NO, J2-11 NC, Output Status J2-12 common

1A9 Optional Quad Relay OPST Relay #1 Chiller Maximum Capacity J2-1 NO, J2-2 NC, Output Status J2-3 common

1A9 Optional Quad Relay OPST Relay #2 Chiller Head J2-4 NO, J2-5 NC, Output Status Relief Request J2-6 common

1A9 Optional Quad Relay OPST Relay #3 Circuit 2 J2-4 NO, J2-5 NC Output Status Purge Alarm to J2-6 common

1A9 Optional Quad Relay OPST Relay #4 Circuit 1 J2-1 NO, J2-2 NC, Output Status Purge Alarm to J2-3 common

auxiliary contacts 5K1 on terminals 1X1-5 and 1A6-J3-2. Proof of condenser water flow for the condenser is made by the closure of flow switch 5S2 and the closure of

auxiliary contacts 5K2 on terminals 1X1-6 and 1A6-J2-2.

Head Relief Request Output

When the chiller is running in Condenser Limit Mode or in Surge Mode, the head relief request relay on the 1A9–J2-6 to J2-4 will be energized (1 minute default) and can be used to control or signal for a reduction in the entering condenser water temperature. Designed to prevent high refrigerant pressure tripouts during critical periods of chiller operation.

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,

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without the head relief request relay, by limiting inlet guide vane stroke and chiller capacity.

Keep in mind that Condenser Limit Control supplements the protection provided by the condenser pressure high pressure cutout switch 3S1.

Motor Temperature sensor module

The motor temperature module 1A26 connects via unit wiring to the three motor winding temperature sensors. This module is located in the control panel where the module is connected to the IPC bus.

Default status relay selections are shown. Selections can be altered using service tool. Other choices are: Circuit 1 Running, Circuit 2 Running, Chiller Alarm, Circuit 1 Alarm, Circuit 2 Alarm, and Purge Alarm.

Maximum Capacity Relay

When the chiller has been operating at maximum capacity for 10 minutes (TechView adjustable) this relay will activate. Also upon being less than maximum capacity for 10 minutes this relay will deactivate.

Compressor Running Relay

Relay activates while compressor is running.

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 module J2-12 common

1A17 Optional Dual Analog EXOP Signal #1 External Base Loading J2-1 Output #1, Input/Output Module Setpoint input J2-3 Ground

1A17 Optional Dual Analog EXOP Signal #2 Refrigerant monitor inputs J2-4 Output #2, Input/Output Module J2-6 Ground

1A18 Optional Dual LV EXOP Signal #1 External Base Loading J2-1 Binary Input Signal #1, Binary input module Enable or Disable input, points J2-2 Ground

1A18 Optional Dual LV EXOP Signal #2 External Hot Water Control J2-3 Binary Input Signal #2, Binary input module Enable or Disable input J2-4 Ground

1A19 Optional Dual LV EXOP Signal #1 Ice Building Control J2-1 Binary Input Signal #1, Binary input module Enable or Disable input point J2-2 Ground

Refrigerant Monitor Input 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

TRMM TRM4 (Tracer Comm 4 interface)

1A14 Optional TRM4 Tracer Communications J2-1 COMM+, J2-2 COMM -J2-3, Communication or COMM +J2-4, COMM -,

Interface Module LCI-C

CDRP (Condenser Refrigerant Pressure Output)

1A15 Optional Dual Analog CDRP Signal #2 Condenser Refrigerant J2-4 Output #2, J2-6 Ground Input/output Module Pressure output

EPRO (Enhanced Protection)

4R22 EPRO Condenser Refrigerant Pressure Transducer 4R16 EPRO Compressor Discharge Refrigerant Temperature Sensor. (This is also included with HGBP). 4R1 EPRO Inboard Bearing Temperature Sensor 4R2 EPRO Outboard Bearing Temperature Sensor

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Control System Components

CDRP Refrigerant Pressure Output Option 1A15:

Refrigerant Pressure Output can be configured at commissioning to correspond to either A) the absolute condenser pressure, or B) the differential pressure of the evaporator to condenser pressures.

This vdc output is located at 1A15 – J2 – 4 (+) to J2-6 (Ground)

The Voltage DC Output can source a maximum of 22 mA of current.

This output is Voltage DC only, 4-20 mA is not supported.

A) Condenser Pressure Output.

2 to 10 Vdc corresponds to 0 Psia to the HPC (in Psia) setting.

Note: CH530 control allows for Delta Pressure, or, condenser pressure but not both on one circuit.

Temperature based

On standard machines the Percent Condenser Pressure Indication Output is based on the Saturated Condenser Refrigerant and a temperature to pressure conversion is made.

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.

Figure 25. Condenser pressure based output

Pressure based

With the Enhanced Protection EPRO option, a condenser pressure transducer is installed and the pressure is measured.

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.

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Control System Components

B) Refrigerant Differential Pressure Indication Output:

A 2 to 10 VDC analog output is provided instead of the previous condenser pressure output signal. This signal corresponds to a predetermined minimum and maximum pressure settings setup at commissioning of this feature. This relationship can be altered using the service tool if required.

Figure 26. Delta pressure setting - differential pressure based output (Defaults shown)

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.

The Minimum Delta Pressure Calibration setting has a range of 0400 psid (0-2758 kPa) in increments of 1 psid (1kPa). The Maximum Delta Pressure Calibration setting has a range of 1-400 psid (7-2758 kPa) in

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.

The evaporator refrigerant pressure is based on the Saturated Evaporator Refrigerant Temperature Sensor.

See CTV-PRB006-EN for additional information about condenser water temperature control.

Note: In this example, 2 vdc corresponds to OPSI differential and 10 vdc corresponds to 30 psi differential. The minimum value of 0 psi, and maximum value of 30 psi are individually adjustable via the service tool.

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Control System Components

GBAS (Generic Building Automation System)

1A15 Optional Dual GBAS Signal #1 Percent RLA Compressor Output J2-1 Output #1, J2-3 Ground Analog Input/

output Module 1A16 Optional Dual GBAS Signal #1 External Current limit Setpoint J2-2 Input #1, J2-3 Ground

Analog Input/ output Module 1A16 Optional Dual GBAS Signal #2 Chilled Water Reset input, J2-5 Input #2, J2-6 Ground

Analog Input/ or External Chiller Water Setpoint output Module

Percent RLA Output

2 to 10 Vdc corresponding to 0 to 120% RLA. With a resolution of

0.146%. The Percent RLA Output connections are on the terminals 1A15 –J2-1 (+) to J2-3 (Ground). The Percent RLA Output is polarity sensitive.

The following graph illustrates the output:

Figure 27. Voltage versus percent RLA

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Control System Components

External Chilled Water Setpoint (ECWS)

The External Chilled Water Setpoint allows the chilled water setpoint to be changed from a remote location. The External Chilled Water Setpoint is found on 1A16 J2-5 to J2-6 (Ground). 2-10 vdc and 4-20 ma corresponds to a default 34°F to 65°F (-17.8 to 18.3°C) adjustable via service tool.

WPSR (WFC Water Pressure Sensing Option)

1A21 Optional Dual WPSR = WFC Signal #1 Evaporator Differential Not for field use Analog Input or output Water Pressure

Module 1A21 Optional Dual WPSR = WFC Signal #2 Condenser Differential Not for field use

Analog Input or output Water Pressure Module

Module Characteristics

1A1, 1A2 Power Supply :

Unit Control Power Supply Module Converts 27 vac to 24 vdc.

Power Input Voltage: 23VRMS minimum, 27VRMS Nominal, 30VRMS maximum

Frequency: 50-60 Hz

Current: Full load 27 VAC – 4.30 A (RMS)

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

Power Output: Class II Voltage 24 VDC, Rated Current 2.44 Amps.

Fused at 3 amps (FUS01513)

1A3, 1A5, 1A10 Dual Relay Output modules :

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

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

Relay Outputs at 120 VAC: 7.2 Amps resistive, 2.88 Amps pilot duty, 1/3 HP, 7.2 FLA at 240 VAC: 5 Amps general purpose, 14 - 26 AWG with a maximum of two 14 AWG.

Power, 24 +/- 10 percent VDC, 60 mA maximum, Trane IPC3 protocol. J1-1 +24VDC, J1-2 Ground, J1-3 COMM + J1-4 COMM -

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.

1A4, 1A6 Dual High Voltage Binary input module:

Binary Input Signal #1 J2-1 to 2

Binary Input Signal #2 J3-1 to 2

High Voltage Binary Input: Off Voltage: 0 to 40 VAC RMS , On Voltage: 70 to 276 VAC RMS

Input is not polarity sensitive (Hot and neutral can be switched), Input impedance 130K to 280K ohms

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 Output Module

Relay contacts at 120 VAC:

16 amps resistive, 6.4 amps,pilot duty, 1 HP

J2-14-26 awg witha maximum of two 14 awg

J2-1 J2-2 no, J2-3 NC, J2-4 com

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Control System Components

1A8, 1A9, 1A11, 1A12 Quad Relay Output Status:

Relay #1 J2-1 NO, J2-2 NC, J2common

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

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

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

Relay Outputs: at 120 VAC: 7.2 Amps resistive, 2.88 Amps pilot duty, 1/3 HP, 7.2 FLA, at 240 VAC: 5 Amps general purpose 14-26 AWG, two 14 AWG Maximum Power, 24 +/-10 percent VDC, 100 ma maximum. Trane IPC3 protocol.

J1-1 +24 VDC J2-1 COMM +. J11-1+24 VDC J1-2 Ground J2-2 COMM - J11-2 Ground J1-3 COMM + J2-3 COMM + J11-3 COMM + J1-4 COMM - J2-4 COMM - J11-4 COMM -

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

Binary Input: Looks for a dry contact closure. Low Voltage 24V 12 mA.

14 - 26 AWG with a maximum of two 14 AWG

Power, 24 +/- 10 percent VDC, 40 mA maximum Trane IPC3 protocol.

1A14 Communication interface Module

Power, 24 +/- 10 percent VDC, 50 mA maximum. Trane IPC3 protocol.

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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

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 Length (Feet) Maximum Length (Meters)

14 0.00 2823 1062.7 324 16 0.004489 668.3 203.8 18 0.007138 420.3 128.1 20 0.01135 264.3 80.6 22 0.01805 166.3 50.7 24 0.0287 104.5 31.9 26 0.04563 65.7 20 28 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.

2-10 Vdc or 4-24 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.

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.

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Control System Components

Unit mounted devices

Vane Actuator Control

The Stepper Module within the stepper vane actuator (4M2) (and 4M4 extended capacity) pulses a DC voltage to the windings of the Stepper Motor Actuator(s) to control inlet guide vane position. While operation of this stepper motor is automatic, manual control is possible by going to the Mode Overrides settings menu within the DynaView Signal allow the operator to manually increase or decrease the compressor load by adjusting the compressor control signal.

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 operation.

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.

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. Probe Operating Temperature Range 40 to 250°F (-40 to 121 Accuracy +/- 0.25 to 122°F (-20 to 50 the range -40 to 250°F (-40 to 121 Power and Communications and Terminations Power 24 +/- 10% VDC, 20 mA maximum. Trane IPC3 protocol Communications.

™

. Compressor Control

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manual modes of

C over the range -4

C), +/- 0.50oC over

Pressure sensors

Oil tank sump 4R4 and oil pump discharge 4R3, evaporator and condenser refrigerant pressure 4R22, Working Pressure Range: 0 to 50 Psia 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.

Starter Module

In the hierarchy of modules the Starter module 2A1 (1A23 when customer supplied starter specified) is second only to the DynaView

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. 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.

EarthWise

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Purge

Trane has also revolutionized its 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.

Unit-mounted medium - voltage starter

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 unitmounted medium - voltage starter from Cutler-Hammer.

The following two figures illustrate the typical location of various standard and optional unit mounted control and sensor devices.

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Control System Components

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Control System Components

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Control Sequence of Operation

Electrical Sequence

This section will acquaint the operator with the control logic governing CDHF/CDHG chillers equipped with Tracer CH530 UCP based control systems. When reviewing the step-by-step electrical sequences of operation, refer to the typical wiring schematics for Unit mounted Wye Delta starter shown in the installation manual shipped with the chiller.

Note: The typical wiring diagrams are representative of standard units and are provided only for general reference. 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.

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:

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 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 1A6J2-2.

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 1A22, receives 24 vdc power from the IPC bus.

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display module

UCP and Wye-Delta Starter Control Circuits

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 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 30 continuous seconds and condenser water flow verified within 4 minutes 15 seconds minutes for the compressor start sequence to be initiated.

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Control Sequence of Operation

When less than 5 seconds remain before compressor start, a starter test is conducted to verify contactor states prior to starting the compressor. The following test or start sequence is conducted for ‘‘Wye-Delta’’ starters: Also refer to Figure 24.

A. Test for transition complete contact open (2A1-J12-2) –160 to 240 msec. An MMR diagnostic will be generated if the contact is closed.

B. Delay time - 20 msec.

C. Close start contactor (2K1) and check for no current - 500 msec. If currents are detected, the MMR diagnostic ‘‘Starter Fault Type I’’ is generated.

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)

G. If no diagnostics are generated in the above tests, the Stop Relay (2A1J10) 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. Additonally, 2K11 pulls in to hold the oil pump on. This is parallel to 1A7 contacts.

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.

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.

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.

L. The run contactor (2K2) is closed through relay 2A1-J6, shorting out the transition resistors 260 milliseconds after the opening of the shorting relay 2A1-J4. This places the compressor motor in the ‘‘Delta’’ configuration and the starter module waits to look for this transition for

2.35 seconds through the closure of the transition complete contacts 2K2Aux at module 2A1-J12 input)

M. The starter module must now confirm closure of the transition complete contact (2K2-AUX) within

2.32 to 2.38 seconds after the run relay (2A1-J6) is closed. Finally, the transition relay (2A1-J2) is opened deenergizing the transition contactor (2K4) and the compressor motor starting sequence is complete. An MMR diagnostic will be generated if the transition complete contacts (2K2AUX) do not close. A diagram of this test or start sequence is shown in Figure 24.

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Control Sequence of Operation

Now that the compressor motor (4M1) is running in the ‘‘Delta’’ configuration, the inlet guide vanes will modulate, opening and closing to the chiller load variation by operation of the stepper vane motor actuator (4M2) 4M4 (extended capacity) to satisfy chilled water setpoint. The chiller continues to run in its appropriate mode of operation: Normal, Softload, Limit Mode, etcetera. As explained in the General Information section.

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.)

1. The inlet guide vanes are driven closed for 50 seconds.

2. After the 50 seconds has elapsed, the stop relay (2A1-J10) and the condenser water pump relays (1A5J2) 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 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.

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.

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Figure 24. Test and start timing sequence

Control Sequence of Operation

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

Steps A to F: Starter Integrity Test Steps G to N: Starter Timing

Interval Minimum Maximum Units Actual Design A. (Test for transition complete input open) 160 to 240 milliseconds B. (Just delay time) 20 milliseconds C. (Close 1M (2K1) Contactor and test for no current.) (Starter integrity test) 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 milliseconds 1 second (Minimum) G. (Close 1M (2K1 and 2K11) 2.0 second 2 second H. (Wait 1.5 seconds after phase currents drop to 85 percent) 1 2 second 1.5 second

J. (Begin Transition sequence) 85 100 milliseconds 100 milliseconds K. (Open S (Shorting) Contactor) 250 300 milliseconds 260 milliseconds L. (Close 2M (2K2) Contactor 140 milliseconds M. (Wait to look for Transition complete) milliseconds 2.32 to 2.38 second N. (Filtering time on Transition complete input) milliseconds 160 to 240 milliseconds

MMR diagnostic shall be generated.

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Control Sequence of Operation

Current passing through circuit breaker 1Q5 reaches 2 normally open parallel sets of contacts: those of refrigerant and oil pump relay (1A7J2-5 to 1), and the 2K11 interlocking relay. Connected at module 1A7-J2-2 to 4.

Note: While the (1A7-J2-5 to 1) relay automatically is closed by the main processor 1A22 as a part of the start sequence. It can also be closed manually by changing the oil pump status to “ON” in the manual over ride mode menu of DynaView

Closure of the (1A7-J2-5 to 1), or 2K11 contacts also allows current to pass through the coil of the refrigerant

Maximum Acceleration

Timer Setting

by Starter Type Wye-Delta 27 Seconds Auto-Transformer 16 Primary Reactor 16 Across the Line 6 Solid State 15 AFD 30

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pump starter relay (4K8), 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 of 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.

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Machine Protection and Adaptive Control

Momentary Power Loss (MPL) Protection.

Improved power measurement and protection algorithms allow the unit to accommodate more power anomalies than ever. If the chiller must shut down, faster restarts get the machine up and running as soon as possible.

Momentary power loss (MPL) detects the existence of a power loss to the compressor motor and responds by initiating the disconnection of the compressor motor from the power source. Power interruptions of less than 30 line-cycles are defined as momentary power losses. Tests have shown that these short-term power

Figure 29. Sequence of operation: momentary power loss, (DynaView™ and starter module remain powered)

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 inrush currents resulting from reconnecting the compressor motor to the power source following a momentary loss of power.

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).

MPL is enabled however can be disabled, if required via the service tool.

Enforce Stop to Start Timer

(5 to 200 Seconds 7 Sec is Default)

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Machine Protection and Adaptive Control

Current Overload Protection

Motor currents are continuously monitored for over current protection and locked rotor protection. This protects the Chiller itself from damage due to current overload during starting and running modes but is allowed to reach full load amps. This overload protection logic is independent of the current limit. 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 .

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 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 resettable diagnostic shutting down

Figure 30. Overload trip time versus percent RLA

the compressor when the current 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:

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.) Overload Must Trip in 1.5 seconds = 140 Percent RLA (Nominal)

The linear time-trip curve is as follows:

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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

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.

The current limit control logic attempts to prevent the motor from shutting down on a diagnostic trip by limiting compressor current draw relative to an adjustable current limit DynaView 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 tripping off via a diagnostic.

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Current Limit Setpoint.

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.

The Current Limit Setpoint (CLS) can be changed from: Front Panel, External Analog input (with GBAS (external) option), or Tracer (Tracer option). However, If present Tracer current setpoint has the highest priority, unless disabled in the DynaView menu. The External CLS has second priority, and will be used if Tracer is disabled or not installed. The Front Panel Setpoint has the lowest priority, and will be used if Tracer and the External CLS are both disabled.

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Setpoint source override

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.

Reverse Rotation Protection

This function protects the 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.

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Machine Protection and Adaptive Control

Differential to Start or Stop

The Differential to Start setpoint is adjustable from 1 to 10°F (0.55 to

5.55°C) and the Differential to Stop setpoint adjustable from 1 to 10°F (0.55 to 5.55°C). Both setpoints are with respect to the Active Chilled Water Setpoint. When the chiller is running and the LWT (Leaving Water Temperature) reaches the Differential to Stop setpoint the chiller will go through its shutdown sequence to AUTO. (Refer to Figure 10.)

SoftLoading

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 quickly to the system load value. If it is not able to unload quickly enough, the supply water temperature will

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 compressor has been started, the starting point of the filtered setpoint is initialized to the value of the Evaporator Leaving Water temperature and the percent RLA.

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

Service tool provides access to these three setpoints, if it is determined necessary to change from the defaults.

Softloading is not active during Ice Making or during the Ice To normal Transition. Softloading will be enabled after the Ice to normal Transition timer has expired.

Minimum and Maximum Capacity Limit

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.

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.

The minimum (default at 0 percent) and maximum (default at 100 percent) capacity are adjustable via the service tool.

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Machine Protection and Adaptive Control

Evaporator Limit

Evaporator refrigerant temperature is continuously monitored to provide a limit function that prevents low refrigerant temperature trips which allows the chiller to continue to run at a reduced load instead of tripping off at the Low Evaporator Refrigerant Temperature Cutout Setpoint (LRTC).

Evaporator limit could occur with an initial pull down of a loop where the Condenser is colder than the Evaporator (Inverted Start), the 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.

Evaporator Limit uses the Evaporator Refrigerant Temperature sensor in a PID algorithm (Similar to the Leaving Water Temperature control) that allows the chiller to run at the LRTC + 2 degree F.

When actively limiting machine control “Evaporator Temperature Limit” will be displayed as a suboperating mode.

Leaving Water Temperature Cutout

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.

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

Cutout results in an automatically resettable diagnostic (MAR). The DynaView indicates when the “Leaving Water Temperature Cutout Setpoint” 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.

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Operating Mode

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Machine Protection and Adaptive Control

Low Refrigerant Temperature Cutout

The purpose of the low evaporator refrigerant temperature protection is to prevent water in the evaporator from freezing. When the Low Evaporator Refrigerant Temperature Cutout (LRTC) trip point is violated, a latching diagnostic indicating the condition is displayed. The Low Evaporator Refrigerant Temperature Diagnostic is active in both the Running and Stopped modes.

The Low Evaporator Refrigerant Cutout Setpoint is factory set to 36°F. This can be altered via the service tool. A Service Tool adjustable setpoint that should be based on the 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 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.

Head Relief Relay

Surge, condenser limit, and certain conditions in ice mode can energize the head relief relay. Note: There is a TechView programmable head relief relay filter time setpoint. The default is 1 minute.

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Figure 31. Cutout strategy

Machine Protection and Adaptive Control

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 31 illustrates these functions as follows:

• chilled water setpoint (top bold line)

• evap leaving water temp cutout (center bold line)

• evap rfgt temp cutout (bottom bold line)

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Machine Protection and Adaptive Control

Condenser Limit

Condenser pressure is continuously monitored to provide a limit function that prevents High Pressure Cutout (HPC) trips. This protection is called Condenser Refrigerant Pressure Limit, or High Pressure Limit. A fully loaded compressor, operating at high Evaporator Leaving Water Temperature (ELWT) and high condenser temperatures causes high condenser pressures. 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.

The Condenser Limit will be based 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 installed, then the limit will be based from the Pressure sensor.

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.

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Machine Protection and Adaptive Control

Restart Inhibit

This function provides short cycle protection for the motor, and indirectly also short cycling protection for the starter since the starter is designed to operate the motor under all the conditions of motor performance.

Restart Inhibit Free Starts

Restart Inhibit Start to Start Time Setting

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 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.

Clear Restart Inhibit

The restart inhibit function, setpoints and clear features exist for each compressor and operate independently of other compressors on that chiller.

During the time the start is inhibited 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.

A “Restart Inhibit Invoked” warning diagnostic will exist when the attempted restart of a compressor is inhibited

If all three motor winding temperatures are less than the “Restart Inhibit Temperature” Setpoint (default 165°F/74°C) then restart is allowed.

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

Note: When one of the three motor winding temperatures is 265°F/

129.4°C or greater, a High Motor Winding Temperature diagnostic will occur.

Note: When the start is inhibited by the restart inhibit function, the time remaining will be displayed along with the restart inhibit mode.

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Machine Protection and Adaptive Control

High Vacuum Lockout

The oil sump pressure is below the lockout setpoint. Starting of compressor is inhibited as a result.

Low Oil Temperature Start Inhibit

The oil temperature is at or below the low oil temperature start inhibit setpoint (143°F/61.7°C). The heater is energized to raise the oil temperature.

Low oil temperature is indicative of refrigerant dilution in the oil. 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.

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 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

Oil Temperature Control

The oil heater is used to maintain the oil temperature within +/- 2.5°F (1.4°C) of the oil temperature control setpoint. The oil heater is commanded off when the oil pump is commanded on.

If the oil temperature is at or below the Low Oil Temperature Cutout setpoint, this diagnostic will be issued and stops the compressor.

This diagnostic is ignored for the first 10 minutes of compressor run. 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.

If the oil temperature is at or above the High Oil Temperature Cutout setpoint this diagnostic will be issued

- which will stop the compressor.

If Oil Temperature violates this temperature cutout for more than 120 seconds this diagnostic is issued.

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.

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Machine Protection and Adaptive Control

Controls Chilled Water Reset (CWR)

Chilled water reset is designed for those applications where the design chilled water temperature is not required at partload. In these cases, the leaving chilled water temperature setpoint can be reset upward using the CWR features.

When the CWR function is based on return water temperature, the CWR feature is standard.

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.

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 following equations and parameters apply for CWR.

Return Water

CWS’ = CWS + RATIO (START RESET - TWE - TWL) and CWS’ > or = CWS and CWS’ - CWS < or

Maximum Reset.

Outdoor Air Temperature

CWS = CWS + RATIO (START RESET

- TOD) and CWS’ > or = CWS and CWS - CWS < or = Maximum Reset.

Where

CWS’ is the new chilled water setpoint.

CWS is the active chilled water setpoint before any reset has occurred.

RESET RATIO is a user adjustable gain.

START RESET is a user adjustable reference.

TOD is the Temperature Outdoor Sensor.

TWE is entering evaporator water temperature.

TWL is the Leaving Evaporator Temperature.

MAXIMUM RESET is a user adjustable limit providing the maximum amount of reset. For all types of reset, CWS - CWS < or = Maximum Reset.

Both Return and Outdoor Reset do not apply to Heating Mode where the UCP is controlling the Leaving Condensing Hot Water Temperature.

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 MAXIMUM RESET to the following:

The RATIO = 100 percent The START RESET = Design Delta Temperature The MAXIMUM RESET = Design Delta Temperature

The equation for Constant Return is as follows:

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Machine Protection and Adaptive Control

Table 3. Values for start reset types

The values for “RESET TYPE” are: Reset Outdoor Return Const Return Type: Disable Air Reset Reset Reset

The values for “RESET RATIO” for each of the reset types are: Reset Reset Increment Increment Factory Type Ratio English SI Units Default

Range Units Value

Return 10 to 120 percent 1 percent 1 percent 50 percent Outdoor -80 to 80 percent 1 percent 1 percent 10 percent

The values for “START RESET “ for each of the reset types are: Reset Start Increment Increment Factory Type Reset English SI Units Default

Range Units 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 0.1°F 0.1°C 90°F

(10 to 54.44°C) (32.22°C) The values for “MAXIMUM RESET” for each of the reset types are: Reset Maximum Increment Increment Factory

Reset English SI Units Default

Range Units Value Return 0 to 20°F 0.1°F 0.1°C 5°F

(0.0 to 11.11°C) (2.78°C) Outdoor 0 to 20°F 0.1°F 0.1°C 5°F

(0.2 to 11.11°C) (2.78°C)

Constant Return

CWS’ = CWS + 100 percent (Design Delta Temperature) - (TWETWL) and CWS’ > or = CWS and CWS’ -CWS < or = Maximum Reset

Notice that Constant Return is nothing more than a specific case of Return Reset offered for operator convenience.

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.

Using the Equation for calculating CWR for Outdoor Air Temperature

Equation:

Degrees of Reset = Reset Ratio*(Start Reset - TOD)

The chiller will start at the Differential to Start value above a fully reset CWS or CWS for both Return and Outdoor Reset.

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 or 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

Reset Ratio:

The Reset Ratio is displayed as a percentage. To use it in the above equation it must be converted to it’s decimal form.

Reset Ratio percent /100 = Reset Ratio decimal

Example of converting Reset Ratio:

If the Reset Ratio displayed on the CLD is 50 percent then use (50/100)= .5 in the equation

TOD = Outdoor Air Temperature

Figure 32. Outdoor air temperature versus degrees of reset

Start Reset = Outdoor Air Start Reset

Example of Calculating Reset for Outdoor Air Temperature:

If: Reset Ratio = 35 percent Start Reset = 80 TOD = 65 Maximum Reset = 10.5

How many Degrees of Reset will there be?

Degrees of Reset = Reset Ratio*(Start Reset - TOD) Degrees of Reset = .35*(80-65) Degrees of Reset = 5.25

If: Reset Ratio = -70 percent Start Reset = 90 TOD = 100 Maximum Reset = 17

How many Degrees of Reset will there be?

Degrees of Reset = Reset Ratio* (Start Reset - TOD) Degrees of Reset = -7* (90-100) Degrees of Reset = 7

(* = multiply)

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Figure 33. Reset function for return CWR

Machine Protection and Adaptive Control

Figure 34. 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

Example of Calculating Return Reset:

If: Reset Ratio = 50% Start Reset = 25 TWE = 65 TWL = 45 Maximum Reset = 8

How many Degrees of Reset will there be?

Degrees of Reset = Reset Ratio*(Start Reset - (TWE-TWL)) Degrees of Reset = .5*(25-(65-45)) Degrees of Reset = 2.5

If: Reset Ratio = 70% Start Reset = 20 TWE = 60 TWL = 53 Maximum Reset = 14

How many Degrees of Reset will there be?

Degrees of Reset = Reset Ratio*(Start Reset - (TWE-TWL)) Degrees of Reset = .7*(20-(60-53)) Degrees of Reset = 9.1

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Figure 35. Return CWR

Machine Protection and Adaptive Control

Figure 36. Constant CWR

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Unit Startup

Unit Start-Up Procedures

Daily Unit Start-Up

1. Verify the chilled water pump and condenser water pump starter are in “ON” or “AUTO”.

2. Verify the cooling tower is in “ON” or “AUTO”.

3. Check both oil tank oil level(s); the level must be visible in or above the lower sight glass. Also, be sure to check the oil tank temperature; normal oil tank temperature before start-up is 140°F to 145°F (60 to 63°C).

4. Note: Each oil heater is energized during the compressor off cycle. During unit operation, the oil tank heater is de-energized.

5. Check the chilled water setpoint and readjust it, if necessary, in the Chiller Settings menu.

6. If necessary, readjust the current limit setpoint in the Chiller Setpoints menu.

7. Press “AUTO”.

The UCP also checks compressor motor winding temperature, and a minimum restart time is initiated if the winding temperature is less than 265°F. The chilled water pump relay is energized and evaporator water flow is proven.

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 UCP determines that the difference between the evaporator leaving water temperature and chilled 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.

Oil pressure must be verified within 3 minutes or a MMR diagnostic is generated.

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.

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.

Note: Whenever the UCP detects a MMR diagnostic condition during start-up, unit operation is locked out, 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.

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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 3minute post-lube period. The compressor motor and condenser water pump starter are de-energized immediately, but the oil pump continues to run during this 3-minute interval; the evaporator pump will continue to run.

Once the post-lube cycle is done, the unit returns to auto mode.

Seasonal Unit Start-Up

1. Close all drain valves, and reinstall the drain plugs in the evaporator and condenser headers.

2. Service the auxiliary equipment according to the start-up and maintenance instructions provided by the respective equipment manufacturers.

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.

4. Open all of the valves in the evaporator chilled water circuit.

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.

6. Lubricate the external vane control linkage as needed.

7. Check the adjustment and operation of each safety and operating control.

8. Close all disconnect switches.

9. Perform instructions listed in “Daily Unit Start-up” section.



 WARNING



Live Electrical Components!

During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.



 WARNING



Toxic Hazards!

• Do not run evaporator water pump longer than 30 minutes after the chiller is shutdown.

• 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 signifcant 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 reuslt in death or serious injury.

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Unit Shutdown

Unit Shutdown Procedures

Daily Unit Shutdown

Note: Refer to Start-Run Shutdown

sequence in General Information Overview Sequence of Operation.

1. Press STOP.

2. After compressor and water pumps shutdown turn Pump Contactors to OFF or open pump disconnects.

Seasonal Unit Shutdown

CAUTION

Oil Pump Heater Operation!

CONTROL POWER DISCONNECT SWITCH MUST REMAIN CLOSED TO ALLOW OIL SUMP HEATER OPERATION. Failure to do this will allow refrigerant to condense in the oil pump.

3. 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 manual should be performed by qualified Trane service technicians.

Note: During extended shutdown, be sure to operate the purge unit for a 2hour period every two weeks. This will prevent the accumulation of air and noncompensable in the machine. To start the purge, change the purge mode to ON in the DynaView Remember to turn the purge mode to AUTO after the 2-hour run time.

™

Settings Purge Menu.

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.

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Periodic Maintenance

Overview

This section describes the basic chiller preventive maintenance procedures, and recommends the intervals at which these procedures should be performed. Use of a periodic maintenance program is important to ensure the best possible performance and efficiency from a CenTraVac

Recommended purge maintenance procedures for the EarthWise Purge unit are covered by PRGD-SVU01AEN or the latest revision which can be obtained at the nearest Trane office.

chiller.

Record Keeping Forms

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 Commissioning Checklist and a ‘‘Start-Up Report’’ with a TechView settings 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.

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)

Daily Maintenance and Checks

[ ] Check the chiller’s evaporator and condenser pressures, oil tank 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.

CAUTION

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.

[ ] 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.

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Periodic Maintenance



 WARNING



Hazardous Voltage w/Capacitors!

Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s literature for allowable waiting periods for discharge of capacitors. 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

Weekly Maintenance

[ ] 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

CDHF-SVU01C-EN

Normal Chiller Operating Characteristics

Operating Characteristic Normal Reading Approx. Evaporator Pressure 6 to 9 PSIA (-9 to -6 PSIG) Approx. Condenser Pressure 17 TO 27 PSIA (2 to 12 PSIG)

(See Notes 1 and 2) (Standard Condensers)

Oil Sump Temperature:

Unit Not Running 140°F to 145°F

(60°C to 63°C)

Unit Running 80°F to 162°F

(26.6°C to 72°C)

Differential Oil Pressure 18 to 22 psid

Page 94

Periodic Maintenance

[ ] Complete all recommended quarterly maintenance procedures.

[ ] Lubricate the vane control linkage bearings, ball joints, and pivot points; as needed a few drops of light machine oil (SAE-20) is sufficient.

[ ] Lubricate vane operator tang o-rings as described in the maintenance section.

[ ] Lubricate the oil filter shutoff valve o-rings by removing the pipe plug and adding several drops of Trane OIL00022. Replace plug.

[ ] 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.

Also, apply one or two drops of oil on the vane operator shaft and spread it into a very light film; this will protect the shaft from moisture and rust.

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.

Annual Maintenance

Shut down the chiller once each year to check the items listed ; a more detailed inspection checklist is

provided on the ‘‘Annual Inspection Checklist and Report’’ illustrated in this manual.

[ ] Perform the annual maintenance procedures referred to in the Maintenance Section of the purge manual.

[ ] 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 4degree tolerance range, replace the sensor.

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.

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Oil Maintenance

Compressor Oil Change

It is recommended to change the oil and oil filter:

• After the first 1000 hours of chiller operation. For a chiller operated continuously this oil and oil filter change may be performed as soon as 1.5 months after first start-up, for a chiller operated intermittently it may be 4 or 6 months after first start-up.

• Again at the first scheduled annual mainenance, preferably within 6 to 12 months of the first oil change.

Note: Use only Trane OIL00022. A full oil change is 9 gallons of OIL00022.

Beyond the first year, 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 laboratory that is experienced in refrigerant and oil chemistry and in the servicing of Trane centrifugal chillers.

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 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.

Oil Change Procedure

When oil analysis indicates the need to change compressor oil, use the following procedure for removing oil.

CAUTION

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.

[ ] Draw the oil from the chiller through the oil charging valve on the chiller oil sump into an approved, evacuated tank; or,

[ ] Pump the oil from the chiller through the oil charging valve into an airtight resealable container, using a magnetically-driven auxiliary pump.

Forcing the oil from the oil sump by pressurizing the chiller (by raising chiller temperature or adding nitrogen) is not recommended.

Refrigerant dissolved in the oil can be removed and returned to the chiller by using an appropriate deepvacuum recovery unit and heating and agitating the oil container. Follow all Federal, State and Local regulations with regard to disposal of waste oil.

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Oil Maintenance

Replacing Oil Filter

Replace oil filter: (1) annually, (2) at each oil change, (3) or if erratic oil pressure is experienced during chiller operation.

Oil Filter Replacement

Use the following procedure to service the oil filter. Refer to Figure

34.

1. Run the oil pump for two to three minutes to insure that the oil filter is warmed up to the oil sump temperature.

2. Turn the oil pump motor off.

3. 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.

4. Allow at least 15 minutes for the oil to drain from the filter back into the oil sump.

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.

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.

7. Purge unit.

8. Check oil pressure 18-22 psi.

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Maintenance

Other Maintenance Requirements

Compressors using new seal technology will not use O-rings. The O-ring has been replaced by Loctite 515 applied at a minimum film thickness of .010 applied across the width of the flange. The current jack bolt holes remain for disassembly.

CAUTION

Oil Supply System Problems!

Plugging of oil supply system could lead to bearing failure. Failure to use care could result in Loctite getting into the chiller which may cause problems with the Oil supply system and eductor system.

[ ] Inspect the condenser tubes for fouling; clean if necessary.



 WARNING



Hazardous Voltage w/ Capacitors!

[ ] Measure the compressor motor winding resistance to ground; a qualified service technician should conduct this check to ensure that the findings are properly interpreted.

Contact a qualified service organization to leak-test the chiller; this procedure is especially important if the system requires frequent purging.

[ ] Use a nondestructive tube test to inspect the condenser and evaporator tubes at 3-year intervals.

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.

[ ] 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 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.

[ ] 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.

Lubrication

The only chiller component that requires periodic lubrication is the external vane linkage assembly and Rotary oil valve.

Lubricate the vane linkage shaft bearings and rod end bearings as needed with a few drops of lightweight machine oil.

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)

To service the 1st stage tang operator of all units except CDHF extended capacity chillers with 1470 or 1720 compressors.

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.

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.

7. Tighten the plug that was loosened in step 4. Tighten the plug to hand tight plus 1/4 to 1/2 turn.

8. Remove the grease fitting, if used.

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Maintenance

DO NOT LEAVE GREASE FITTINGS INSTALLED. If grease fittings have been used for this procedure then they MUST BE REMOVED before returning the unit to service. Grease fittings are not vacuum-tight and will become a leak path.

9. Using a clean wooden dowel or other similar tool, remove excess grease from the remaining open lubrication port.

10. Clean and then lightly coat the threads of the plug with Rheolube grease and re-install it into the lubrication port. 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.

To service the 1st and 2nd stage tang operators on 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

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 “hydraulically locked” condition.

Figure 37. Rotary valve in drain position

Front View with Refrigerant Pump

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.

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Maintenance

Refrigerant Charge



 WARNING



Contains Refrigerant!

System contains oil and refrigerant and may be under positive pressure. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant additives. 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.

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.

2. Always use refrigerant compatible hoses or copper-tubing with selfsealing connections or shut-off valves.

3. Transfer the refrigerant using one of the following (listed in order of preference):

a. An approved Trane low-

pressure refrigerant recovery and recycle unit.

b. The available pressure

differential.

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.

6. Weigh in the proper charge.

7. Use recovery and recyle unit or vacuum pump to evacuate hoses; discharge outdoors.

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.

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.

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 4-years or 40,000 operating hours, whichever occurs first. This inspection will include, at a 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.

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Maintenance

Recovery and Recycle Connections

To facilitate refrigerant removal and replacement, newer-design CDHF, CDHG units are provided with a 3/4inch vapor fitting with shutoff valve on the chiller suction and with a 3/4inch liquid connection with shutoff valve at the bottom of the evaporator shell. (Refer to Refrigerant Handling Guidelines)

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.

Figure 38. Typical chemical cleaning setup

Cleaning the Condenser

CAUTION

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.

See Figure 38 which shows a Typical Chemical Cleaning Setup.

100

CDHF-SVU01C-EN

American Standard CH530 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Warnings and Cautions

Contents

General Information

Unit Control Panel (UCP)

Operator Interface

Interprocessor Communication

Control System Components

Control Sequence of Operation

Machine Protection and Adaptive Control

Unit Startup

Unit Shutdown

Periodic Maintenance

Oil Maintenance

Maintenance