American Standard CH530 User Manual

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.

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 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

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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.

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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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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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

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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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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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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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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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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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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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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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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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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

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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

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(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

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, is fast and keeps the

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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

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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

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is capable of displaying English text or one of the two alternate languages that are stored in DynaView

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at one time. Switching languages is simply accomplished from a settings menu.

Similarly, TechView

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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.

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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.

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operator interface. Such

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+ 86 hidden pages

American Standard CH530 User Manual

Warnings and Cautions

Contents

General Information

Unit Control Panel (UCP)

Operator Interface