Trane Arctic PolyTherm TP Installation And Maintenance Manual

Page 1

Installation, Operation, and M aintenance

PolyTherm™ Simultaneous Chiller/ Heater

SAFETY WARNING

Only qualified personnel should install and service the equipment . The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury. When w orking on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment.

December 2021

ARTC-SVX005B-EN

Page 2

Introduction

WARNING

CAU

TION

NOTICE

Read this manual thoroughly before operating or servicing this unit.

Warnings, Cautions, and Notices

Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

The three types of advisories are defined as follows:

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It could also be used to alert against unsafe practices.

Indicates a situation that could result in equipment or property-damage only accidents.

Important Environmental Concerns

Scientific research has shown that certain man-made

chemicals can affect the earth’s naturally occurring

stratospheric ozone layer when released to the

atmosphere. In particular, several of the identified

chemicals that may affect the ozone layer are

refrigerants that contain Chlorine, Fluorine and Carbon

(CFCs) and those containing Hydrogen, Chlorine,

Fluorine and Carbon (HCFCs). Not all refrigerants

containing these compounds have the same potential

impact to the environment. Trane advocates the

responsible handling of all refrigerants-including

industry replacements for CFCs and HCFCs such as

saturated or unsaturated HFCs and HCFCs.

Important Responsible Refrigerant

Practices

Trane believes that responsible refrigerant practices

are important to the environment, our customers, and

the air conditioning industry. All technicians who

handle refrigerants must be certified according to local

rules. For the USA, the Federal Clean Air Act (Section

608) sets forth the requirements for handling,

reclaiming, recovering and recycling of certain

refrigerants and the equipment that is used in these

service procedures. In addition, some states or

municipalities may have additional requirements that

must also be adhered to for responsible management

of refrigerants. Know the applicable laws and follow

them.

WWAARRNNIINNGG

PPrrooppeerr FFiieelldd WWiirriinngg aanndd GGrroouunnddiinngg RReeqquuiirreedd!!

FFaaiilluurree ttoo ffoollllooww ccooddee ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. AAllll ffiieelldd wwiirriinngg MMUUSSTT bbee ppeerrffoorrmmeedd bbyy qquuaalliiffiieedd ppeerrssoonnnneell.. IImmpprrooppeerrllyy iinnssttaalllleedd aanndd ggrroouunnddeedd ffiieelldd wwiirriinngg ppoosseess FFIIRREE aanndd EELLEECCTTRROOCCUUTTIIOONN hhaazzaarrddss.. TToo aavvooiidd tthheessee hhaazzaarrddss,, yyoouu MMUUSSTT ffoollllooww rreeqquuiirreemmeennttss ffoorr ffiieelldd wwiirriinngg iinnssttaallllaattiioonn aanndd ggrroouunnddiinngg aass ddeessccrriibbeedd iinn NNEECC aanndd yyoouurr llooccaall// ssttaattee//nnaattiioonnaall eelleeccttrriiccaall ccooddeess..

WWAARRNNIINNGG

PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!

FFaaiilluurree ttoo wweeaarr pprrooppeerr PPPPEE ffoorr tthhee jjoobb bbeeiinngg uunnddeerrttaakkeenn ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. TTeecchhnniicciiaannss,, iinn oorrddeerr ttoo pprrootteecctt tthheemmsseellvveess ffrroomm ppootteennttiiaall eelleeccttrriiccaall,, mmeecchhaanniiccaall,, aanndd cchheemmiiccaall hhaazzaarrddss,, MMUUSSTT ffoollllooww pprreeccaauuttiioonnss iinn tthhiiss mmaannuuaall aanndd oonn tthhee ttaaggss,, ssttiicckkeerrss,, aanndd llaabbeellss,, aass wweellll aass tthhee iinnssttrruuccttiioonnss bbeellooww::

•• BBeeffoorree iinnssttaalllliinngg//sseerrvviicciinngg tthhiiss uunniitt,, tteecchhnniicciiaannss MMUUSSTT ppuutt oonn aallll PPPPEE rreeqquuiirreedd ffoorr tthhee wwoorrkk bbeeiinngg uunnddeerrttaakkeenn ((EExxaammpplleess;; ccuutt rreessiissttaanntt gglloovveess//sslleeeevveess,, bbuuttyyll gglloovveess,, ssaaffeettyy ggllaasssseess,, hhaarrdd hhaatt//bbuummpp ccaapp,, ffaallll pprrootteeccttiioonn,, eelleeccttrriiccaall PPPPEE aanndd aarrcc ffllaasshh ccllootthhiinngg)).. AALLWWAAYYSS rreeffeerr ttoo aapppprroopprriiaattee SSaaffeettyy DDaattaa SShheeeettss ((SSDDSS)) aanndd OOSSHHAA gguuiiddeelliinneess ffoorr pprrooppeerr PPPPEE..

•• WWhheenn wwoorrkkiinngg wwiitthh oorr aarroouunndd hhaazzaarrddoouuss cchheemmiiccaallss,, AALLWWAAYYSS rreeffeerr ttoo tthhee aapppprroopprriiaattee SSDDSS aanndd OOSSHHAA//GGHHSS ((GGlloobbaall HHaarrmmoonniizzeedd SSyysstteemm ooff CCllaassssiiffiiccaattiioonn aanndd LLaabbeelllliinngg ooff CChheemmiiccaallss)) gguuiiddeelliinneess ffoorr iinnffoorrmmaattiioonn oonn aalllloowwaabbllee ppeerrssoonnaall eexxppoossuurree lleevveellss,, pprrooppeerr rreessppiirraattoorryy pprrootteeccttiioonn aanndd hhaannddlliinngg iinnssttrruuccttiioonnss..

•• IIff tthheerree iiss aa rriisskk ooff eenneerrggiizzeedd eelleeccttrriiccaall ccoonnttaacctt,, aarrcc,, oorr ffllaasshh,, tteecchhnniicciiaannss MMUUSSTT ppuutt oonn aallll PPPPEE iinn aaccccoorrddaannccee wwiitthh OOSSHHAA,, NNFFPPAA 7700EE,, oorr ootthheerr ccoouunnttrryy--ssppeecciiffiicc rreeqquuiirreemmeennttss ffoorr aarrcc ffllaasshh pprrootteeccttiioonn,, PPRRIIOORR ttoo sseerrvviicciinngg tthhee uunniitt.. NNEEVVEERR PPEERRFFOORRMM AANNYY SSWWIITTCCHHIINNGG,, DDIISSCCOONNNNEECCTTIINNGG,, OORR VVOOLLTTAAGGEE TTEESSTTIINNGG WWIITTHHOOUUTT PPRROOPPEERR EELLEECCTTRRIICCAALL PPPPEE AANNDD AARRCC FFLLAASSHH CCLLOOTTHHIINNGG.. EENNSSUURREE EELLEECCTTRRIICCAALL MMEETTEERRSS AANNDD EEQQUUIIPPMMEENNTT AARREE PPRROOPPEERRLLYY RRAATTEEDD FFOORR IINNTTEENNDDEEDD VVOOLLTTAAGGEE..

ARTC-SVX005B-EN

Page 3

IInnttrroodduuccttiioonn

WWAARRNNIINNGG

FFoollllooww EEHHSS PPoolliicciieess!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..

•• AAllll TTrraannee ppeerrssoonnnneell mmuusstt ffoollllooww tthhee ccoommppaannyy’’ss EEnnvviirroonnmmeennttaall,, HHeeaalltthh aanndd SSaaffeettyy ((EEHHSS)) ppoolliicciieess wwhheenn ppeerrffoorrmmiinngg wwoorrkk ssuucchh aass hhoott wwoorrkk,, eelleeccttrriiccaall,, ffaallll pprrootteeccttiioonn,, lloocckkoouutt// ttaaggoouutt,, rreeffrriiggeerraanntt hhaannddlliinngg,, eettcc.. WWhheerree llooccaall rreegguullaattiioonnss aarree mmoorree ssttrriinnggeenntt tthhaann tthheessee ppoolliicciieess,, tthhoossee rreegguullaattiioonnss ssuuppeerrsseeddee tthheessee ppoolliicciieess..

•• NNoonn--TTrraannee ppeerrssoonnnneell sshhoouulldd aallwwaayyss ffoollllooww llooccaall rreegguullaattiioonnss..

This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part without written permission. Trane reserves the right to revise this publication at any time, and to make changes to its content without obligation to notify any person of such revision or change.

Trademarks

All trademarks referenced in this document are the trademarks of their respective owners.

Revision History

• Updated controller terminology.

• Minor updates to document.

ARTC-SVX005B-EN

Page 4

Table of Contents

Model Number Descriptions. . . . . . . . . . . . . . . . 7

Model Number and Coding . . . . . . . . . . . . . . . . . 8

Chiller/heater Model and Serial

Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Model Coding Key . . . . . . . . . . . . . . . . . . . . . . . . 8

General Information . . . . . . . . . . . . . . . . . . . . . . . . 9

Inspect and Report Damage . . . . . . . . . . . . . . . 9

Inspection of Delivered

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Warranty Issues. . . . . . . . . . . . . . . . . . . . . . . 9

Long Term Storage Requirements . . . . . . . . . 9

Factory Preparation . . . . . . . . . . . . . . . . . . . 9

Customer Responsibilities . . . . . . . . . . . . 10

Chiller Dimensions . . . . . . . . . . . . . . . . . . . . . . 10

Handling of the Modules . . . . . . . . . . . . . . . . . 10

Site Preparation and Clearances . . . . . . . . . . 11

Chiller/Heater Clearances . . . . . . . . . . . . . 12

Rigging, Lifting, and Moving the

Chiller/Heater . . . . . . . . . . . . . . . . . . . . . . . . 13

Chiller/Heater Description . . . .. .. . . .. .. . . . . 14

Chiller/Heater Scope . . . . . . . . . . . . . . . . . . . . . 14

Chiller/Heater Capacities . . . . . . . . . . . . . . . . . 14

Component Description . . . . . . . . . . . . . . . . . . 14

Evaporators, Condensers and

Source/Sink Heat Exchanger . . . . . . . . . . 14

Components Parts . . . . . . . . . . . . . . . . . . . 15

Pre-Installation . . . . . . . . . . . . . .. . . . . . . . . . . . . . 18

Preparation for Initial Startup . . . . . . . . . . . . . 18

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . 18

Installation Piping . . . . .. . . . . .. . . . . . . .. . . . . . 21

Install Piping and External

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Initial Flushing of Piping. . . . . . . . . . . . . . . . . . 21

Fill with Water/Glycol Solution . . . . . . . . 21

Connecting Module Couplings . . . . . . . . 22

Installation Electrical . . . . . . . . . . . . . . . . . . . . . . 23

Wiring and Piping . . . . . . . . . . . . . . . . . . . . . . . 23

Connecting Module Power and Control

Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Service Access. . . . . . . . . . . . . . . . . . . . . . . 23

Chiller/Heater Module Main

Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Module Control Wiring . . . . . . . . . . . . . . . 23

Phase Monitor Installation . . . . . . . . . . . . 23

Power Interlock Switch . . . . . . . . . . . . . . . 24

Operating Principles. . . . . . . . . . . . . . . . . . . . . . . 25

Operating Procedures . . . . . . . . . . . . . . . . . . . . . 27

Operator Interface . . . . . . . . . . . . . . . . . . . . . . . 27

Chiller/Heater Power Panels. . . . . . . . . . . 27

Panel-Mounted Disconnect

Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Power Distribution Panels . . . . . . . . . . . . 27

Module Electrical and Control

Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Electronic Control . . . . . . . . . . . . . . . . . . . . 28

Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Operating the Microprocessor . . . . . . . . 29

Microprocessor Functions . . . . . . . . . . . . 30

Password Protection . . . . . . . . . . . . . . . . . 30

Operator Control. . . . . . . . . . . . . . . . . . . . . 30

How to Use the Touchscreen

Interface Panel. . . . . . . . . . . . . . . . . . . . . . . 30

Touchscreen Interface Tutorial. . . . . . . . . . . . 30

Interface Menu Structure . . . . . . . . . . . . . . . . . 30

Home Screen Features . . . . . . . . . . . . . . . . . . . 32

Top Section Functions. . . . . . . . . . . . . . . . 32

Project Name . . . . . . . . . . . . . . . . . . . . . . . . 33

Software Version . . . . . . . . . . . . . . . . . . . . 33

Middle Section Functions. . . . . . . . . . . . . 33

Bottom Section Functions . . . . . . . . . . . . 33

Current Access Level . . . . . . . . . . . . . . . . . 34

User Level. . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Tech Level. . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Admin Level . . . . . . . . . . . . . . . . . . . . . . . . . 35

Log Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Modules Layout Screen . . . . . . . . . . . . . . . . . . 35

Module Layout Screen Status

Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Modules Overview Screens. . . . . . . . . . . . . . . 36

Module Indicators . . . . . . . . . . . . . . . . . . . . . . . 37

Module En/Dis . . . . . . . . . . . . . . . . . . . . . . . 37

Module Status . . . . . . . . . . . . . . . . . . . . . . . 37

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TTaabbllee ooff CCoonntteennttss

Module Cntrl Status . . . . . . . . . . . . . . . . . . 37

Primary Status. . . . . . . . . . . . . . . . . . . . . . . 37

Lead Module . . . . . . . . . . . . . . . . . . . . . . . . 38

Mode Status. . . . . . . . . . . . . . . . . . . . . . . . . 38

Heat Exchanger Indicators. . . . . . . . . . . . . . . . 38

Refrigeration Indicators. . . . . . . . . . . . . . . 38

Solenoid ‘E’ . . . . . . . . . . . . . . . . . . . . . . . . . 38

Solenoid ‘S’ . . . . . . . . . . . . . . . . . . . . . . . . . 38

EX Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

D1/D2/S1/S2 . . . . . . . . . . . . . . . . . . . . . . . . . 38

Compressor Overview Screens . . . . . . . . . . . 39

Compressor 1 and Compressor

2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Compressor En/Dis. . . . . . . . . . . . . . . . . . . 39

Comp Status. . . . . . . . . . . . . . . . . . . . . . . . . 39

Communication. . . . . . . . . . . . . . . . . . . . . . 39

Module I/O Screens . . . . . . . . . . . . . . . . . . . . . . 40

Analog Inputs. . . . . . . . . . . . . . . . . . . . . . . . 41

Analog Outputs . . . . . . . . . . . . . . . . . . . . . . 41

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . 42

Digital Outputs. . . . . . . . . . . . . . . . . . . . . . . 42

Expansion IO Screen . . . . . . . . . . . . . . . . . 43

Active Alarms Screen . . . . . . . . . . . . . . . . . . . . 43

Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Action. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Description . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Check / Uncheck All . . . . . . . . . . . . . . . . . . 44

‘Hide Not Triggered’ Drop Down

Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Ack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Reset PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Alarm History. . . . . . . . . . . . . . . . . . . . . . . . 44

Trend Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Cooling and Heating Demand . . . . . . . . . 45

Operator Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Normal Power Up. . . . . . . . . . . . . . . . . . . . 47

Emergency Power Shutdown . . . . . . . . . . . . . 48

Water Quality Guidelines. . . . . . . . . . . . . . . . . 48

Monitor Water Quality . . . . . . . . . . . . . . . . . . . 48

Maintain Glycol Level . . . . . . . . . . . . . . . . 49

Prevent Freezing . . . . . . . . . . . . . . . . . . . . . 49

Controls Interface . . . . . . . . . . . . . . . . . . . . . . . . . 51

Chiller Controls. . . . . . . . . . . . . . . . . . . . . . . . . . 51

Power Distribution . . . . . . . . . . . . . . . . . . . 51

Touchscreen Interface Panel. . . . . . . . . . . . . . 53

Microprocessor Control System . . . . . . . . . . 53

Primary Microprocessor

Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Secondary Microprocessor

Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Microprocessor Controller

Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Thermal Capacity. . . . . . . . . . . . . . . . . . . . . . . . 54

Electronic Controls . . . . . . . . . . . . . . . . . . . 54

Sequence of Operations . . . . . . . . . . . . . . . . . . . 55

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Chiller/Heater Performance Data . .. .. . . .. . 56

Maintenance Procedures . . . . . . . . . . . . . . . . . . 57

Maintenance Strategy. . . . . . . . . . . . . . . . . . . . 57

Power Disconnect Switch . . . . . . . . . . . . . . . . 57

Inspection and Maintenance

Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . 61

Inspection Methods . . . . . . . . . . . . . . . . . . 61

Critical Cleaning Tasks . . . . . . . . . . . . . . . 61

Compressor Tasks . . . . . . . . . . . . . . . . . . . 62

Chiller/Heater Troubleshooting . . . . . . . . . . . . 64

General Approach to Fault Isolation . . . . . . . 64

Controller Diagnostic Codes . . . . . . . . . . . . . . 64

Compressor Flash Codes . . . . . . . . . . . . . 64

Flash Code Description . . . . . . . . . . . . . . . 64

Phase Monitor Protection . . . . . . . . . . . . . . . . 65

Symptoms and Solutions . . . . . . . . . . . . . . . . 66

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Logical Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

High Voltage Logical Flow . . . . . . . . . . . . . . . . 71

Control Logical Flow . . . . . . . . . . . . . . . . . . . . . 71

Water/Glycol Mixture Logical Flow . . . . . . . . 73

Acronyms and Abbreviations. . . . . . .. .. . . .A–1

Acronym List . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1

Request for Initial Startup . . . . . . . .. .. . . .. .B–1

PolyTherm Chiller/Heater . . . . . . . . . . . . . . . B–1

Initial Startup Agreement. . . . . . . . . . . . . . . . B–1

Active Alarm List . . . . . . . . . . . . . . . . . . . . . . . . .C–1

Application . . . . . . . . . . . . . . . . . . . . . . . . . C–1

Alarm List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–1

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Model Number Descriptions

Digit 1— Brand

T = Trane

Digit 2 — Model Series

P = Process and Modular Series M = Medical and Critical Duty Series

Digit 3, 4, 5 — Condenser Type

ACH = Air-Cooled, Horizontal Air Flow ACV = Air-Cooled, Vertical Air Flow ACR = Air-Cooled Remote Condenser WCC = Water-Cooled Condenser

Digit 6 — Chilled Water System

P = Recirculating System, Tank and Pump M = Single Pass Chiller Unit, no Tank and

Pump

Digit 7 — Cabinet Type

H = Horizontal Low Profile V = Vertical Upright

Digit 8, 9, 10, 11— Chiller Capacity

0030 = 3 Ton Capacity 0300 = 30 Ton Capacity

Digit 12 — Refrigeration Circuits

Digit 14, 15 — Chiller Application

MM = Modular

CP = Cold Plunge Process

DW = Drinking Water and Filtration

Digit 16, 17 — Configuration 1

DS = Digital Scroll DS1 = Digital Scroll (Lead Compressor) DS2 =Digital Scroll (Both Circuits)

Digit 18, 19 — Configuration 2

DS1 = Digital Scroll (Lead Compressor) DS2 =Digital Scroll (Lead Compressor) HP = Heat Pump HR = Heat Recovery FC = Integral Free Cooling VS = Variable Speed VS1 = Variable Speed (Lead Compressor) VS2 = Variable Speed (Lead Compressors)

Digit 20, 21, 22 — Configuration 3

3HX = 3 Heat Exchanger (PolyTherm or

Ecotherm)

HP = Heat Pump HR = Heat Recovery FC = Integral Free Cooling

D = Dual Independent Refrigeration Circuits S = Single Refrigeration Circuit R = Redundant Refrigeration T = Tandem Compressors Set in Single Circuit

Digit 13 — Voltage

1 = 208/230/60/1 2 = 460/60/1 3 = 208/230/60/3 4 = 460/60/3 5 = 575/60/3 7 = 380/50/3

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Model Number and Coding

When contacting Trane for technical support, customer service, or parts information, be prepared to provide the model number and serial number of the chiller modules in question. This information is located on the blue plastic chiller nameplate that is affixed to each module in the following figure.

Table 1. Chiller/Heater reference data

Module Model Number Serial Number

Chiller/heater Model and Serial Numbers

For future reference, record the model number and serial number for each module in the chiller in the table below, Chiller Reference Data. Refer to the Trane nameplate on each module in the installed unit for the serial number and model number. See figure below for example nameplate.

Figure 1. Typical PolyTherm chiller/heater nameplate

Model Coding Key

Model numbers assigned to Trane systems provide a wealth of information about the features for a chiller/ heater’s “as-built” configuration.

NNoottee:: Critical information for contacting Trane

technical support. Reference to the actual chiller/ heater module serial number may also be beneficial. Each module has its own unique serial number.

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General Information

Inspect and Report Damage

Upon delivery, inventory the shipment against the Trane bill of lading to ensure all modules and components have been received.

Inspect each package in the shipment for visible damage. Verify the correct model number and that all skids and cartons have been delivered. Any damage must be reported to the motor carrier and Trane within five days of receipt of the shipment.

Inspect all exterior components for concealed damage as soon as possible. Do not proceed with the installation of damaged equipment without prior approval of Trane.

Do not refuse delivery of damaged goods without prior authorization. Unauthorized refusal of the shipment will result in a 20% restocking charge to the customer.

The ownership of the equipment is transferred to the consignee at point of shipment. Refusal of delivery may impede recovery of damages.

It is the consignee’s responsibility to accept delivery of damaged goods unless permission to refuse delivery has been granted by Trane.

Inspection of Delivered Equipment

To report damage incurred in transit, complete the following:

1. Inspect each piece of equipment for visible damage before accepting delivery. Check for torn cartons, broken skids, bent metal and torn shrink wrap.

2. Ensure the delivery driver notes any damage on the bill of lading and completes a Carrier Inspection Report. Failure to comply may result in difficulties in resolving any claims for damage.

3. Inspect each piece of equipment for concealed damage before storage or as soon as possible after delivery.

4. In the event of suspected concealed damage, ask the driver to wait until you inspect the equipment. Concealed damage must be reported within five days of receipt of equipment.

5. If concealed damage is found, stop unpacking the shipment. Do not remove damaged material from the receiving location, take photos of the damage. The owner must provide reasonable evidence that the damage did not occur after delivery.

6. Notify the carrier of the damage as soon as possible. Request an immediate joint inspection by the carrier and consignee. A determination of responsibility will be made and the carrier will authorize repairs in the event of admission of fault.

7. Notify Trane customer service department (803321-1891) immediately. Trane will coordinate

repairs with the owner and carrier. Do not attempt to make repairs locally without permission.

Warranty Issues

Trane is not responsible for damages or for filing damage claims. It is the customer’s responsibility to ensure that the necessary long term storage procedures have been completed and any deviations are reported to Trane immediately.

Long Term Storage Requirements

Appropriate preparation and storage of PolyTherm Chiller/Heater components during extended periods of dormancy is essential to ensure the equipment does not sustain damage or degradation due to inactivity and operates properly after installation.

The customer must notify Trane during the sales process that the chiller system may be transported by ocean freight or placed in long-term storage under any of these conditions:

• The chiller/heater will not be placed into operation for a period exceeding six months after leaving the Trane factory. That is, the initial start-up date will not occur within a six-month maximum dormancy window.

• The chiller/heater will be shipped using ocean transit for all or part of the delivery process.

• Cold temperature storage conditions fall below -20 ° F (-29 °C).

• Ambient temperature storage conditions exceed 150 °F (66 °C).

Factory Preparation

Upon confirmation of an order requiring long-term storage or protection against extreme environments, Trane will inspect and protect vendor-supplied components before installation.

Prior to shipment, Trane will prepare each chiller system for long-term storage in coastal or tropical environments by:

• Placing silica gel packs in all electrical panels and variable speed drive panels to prevent corrosion of electrical contacts and moisture from degrading sensitive controllers.

• Shrink-wrapping each chiller using polyethylene film to limit environmental exposure and protect the chillers from damage during shipping.

• For multiple modular chiller system assemblies shipped on a common skid, shrink wrap the entire skid rather than the individual modules.

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GGeenneerraall IInnffoorrmmaattiioonn

Trane will document and photograph the status of the unit prior to shipment and carry out the instructions detailed in the factory order regarding in-shop preparation of units for long-term storage.

Customer Responsibilities

Upon receipt of a chiller system, the customer must conduct thorough internal and external inspections, removing packaging material as needed for access to all components.

Visible damage must be noted on the signed and dated bill of lading. The customer may request a carrier inspection by telephone or in person, but any such request should be confirmed in writing. It is recommended that the customer request that the carrier inspect the damage within 72 hours of notification.

The customer must store the chiller system in a dry, non-corrosive, dust- and vibration-free environment due to the exposure sensitivities of the microprocessor controllers and to prevent electrical terminations from deteriorating from non-use. Conditions in storage locations should not fall below -20 °F (-29 °C) or exceed 150 °F (66 °C).

Components sealed in plastic shrink-wrap are not exempt from these storage requirement. Moisture can potentially collect inside the plastic film, resulting in corrosion of the cabinet and electronic components. Any chiller system packaging that is removed must be replaced with similar protective covering as soon as possible.

Failure to adhere to these long-term storage requirements may void the Trane warranty. Any component that is damaged or inoperable due to improper storage may have its warranty voided.

Chiller Dimensions

Depending upon the number of modules, the assembled chiller will occupy the dimensions shown in

Figure 2, p. 11 and Table 2, p. 11, depending upon the

rated tonnage of the chiller modules.

WWAARRNNIINNGG

EElleeccttrriiccaall SShhoocckk,, EExxpplloossiioonn,, oorr AArrcc FFllaasshh HHaazzaarrdd!!

FFaaiilluurree ttoo ffoollllooww tthheessee iinnssttrruuccttiioonnss ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..

•• IInnssttaallll tthhee pprroodduucctt iinn aann aapppprroopprriiaattee eelleeccttrriiccaall//ffiirree eenncclloossuurree ppeerr llooccaall rreegguullaattiioonnss.. DDoo nnoott iinnssttaallll tthhee pprroodduucctt iinn hhaazzaarrddoouuss oorr ccllaassssiiffiieedd llooccaattiioonnss..

•• DDoo nnoott uussee tthhee pprroodduucctt ffoorr lliiffee oorr ssaaffeettyy aapppplliiccaattiioonnss..

•• DDoo nnoott eexxcceeeedd tthhee pprroodduucctt rraattiinnggss oorr mmaaxxiimmuumm lliimmiittss.. PPrroodduuccttss rraatteedd oonnllyy ffoorr bbaassiicc iinnssuullaattiioonn mmuusstt bbee iinnssttaalllleedd oonn iinnssuullaatteedd ccoonndduuccttoorrss..

•• CCuurrrreenntt ttrraannssffoorrmmeerr sseeccoonnddaarriieess ((ccuurrrreenntt mmooddee)) mmuusstt bbee sshhoorrtteedd oorr ccoonnnneecctteedd ttoo aa bbuurrddeenn aatt aallll ttiimmeess..

•• RReemmoovvee aallll wwiirree ssccrraappss,, ttoooollss,, rreeppllaaccee aallll ddoooorrss,, ccoovveerrss aanndd pprrootteeccttiivvee ddeevviicceess bbeeffoorree ppoowweerriinngg tthhee eeqquuiippmmeenntt..

WWAARRNNIINNGG

PPrrooppeerr FFiieelldd WWiirriinngg aanndd GGrroouunnddiinngg RReeqquuiirreedd!!

Handling of the Modules

The packaging from the factory permits lifting with a suitable crane. Ensure straps are in good working condition and that they are rated for the weight of the machines. Spreader bars may be required for effective rigging and to avoid damage to the chiller/heater modules.

The chiller modules arrive fully charged with refrigerant. As required under Federal regulations, installation, start-up and service should be performed by fully-qualified, factory-certified, personnel.

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Page 11

Figure 2. Chiller/Heater installation recommendations

GGeenneerraall IInnffoorrmmaattiioonn

Site Preparation and Clearances

Chiller/heater modules must be installed on 4-inch tubing or 6-inch I beams on a level surface that has been checked by a qualified structural engineer to support the weight of the fluid-filled modules and the

Table 2. Chiller/Heater bank dimensions for all configurations

# OF

MODULES

30 Ton

PolyTherm

40 Ton

PolyTherm

50 Ton

PolyTherm

DIM

A 34 68 102 136 170 204 238 272 306 304

C 13 13 13 13 13 13 13 13 13 13

LBS

A 34 68 102 136 170 204 238 272 306 304

C 13 13 13 13 13 13 13 13 13 13

LBS

A 42 84 126 168 210 252 294 336 378 420

B 84 84 84 84 84 84 84 84 84 84

D 75 75 75 75 75 75 75 75 75 75

LBS

1 2 3 4 5 6 7 8 9 10

INCH INCH INCH INCH INCH INCH INCH INCH INCH INCH

81 1/16 81 1/16 81 1/16 81 1/16 81 1/16 81 1/16 81 1/16 81 1/16 81 1/16 81 1/16

65 7/8 65 7/8 65 7/8 65 7/8 65 7/8 65 7/8 65 7/8 65 7/8 65 7/8 65 7/8

1,400 2,800 4,200 5,600 7,000 8,400 9,800 11,200 12,600 14,000

81 1/16 81 1/16 81 1/16 81 1/16 81 1/16 81 1/16 81 1/16 81 1/16 81 1/16 81 1/16

65 7/8 65 7/8 65 7/8 65 7/8 65 7/8 65 7/8 65 7/8 65 7/8 65 7/8 65 7/8

1,500 3,100 4,650 6,200 7,750 9,300 10,850 12,400 13,950 15,500

17 1/2 17 1/2 17 1/2 17 1/2 17 1/2 17 1/2 17 1/2 17 1/2 17 1/2 17 1/2

1,840 3,680 5,520 7,360 9,200 11,040 12,880 14,720 16,560 18,400

connective piping to and from the chiller/heater. Installations must account for minimum service access clearance as may be practical or required by local building codes.

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GGeenneerraall IInnffoorrmmaattiioonn

Table 2. Chiller/Heater bank dimensions for all configurations (continued)

# OF

MODULES

60 Ton

PolyTherm

DIM

A 42 84 126 168 210 252 294 336 378 420

B 84 84 84 84 84 84 84 84 84 84

D 75 75 75 75 75 75 75 75 75 75

LBS

1 2 3 4 5 6 7 8 9 10

INCH INCH INCH INCH INCH INCH INCH INCH INCH INCH

17 1/2 17 1/2 17 1/2 17 1/2 17 1/2 17 1/2 17 1/2 17 1/2 17 1/2 17 1/2

2,040 4,080 6,120 8,160 10,200 12,240 14,280 16,320 18,360 20,400

Chiller/Heater Clearances

The National Electric Code or local, state, and regional building codes may require greater clearance for the modular chiller/heater than the figures listed in this publication. Always consult local regulatory agencies to ensure additional clearances are not required by building codes.

Minimum Clearances

The unit must maintain a minimum of 36-inch clearance on all sides. See

NNoottee:: These clearances are general recommendations.

Each installation has specific considerations. Contact Trane for definitive guidance and approval on a job-by-job basis.

Mounting Rails

The chiller/heater must be positioned on a firm, level surface. All modules should be installed onto structural steel rails. The rails must be level, be a minimum of 4inch wide (preferably 6-inch wide), and seated on springs/pads.

Figure 3, p. 12.

Custom modules may have different requirements. Consult submittal drawings to confirm dimensions.

After setting and lubricating the mounting rails, begin installing the modules. All of the modules arrive with labels on the electrical and control panel. Review the installation drawings to determine which is the first, primary module. Typically the primary module also has the main power distribution panel attached to it.

For vibration isolation, spring isolators or rubber-inshear isolator pads must be installed under the structural steel mounting rails.

NNOOTTIICCEE

CCoonnnneeccttiioonn LLeeaakkss!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd rreessuulltt iinn ddaammaaggee ttoo tthhee ccooiill hheeaaddeerr aanndd ccaauussee ccoonnnneeccttiioonn lleeaakkss.. UUssee aa bbaacckkuupp wwrreenncchh wwhheenn aattttaacchhiinngg ppiippiinngg ttoo ccooiillss wwiitthh ccooppppeerr hheeaaddeerrss.. DDoo nnoott uussee bbrraassss ccoonnnneeccttoorrss bbeeccaauussee tthheeyy ddiissttoorrtt eeaassiillyy..

Figure 3. Recommended chiller/heater clearances

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Page 13

Figure 4. Recommended chiller/heater module rigging

GGeenneerraall IInnffoorrmmaattiioonn

After setting each module, remove front or rear access panels to improve access to components when making connections.

Rigging, Lifting, and Moving the Chiller/ Heater

The PolyTherm Simultaneous Chiller/Heater is delivered to the customer’s site as individual modules. Limitations on the methods and materials that can be used to rig, lift, or move a chiller/heater or an individual module include:

• Maintain the module in an upright position at all times.

• Rig, lift, and move by strapping and lifting by overhead means.

• Position lifting beams or spreader beams to prevent lifting straps from rubbing or contacting module side panels or electrical boxes. Attach rigging bar on each end of module where 1 3/8 inch holes are provided.

• Use caution when lifting due to configuration of components. Module could be heavier on one side than the other.

• Certain configurations of modules can be topheavy. Move modules slowly with consideration to each module’s center-of-gravity.

• Do not use cables, chains, or any other type of metalized strapping to lift a module.

• Do not push a chiller/heater module along the floor using manual or mechanical means.

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Chiller/Heater Description

Chiller/Heater Scope

This manual provides relevant data to properly operate, maintain, and troubleshoot the Trane PolyTherm Simultaneous chiller/heater. Operator and maintenance personnel must be a qualified refrigeration technician and have a working knowledge of high voltage systems, low voltage control circuits, and components and functions.

Chiller/Heater Capacities

The PolyTherm chiller/heater model is available in 30-, 40-, 50-, and 60-ton capacity modules. Up to 10 modules may connect together in a standard primary/ secondary control arrangement. Simultaneous heating and cooling modules are equipped with single point power supply connection to a central distribution block inside an electrical power distribution panel and incorporates circuit breaker overload protection for each PolyTherm module. It is important to connect modules in the correct sequence as detailed in Handling of the Modules section of the Installation Mechanical chapter.

WWAARRNNIINNGG

HHaazzaarrddoouuss VVoollttaaggee!!

FFaaiilluurree ttoo ddiissccoonnnneecctt ppoowweerr bbeeffoorree sseerrvviicciinngg ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. DDiissccoonnnneecctt aallll eelleeccttrriicc ppoowweerr,, iinncclluuddiinngg rreemmoottee ddiissccoonnnneeccttss bbeeffoorree sseerrvviicciinngg.. FFoollllooww pprrooppeerr lloocckkoouutt//ttaaggoouutt pprroocceedduurreess ttoo eennssuurree tthhee ppoowweerr ccaann nnoott bbee iinnaaddvveerrtteennttllyy eenneerrggiizzeedd.. VVeerriiffyy tthhaatt nnoo ppoowweerr iiss pprreesseenntt wwiitthh aa vvoollttmmeetteerr..

The water-source modular simultaneous heating and cooling system consists of individual modules that are assembled on site. Each PolyTherm module is factory wired and tested prior to shipment. Each module includes a compressor, a brazed plate evaporator, a brazed plate condenser, a source/sink brazed plate heat exchanger, and controls. The controls operate as a distributed primary control system that allows each secondary microprocessor to operate its own temperature sensors if the primary microprocessor fails.

Component Description

Every chiller is comprised of four basic components: compressor, condenser, expansion valve, and evaporator. Each PolyTherm Chiller/Heater module contains one or more of these primary refrigeration components.

Tandem Compressors

The tandem compressor set to have advanced technology for protection, diagnostics, communication, and verification of their performance. Technicians can make faster, more accurate, decisions resulting in improved compressor performance and reliability.

Evaporators, Condensers and Source/ Sink Heat Exchanger

Each single circuit, brazed plate evaporator, condenser and source/sink heat exchanger is constructed of 316 stainless steel plates and copper brazing and insulated with closed cell insulation. The fluid piping in each module uses an electronic two-way valve for selecting geothermal fluid or load hot or cold fluid depending on the building heating or cooling demands.

The return fluid piping from each evaporator and condenser includes an electronic valve for servicing each module individually while the remaining modules continue to operate, to allow for variable flow and, on each condenser and source/sink heat exchanger operating as a condenser, to control head pressure. The fluid connections to each heat exchanger use roll grooved couplings for service convenience and ease of installation.

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Page 15

Condenser

Evaporator

CChhiilllleerr//HHeeaatteerr DDeessccrriippttiioonn

The condenser is a key chiller/heater component that receives refrigerant in the form of gas from the compressor and changes it to liquid that absorbs the heat dissipated by a cooling tower or ground source well system.

The brazed plate heat exchanger that is the evaporator is constructed as a plate package of corrugated channel plates with filler material between each plate. The filler material forms a brazed joint at every contact point on the plates, creating complex channels. This allows fluid to come into close proximity, separated only by channel plates, that enable heat from one fluid to be transferred to the other with very high efficiency, but without gaskets and frame parts.

Models with the brazed plate heat exchanger are made of SAE Grade 316 stainless steel and

99.9% copper brazing materials. Interconnecting headers are carbon steel.

Water quality must be verified and maintained by a professional in water treatment and familiar with the materials of construction and operation of the equipment.

Source/Sink Heat Exchanger

The brazed plate heat exchanger that is the source/sink heat exchanger is constructed as a plate package of corrugated channel plates with filler material between each plate. The filler material forms a brazed joint at every contact point on the plates, creating complex channels. This allows fluid to come into close proximity, separated only by channel plates, that enable heat from one fluid to be transferred to the other with very high efficiency, but without gaskets and frame parts.

Models with the brazed plate heat exchanger are made of SAE Grade 316 stainless steel and 99.9% copper brazing materials. Interconnecting headers are carbon steel.

Water quality must be verified and maintained by a professional in water treatment and familiar with the materials of construction and operation of the equipment.

Components Parts

The systems and subsystems of the PolyTherm Simultaneous Chiller/Heater are configured and matched to enhance performance and operating efficiency:

Frame

The PolyTherm Chiller/Heater frame is constructed of formed sheet metal externally coated with white painted finish and coated in black.

Cabinet

Cabinet panels are made of sheet metal externally coated with white painted finish and internally coated in black. For service, the cabinet enclosure is composed of easily removable access panels. Access panels are removable via stainless steel fasteners and retaining clips.

Strainers

A compact design suction diffuser with stainless steel 40 Mesh strainer is factory-installed on the branch line

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Page 16

CChhiilllleerr//HHeeaatteerr DDeessccrriippttiioonn

to each evaporator, condenser and source/sink heat exchanger inlet.

Isolation Valves

The strainer and flow switch are serviced by manually closing the isolation valves on each evaporator, condenser and source/sink heat exchanger branch line. With these components independently isolated, they can be removed or replaced as required and the strainer cleaned without shutting down the fluid flow to the entire system while the remaining modules to continue to operate.

Reversing Valve

Each module contains refrigeration valves on each refrigeration circuit that open and close to allow the

Electronic Expansion Valve

An expansion valve is a metering device controlling the flow of refrigerant to the evaporator based on evaporator superheat. The electronic expansion valve is designed to act as the expansion device for the PolyTherm Chiller/Heater. Incorporated sight glass monitors movement of the movable element and refrigerant flow inside the system. The valve is made from modular elements assembled during installation, to simplify maintenance and inspection of the components.

source/sink heat exchanger to operate as an evaporator or condenser.

Refrigerant Piping

Piping is Type K seamless copper suction line covered in closed-cell foam insulation, compressor rotalock service valves, solenoid valves for compressor pumpdown, and Schrader service valves in the suction, discharge, and liquid lines.

Fluid Piping

The fluid piping is Schedule 10 steel covered in closedcell foam insulation to prevent condensation and retain heat and cold. Each heat recovery module is connected to the adjacent module using roll grooved steel couplings and neoprene gaskets on all joints.

Flow Switch

A flow switch is wired into the low voltage control circuitry used to detect the flow of liquid throughout the closed loop piping system. The differential pressure switch detects water/glycol mixture flow through a pressure differential in the discharge line. Flow switches are found on all evaporators with isolation valves. Flow switches close when flow is detected allowing compressors to start. If there is no flow, compressors cannot operate.

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Page 17

CChhiilllleerr//HHeeaatteerr DDeessccrriippttiioonn

NNOOTTIICCEE

PPrrooooff ooff FFllooww SSwwiittcchh!!

FFaaiilluurree ttoo pprroovviiddee ffllooww sswwiittcchheess oorr jjuummppiinngg--oouutt ooff sswwiittcchheess ccoouulldd rreessuulltt iinn sseevveerree eeqquuiippmmeenntt ddaammaaggee.. EEvvaappoorraattoorr aanndd ccoonnddeennsseerr wwaatteerr cciirrccuuiittss rreeqquuiirree pprrooooff ooff ffllooww sswwiittcchheess..

•• FFaaiilluurree ttoo iinncclluuddee tthhee pprrooooff ooff ffllooww ddeevviicceess aanndd// oorr jjuummppiinngg oouutt tthheessee ddeevviicceess ccoouulldd ccaauussee tthhee uunniitt ttoo ssttoopp oonn aa sseeccoonnddaarryy lleevveell ooff pprrootteeccttiioonn..

•• FFrreeqquueenntt ccyycclliinngg oonn tthheessee hhiigghheerr lleevveell ddiiaaggnnoossttiicc ddeevviicceess ccoouulldd ccaauussee eexxcceessssiivvee tthheerrmmaall aanndd pprreessssuurree ccyycclliinngg ooff uunniitt ccoommppoonneennttss ((OO--rriinnggss,, ggaasskkeettss,, sseennssoorrss,, mmoottoorrss,, ccoonnttrroollss,, eettcc..)) aanndd//oorr ffrreeeezzee ddaammaaggee,, rreessuullttiinngg iinn pprreemmaattuurree ffaaiilluurree ooff tthhee cchhiilllleerr..

Refrigeration Controls

Controls on the refrigeration system are designed to provide safety for the major components and for proper operation of the system.

Sight Glass

When the sight glass shows a green indicator, no moisture is present. When the sight glass shows a yellow indicator, there is moisture in the refrigerant line. Bubbles can be observed whenever chiller/heater cycling causes the pressure to change up or down.

Pressure transducers convert pressure into an electronic signal that the microprocessor displays in pounds per square inch (psi). Transducers vary in pressure ranges that depend on the type of refrigerant used. Pressure transducers are calibrated using the touchscreen interface panel.

Temperature sensors transmit temperature data electronically to the microprocessor for display in either Fahrenheit (°F) or Celsius (°C). Temperature sensors are calibrated using the touchscreen interface panel.

Low Pressure Bypass

Logic that uses a time delay that temporarily bypasses the low-pressure switch for compressor start up. Once the delay times out the normal controls are put back on line within the control circuit.

NNOOTTIICCEE

EEqquuiippmmeenntt DDaammaaggee!!

FFaaiilluurree ttoo rreemmoovvee mmooiissttuurree ffrroomm ssyysstteemm ccoouulldd ccaauussee ccoorrrroossiioonn wwiitthhiinn tthhee cchhiilllleerr//hheeaatteerr ccoommppoonneennttss,, aanndd ddeeggrraaddee ppeerrffoorrmmaannccee.. PPeerrffoorrmm vvaaccuuuumm eevvaaccuuaattiioonn ooff ssyysstteemm ttoo rreemmoovvee mmooiissttuurree..

Phase Monitor

A compressor can fail if operated in reverse for more than a minute. A phase monitor is used on three phase power systems to ensure that the electricity supplying the chiller/heater is configured appropriately. A phase monitor prevents a motor from operating in reverse—if any of the three legs of power are landed incorrectly—and will shut the system down upon detection of a reversed phase condition.

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Page 18

Pre-Installation

Preparation for Initial Startup

After the system is completely installed with all wires connected and all piping securely coupled, the chiller/ heater can be prepared for initial startup.

Ensure there is a sufficient cooling load available for proper testing of the chiller/heater system.

Initial Startup

1. Close all drain valves and header purge valves.

2. Fill the chiller/heater with clean water/glycol mixture.

3. Inspect all connections for leaks during the filling process.

4. De-energize using industry-standard lockout/tagout procedures. Verify main power is turned off at the power distribution panel. Validate de-energization using voltage meter.

WWAARRNNIINNGG

HHaazzaarrddoouuss VVoollttaaggee!!

5. Inspect all electrical connections to ensure terminals are secure.

6. Inspect all fuses and overload settings to ensure they conform to specifications.

NNoottee:: If Trane pumps are provided, check that each

pump’s overload setting matches the nameplate amperage of the pumps as described previously. “Bump” pump motors on to verify correct rotation.

7. Inspect all refrigerant pressures for each module to ensure no refrigerant has been lost.

8. Check that pressure switches and thermostats have correct “cut-in” and “cut-out” settings.

9. Confirm the oil level is correct in each compressor.

NNOOTTIICCEE

CCoommpprreessssoorr FFaaiilluurree!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd rreessuulltt iinn ccaattaassttrroopphhiicc ccoommpprreessssoorr ffaaiilluurree.. DDoo nnoott ooppeerraattee wwiitthh iinnssuuffffiicciieenntt ooiill..

10. Connect phase monitor wiring, if required.

11. Connect remote flow switch if the chiller/heater is so equipped.

12. Ensure refrigerant valves are open at the compressors.

13. Confirm that pressure and temperature switches are in the closed position.

14. Apply power to all modules in the chiller.

15. Turn on the condenser and evaporator fluid pumps and ensure there is proper flow and the pressure drop across the system is as expected.

16. Monitor and record all temperatures and refrigerant pressures.

Request Initial Startup

Initial startup is an exacting, complex, procedure. Successful initial startup is directly attributable to thorough preparation and completion of all essential tasks prior to the scheduled initial start-up date.

A completed Request for Initial Startup form is required prior to scheduling a startup.

Submission of this form indicates all critical work described on the form has been completed. To prevent incurring additional startup charges, it is critical that all items listed on the form are completely functional and operating, with this form signed and returned to Trane, at least 10 working days prior to scheduling an initial startup. (See

As part of a continuous commitment to quality, initial startup of this chiller/heater by a certified factory technician may be purchased from Trane.

“ PolyTherm Chiller/Heater ,” p. B–1)

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Page 19

PPrree--IInnssttaallllaattiioonn

Table 3. Initial startup readiness checklist

Startup Readiness Dimension

☐☐

Describe voltage service:

☐ Fused disconnect

☐ Non-fused disconnect

☐

☐ 50 Cycle

☐ 60 Cycle

Record rated power supply: __________volts_______ phase

☐

• Circuit breaker rating: _______

Record supply voltage on chiller nameplate: _________________

☐

Record power supply voltage to ground: L-1= _______, L-2 = _______, L-3 = _______

☐

Record voltage between each phase: L-1 to L-2 = ______, L-2 to L-3 = ______, L-1 to L-3 = ______

☐ Agrees with nameplate values?

☐

☐ Voltages must be within 2%.

Check the box if all electrical connections inside the power distribution panel are tight.

☐

Check the box if all electrical connections inside each module electrical and control panel are tight. Ensure all components inside each module are securely mounted and have not shifted during shipment.

☐

Record the control voltage between TB-1-1 and TB-2-1: ________

☐

Check the box if chiller/heater system includes any remote panels (city water switchover, remote control panel, or customer supplied control devices). If so, voltage drops are likely to occur. Measure and record all control voltages:

☐

List devices: Voltage 1=_____________________ Voltage 2=_____________________ Voltage 3=___________________

Check the box if there are any field-supplied wiring junction boxes located between the chiller/heater and any remote panels.

☐

Check the box if there are any splices made in the field-supplied wiring junction boxes.

☐

Check the box if there are any customer-supplied devices connected to the chiller/heater wiring.

☐

List devices: ______________________________________________________________________________________

Check the box if there are any Trane remote devices connected to the chiller/heater wiring.

☐

Check the box if voltage drops are detected.

☐

Check the box if the appropriate water/glycol mixture has been added to the chiller.

☐

Check the box if all chiller/heater modules are installed with minimum clearances available from all sides.

☐

Check the box if refrigeration gauges (or on the touchscreen interface) are indicating equal refrigerant pressures.

☐

Check the box if chilled water lines from chiller to customer’s equipment are permanently connected.

☐

Check the box if chilled water lines have been flushed clean of mud, slag, and other construction debris.

☐

Check the box if all chilled water line filters and strainers are clean.

☐

Check the box if chilled water lines have been leak tested according to pre-startup instructions.

☐

Check the box if evaporator reservoir (if included) is at operating level with correct water/glycol mixture.

☐

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PPrree--IInnssttaallllaattiioonn

Table 3. Initial startup readiness checklist (continued)

Startup Readiness Dimension

☐☐

Check the box if all condenser chilled water line filters and strainers are clean.

☐

Check the box if condenser chilled water lines have been leak tested according to pre-startup instructions.

☐

Check the box if condenser reservoir (if included) is at operating level with correct water/glycol mixture.

☐

Check the box if all source/sink chilled water line filters and strainers are clean.

☐

Check the box if source/sink chilled water lines have been leak tested according to pre-startup instructions

☐

Check the box if source/sink reservoir (if included) is at operating level with correct water/glycol mixture.

☐

Check the box if high voltage wiring is installed, tested, and functional.

☐

Check the box if all water, refrigeration, electrical, and control connections between chiller/heater modules are completed.

☐

Check the box if all control wiring between modular chiller/heaters is installed, tested, and functional.

☐

Check the box if control wiring is complete, including any remote interface panel or special-purpose module wiring.

☐

Check the box if all responsible installing contractors and sub-contractors have been notified to have representatives available on site to provide technical support for the initial start-up procedure.

☐

Check the box if full load will be available for chiller/heater on the initial start-up date.

☐

Touchscreen Interface Panel: Record version and date of the software loaded into the touchscreen interface panel: Version: ____________________________________ Date: ________________

☐

Note: To view the software version, from the home screen, press the software button on the System Control screen.

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Installation Piping

Install Piping and External Components

Proper support of piping and pipe hangers must consider the weight of the piping as well as the water

Figure 5. Recommended PolyTherm chiller/heater piping

IImmppoorrttaanntt:: An electronic expansion valve is a butterfly

valve used on an evaporator when the water/glycol mixture flow is variable or to operate an ‘N+1’ chiller/heater module configuration. (‘N+1’ is a configuration whereby a spare module is brought on line should an operating module fail. The spare module’s electronic expansion valve opens, and the failed module’s valve closes thereby keeping the pressure drop and flow through each evaporator in the system constant). Each valve has a 24 Vac power supply opening, closing or modulation by a 0 to 10 Vdc signal. A sensor in the water/ glycol mixture header detects temperature or pressure via an electronic signal to the microprocessor that in turn controls the voltage to the valve actuator motor. The signal is either 0 or 10 volts.

Initial Flushing of Piping

After installation of system piping and before connection to the chiller/heater system, it is important to clean and remove debris, weld slag, and other contamination deposited during fabrication of the piping system. Typical flushing includes hot water with mild detergent followed by a dilute phosphoric acid solution until all visible residue is removed.

Only cleaning liquids, acids, and detergents compatible with SAE Grade 316 stainless steel, copper, and carbon steel should be used. Consult a professional water treatment specialist when in doubt.

weight inside the pipes. A 40-mesh screen strainer must be installed in each water/liquid system piping inlet for proper filtration an protection of the heat exchangers. The following figure provides a recommended installation of components.

Flushing should take place across a filter/strainer with a maximum 30 mesh screen and continue for a minimum of six hours with frequent removal of the screen to capture residue or until the strainer is clean.

After detergent and chemical cleaning, flush the water piping with fresh water for one hour to remove any remaining cleaning compounds.

Fill with Water/Glycol Solution

The installing contractor is responsible for charging glycol into the chiller/heater hydronic system. These instructions are typically for water cooled as air cooled modules have more work space.

1. Mix the concentrate of propylene glycol in a tank or drum for transfer into the chiller. Use

to determine the appropriate glycol

concentration.

2. Mix the glycol and water externally before filling the chiller/heater to prevent clogging of the chiller piping with a heavy concentrate.

3. Fill the tank using the manual fill port on the cabinet. Fill so that the mixture reaches near the top. Stop every so often so the fill level can be monitored.

NNoottee:: Do not use a glycol feeder pump to fill the chiller/

heater loop. It is not designed for continuous use and will fail.

Only after the above steps have been completed should the water piping be connected to the chiller/ heater system.

Table 11, p.

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IInnssttaallllaattiioonn PPiippiinngg

Dowfrost

IImmppoorrttaanntt:: Dowfrost inhibited propylene glycol-based

solution is listed as chemically acceptable by the US Department of Agriculture (USDA). The two ingredients in Dowfrost water/glycol mixture are generally recognized by the FDA as safe food additives under Parts 182 and 184 of the Food Additive Regulations.

Connecting Module Couplings

Install each module according to its position number indicated on its electrical distribution cabinet. Install the primary module first. Each secondary module has the same installation procedure as the previous module.

1. Remove the coupling that attaches the headers to the heat exchangers in order to position the header with the next module and attach the header coupling.

2. Remove all four small couplings to allow the main headers to slide into the previous module.

3. Position each subsequent module approximately 16-inch from the previous module when positioning the headers.

4. Lubricate the main header coupling gasket with an approved lubricant and re-install onto the roll grooved header pipe. Push the gasket flush with the pipe end to avoid damage when installing the next module.

5. Remove the small coupling that attaches the main header to the heat exchanger.

6. After positioning the module, slide the header and rotate it to avoid damage to the refrigeration piping.

7. Note the refrigeration pipe above the header. Note the position of modules and headers extended.

8. Position each of the four headers and attach the roll grooved couplings. Start by positioning the lubricated gasket so that the gasket fits inside the two grooves, one from each of the headers.

9. Loosen one side of the metal coupling and remove the bolt from the other side to allow you to position it over the gasket.

10. Install and tighten each of the four couplings. Begin with the inside headers, then the outside headers. Slide the module back to the previous module and re-attach the header to the small coupling for the heat exchanger.

11. Install the remaining modules using this procedure.

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Installation Electrical

Wiring and Piping

Modules must be installed in accordance with the manufacturer’s recommendations where shown on the drawings and other installation documents.

Each PolyTherm Chiller/Heater module is shipped individually for field assembly. Field assembly of a PolyTherm Chiller/Heater system consists of the following minimum steps:

1. Connect chilled fluid/heating fluid piping with factory supplied roll grooved connections.

2. Insulate roll grooved connections after assembly.

3. Connect factory-supplied power supply wiring harnesses to the power distribution panel. Install wires to the proper terminals for proper phasing. The panel is wired for A, B, C phase right-to-left in the power distribution panel. Each wire on the wire harness is identified as to its respective phase.

4. Connect each module microprocessor to the Ethernet switch to form the local communication network. Ethernet cable Cat-5e must be used for all communication connections.

Connecting Module Power and Control Wires

Connections are made at the primary module, which typically contains the power distribution panel.

Labeled control and communication cables are coiled inside each module and are connected to an Ethernet switch. The Ethernet cable tuns from the switch to each module’s microprocessor controller at the JJ3300 connector.

IImmppoorrttaanntt:: Electrical Hazards: Read before installing!

This equipment must be installed by qualified personnel in accordance with all local and national codes. An earth ground lug is provided on the cabinet exterior for proper grounding according to national electrical codes. An earth ground is necessary to ensure personnel safety to prevent electrical hazards around this equipment. Read and follow installation instructions for proper operation.

This unit is equipped with a flow switch. The chiller/ heater will not run unless the pump is circulating water through the system.

Service Access

Compressors, filter-strainers, and liquid line shutoff valves are accessible on each side or end of the unit.

Chiller/Heater Module Main Power

Modular systems feature single-point power connection from the utility service to the power distribution panel on the primary module as standard. Main power phases A, B, and C are connected to terminals A, B, and C respectively from left to right. (Some custom systems may have individual power supplied to each module in lieu of single point power.)

Module Control Wiring

The primary controller communicates with the secondary controller in each chiller module via a communication circuit. Each secondary controller is wired back to the Ethernet switch on the primary microprocessor controller. See following figure.

Figure 6. Typical controller network

Phase Monitor Installation

The chiller/heater is equipped with a phase monitor on the power distribution panel. It communicates with the primary microprocessor controller in the primary module electrical and control panel via the id9

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terminal. Ensure that the wiring from the primary microprocessor controller and terminal blocks to the phase monitor are connected and secure.

The phase monitor continuously monitors each of the three phases. The microprocessor receives input from

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IInnssttaallllaattiioonn EElleeccttrriiccaall

the phase monitor indicating whether the voltage is within acceptable values. The phase monitor design protects against under-voltage, voltage unbalance, phase loss, and phase reversal.

Set voltage adjustment knob at the desired operating line voltage for the equipment. This adjustment automatically sets the under-voltage trip point. Check the phase monitor after initial startup. If it fails to energize, (the LED glows or blinks red) check the wiring of all three phases, voltage, and phase sequence. If phase sequence is incorrect, the LED flashes green/red. To correct this, swap any two line voltage connections at the mounting socket. No further adjustment should be required.

Power Interlock Switch

Some PolyTherm Chiller/Heater systems are optionally equipped with a panel-mounted disconnect switch installed on the outside of the power distribution panel. The disconnect switch must be turned to the off position before the panel can be opened for service.

WWAARRNNIINNGG

HHaazzaarrddoouuss VVoollttaaggee!!

Single Point Connections

For systems with single point power connections, detach the power cable on each module by cutting the wire tie installed for shipping.

1. Uncoil the power cable and snake it through each module to reach the power distribution panel.

2. Feed the taped end of the cable through the round opening on the extreme left of the power distribution panel.

3. Remove the tape and connect and tighten the cable ends to the breaker corresponding to the module number being connected. (For example, connect the cable for module #8 to the breaker labeled #8.)

4. Connect the green ground lead to the ground lug at the base of the enclosure.

5. Do not secure the ground wire until all of the ground wires are connected to the ground lug and then each can be tightened.

6. After connection, secure all power cables with standard wire ties.

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Operating Principles

The PolyTherm Simultaneous Chiller/Heater is a stateof-the-art six-pipe multipurpose system (See

) featuring independent water circuits to satisfy

p. 25

end user's requirements for heating and cooling yearround. It eliminates the need for duplicate equipment and significantly reduces space requirements by combining duties and reducing glycol requirements.

Figure 7. PolyTherm simultaneous chiller/heater

Figure 7,

The PolyTherm Chiller/Heater is designed to operate with a water/glycol mixture to prevent rust, scaling, and organic growth and uses R-410A or R-134a refrigerant.

The simultaneous heating and cooling system is designed to operate in heating mode, cooling mode, or simultaneous heating and cooling based on the system demand by opening and closing electronic diverting valves on the evaporators, condensers, and the source/ sink heat exchanger and redirecting refrigerant flow to the operating brazed plate heat exchangers.

Figure 8. 30 and 40 tons PolyTherm dimensions

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OOppeerraattiinngg PPrriinncciipplleess

In cooling mode, the diverting valves direct the load chilled fluid to the evaporator and simultaneously direct the source/sink fluid to the source/sink brazed plate heat exchanger operating as a condenser.

Figure 9. 50 and 60 tons PolyTherm dimensions

In heating mode, the diverting valves direct the load heating fluid to the condenser and the source/sink fluid to the source/sink brazed plate heat exchanger as refrigerant has been redirected such that it operates as an evaporator.

In simultaneous heating and cooling mode, the diverting valves direct the load heating fluid to the condenser and the load cooling fluid to the evaporator.

Electronic valves on the brazed plate source/sink heat exchanger outlet modulate to control refrigeration

head pressure. Electronic valves on the evaporator and condenser outlet also allow for variable flow. See

Figure 8, p. 25 and Figure 9, p. 26.

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Page 27

Operating Procedures

Operator Interface

All PolyTherm Simultaneous chiller/heater units, whether they are composed of a single module or up to 10 modules, are automated systems that use a touchscreen interface panel to monitor, report, and modify critical system functions.

Chiller/Heater Power Panels

There are two different electrical panels used in thePolyTherm Chiller/Heater. The power distribution panel receives power from the building source and distributes it to individual modules. The electrical and control panel receives power from the power distribution panel and provides power to the individual electrical components in that module.

Figure 10. Power distribution panel

Panel-Mounted Disconnect Switch

SomePolyTherm Chiller/Heater systems are optionally equipped with a panel-mounted disconnect switch installed on the outside of the power distribution panel (or on each module’s electrical and control panel if the chiller/heater has power supplied to each individual module). The disconnect switch must be turned to the OFF position before the panel can be opened for service. When the panel door is open, the power is disengaged.

Power Distribution Panels

The power distribution panel distributes electricity from the external building power supply. It also houses a circuit breaker for each module, a phase monitor, and an optional main power disconnect switch. See following figure.

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Page 28

Contro ll er Relay Exp an sion Boar d Contro ll er

Elect ron ic Expansi on Valv e Con t roller

TB- 1 Ter m inal Block

TB- 2 Ter m inal Block

TB- 3 Ter m inal Block

TB- 4 Ter m inal Block

TB- 5 Ter m inal Block

OOppeerraattiinngg PPrroocceedduurreess

Module Electrical and Control Panel

Each module has its own electrical panel that distributes electricity to individual components. It also

Figure 11. Module electrical panel

Each module has its own control panel that houses the microprocessor controller. It also has relays, an expansion board, an electronic expansion valve controller, and low-power terminal blocks. See

12, p. 28

Figure

has fuses and breakers, compressor switches, and the microprocessor controller. See following figure.

Electronic Control

PolyTherm Chiller/Heater models use electronic controllers to monitor and report critical operating parameters. The module uses a microprocessor controller located in the module control panel. See

Figure 12, p. 28 and Figure 13, p. 29.

Figure 12. Module control panel

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Figure 13. Microprocessor controller

OOppeerraattiinngg PPrroocceedduurreess

A primary controller is used to control and coordinate the functioning of all the modules that make up the chiller/heater unit. For units consisting of more than a single chiller/heater, each module has its own controller. The primary microprocessor controller has built-in BACnet MSTP and Modbus RTU capabilities. An optional card must be installed to connect to a BAS using BACnet IP, Modbus IP, or LonWorks.

Controllers

The distributed microprocessor control system enables all secondary modules to operate independently in the event that the primary microprocessor controller fails. All chiller/heater safeties including temperature set point, refrigerant pressures, and freeze protection are

Figure 14. Typical controller network

preserved. The distributed microprocessor control programming only lacks the ability to rotate the lead compressors which typically occurs every 168 compressor operating hours.

In a normal configuration, a secondary controller controls the single module to which it is dedicated.

The secondary controller monitors key performance parameters for its module and sends real-time information to the primary controller. The primary controller monitors the performance of the chiller/ heater, activating and deactivating modules as needed to maintain the leaving water temperature for the chiller/heater.

Operating the Microprocessor

The touchscreen interface panel is ready to use when it is connected to the Ethernet switch and chiller/heater power is ON.

ARTC-SVX005B-EN

Upon initial startup, the status line will indicate that the chiller/heater is OFF. Press and hold the ON/OFF button on the touchscreen interface panel; for few seconds to

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turn the chiller/heater on and the touchscreen will indicate that it is powered on.

Press and hold ON-OFF button to toggle the chiller/ heater ON and OFF.

Microprocessor Functions

For practical purposes, all essential control information and operator actions are read and responded to using the touchscreen interface panel. The touchscreen interface panel is connected to the primary microprocessor controller via the Ethernet switch and is the only way to access many primary controller functions.

NNOOTTIICCEE

CCoommppoonneenntt DDaammaaggee!!

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controls, and so forth) are written assuming the operator is using the touchscreen interface panel.

When connected to the Ethernet switch, the touchscreen interface panel displays current, real-time, information about the chiller/heater, as well as the status of critical parameters within each module of the chiller/heater.

How to Use the Touchscreen Interface Panel

The touchscreen interface panel is used to adjust set points, clear alarms, and perform detailed setup of the microprocessor controllers.

The touchscreen interface panel displays information on its touchscreen whenever specific keys and buttons are pressed by the operator (See following figure).

Basic operator tasks are described in the following sequence of illustrations that comprise a controller tutorial.

Figure 15. Touchscreen interface panel

Password Protection

There are three levels of access to the functions displayed on the interface. The basic level, ‘user,’ does not require a password. The higher access levels are the technician (‘tech’) and administrator (‘admin’) levels that can only be accessed by Trane technical personnel. Contact Trane technical support regarding the possibility of any potential issues involving the higher-level functions.

Operator Control

A touchscreen interface panel is the primary means for the operator or maintainer to monitor and modify a host of functions involving temperatures, pressures, set points alarms, operating schedules, and elapsed operating hours. This touchscreen interface panel is typically located on the exterior door of the power distribution panel.

The touchscreen interface is connected to and communicates with all module controllers via the Ethernet switch. It accesses overall chiller/heater functions and settings as well as individual module settings.

In this manual, all functions, procedures, checklists, system information, and changes in system parameters (set points, alarms, primary chiller/heater

Touchscreen Interface Tutorial

This section consists of a tutorial that first-time personnel can use to navigate through the various functions and features that are available in the interface.

Each of the main screens in the interface contains active hot spots to activate virtual buttons and switches by simply touching the screen.

Interface Menu Structure

Key interface screens are organized according to system, primary module, and secondary modules functions. See

Figure 16, p. 31.

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Page 31

Figure 16. Interface navigation scheme

Syst em

Prim ary Module

Secondar y Modu les

OOppeerraattiinngg PPrroocceedduurreess

Home Screen

On startup, the home screen, entitled ‘System Control,’ is displayed. From the home screen, all major function at each access level can be accessed. The system control screen is the home screen that is a convenient starting point for most interactions described below.

Modules Layout Screen

On the home screen, pressing the module layout button displays the modules layout screen (

p. 35 ). This screen is a graphical representation of the

modules that are available in the chiller/heater.

Overview Screens

Overview of main chiller/heater module refrigeration parameters and status of its components: refrigeration circuit, heat exchangers, compressors, and the module itself. There are two overview screens for each module.

Figure 20,

These screens are different for the primary module and the secondary modules.

Input/Output Screen

The state and description of the module microprocessor controller’s digital and analog inputs and outputs. The I/O menu is comprised of four screens for primary module and three screens for secondary module.

Trend Screens

Trending curves for cooling and heating demand are displayed here. There are two trend screens: cooling trends and heating trends. The trend screens apply only to the primary module.

Setup Screens

Setup screens are available only for the ‘admin’ level. Setup screens contain all the chiller/heater settings applied to system and for individual module settings. Access to these screens is restricted to administrator level only.

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Home Screen Features

There are three primary sections in the home screen: top, middle, and bottom.

Top Section Functions

Features in the top section include:

• The home screen button appears on every screen for fast display of the home screen from any screen in the interface.

• The module access buttons display the overview screen for each module. These buttons provide access all chiller/heater modules screens individually. The number on the Mx button stands for the module number in the chiller/heater. Only

Home Screen

The home screen button appears on every screen for fast display of the home screen from any screen in the interface.

Module

The module access buttons display the overview screen for each module. These buttons provide access all chiller/heater modules screens individually. The number on the MX button stands for the module number in the chiller/heater. Only modules that communicate directly with the touchscreen interface are viewable via the module access buttons.

modules that communicate directly with the touchscreen interface are viewable via the module access buttons.

• The software access button identifies the software version currently loaded.

• The log-in access button displays the appropriate log-in screen.

• The module layout access button provides fast access to the module layout screen.

• The active alarm access button provides fast access to a list of currently active system alarms.

• The date/time displays the current settings of the system isochronon.

Software Icon

Log-in option

Module Layout

Alarm

Date and Time

The software access button identifies the software version currently loaded.

The module layout access button provides fast access to the module layout screen.

The active alarm access button provides fast access to a list of currently active system alarms.

The date/time displays the current settings of the system isochronon.

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Figure 17. The home screen, ‘System Control’

OOppeerraattiinngg PPrroocceedduurreess

Project Name

This is the name of the interface software currently loaded into the system.

Software Version

Pressing the Software Version button displays pop up window.

Figure 18. Interface software version pop-up window

This is the version of the interface software currently loaded in the system. This number consists of four sets of two-digit numbers.

• The first two sets indicate major and minor software revisions.

• The third set has an initial value of ‘00.’ If this is a special edition of the software, this number will be designated something other than ‘00.’ See

18, p. 33

• The fourth number indicates the beta software revision sequence.

Figure

Middle Section Functions

Chiller Status. Features in the middle section include status indicators and controls for the chiller/heater system as a whole:

• Chiller/heater temperature set points for cooling and heating

• Chiller/heater system cooling in and out water temperatures

• Chiller/heater system heating in and out water temperatures

• Chiller/heater system source sink in and out water temperatures

• Chiller/heater system power on or power off status

• Chiller/heater system operational mode: cooling, heating, or simultaneous

Bottom Section Functions

Module and Compressor Status. Features in the bottom section include:

System On

This button powers the chiller/heater (and all its modules) on and off via a software switch. The button

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should be pressed for few seconds to power the chiller/ heater.

Cool and Heat Demand Comp / %

This is the cooling and heating demand value in terms of the number of requested compressors as well as continuous value as a percentage. A bar graph representation of cooling or heating demand is adjacent to the numeric value.

Setup

This is the number of chiller/heater modules set up at the factory.

Online

This is the number of chiller/heater modules currently communicating with the primary microprocessor controller, including the primary module.

Evaporator / Condenser / Source

This is the pumps operating state. A green LED indicates that corresponding set of pumps is being requested by the chiller/heater; otherwise pumps are not requested.

Cool / Heat / Simult

This is the number of modules currently running in cooling, heating, or simultaneous mode, in terms of number of modules and number of compressors.

Pressing the Log-in button displays the Log-in window where the access-level password is entered for the ‘tech’ and ‘admin’ levels. There is no name or password required for the ‘user’ access level. Pressing the sign in button automatically logs the operator into the ‘user’ access level. See the following figure.

Figure 19. User logging screen

Current Access Level

This item indicates which access level is currently logged-in. There are three access levels for the PolyTherm interface: ‘user,’ ‘tech,’ and ‘admin.’ See the following table.

Table 4. Log-in screens

User Access Level

Tech Access Level

User Level

This is the default access level. This level has access for viewing chiller/heater status information. The only controls that this level can activate are turning the chiller/heater on and off and turning compressors on and off (as described below). There is no password required for this access level.

Admin Access Level

Tech Level

This is a higher access level than ‘user,’ but still limited. The ‘tech’ level can adjust cooling and heating set points, turn individual modules on and off, and access some basic temperature control settings. This level of access is only available to service technician personnel.

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Admin Level

This is the highest access level and provides access and the ability to modify all settings included in the interface. This level of access is only available to factory technical support personnel.

Log Out

Pressing the Logout button displays the Log Out window. This dialog box is visible for the ‘admin’ and ‘tech’ levels only. It logs out the ‘admin’ or ‘tech’ level to the default ‘user’ level.

Figure 20. Modules layout screen showing four compressors on two modules

Modules Layout Screen

The chiller/heater can be composed of up to a maximum of ten modules. Pressing the Layout button displays the screen showing the status of compressors and valves in each module. See the following figure

Each module diagram is a set of symbols and colors that show the real-time status of the compressors, the refrigeration circuit, the isolation valves and the module overall. See

Table 5, p. 36.

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Module Layout Screen Status Conditions On the home screen, pressing the alarm button

displays the active alarms screen. See

Table 5. Module status conditions

Figure 20, p. 35.

Module in simultaneous mode; compressors

Module in heating mode; compressors off

Isolation Valves:

- Valve LED is green = valve is open

- Valve LED is gray = valve is closed

Compressor 1 is in alarm and Compressor 2 is

Refrigeration circuit in normal state; both

compressors on

Modules Overview Screens

Each module controlled by the microprocessor controller has its own module screen within which the operator can monitor and maintain conditions affecting that module. Primary module access is made through the system control screen containing multiple controls and indicators:

Module turned off by alarm and unavailable;

Module in cooling mode; compressors off

Refrigeration circuit in alarm state;

compressors off

On the home screen, pressing the MM11 button displays the Module #1 (primary module) overview 1 screen.

Use the left and right scrolling buttons to scroll through the overview screens.

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Table 6. The overview screens

OOppeerraattiinngg PPrroocceedduurreess

Primary Overview 1 Screen

Module Indicators

The overview screen for each module contains a wealth of controls and indicators specific to that module:

Module En/Dis

Press this button to enable or disable the module. If the module is disabled, it is excluded from the primary controller compressor sequence.

Module Status

Possible states indicating the module’s status include:

• MMoodduullee OONN - The module is ready to run.

• OOFFFF bbyy SScchheedduullee - The module operates according to predefined schedule and is currently off as scheduled.

• OOFFFF bbyy DDiiggiittaall IInnppuutt - The module is turned off by the opened state of microprocessor controller DI1

• OOFFFF bbyy KKeeyyppaadd - The module is turned off by module EN/DIS button.

• OOFFFF bbyy AAllaarrmm - The module is locked out by one of the major alarms.

• OOFFFF bbyy PPrriimmaarryy - The module is switching between control states primary, secondary, and stand-alone.

• OOFFFF bbyy SSyysstteemm - The module is turned off by one of the system off conditions.

• MMaann MMooddee - The module is in manual mode.

• SSaaffeettyy MMooddee - This display indicates the module is running in one of the Safety Modes.

Module Cntrl Status

Possible options for each module include:

• Primary Module

Secondary Overview 2 Screen

The module is acting as the primary module and performs temperature control function for both heating and cooling loads. It also acts as a supervisor when communicating with the secondary modules and defines how many modules need to run compressors in order to satisfy heating and cooling loads.

NNoottee:: Primary Module is defined by its PLC IP address.

So in the chiller primary PLC IP address is always

192.168.1.11. All secondary IP addresses go from

192.168.1.12 to 192 to 192.168.1.20 which amounts to nine secondary. Each IP address has to be unique for all the chiller devices to communicate properly including HMI which IP address is 192.168.1.10.

Primary Status

This applies to the primary microprocessor controller only. Possible options:

• PPrriimmaarryy OONN - All primary module conditions are satisfied by this module.

• WWaaiittiinngg …… - All primary module conditions are satisfied and the module is counting down a delay before attaining Primary ON status.

• OOFFFF bbyy CCooooll SSeennssoorr - The chiller/heater cooling temperature sensor has failed.

• OOFFFF bbyy HHeeaatt SSeennssoorr - The chiller/heater heating temperature sensor has failed.

• OOFFFF bbyy NNoo SSeeccoonnddaarriieess - The primary microprocessor controller cannot communicate with any of the secondary modules.

• OOFFFF bbyy EExxpp IIOO FFaauulltt - A failure occurred in the primary microprocessor controller IO expansion module which renders all system temperature sensors failed. All primary status states 3 through 6 will cause all modules to run in the stand-alone mode. These failing conditions are avoided in normal primary and secondary operations.

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Lead Module

By default, the primary module is the lead module (the module that is the first to be engaged). The lead module always starts first. When there are no compressors running, the lead module always keeps its evaporator or condenser valves open (depending on the current mode) to allow for chilled water or hot water circulation.

The indicator reads YES or NO to indicate if the module is currently the lead module.

• PPrriimmaarryy OOnnlliinnee - This applies to secondary microprocessor controllers only.

• LLEEDD IIlllluummiinnaatteedd GGrreeeenn - The secondary microprocessor controller is communicating with the primary microprocessor controller.

• LLEEDD IIlllluummiinnaatteedd GGrraayy - The secondary microprocessor controller is not communicating with the primary microprocessor controller.

• SSttaanndd--aalloonnee - A chiller/heater that consists of only a single module always operates in Stand-alone Mode since the primary microprocessor controller does not have subordinate secondary modules with which to communicate. A module in a multiplemodule chiller/heater operates in the stand-alone mode whenever it does not meet either primary module or secondary module operating conditions. A module temporarily forced to operate in the stand-alone mode controls cooling and heating temperatures locally based on:

– Its evaporator and condenser EWT and LWT.

– Its cooling and heating and simultaneous mode.

– Its control temperature sensor selection.

The module runs temporarily in this mode until normal primary and secondary operation is restored.

• SSeeccoonnddaarryy MMoodduullee - A module acts as a secondary module when

– Its microprocessor controller has been assigned

the IP address from the secondary address range.

– It is communicating with primary module.

– The primary module exists on the network. The

primary microprocessor controller meets primary module conditions.

Mode Status

There are six possible values:

• SSiimmuullttaanneeoouuss - The module is in simultaneous mode.

• HHeeaattiinngg - The module is in heating mode.

• CCoooolliinngg - The module is in cooling mode.

• SSwwiittcchhiinngg ttoo SSiimmuulltt - The module is switching to simultaneous mode.

• SSwwiittcchhiinngg ttoo HHeeaatt - The module is switching to heating mode.

• SSwwiittcchhiinngg ttoo CCooooll - The module is switching to cooling mode.

Heat Exchanger Indicators

This displays each heat exchanger (evaporator, condenser, or source) inlet and outlet temperatures as well as the condition of its isolation valves.

Refrigeration Indicators

The refrigerant temperatures and pressures are displayed: suction pressure, discharge pressure, suction temperature, and suction super heat temperature.

Solenoid ‘E’

This is the solenoid valve installed at the evaporator heat exchanger inlet. It opens when compressors are running in simultaneous or cooling mode.

Solenoid ‘S’

This is the solenoid valve installed at the source heat exchanger inlet. It opens when compressors are running in heating mode.

EX Valve

This indicates the position of electronic expansion valve.

D1/D2/S1/S2

These are the discharge and Suction Refrigerant Valves. Depending on the Module Thermal Mode, valves are automatically positioned as follows:

Table 7. D1/D2 and S1/S2 values

Value

Discharge 1 (D1) Open

Discharge 2 (D2)

Discharge 3 (D3) Open Open

Discharge 4 (D4)

Simultaneously Mode Cooling only Mode Heating only Mode

Closed

Closed Closed

Closed

Open

Closed

Open

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Compressor Overview Screens

Use the left and right scrolling buttons to scroll through the overview screens.

Table 8. The overview screens 2

Primary Overview 2 Screen Secondary Overview 2 Screen

OOppeerraattiinngg PPrroocceedduurreess

The overview menu is comprised of two screens: Overview 1 and Overview 2. These two screens are different for the primary and secondary modules.

Compressor 1 and Compressor 2

Each module is equipped with tandem compressors. The module overview screen reports conditions in each compressor individually:

Compressor En/Dis

Pressing this button enables or disables a compressor. It is used for testing and maintenance purposes.

Comp Status

• CCoommpprreessssoorr OOffff - The compressor is off and can’t be turned on.

• RReeaaddyy - Compressor is off but can be turned on.

• OOFFFF bbyy SSoouurrccee FFllooww - The compressor is waiting for the Source Flow.

• OOFFFF bbyy CCoonndd FFllooww - The compressor is waiting for Condenser Flow.

• OOFFFF bbyy EEvvaapp FFllooww - The compressor is waiting for the Evaporator Flow.

• OOFFFF bbyy MMiinn OOffff - The compressor is cycling through safety Minimum Off Time.

• OOFFFF bbyy SSwwiittcchh - The compressor is off by HMI En button.

• OOFFFF bbyy AAllaarrmm - The compressor is off by alarm.

• RRuunnnniinngg - The compressor is running.

• OONN bbyy MMiinn OOnn - The compressor is running and cycling through safety Minimum On Time.

• SSttaarrtt DDeellaayyeedd - First Compressor - waiting for EXV to open to preset position (70% by default); Second

Compressor - cycling through Compressor Staging Delay.

• OOFFFF bbyy SSSSTT - The second compressor is off by too low Saturated Suction Temperature.

• OOFFFF bbyy SSDDTT - The second compressor is off by too high Saturated Discharge Temperature.

Communication

This LED indicates if PLC is communicating to compressor control device either protection module or VSD (Variable Speed Drive).

Local Temp Cntrl

This indicator applies only if module is running in stand-alone mode:

• CCnnttrrll TTeemmpp HHoott // CCoolldd - This is the local module’s hot or chilled water temperature control sensors.

• TTeemmpp SSPP HHoott // CCoolldd - This is the local module’s heating and cooling temperature control set points. This can only be adjusted by ‘tech’ or ‘admin’ access levels.

• DDeemmaanndd HHoott // CCoolldd - This is the local cooling and heating demand value in terms of the number of requested compressors.

• TTeemmpp DDiiffff ++ - This is the temperature control differential above the set point or positive dead band.

• TTeemmpp DDiiffff -- - This is the temperature control differential below the set point or negative dead band. Together, both of differentials define the temperature control dead band.

• TTeemmpp SSttaaggee--UUpp DDeellaayy - When a compressor has been staged up, this delay must elapse before the next compressor can stage up.

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• TTeemmpp SSttaaggee--DDoowwnn DDeellaayy - When a compressor has been staged down, this delay must elapse before the next compressor can stage down.

Module I/O Screens

Data is collected by sensors as either analog or digital signals and displayed on the IO Status screens.

When the module screen is displayed, pressing the I/O button displays the I/O menu.

The I/O menu is comprised of four screens for primary module and three screens for secondary module. Both primary and secondary modules have Analog I/O

Table 9. The input/output screens

(analog input and analog output), Digital I/O (digital input and digital output), and Expansion #2 I/O screens. The fourth screen Expansion #1 I/O applies to primary module only.

Primary I/O Analog Screen

Primary I/O Digital Screen Secondary I/O Digital Screen

Secondary I/O Analog Screen

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Table 9. The input/output screens (continued)

Primary I/O Expansion #2 Screen Secondary I/O Expansion #2 Screen

OOppeerraattiinngg PPrroocceedduurreess

Primary I/O Expansion #1 Screen

When an I/O screen is displayed, switching to other I/O screens is accomplished by pressing their respective buttons:

• The ANALOG button displays the analog screen.

• The DIGITAL button displays the digital screen.

• The EXP I/O button displays the expansion IO screen.

Analog Inputs

AI1 – AI3, AI6 – AI8

These inputs indicate the inlet or outlet temperatures for each of the three heat exchangers: evaporator, condenser, or source.

AI4

This input indicates suction pressure.

AI5

This input indicates discharge pressure.

AI9

This input indicates the panel temperature (optional). It is used when the temperature control inside the control panel requires either heating (for a cold environment) or cooling (for a hot environment).

Analog Outputs

Analog output (AO) data includes these parameters:

AO1, AO2, AO3

These outputs indicate the evaporator, condenser, or source isolation valve position as a percentage of opened condition.

AO5

This indicates compressor speed (optional). It is used in case of VSD-controlled compressors.

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Digital Inputs

Digital input (DI) data includes these parameters:

Digital LEDs

Figure 21. Digital inputs

There is an LED for each digital input that indicates its current state. For all inputs, the color of the LED signifies its current state:

GGrreeeenn LLEEDD — This digital input is energized, the connected device is closed.

GGrraayy LLEEDD — This digital input is de-energized, the connected device is open.

DI1 Remote On/Off

This activates a module on or off via digital input. If the primary digital on-off input is enabled, toggling the DDII11 on the primary module will turn the entire chiller/heater on or off.

DI2, DI3, and DI4

These show the states of the evaporator, condenser, or source flow switches. If the digital input for a switch indicates closed, flow is present. If the digital input for a switch indicates open, flow is absent.

DI7 and D8

These show the discharge and suction pressure switches. If the digital input for a switch indicates closed, the pressure is in the normal range. If the digital input for a switch indicates open, the pressure is exceeding normal range threshold (that is, faulty state).

DI9 Phase Monitor

This is feedback for the three-phase power supply protection feature. If the digital input for this switch indicates closed, there are no power supply issues. If the digital input for this switch indicates open, a power supply failure has been detected.

If the primary phase monitor is enabled, the common power supply protection module is active for the chiller/heater. Failure of the phase monitor will affect

all modules in the chiller/heater. In this case, digital input is optional for the secondary modules.

Digital Outputs

There is an LED for each digital output which shows its current state.

DO1, DO2 Comp On/Off

This digital output turns a compressor on and off.

DO3 Liq Line Solenoid ‘E’

This digital output energizes and de-energizes the liquid line solenoid valve ‘E’.

DO4 Liq Line Solenoid ‘S’

This digital output energizes and de-energizes the liquid line solenoid valve S.

DO6, DO7, DO8, DO9

Valve D1, D2, S1, S2. Used to command refrigerant valves open / closed. Green LED - valve is commanded open. Grey LED - valve is commanded closed.

DO10 General Alarm

This digital output energizes when any of the following alarms occur:

• An alarm that shuts down and locks out compressor 1 or 2.

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• An alarm that shuts down and locks out the entire module.

DO11 Panel Heater / Fan (optional)

This is the digital output is used when temperature control inside control panel is required (identical to AI9).

Expansion IO Screen

This screen controls analog inputs and digital requests. There is an LED for each digital output that shows its state:

• Green LED - Indicates the valve has reached the respective position.

• Gray LED - specified valve position hasn't been reached

Expansion #1 (Primary Only)

AI1 – AI6

These inputs indicate the inlet or outlet temperatures for each of the three heat exchangers: evaporator, condenser, or source.

AI7, AI8 - Cool SP / Heat SP (optional)

his is the external cooling or heating set point used when the cooling and heating set points are controlled by the BAS as hard-wired analog input signals.

Another way to set cooling or heating set points is via BAS communication.

All microprocessor Analog Inputs (AI) are actually Universal Inputs (UI), the same as the microprocessor controller UI. So any microprocessor UI can be reconfigured to be either analog input, digital input, or analog output.

Expansion #2

DI1 – DI8

Indicates the status of the Discharge / Suction refrigerant valves D1, D2, S1, S2.

Active Alarms Screen

Figure 22. Active alarms for the chiller/heater

The active alarms screen lists all active (triggered) and non-active alarms in tabular form. See following figure.

Information presented in this screen in tabular form includes:

Select

This column indicates if the alarm is selected or unselected for acknowledgment or resetting.

Action

This column brings up more details upon tapping. “Action” applies for each module compressor alarms/ warnings such as Compressor Warning, Compressor Failure, Compressor Lockout, and Compressor CoreSense Failure.

Name

This column displays the descriptive title each alarm.

Status

This column displays the alarm state. There are four possible states for any alarm:

• TRIGGERED (ACTIVE) / NOT ACKNOWLEDGED

• TRIGGERED (ACTIVE) / ACKNOWLEDGED

• NOT TRIGGERED / NOT ACKNOWLEDGED

• NOT TRIGGERED / ACKNOWLEDGED

Both active and non-active alarms can be acknowledged. When a non-active alarm is acknowledged, it can be reset, which immediately removes it from the active alarms list.

When all non-active alarms have been acknowledged, only active alarms will remain on the list.

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State

This column displays the numeric value of each alarm.

An alarm is considered “Active” (Triggered) if “State” = 1, meaning that it is still active in the PLC.

An alarm is considered “Not Active” (Not Triggered) if “State” = 0, and it can be reset using Reset button.

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Description

This column describes all refrigeration cycle related alarms, and captures the instantaneous values of the following parameters: Discharge Pressure, Suction Pressure, EXV Position, Suction Superheat Temperature, Evaporator Leaving Water Temperature, Condenser Leaving Water Temperature, Source Leaving Water Temperature. This functionality applies to the following alarms: Compressor Failure, Compressor Lockout, Evaporator Freeze Alarm, Source Freeze Alarm, Evaporator Flow Alarm, Condenser Flow Alarm, Source Flow Alarm, Discharge Pressure and Suction Pressure.

Time

This column is the date-time stamp indicating exactly when the alarm occurred.

Check / Uncheck All

This button is used for selecting and deselecting all listed alarms with a single action.

‘Hide Not Triggered’ Drop Down Menu

This is used to either list all the alarms, both active and non-active, or only active alarms (the default selection).

Ack

Pressing this button acknowledges the alarm and removes it from the active alarms list.

Reset

Pressing this button allows a specific non-active alarm to remain on the active alarms list.

Save

Pressing this button saves the changes made to the active alarms list. Any changes that are made without saving will be lost.

Reset PLC

This button, located in the upper right portion of the screen, resets the active alarms in the primary microprocessor, so they could be further acknowledged or reset on the touchscreen interface.

Only those alarms for which the alarm condition is ‘false’ can be reset in the microprocessor controller; otherwise, the RESET PLC button will have no effect.

Example: An evaporator freezing alarm occurs when the evaporator Leaving Water Temperature (LWT) drops below the freezing alarm threshold, which is 36.0 °F (2.2 °C). The alarm occurs and:

• The alarm can be reset when the reset PLC button is pressed and the evaporator LWT is below the freezing alarm threshold. The freezing alarm threshold equals 36.0 °F (2.2 °C) by default.

• The LWT is below 36.0 °F (2.2 °C). The alarm cannot be reset until the evaporator LWT exceeds 37.0 °F (2.8 °C).

• The LWT is above 37.0 °F (2.8 °C). Pressing the reset PLC button clears the alarm.

A list of all chiller/heater alarms are found in

Alarm List,” p. C–1

“Active

Alarm History

On the active alarms screen, pressing the alarm history button displays the alarm history screen.

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Figure 23. Alarm history

OOppeerraattiinngg PPrroocceedduurreess

The alarm history screen displays the history of alarms recorded by the primary microprocessor (See Figure

23, p. 45

Sort History Items

The alarm history list can be sorted by any column in ascending or descending order by tapping the corresponding column heading. The triangle that appears next to the heading indicates which column is being sorted and the direction of sorting.

Sorting is applied to the alarm time column in ascending order by default, which is indicated when the triangle is pointing up. Ascending order for the alarm time column requires that earlier records appear on the list first. For all other columns, alphabetical sorting applies.

Duration

Allows the selection of the time period for which the alarm history is displayed. Once the selection is made from the drop-down menu, pressing the REFRESH button updates the list and the ‘From’ and ‘To’ timestamps will update accordingly.

Time

This is the time stamp that is displayed when the alarm state changes.

Status

This is the same as “Status” for active alarms.

State

This is the same as ‘State’ for active alarms.

Trend Screen

When on the primary module screen, pressing the trend button displays the trend screen. There are two trend screens: cooling trend screen and heating trend screen.

Since only system variables are tracked, the trend screens apply to the primary module only. Both the cooling trend and heating trend screens display three trends:

• Chilled water inlet and outlet temperatures.

• Hot water inlet and outlet temperatures.

• Cooling and heating demand.

Cooling and Heating Demand

Trends can be viewed in real time as well as for the previous seven days. Each variable is trended every three seconds. Trending data is stored in internal memory. See

Both the cooling trend and heating trend screens have similar but independently managed controls and trends for viewing.

Figure 24, p. 46.

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Figure 24. Cooling trend screen

Cooling Trend Screen

Use the left and right scrolling buttons to switch between the cooling trend and heating trend screens.

Trending variables instantaneous values according to cursor position. Current cursor time stamp is displayed as well.

This is the drop-down text box used to select the trending time span. It is used to for focusing on a specific time period. Options available for selection include:

Figure 25. Time span selection options menu

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Heating Trend Screen

Use the left and right scrolling buttons to switch between cooling trend and heating trend screens. The heating trends screen is similar to the cooling trends screen.

Figure 26. Heat trend screen

OOppeerraattiinngg PPrroocceedduurreess

Operator Tasks

Before operating the unit, ensure that all compressor refrigeration service valves are fully back-seated counterclockwise.

NNOOTTIICCEE

CCoommpprreessssoorr DDaammaaggee!!

FFaaiilluurree ttoo pprrooppeerrllyy bbaacckk--sseeaatt rroottaalloocckk vvaallvveess ccaann ccaauussee ccoommpprreessssoorr ffaaiilluurree.. VVeerriiffyy tthhee cciirrccuuiitt bbrreeaakkeerrss oonn tthhee mmoodduullee eelleeccttrriiccaall ppaanneell aarree ttuurrnneedd ttoo OOFFFF ppoossiittiioonn pprriioorr ttoo aappppllyyiinngg ppoowweerr..

Normal Power Up

The following procedure is used for a startup resulting from scheduled seasonal or programmed cold shut down of the chiller/heater.

WWAARRNNIINNGG

HHaazzaarrddoouuss VVoollttaaggee ww//CCaappaacciittoorrss!!

FFaaiilluurree ttoo ddiissccoonnnneecctt ppoowweerr aanndd ddiisscchhaarrggee ccaappaacciittoorrss bbeeffoorree sseerrvviicciinngg ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. DDiissccoonnnneecctt aallll eelleeccttrriicc ppoowweerr,, iinncclluuddiinngg rreemmoottee ddiissccoonnnneeccttss aanndd ddiisscchhaarrggee aallll mmoottoorr ssttaarrtt//rruunn ccaappaacciittoorrss bbeeffoorree sseerrvviicciinngg.. FFoollllooww pprrooppeerr lloocckkoouutt// ttaaggoouutt pprroocceedduurreess ttoo eennssuurree tthhee ppoowweerr ccaannnnoott bbee iinnaaddvveerrtteennttllyy eenneerrggiizzeedd.. VVeerriiffyy wwiitthh aa CCAATT IIIIII oorr IIVV vvoollttmmeetteerr rraatteedd ppeerr NNFFPPAA 7700EE tthhaatt aallll ccaappaacciittoorrss hhaavvee ddiisscchhaarrggeedd..

IImmppoorrttaanntt:: This start-up procedure is not to be used for

the first-time initial startup for a newly installed chiller. See Preparation for Initial Startup in the Installation section of this manual for instructions regarding that situation.

1. De-energize the chiller/heater using standard lockout/tagout procedures.

2. Using a known operational voltage meter, test and confirm the chiller/heater is de-energized before proceeding further.

3. Inspect power distribution fuses and overload settings to verify they are correct.

4. Verify that the oil level is correct in each compressor using the compressor sight glass.

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NNoottee:: See recommended inspection interval in the

maintenance section of this manual.

NNOOTTIICCEE

CCoommpprreessssoorr FFaaiilluurree!!

5. Verify that pressure and temperature switches are closed.

6. Restore power to all modules.

7. Inspect refrigerant pressures for each module using the touchscreen interface panel.

8. Verify that pressure switches and thermostats have the correct cut-in and cut-out settings using the touchscreen interface panel.

9. Verify chiller/heater water flow to condenser and evaporator.

10. Monitor and record temperature and refrigerant pressures registering on the touchscreen interface panel.

Emergency Power Shutdown

The chiller does not include a disconnect to turn off the high voltage to the modules. As per NFPA 70, The National Electrical Code, a disconnect must be installed within the line of sight of the electrical and control panel. Should an emergency condition arise, the disconnect must be opened to shut down all voltage to the chiller/heater.

There are several ways to interrupt power to all or part of the chiller/heater:

• Disconnect the primary power source from the building that feeds electricity to the chiller. This occurs in sudden emergencies (usually weatherrelated) or planned maintenance shut-downs.

• Press the panel disconnect switch on the exterior door of the chiller/heater’s main power distribution panel, if so equipped.

• Move the circuit breaker switch to the OFF position (CB-1 and CB-2) on the power distribution panel. This cuts power to all of the chiller/heater modules.

• Move the circuit breaker switch to the OFF position (CB-1 and CB-2) on a module’s electrical and control panel. This cuts power to the compressors in a single module. It does not cut power to electrical and control panel or other chiller/heater modules.

• Press the SYSTEM ON button on the touchscreen interface panel that is built into the power distribution panel door.

NNoottee:: Pressing the SYSTEM ON button on the

touchscreen interface panel does not de-energize the chiller or the high voltage current into each module’s electrical and control panel. This action sends a command to the controller in each module’s compressors to discontinue electrical current to that component.

Water Quality Guidelines

The chiller is equipped with high efficiency compact brazed plate heat exchangers (BPHX). Water quality must be maintained periodically by the end user to avoid scaling and corrosion inside the heat exchangers.

Table 10. Water quality guidelines

Element /Compound/

Property

Conductivity < 500 μS/cm

Total Hardness 4.5 - 8.5 dH°

Free Chlorine

Ammonia (NH

Sulphate (SO

Hydrogen Carbonate (HCO

(HCO3–) / (SO

(Ca + Mg) / (HCO3–)

Chloride (Cl-) < 200 ppm

Notes:

1. Total Hardness/corrosion: Water with high hardness can cause corrosion problems due to its high ion content (Ca+2, Mg+2, Fe+2) which also means a high electrical conductivity and a high total dissolved solid (TDS). For this reason, too high hardness values should be avoided, not only due to higher risk of scaling, but also for corrosion risk. On the other hand, soft water, but not necessarily cation exchange softened water, may in contrast have a low buffering capacity and so be more corrosive. If the hardness values are outside the recommended range, other parameters such as oxygen content, conductivity, and pH values should be considered to evaluate the corrosion risk

2. Fe3+ and Mn4+ are strong oxidants and may increase the risk for localized corrosion on stainless steels in combination with brazing material copper.

) < 0.5 ppm

2–

) < 100 ppm

3–

2–

)

Value/Unit

7.5 - 9.0

< 1.0 ppm

60 – 200 ppm

> 1.5

> 0.5

Monitor Water Quality

Maintaining water/glycol mixture quality and cleanliness is critical to chiller/heater health and maintainability. Strainers should be checked and cleaned on a regular basis. Water/glycol mixture samples should be taken and tested by a professional lab. The results will enable the accurate adjustment of

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quality thereby increasing the operational life of the chiller/heater.

NNoottee:: Trane will not validate the chiller warranty if the

proper water/glycol mixture composition and quality is not maintained.

Protect the chiller/heater from freezing, particularly if the chiller has a set point that is lower than the freezing point of the water/glycol mixture in the chiller/heater. The chiller/heater is designed to operate with a maximum propylene glycol concentration of 50%. See

Table 11, p. 49, for the effects on the chiller when

Table 11, p. 49 shows the capacity reduction and the

pressure drop that occurs when higher concentrations of glycol are used.

Maintain Glycol Level

When the chiller has a water set point that is below the freezing point of the water/glycol in use, take precautions against freezing.

The glycol concentration should be based on the lowest fluid design temperature. See , provides guidelines for adding propylene glycol.

operating with other glycol concentrations.

Table 11. Glycol performance impact factors

Range Factor

Propylene Glycol

Concentration

Lowest Ambient Temperature 10 °F (-12 °C) -4 °F (-10 °C) -20 °F (-29 °C)

Recommended Minimum

Leaving Fluid Temperature

Leaving Temperature

70 °F (21 °C)

60 °F (15.6 °C)

55 °F (13 °C)

50 °F (10 °C)

Capacity

Reduction

Factor

0.96 1.27 0.93 1.43 0.91 1.63

0.95 1.31 0.92 1.47 0.90 1.68

0.95 1.31 0.92 1.50 0.89 1.73

0.94 1.33 0.91 1.51 0.88 1.75

Glycol Concentration Percentages and Performance Impact

30% 40% 50%

25 °F (-4 °C) 10 °F (-12 °C) -10 °F (-23 °C)

Pressure Drop

Factor

Capacity

Reduction

Factor

Pressure Drop

Factor

Capacity

Reduction

Factor

Pressure Drop

Factor

A 10% to 50% solution of glycol should be added to prevent pipe corrosion regardless of the fluid temperature. Propylene glycol has corrosion inhibitors that protect piping and components from corrosion and buildup of rust and other deposits. Trane recommends against using water/glycol solution in excess of 50% regardless of the ambient temperature conditions.

NNOOTTIICCEE

EEqquuiippmmeenntt DDaammaaggee!!

FFaaiilluurree ttoo ffoollllooww iinnssttrruuccttiioonnss bbeellooww ccoouulldd rreessuulltt iinn ppeerrmmaanneenntt ddaammaaggee ttoo ppuummpp aanndd iinntteerrnnaall ccoooolliinngg ssuurrffaacceess.. DDoo nnoott uussee aauuttoommoottiivvee aannttiiffrreeeezzee..

NNoottee:: If glycol-free solutions are mandated at the

chiller site, special inhibitors are available for rust prevention, mineral deposit inhibition, and biological suppression. Adding these inhibitors to the water solution is strongly recommended.

Heaters, heat tracing cable, and closed cell insulation can be installed on any exposed “wet” chiller components and tank and pump modules for protection against freezing in low ambient temperature and low refrigerant pressure conditions. However, the best freeze prevention is using the appropriate

concentration of glycol. Trane does not warranty any component that fails due to freezing.

Prevent Freezing

Many liquids expand in volume upon cooling. This expansion may cause pipes and other enclosed systems containing a liquid to rupture or burst when exposed to low temperature conditions. Burst protection is needed to protect piping and other enclosed systems when they are inactive as they could rupture due to expansion during cold weather or low refrigerant pressure.

Freeze points and burst points of glycol-water solutions are shown in .

In order to maintain a high quality glycol solution, the water used in the glycol mixture must have very few impurities. Impurities in the water can increase metal corrosion, aggravate pitting of cast iron and steel, reduce the effectiveness of the corrosion inhibitors, and increase the depletion rate of the inhibitor package.

To assure inhibitor effectiveness, the levels of chlorides and sulfates in the water should not exceed 25 ppm each. The total hardness in terms of calcium carbonate should be less than 100 ppm. For best long-term results, de-ionized or distilled water is recommended.

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OOppeerraattiinngg PPrroocceedduurreess

Trane can provide concentrated solutions of Dowfrost, propylene glycol, or premixed solutions for use with the chiller.

NNOOTTIICCEE

EEqquuiippmmeenntt DDaammaaggee!!

Propylene Glycol

IImmppoorrttaanntt:: The fluid volume increases as this slush

forms and the temperature cools, flowing into available expansion volume in the chiller/heater. If the concentration of glycol is sufficient, no damage to the chiller/ heater from fluid expansion should occur within the temperature range indicated in

Figure 27, p. 50. When liquids are cooled

they eventually either crystallize like ice or become increasingly viscous until they fail to flow and set up like glass. The first type of behavior represents true freezing. The second is known as super-cooling. Glycols do not have sharp freezing points. Under normal conditions, propylene glycol sets to a glass-like solid, rather than freezing. The addition of glycol to water yields a solution with a freezing point below that of water. This has led to the extensive use of glycolwater solutions as cooling media at temperatures appreciably below the freezing point of water. Instead of having sharp freezing points, glycol-water solutions become slushy during freezing. As the temperature falls, the slush becomes more and more viscous and finally fails to flow.

The calculations in this table are most accurate for Dowfrost (propylene glycol) and Dowtherm (ethylene glycol) branded products. Consult your local supplier or engineering contractor for more precise recommendations.

The precise concentration of glycol for a particular chiller/heater is affected by several key factors such as ambient temperature extremes, entering and leaving water temperatures, and chiller/heater size. A chiller’s optimum glycol concentration is modified by these considerations as reflected in capacity correction factors are the “best informed estimates” for chillers with copper evaporators. The percentages may vary depending on the materials and

Table 11, p. 49. These

alloys of the heat exchangers, total surface area, the amount of present or future fouling, and the brand of glycol used.

Table 12. Freeze and burst protection chart

Water/Glycol Temperature

20 °F (-7 °C) 18% glycol mixture 12% glycol mixture

10 °F (-12 °C) 29% glycol mixture 20% glycol mixture

0 °F (-17.8 °C) 36% glycol mixture 24% glycol mixture

-10 °F (-23 °C) 42% glycol mixture 28% glycol mixture

-20 °F (-29 °C) 46% glycol mixture 30% glycol mixture

Freeze

Protection

Burst Protection

Storage Provisions

The chiller controls are designed for storage in ambient temperatures from -20 °F (-29 °C) to 145 °F (63 °C) with relative humidity from 0% to 100%. The glycol should be removed from the chiller if the unit is to be stored for extended periods. Although fluids can be drained via the plug in the bottom of the evaporator, the inhibitors in an approved glycol solution will best protect the surfaces of the evaporator against oxidation if the glycol remains inside the chiller during storage.

Figure 27. Water/Glycol concentration freezing points (in degrees fahrenheit)

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Controls Interface

Chiller Controls

Each system is provided with a touchscreen interface panel that is used to turn the chiller/heater on and off, adjust set points, clear alarms, and perform detailed set-up of the microprocessor controllers.

The primary module contains the primary microprocessor controller. The primary

Figure 28. PolyTherm chiller/heater primary module control panel

Each chiller/heater control system includes operational switches for each compressor; high- and low-pressure transmitters to indicate refrigeration pressures in each circuit; high and low refrigeration pressure alarms (including shutting shut down the responsible compressors); anti-short cycling compressor timers; minimum compressor run timers; and connection to the BAS. See Figure 28, p. 51.

Power Distribution

There are two different electrical panels used in the PolyTherm chiller/heater. The main power distribution panel receives power from the building source and distributes it to the individual modules. The module electrical and control panel receives power from the power distribution panel and provides power to individual electrical components.

microprocessor communicates with the secondary microprocessor in each module via a local network communications protocol. The primary module also includes a phase monitor to protect against low voltage, phase imbalance, phase loss, and phase reversal conditions.

HHaazzaarrddoouuss VVoollttaaggee!!

Main Power Distribution

The power distribution panel distributes electricity from the external building power supply. It also houses breakers, phase monitor, and a touchscreen interface.

WWAARRNNIINNGG

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CCoonnttrroollss IInntteerrffaaccee

Figure 29. PolyTherm power distribution panel

Panel Disconnect

Some PolyTherm chiller/heater systems are optionally equipped with a panel-mounted disconnect switch installed on the outside of the power distribution panel (or on each module’s electrical and control panel if the chiller/heater has power supplied directly to each individual module). The disconnect switch must be

Figure 30. PolyTherm primary module high voltage

turned to the off position before the panel can be opened for service.

Module Electrical Panel

From the power distribution panel, power is fed to the individual modules in the chiller/heater and connects to each module’s electrical panel. See the following figures.

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Page 53

Figure 31. PolyTherm secondary module high voltage

CCoonnttrroollss IInntteerrffaaccee

Touchscreen Interface Panel

The touchscreen interface panel is the primary means for controlling and monitoring the system for operator and maintainer. An operator touch screen interface panel is installed on the primary module to allow operator adjustment of user set points and alarm monitoring. See

Figure 32. PolyTherm chiller/heater touchscreen interface panel

Figure 32, p. 53.

Microprocessor Control System

PolyTherm chiller/heater models employ an all-digital data control system to control and report key system settings and indicators.

Primary Microprocessor Controller

A microprocessor controller is used to control tasks and automate functions. One microprocessor controller is designated the primary controller. All others are called secondary controllers. The primary

microprocessor controller rotates the lead compressors every 168 system operating hours. The primary controller reads all analog and fault port values from the secondary controllers and passes these values to the Building Automation System (BAS). This controller must have the optional BAS card installed to connect to a building automation system.

Figure 33. PolyTherm chiller/heater controller

Secondary Microprocessor Controller

In a normal configuration, a secondary controller controls the single module to which it is dedicated. The distributed design of the microprocessor controller system enables the chiller/heater to operate in the event the primary microprocessor controller fails. The system automatically fails-over to distributed primary control where each secondary controller operates its own module in the normal fashion, but lacks the ability to rotate the lead compressors every 168 system operating hours. See Figure 33, p. 53.

Microprocessor Controller Functions

The microprocessor provides the following functions and alarms:

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CCoonnttrroollss IInntteerrffaaccee

• Adjustable fluid temperature set point

• Multiple stage compressor control, including compressor rotation to provide balanced compressor usage and wear

• Reset temperature control set point based on decreased load

• High and low fluid temperature alarm set points

• Fluid inlet and outlet temperature

• Suction and discharge refrigeration pressures on each refrigeration circuit

• Compressor run status

• Current alarm status

• Demand load

• Compressor run hours

• Running count of compressor starts

• Alarm logging with the time/date of the previous 1,000 alarms

• Remote start-stop input

• Dry contact for general alarm

Thermal Capacity

The thermal capacity of the chiller/heater modules is dependent on the leaving temperature of the chilled water/glycol mixture, maintaining a minimum flow of water through the heat exchangers. In applications where it is desired to operate with a lower flow rate or higher temperature change, consult Trane technical support for recommendations.

Electronic Controls

The PolyTherm Chiller/Heater is provided with a robust set of controls and indicators to monitor system performance and notify operators if problems arise. See

“Operating Principles,” p. 24 for a complete

description of the touchscreen interface.

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Sequence of Operations

This manual describes a typical water-cooled chiller/ heater system with few, if any, optional components or devices attached.

Description

Simultaneous heating and cooling modules are built for single point power supply connection to a central distribution block inside the power distribution panel and incorporates circuit breaker overload protection for each module. Electrical supply to each module consists of flexible conduit from the power distribution panel. No electrical connection to a module carries the load of only that module. The electrical supply conduit is factory assembled and shipped with each module for field connection into the power distribution panel.

valves on the evaporators, condensers and source/sink heat exchanger.

When in cooling mode, the diverting valves direct the load chilled fluid to the evaporator and simultaneously direct the source/sink fluid to the brazed plate heat exchanger operating as a condenser.

When in heating mode, the diverting valves direct the load heating fluid to the condenser and the source/sink fluid to the source/sink brazed plate heat exchanger as refrigerant has been redirected such that it operates as an evaporator.

When in simultaneous heating and cooling mode, the diverting valves direct the load heating fluid to the condenser and the load cooling fluid to the evaporator.

Electronic valves on the brazed plate source/sink heat exchanger outlet modulate to control refrigeration head pressure. Electronic valves on the evaporator and condenser outlet also allow for variable flow.

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Chiller/Heater Performance Data

This manual uses a typical 120-ton water-cooled chiller/ heater consisting of four modules with brazed plate heat exchangers and condensers for example

purposes. The model number and a chiller/heater’s precise configuration can be found on the model nameplate. See

“Model Number and Coding,” p. 8.

Table 13. PolyTherm chiller/heater example specifications)

Chiller/Heater (Four 30-ton Modules (TPWCCMV0300T3-MM-HR-3HX))

Evaporator Type: Brazed plate Fluid: Water

Condenser: Brazed plate Fluid: Water

Source/Sink Hx: Brazed plate Fluid: 30% Glycol

Cooling Mode

Load

EFT = 55 °F (13 °C) LFT = 45 °F (7 °C) EFT = 65 °F (18 °C) LFT = 77 °F (25 °C)

Flow Rate: 600 gpm Flow Rate: 650 gpm

Pressure Drop: 3.8 psi Pressure Drop: 4.2 psi

Cooling Capacity: 3,480,000 btu/hr (290 tons)

Heating Mode

Load

EFT = 100 °F (38 °C) LFT = 120 °F (49 °C) EFT = 60 °F (16 °C) LFT = 50 °F (10 °C)

Flow Rate: 300 gpm Flow Rate: 424 gpm

Pressure Drop: 1.6 psi Pressure Drop: 2.4 psi

Cooling Capacity: 2,968,000 Btu/hr (870 kW)

Simultaneous Heating and Cooling Mode

Load (Cold) Load (Hot)

EFT = 55 °F (13 °C) LFT = 45 °F (7 °C) EFT = 100 °F (38 °C) LFT = 120 °F (49 °C)

Flow Rate: 476 gpm Flow Rate: 346 gpm

Pressure Drop: 2.7 psi Pressure Drop: 2.0 psi

Cooling Capacity: 2,380,000 Btu/hr (198.3 tons)

Heating Capacity: 3,480,000 Btu/hr (1,010 kW)

Key: Btu/hr = British Thermal Units per hour; EFT = Entering Fluid Temperature; gpm = gallons per minute; Hx = Heat exchanger; kW = kilowatt; LFT = Leaving Fluid Temperature; psi = pounds per square inch.

Source/Sink Heat Exchanger

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Maintenance Procedures

Maintenance Strategy

The primary goal of preventive maintenance is to avoid the consequences of failure of equipment. This may be by preventing the failure before it actually occurs which preventive maintenance helps to achieve. It is designed to preserve and restore equipment reliability by replacing worn components before they actually fail. In addition, operators can record equipment operating conditions, temperatures, and pressures so they know to replace or repair worn parts before they cause chiller failure. The ideal maintenance program predicts and prevents unnecessary and costly repairs and chiller down time. Trane chillers are designed for ease of access with a premium placed on locating key components to facilitate visual inspection and handson verification.

One approach to chiller maintenance envisions three levels of maintenance effort reflecting frequent, periodic, and scheduled maintenance tasks, with each

Figure 34. An approach to chiller/heater maintenance

level building on the previous level. A daily or weekly “health check” involves habitual visual and manual inspections of the components of the chiller so that anomalies become evident when they occur. Weekly or monthly periodic maintenance involves cleaning specific components and inspecting glycol and lubrication fluids. Finally, since all components will eventually wear out, a prudent maintenance strategy will anticipate and schedule replacement or rebuilding of critical components before they fail and require emergency response to keep chillers operational. See below figure.

Maintenance for HVAC equipment and facilities can include a “preventive maintenance checklist” which includes small checks which can significantly extend service life. Other considerations such as weather and equipment age are taken into account; maintenance and equipment replacement is often performed before the hottest time of the year.

Power Disconnect Switch

Some Chiller/heater units are optionally equipped with a panel-mounted disconnect switch installed on the outside of the power distribution panel (or on each module’s electrical and control panel if the chiller has power supplied to each individual module). The disconnect switch must be turned to the off position before the panel can be opened for service. When the panel door is open, power can be reconnected by turning the handle located on the inside of the panel to the ON position.

ARTC-SVX005B-EN

Appropriate Arc Rated PPE must be worn when the panel door is open and the unit is energized.

Page 58

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Inspection and Maintenance Schedule

Proactive measures should be taken to prevent potential problems with the chillers. These include maintaining a operational log and conducting weekly, quarterly, and annual inspections of the chiller/heater. See following table.

nneecceessssaarryy PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)),, iinn aaccccoorrddaannccee wwiitthh NNFFPPAA7700EE ffoorr aarrcc//ffllaasshh pprrootteeccttiioonn,, PPRRIIOORR ttoo eenntteerriinngg tthhee ssttaarrtteerr ppaanneell ccaabbiinneett..

Daily

A daily visual inspection can reveal obvious problems. Keep notes of the chiller performance:

NNOOTTIICCEE

CCoommppoonneenntt DDaammaaggee!!

• Log pressures and temperatures.

• Visually inspect of the unit. Check for noises, as well as, oil or refrigerant leaks.

• Inspect touchscreen display for alarms.

• Inspect modules for obvious leaks.

• Listen for any atypical noises or vibrations.

Table 14. Recommended chiller service intervals

Task

Visually inspect the chiller/heater Daily

Log pressure and temperatures Daily

Inspect touchscreen interface panel for alarm history Weekly

Clean strainers on the inlet water pipe Monthly

Check the compressor oil level sight glass Monthly

Confirm the glycol concentration Monthly

Confirm the refrigeration pressures Monthly

Check the refrigeration liquid line sight glass Monthly

Inspect refrigerant pressures and temperature set points Quarterly

Inspect superheat (10 °F to 12 °F [5°C to 6°C]) and sub-cooling temperatures (10°F to 15°F [5°C to 8°C]) Quarterly

Inspect the evaporator entering and leaving evaporator temperature Quarterly

Collect water/glycol mixture sample for analysis Quarterly

Inspect crankcase heaters and observe proper operation Quarterly

Inspect water piping for signs of leaks Quarterly

Inspect refrigerant piping for oil or refrigerant leaks Quarterly

Observe refrigeration operating pressures Quarterly

Confirm motor amperage draw and voltage Quarterly

Confirm chiller/heater superheat and sub-cooling Quarterly

Check for worn or burned contactors Quarterly

Inspect all electrical connections and fuses Annually

Inspect each compressor for refrigerant pressures, overheating, oil leaks Annually

Inspect compressor terminals for pitting, corrosion, and loose connections Annually

Inspect compressor oil level Annually

Frequency

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Table 14. Recommended chiller service intervals (continued)

MMaaiinntteennaannccee PPrroocceedduurreess

Task

Confirm and record compressor amperage draw and voltage Annually

Compare water/glycol flow against design specifications Annually

Tighten compressor rotalock nuts Annually

Weekly

Weekly inspection is a continuation and elaboration of daily best practice:

• Inspect touchscreen interface panel for alarm status and additions to the alarm history. (Do not clear alarms as this is a very important performance record if troubleshooting problems occur.)

• Listen for excessive vibrations or motor noise. This usually signals a loose brace or section of piping.

• Measure all refrigerant static pressure on any idle circuits. Record any significant changes or reductions in pressure.

• Clean strainers weekly during initial weeks after initial start up until water quality has been reliably established. Thereafter, inspect and clean strainers at least monthly .

Monthly

The monthly maintenance inspection examines many items that generally require frequent attention. This routine event identifies small problems early before they can become big problems requiring serious repair and refurbishment:

1. Remove the strainer on the inlet water pipe to the chiller/heater and verify that it is clean and free of debris.

2. The 30 Mesh screen is made of SAE Grade 304 stainless steel. Clean the interior of the end cap (or service cap), and the gasket using a soft natural bristle brush and tap water. If fine particles cannot be removed with the water stream, use a mild detergent and a non-abrasive brush to remove them.

3. Check the compressor oil level sight glass. The oil should always be clear and free-flowing. Any milky or “slow rolling” effect indicates that liquid refrigerant is making its way back into the compressor and will cause premature compressor failure.

NNOOTTIICCEE

EEqquuiippmmeenntt DDaammaaggee!!

4. When the compressor is not operating, the oil level should be at least at the bottom of the sight glass, up to two-thirds full. When the compressor is operating, the oil level will normally be at the bottom of the sight glass, or even below, but it must be visible.

5. Low oil sight glass conditions could signify an undercharged chiller that lacks proper refrigerant velocity to return oil to the compressor sump. Eventually, dry compressor starts could occur causing premature compressor failure. This may indicate that some oil has been lost from a previous refrigerant leak repair. The compressor data label indicates the correct oil type and quantity with which it should be filled.

NNoottee:: A flashlight may be required to see the oil

churning in the sump of the compressor. Adjusting the line of sight may be necessary to visually inspect the oil in the compressor sump during operation. At a minimum, the oil must be seen churning in the compressor sump. It should be clear.

NNOOTTIICCEE

CCoommpprreessssoorr FFaaiilluurree!!

6. Check the glycol concentration using a refractometer.

NNOOTTIICCEE

CCoommpprreessssoorr DDaammaaggee!!

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7. Check the refrigeration pressures.

8. For R410A refrigerant, low pressure refrigeration gauge should read 120 to 160 psi and high pressure refrigeration gauge should read 300 to 450 psi.

IImmppoorrttaanntt:: Suction pressures below 90 psi (R410A) is a

clear sign of insufficient refrigerant charge, low water flow, refrigeration obstruction, or valve closed units running only water.

Frequency

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9. For R134A refrigerant, low pressure refrigeration gauge should read 35 to 50 psi and high pressure refrigeration gauge should read 100 to 120 psi.

IImmppoorrttaanntt:: For R134A, suction pressures below 25 psi

can cause extensive damage to a compressor.

10. Check the refrigeration liquid line sight glass for persistent bubbles (“flashing”) in conjunction with a half-full glass may represent a low refrigerant charge.

NNOOTTIICCEE

EEqquuiippmmeenntt DDaammaaggee!!

NNoottee:: Bubbles in the sight glass do not necessarily

indicate loss or lack of refrigerant charge. Bubbles (commonly know as ‘flashing’) will occur until the expansion valve settles out the refrigerant flow. If the refrigeration pressures are in the normal range, the unit is most likely adequately charged. ‘Flashing’ could also indicate excessive superheat adjustment of the thermal expansion valve.

9. Inspect refrigerant piping circuit for signs of oil or refrigerant leakage. Conduct “sniffer test” to find refrigerant leaks. Inspect all pressure switch bellows.

10. Tighten all refrigeration piping connections (e.g. rotalocks stems and packing nuts, Schrader valves, and ball valves).

11. Install a manifold and gauge set to observe chiller/ heater’s refrigeration operating pressures.

a. Verify that the pressure controls (low pressure

and high pressure switches) are “cutting in” and “cutting out” at the appropriate pressures.

b. Verify refrigerant charge by recording the

superheat and sub-cooling temperatures and visually inspect the sight glass..

c. Observe head pressure for signs of improper

condensing from clogged strainers, or a modulating expansion valve issue.

12. Check compressor motor amperage draws and voltage supplies and maintain a record of those values. Verify that they are within the name plate rating. Also, check for voltage imbalance. The chiller/heater’s phase monitor will open if the voltage imbalance exceeds 4%.

13. Check for excessive wear or burned contacts on motor starters. Replace contacts, if in doubt.

Quarterly

The quarterly maintenance inspection is a comprehensive event that examines all aspects of the chiller to identify early problems before they can damage a chiller and require major repair or refurbishment:

1. Inspect refrigerant pressures and temperature set points.

2. Inspect chiller/heater superheat and sub-cooling. System superheat should be 10 °F to 12 °F (5 °C to 6 °C). System sub-cooling should be 10+ °F (5 °C) depending on the ambient conditions.

3. Inspect the approach evaporative - entering evaporator water/glycol mixture temperature and leaving evaporator water/glycol mixture temperature as well as the condenser approach.

4. Inspect strainers.

5. Collect chilled water/glycol mixture sample for professional analysis. Check for cleanliness. Drain and refill with clean solution if excessive sludge or dirt is present. Flush the chiller prior to refilling.

6. Inspect water/glycol mixture levels. Add glycol as required.

7. If equipped, inspect crankcase heaters for proper operation.

8. Inspect the water piping for signs of leaks at joints and fittings.

Annually

The annual chiller maintenance inspection is critical to the long-term performance of the chiller/heater. Whether a chiller has a service life of 15 years or 30 years is almost entirely dependent upon how consistently and how diligently the annual maintenance inspection and tasks are performed. The annual event is a comprehensive inspection that examines all aspect of the chiller/heater to identify and repair small problems before they can become major issues that damage a chiller and require significant repair or refurbishment.

1. Inspect all electrical connections for damage and ensure terminals are tight. Inspect all contactors for pitting and corrosion and replace as necessary.

WWAARRNNIINNGG

HHaazzaarrddoouuss VVoollttaaggee!!

2. Inspect fuses to ensure they are secure, of correct amperage ratng, undamaged and functioning.

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3. Energize each compressor and check refrigerant pressures, signs of overheating, and oil leaks. Check chiller/heater for leaks with a halogen leak detector. Inspect packing nuts on rotalock valves (if so equipped), threaded connections of rotalock valves, flared fittings on refrigeration gauge and pressure switches, and access ports on Schrader valves.

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4. De-energize each compressor and inspect terminals for pitting, corrosion, and loose connections.

5. Inspect that the oil level is visible in each compressor and not discolored. Annual oil samples should be taken to be analyzed for destructive acids, corrosive materials, or metal deposits.

6. Inspect and record the compressor amperage draws and voltage.

7. Record water/glycol mixture flow to ensure it meets design specifications.

8. Tighten rotalock nuts at the compressors. The recommended torque is 80 lbf for 2 inch and larger and 60 lbf for rotalock nuts smaller than 2 inch.

9. Inspect all control capillary tubing to ensure that the lines are separated and not vibrating against one another or the frame or housing.

10. Ensure all refrigeration lines are properly supported to prevent vibration from causing premature failure of copper piping.

11. Inspect all insulation on piping and control sensors. Repair and replace as necessary.

12. Inspect entire plumbing system for leaks.

13. Review logged alarms and look for repetitive trends. The chiller/heater can retain the previous 1,000 alarms with time and date of occurrence.

14. If equipped, inspect crankcase heaters to verify proper operation.

15. Sample refrigerant to analyze for moisture or acid.

16. Inspect operating pressures and temperatures and ensure the chiller has a full refrigerant charge.

Maintenance Tasks

The maintenance tasks described herein present the basic, minimal, steps required to successfully complete

a task. Local policies and protocols may require more elaborate procedures with additional checks and inspections.

Freely substitute in those cases where local procedures are more elaborate and complete than the procedures listed in this manual.

Compressors, filter-strainers, and liquid line shutoff valves are accessible on each side or end of the unit.

Inspection Methods

Appropriate inspection for modern chillers can be described as “hands on.” Where possible and appropriate, visual inspection should include touching the component or apparatus being inspection. The sense of touch provides additional feedback regarding temperature, texture, tightness, and dryness that “eyes only” inspection cannot match. Habitually touching each item to be inspected also ensures that items are not subconsciously skipped during the inspection process. For a summary of tasks, see , Recommended Chiller/heater Service Intervals.

WWAARRNNIINNGG

HHaazzaarrddoouuss VVoollttaaggee!!

Critical Cleaning Tasks

Monitor temperature change and pressure drops across the evaporator and condenser circuit to determine the frequency for strainer cleaning. Monitor water quality in the chiller/heater’s closed system to determine the optimum frequency for evaporator cleaning.

Temperature change and pressure drop across the evaporator circuit should be monitored to determine the frequency needed for strainer cleaning. On multiple module chiller/heaters, Trane provides service isolation valves on each evaporator to isolate each strainer for cleaning without disrupting the operation of any remaining modules in the chiller.

Strainer Cleaning Procedure

Strainers at each evaporator are critical for protecting the brazed plate heat exchanger’s small water passages as well as maintaining water/glycol mixture cleanliness. Service valves on the evaporator isolate each strainer for cleaning without interrupting the operation of other modules in the chiller bank. If a tank and pump module is provided, pot strainers are occasionally included on the pumps’ suction lines.

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NNOOTTIICCEE

EEqquuiippmmeenntt DDaammaaggee!!

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1. De-energize power to the module containing the strainer by turning the power OFF at the breaker and/or disconnect.

2. Close the two service isolation valves between the header and the evaporator.

NNoottee:: If this is a variable flow chiller, the HX outlet may

be equipped with an electronic valve that must be manually locked in the closed position.

3. Remove the insulation to expose the roll grooved blind end cap or service cap on the end of the strainer housing. Utilize a short section of hose to connect to the valve on the end cap to relieve pressure and capture fluid. (Dispose of or re-utilize water/glycol mixture according to local protocols.)

CCAAUUTTIIOONN

EExxpplloossiioonn HHaazzaarrdd!!

FFaaiilluurree ttoo rreelliieevvee pprreessssuurree ggrraadduuaallllyy ccoouulldd rreessuulltt iinn mmiinnoorr ttoo mmooddeerraattee iinnjjuurryy aanndd eeqquuiippmmeenntt ddaammaaggee.. WWaatteerr//ggllyyccooll mmiixxttuurree ccaann bbee uunnddeerr ccoonnssiiddeerraabbllee hhyyddrraauulliicc pprreessssuurree iinn tthhee ssttrraaiinneerr hhoouussiinngg.. CClloossee iissoollaattiioonn vvaallvveess ffuullllyy.. RReelliieevvee pprreessssuurree uussiinngg aa bbooiilleerr vvaallee.. UUssee eexxttrreemmee ccaarree ttoo sslloowwllyy rreemmoovvee tthhee eenndd ccaapp aanndd rreelleeaassee pprreessssuurree ggrraadduuaallllyy..

4. Inspect the gasket and service cap for abrasions, tears, excessive dirt, or deterioration. Replace gasket if necessary.

5. Remove the strainer from the housing.

6. Clean the strainer inside and out using a soft natural bristle brush and tap water.

7. Clean the interior of the end cap (or service cap), and the gasket using a soft natural bristle brush and tap water. Apply a light coating of lubrication to the gasket.

8. Re-install the strainer in the housing (large end first). Replace the gasket and end cap and tighten coupling collar securely.

9. Ensure the water/glycol make-up system is operational to replenish the water/glycol mixture lost during the cleaning process.

10. Energize power to the module containing the strainer by turning power ON at the breaker and/or disconnect.

Figure 35. Chiller strainer

Heat Exchanger Cleaning Procedure

Fouling of the heat exchangers will result in a gradual decline in performance of the chiller/heater.

1. Isolate each heat exchanger using the isolation valves.

2. Back flush using the city water supply forced to a drain.

3. A brazed-plate heat exchanger is cleaned by back washing which is forcing a cleansing water/glycol mixture backwards through it at higher than normal pressures.

4. Flushing should take place across a maximum 30 Mesh screen filter/strainer with frequent screen cleaning to remove the debris from the chiller/ heater. Flushing should continue until the screen is clean. After detergent and chemical cleaning, flush the piping for a minimum of one hour with fresh water to remove any remaining cleaning compounds.

Compressor Tasks

The PolyTherm Chiller/Heater has been designed for ease of maintenance access. When properly positioned within a machine room or space, Trane compressors can be quickly removed for repair or replacement. (See

“Site Preparation and Clearances,” p. 11).

Remove Tandem Compressors

Verify that power is disconnected from the chiller/ heater.

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MMaaiinntteennaannccee PPrroocceedduurreess

WWAARRNNIINNGG

HHaazzaarrddoouuss VVoollttaaggee!!

There are two different methods for removing the tandem compressors, depending on the space in which the chiller/heater is installed and the available space overhead or behind the module:

RReemmoovvee TThhrroouugghh tthhee RRooooff PPaanneell:: Where there is a minimum of 48 inches of overhead clearance, remove the eight fasteners attaching the roof panel to the module. Position a lifting device over the tandem compressors.

RReemmoovvee TThhrroouugghh tthhee SSiiddee CC TToopp PPaanneell:: Where there is a minimum of 36 inches of rear clearance, remove the fasteners attaching the upper Side C panel to the module. Position supports on the middle level framing sufficient to slide the tandem compressors out the rear.

1. Close the suction and discharge rotalock valves (if so equipped). Firmly front-seat both rotalock valves clockwise.

NNoottee:: Do not over-tighten as the valve can become

difficult to loosen if over-tightened.

2. Recover the refrigerant from the high and low sides of the compressor using a suitable vacuum recovery machine and clean recovery cylinder.

3. Detach the refrigeration lines from the compressor suction and discharge stubs. Reconnect rotalock valves.

4. Evacuate the compressor using the connections on the suction and discharge stubs to 500 microns or lower (250 to 500 micron range is ideal).

5. Disconnect the compressor power lines and all associated power leads.

6. Observe the oil level in each compressor via the sight glass and confirm the oil level is below the oil line connector opening.

7. Disconnect and cap the threaded oil line on each compressor.

8. Remove the four mounting bolts holding each compressor to the middle frame.

9. Position a lifting device (top removal) or support bracing (rear removal) and ensure there is sufficient clearance as the compressors are moved.

10. Remove the compressors from the module by lifting or sliding.

Install Tandem Compressor

Verify that power is disconnected from the chiller/ heater.

WWAARRNNIINNGG

HHaazzaarrddoouuss VVoollttaaggee!!

1. Position the tandem compressors into the chiller/ heater using the same method used for removal.

2. Position the compressors in position and attach to the frame with eight mounting bolts, washers, and nuts. Tighten nuts with 1/2-inch socket and wrench.

3. Install the rotalock nuts on the compressor suction and discharge connections. The recommended torque is 80 lbf for 2-inch and larger and 60 lbf for rotalock nuts smaller than 2-inch. Tighten with a narrow spud wrench.

4. Evacuate the compressors using the connections on the suction and discharge stubs to 500 microns or lower (250 to 500 micron range is ideal).

5. Attach compressor power lines, all associated power leads, and safeties in the compressor electrical box.

6. Re-connect the threaded oil line on each compressor.

7. Observe the oil level in each compressor via the sight glass and confirm the oil level is visible.

8. Open all rotalock valves (if so equipped) until fully back-seated counterclockwise.

NNOOTTIICCEE

VVaallvvee DDaammaaggee!!

AAppppllyyiinngg eexxcceessssiivvee ffoorrccee wwhheenn ffuullllyy ooppeenniinngg aann iissoollaattiioonn vvaallvvee ccoouulldd ccaauussee vvaallvvee ddaammaaggee.. TThhee vvaallvvee ccoouulldd bbiinndd iinn tthhee ffuullllyy ooppeenn ppoossiittiioonn aanndd pprreevveenntt pprrooppeerr sseerrvviiccee iissoollaattiioonn.. DDoo nnoott aappppllyy eexxcceessssiivvee ffoorrccee..

9. Restore power to the module containing the compressor by turning the circuit breakers CB-1 and CB-2 to the ON position.

10. Observe the newly installed tandem compressors to verify that all connections have been seated and tightened correctly.

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Chiller/Heater Troubleshooting

General Approach to Fault Isolation

Trane manufactures chillers with embedded fault detection and diagnostics in each module’s controller that offers continuous dedicated monitoring to record and report faults as they occur in real time allowing repairs to be performed in a timely manner.

Various faults occurring in a building’s HVAC system can lead to unnecessary energy consumption and poor thermal comfort for a building’s occupants. Fault detection and isolation plays a significant role in monitoring, maintaining, and repairing chillers to improve operator safety and minimize operating costs.

Fault detection is recognizing that a problem has occurred, even if the root cause is not yet known. Fault isolation is the process of reducing potential causes to determine the most likely source of chiller failure.

Controller Diagnostic Codes

Compressor used in Trane chillers are highly automated with digital capability to record and report a range of operating parameters and critical events. This technology can be employed to assist in troubleshooting compressor faults and potential corrective action.

Compressor Flash Codes

The technology in the Trane compressor will communicate an abnormal system condition through a unique flash code:

AALLEERRTT LLEEDD ((YYeellllooww)):: The ALERT LED will flash a number of times consecutively, pause and then repeat the process. The number of consecutive flashes, defined as the flash code, correlates to a specific anomaly or abnormal condition.

TTRRIIPP//LLOOCCKK LLEEDD ((RReedd)):: indicates either a TRIP or LOCK condition.

• TTRRIIPP is indicated by a solid illumination of the LED. This means the compressor is not running and demand is present at the module.

• LLOOCCKK is indicated by a flashing LED correlating to a lock condition in which the module will prevent the compressor from starting.

Flash Code Description

Compressor will report a range of flash codes when specific critical events occur. See .

CCOODDEE 11 – Long Run Time: The module will flash yellow one time when the compressor operates for longer than 18 continuous hours. This is an alert code only and the module will not lockout the compressor for this condition. (This code is inactive for heat pumps.)

CCOODDEE 22 – Compressor (Pressure) Trips: The module will flash yellow two times when the compressor operates from 12 seconds to 15 minutes followed by a trip condition lasting longer than 7 minutes. When four consecutive or ten total CODE 2 events are recorded, the module will lockout the compressor and flash red two times.

CCOODDEE 33 – Pressure Switch Cycling: The module will flash yellow three times when the compressor operates from 12 seconds to 15 minutes followed by a trip condition lasting between 35 seconds to 7 minutes. When four consecutive or ten total CODE 3 events are recorded, the module will lockout the compressor and flash red three times.

CCOODDEE 44 – Locked Rotor Trip: The module will flash yellow four times when the compressor trips within 12 seconds of operation and does not reset and start within 35 seconds. When ten consecutive CODE 4 events are recorded the module will lockout the compressor and flash red four times.

CCOODDEE 55 – Compressor (Moderate Run) Trip: The module will flash yellow five times when the compressor has operated between 15 minutes and 18 hours, followed by a compressor trip lasting longer than 7 minutes. When four consecutive or ten total CODE 5 events are recorded, the module will lockout the compressor and flash red five times.

CCOODDEE 66 – Open Start Circuit: The module will lockout the compressor and flash red six times if the module detects a demand signal in the Y terminal and current in the S winding of the compressor, but no current is detected in the S winding of the compressor for 2 seconds.

CCOODDEE 77 – Open Run Circuit: The module will lockout the compressor and flash red seven times if the module detects a demand signal in the Y terminal and current in the S winding of the compressor, but no current is detected in the R winding of the compressor for 2 seconds.

CCOODDEE 88 – Welded Contactor: The module will flash yellow eight times if it has detected line currents in the S and R windings and demand is absent for 15 seconds.

CCOODDEE 99 – Low Voltage: The module will flash nine times if the module supply voltage drops below 17 Vac for 2 seconds. The module will prevent the compressor from starting until adequate voltage is established.

CCOODDEE 1100 – Over-Current Protection: When the current at the PROT terminal is greater than 2A for 40 milliseconds, the module will flash a CODE10. The red LED will flash 10 times with the yellow LED remaining off. This event will cause a lockout of the compressor and indicates that the module is mis-wired or the contactor coil is shorted to ground.

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CChhiilllleerr//HHeeaatteerr TTrroouubblleesshhoooottiinngg

The following table assists in explaining the alarm codes that appear in the remote interface panel in the

event of an alarm. The alarm history is accessed by pressing the alarm log key. See the following table.

Table 15. Compressor fault code summary

AlertCode Alert Condition Lockout Level

Normal Run Solid Green

CODE 1

Yellow Flash 1

CODE 2

Yellow Flash 2

CODE 3

Yellow Flash 3

CODE 4

Yellow Flash 4

CODE 5

Yellow Flash 5

CODE 6

Red Flash 6

CODE 7

Red Flash 7

CODE 8

Yellow Flash 8

CODE 9

Yellow Flash 9

CODE 10

Red Flash 10

Normal operation, no alarm status.

Long run time. Compressor is running for more than 18 hours at full load. (CODE 1 is disabled in heat pump mode.)

Compressor pressure trip. Compressor runs for 12 seconds to 15 minutes followed by a compressor trip condition lasting longer than 7 minutes.

Pressure switch cycling. Compressor runs for 12 seconds to 15 minutes followed by a compressor trip lasting 35 seconds to 7 minutes.

Locked rotor. Compressor trips within a compressor run time of 12 seconds and does not start within 35 seconds.

Compressor moderate run trip. Compressor runs for 15 minutes to 18 hours followed by a compressor trip lasting longer than 7 minutes.

Open start circuit. Module has detected Y or Y1, and current in the R winding of the compressor and no current in the S winding of the compressor for 2 seconds.

Open run circuit. Module has detected Y or Y1, and current in the S winding of the compressor and no current in the R winding of the compressor for 2 seconds.

Welded contactor. Module has detected line currents in R and S windings, and Y or Y1 is at 0 Vac for 15 seconds.

Low voltage. Module has detected a 24 Vac supply voltage below 17 Vac ±1 Vac for 2 seconds.

Over current protection. PROT terminal has above a 2A input for more than 40 milliseconds.

N/A N/A

4x consecutive, 10x total

4x consecutive, 10 total

10x consecutive Red:Flash 4

4x consecutive, 10x total

1 occurrence Red:Flash 6

1 occurrence Red:Flash 7

N/A N/A

1 occurrence Red:Flash 10

Lockout Indication

Red:Flash 2

Red:Flash 3

Red:Flash 5

Phase Monitor Protection

If the chiller/heater fails to power up, eliminate electrical phase issues by inspecting the phase monitor device located in the power distribution panel.

When all voltages are acceptable and the phase sequence is correct the output relay is energized and the LED glows green. Under-voltages and unbalanced voltages must be sensed for a continuous trip delay period before the relay de-energizes. Reset is automatic upon correction of the fault condition. The output relay will not energize if a fault condition is sensed as power is applied. The LED flashes red during the trip delay, then glows red when the output de-energizes. The LED flashes green/red if phase reversal is sensed.

Table 16. LED phase monitor diagnostic codes

LED Display Indication

Glowing green: All voltages are acceptable and phase sequence is correct.

Flashing red: Trip delay prior to de-energizing. Glowing red: Output has been de-energized upon fault detection.

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Table 16. LED phase monitor diagnostic codes (continued)

LED Display Indication

Flashing red and green: Phase reversal is detected.

No power to phase monitor.

If the phase monitor fails to energize (the LED glows red) check wiring of all three phases, voltage, and phase sequence. If phase sequence is incorrect, the LED flashes green/red. To correct this, swap any two line voltage connections at the mounting socket. No further adjustment should be required.

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CChhiilllleerr//HHeeaatteerr TTrroouubblleesshhoooottiinngg

Symptoms and Solutions

This section lists the most common troubleshooting symptoms and the closest potential solution for each. This is not an exhaustive listing of all potential causes or resolutions, but represents the best direction in which to initiate a solution.

1. Symptom: Compressor will not start

Possible Causes Potential Solutions

Circuit breakers are in the OFF position

Temperature control not in demand Set point has been reached or still within band

Differential pressure switch open due condenser flow switch open Condenser side loss of flow; clean strainer

Refrigerant low pressure switch open

High pressure switch open

Flow switch defective

Compressor overload opened

No high voltage power to contactor

Phase monitor open or tripped Over or under 4% to 8%; loss of leg

NNoottee:: An anti-short cycle timer is included in the

primary microprocessor controller to prevent the compressors from starting until the delay has elapsed. The microprocessor also provides minimum compressor run timers. Take these fixed timer parameters into consideration when conducting a fault isolation process.

Moves circuit breakers to the ON position in the power distribution panel

Low refrigerant level or low pressure event has occurred four times and locked out the circuit

Low flow rate; check for dirty or clogged strainer. Requires a manual reset

Replace FS-1 and FS-2 switch

Allow motor to cool and reset; high amp load/floodback; loose connection, or low refrigerant charge

Check breakers; energize from power distribution panel and module electrical panel; check ON/OFF button in touchscreen interface

2. Symptom: Compressor will not run

Possible Causes Potential Solutions

Compressor not powered Assure all circuit breakers are in the ON position

Circuit breakers open Check circuits and motor winding for shorts or grounds

Tripped circuit breaker

Investigate for possible overloading

Electrical overamp breaker tripped Repair or replace

Defective contactor or coil

System shut down by safety devices

Liquid line solenoid will not open

Motor electrical trouble

3. Symptom: Compressor has excessive noise or vibration

Possible Causes Potential Solutions

Flooding of refrigerant into crankcase

Improper discharge piping support Repair as necessary. Relocate, add, or remove supports

Improper or worn compressor supports Replace supports

Worn compressor Replace tandem compressors

Reset breakers after fault is corrected

Overloads are auto-reset. Monitor to assure the overload does not reoccur

Determine type and cause. Correct fault before replacing parts.

Repair, replace, or correct safety issue (for example, no flow, low pressure)

Check coil for open circuit, short circuit, or burnout. Replace coil or entire valve, if needed

Replace tandem compressors

Low fluid flow across heat exchanger; clogged strainer. Check setting of expansion valve

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CChhiilllleerr//HHeeaatteerr TTrroouubblleesshhoooottiinngg

4. Symptom: Compressor cycles too short

Possible Causes Potential Solutions

Temperature differential set too low (4 °F (22 °C) minimum)

Erratic water thermostat device

Insufficient evaporator water flow Adjust flow rate or clean strainer.

5. Symptom: Compressor oil level in sight glass low

Possible Causes Potential Solutions

Low refrigerant charge Check for leaks and repair. Add refrigerant to proper charge

Leak in refrigerant line Repair leak; add refrigerant

6. Symptom: Low refrigeration suction pressure

Possible Causes Potential Solutions

Low refrigerant charge Check for leaks and repair. Add refrigerant to proper charge

Leak in refrigerant line Repair leak; add refrigerant

Lack of refrigerant Check for leaks. Repair and add charge

Evaporator fouled Clean chemically

Low water flow Increase flow rate

Condensing temperature too low Check source water modulation valve and temperature

Low water temperature Raise set point and increase flow; check design specification

Low discharge pressure Check for refrigerant leak

Expansion valve malfunctioning

Compressor service valves closed Open service valve (if so equipped) counterclockwise completely

Clogged liquid line filter-drier Replace liquid line filter-drier or core

Excessive glycol concentration Drain, refill (deionized water), retest

Liquid line solenoid restricted or faulty Replace solenoid valve coil

Insufficient chilled water flow

Restricted water/glycol line Clean strainers; check manual and electronic expansion valves

Water/glycol mixture contaminated

Evaporator clogged or fouled

Ramp/set temperature set point. Default 5 °F raise up accordingly with low loads.

Replace thermostat assembly.

Increase suction pressure; suction temperature pressure; check for proper superheat; check electronic expansion valve replace if necessary; cabling to stepping motor; contact Trane technical support

Adjust flow rate across evaporator

Intensive cleanup effort needed to identify source of contamination; external filter may be required

Reverse flush with appropriate chemical solutions following approved procedures

7. Symptom: High refrigeration suction pressure

Possible Causes Potential Solutions

Expansion valve opened too far closed Re-adjust to 10° C to 12° C

Excessive refrigerant charge

Entering water temperature excessive Failing tandem compressors; check design specifications

Creates high pressure alarms; recover excess refrigerant; weigh in correct charge as indicated on data plate

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CChhiilllleerr//HHeeaatteerr TTrroouubblleesshhoooottiinngg

8. Symptom: Low refrigerant discharge pressure

Possible Causes Potential Solutions

Suction shut off valve partially closed Open valve

Insufficient refrigerant in chiller/heater Check for leaks. Repair and add R410A or R134A as needed

Low suction pressure See low pressure below

Source heat exchanger modulating valve not properly adjusted or not functioning

9. Symptom: High refrigerant discharge pressure

Possible Causes Potential Solutions

System overcharged with refrigerant Remove excess refrigerant

Non-condensables in chiller/heater Purge non-condensables according to approved procedures

Restricted bypass line Check valves obstructed; flush line; blow out line with dry nitrogen

Discharge shut off valve partially closed Open valve

Liquid line solenoid valve coil Check valve; replace if defective

10. Symptom: Low chilled water temperature

Possible Causes Potential Solutions

Temperature set point set adjusted too low

Water flow rate through evaporator too low Clean strainer; check pump, and differential pressure settings

System controls malfunctioning Check and replace temperature sensors if necessary

Refer to OEM manufacturer manual for default settings; check Y1 electrical output J6

gas

Reset temperature set point to correct design specifications (low return temperatures)

11. Symptom: High chilled water temperature

Possible Causes Potential Solutions

Refrigeration circuits not cooling Check electronic expansion valve for excessive flow; adjust or replace

Load higher than capacity of chiller/heater Refer to chiller/heater design specifications

Low refrigeration charge Conduct leak check on refrigeration system

Load higher than capacity of chiller/heater Refer to chiller/heater design specifications

Low refrigeration charge Conduct leak check on refrigeration system

Temperature sensor not properly installed Check that sensor is properly installed in well

Fouled evaporator Reverse flush evaporator; check strainer for debris

Excessive flow through evaporator Reverse flush evaporator; check strainer for debris; check pump,

electronic expansion valve

valves

12. Symptom: Compressor thermal protector switch open (overloading)

Possible Causes Potential Solutions

Electrical malfunction

Operating beyond design conditions

Discharge valve partially shut Open valve

Check contactors for damage; check wiring for loose connections; replace compressors

Allocate chiller/heater for use within operating capacity. Add equipment

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CChhiilllleerr//HHeeaatteerr TTrroouubblleesshhoooottiinngg

12. Symptom: Compressor thermal protector switch open (overloading)

Possible Causes Potential Solutions

Liquid floodback Adjust electronic expansion valve, increase flow, or raise set point

Compressors overamping Correct refrigerant charge; check electrical connections

13. Symptom: No low voltage (24 Vac)

Possible Causes Potential Solutions

Control circuit fuse open Check fuse prong contact points; replace fuse

Phase monitor opened or tripped Replace transformer, T1 or T2 primary or secondary fuse blown

No primary voltage on T1 or T2 Check breakers, fuses; check power supply specifications

14. Symptom: Flow switch open

Possible Causes Potential Solutions

Insufficient water flow

Switch defective

15. Symptom: Electronic expansion valve superheat too high

Possible Causes Potential Solutions

Water/glycol temperature too warm

Obstructed filter dryer Replace filter dryer

Low refrigerant charge Adjust refrigerant as per data plate

Improperly set superheat valve setting Reset valve settings to factory specifications

Check strainer for debris; clean strainer

Replace flow switch

Low refrigerant level; adjust chiller/heater refrigerant charge as required

16. Symptom: Electronic expansion valve superheat too low

Possible Causes Potential Solutions

Suction temperature sensor not properly located Check if secured to pipe or insulated; check sensor position on pipe at

Improperly set superheat valve setting Reset valve settings to factory specifications

Low flow Increase flow or clean strainer

4-8-10-2 o’clock positions

17. Symptom: Contactor/relay inoperative

Possible Causes Potential Solutions

Coil shorted or open Replace contactor

Mechanical parts broken or jammed Replace assembly

Coil shorted or open Replace contactor

Contacts broken or jammed Replace contactor

Contacts pitted or burned Replace contactor

No 24 Vac to coil

Bad relay on microprocessor controller Replace microprocessor controller

Temperature set point too low Reset above freezing temperature at evaporator or discharge

Check for loose wiring. Replace secondary fuse to T2 transformer

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CChhiilllleerr//HHeeaatteerr TTrroouubblleesshhoooottiinngg

17. Symptom: Contactor/relay inoperative

Possible Causes Potential Solutions

Low water flow

Low suction pressure See ‘low suction pressure’

Remove restrictions; increase flow; clean strainer

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Logical Flow

High Voltage Logical Flow

The PolyTherm Simultaneous Chiller/Heater is available in a range of voltage/amperage/phase configurations to meet the demands of a worldwide market. The high voltage configuration for a chiller/ heater module is listed on each module’s name plate.

Figure 36. PolyTherm chiller/heater control wiring (primary module)

The chiller/heater is designed to operate with high voltage power supplied to the unit at all times.

Control Logical Flow

The chiller/heater uses low voltage for controller and sensor circuits. See following figure.

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Page 72

LLooggiiccaall FFllooww

Figure 37. Expansion board wiring (primary module)

Figure 38. Expansion valve wiring

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Page 73

LLooggiiccaall FFllooww

Water/Glycol Mixture Logical Flow

Trane recommends using a water/glycol mixture instead of an all water fluid. The water/glycol mixture is

Figure 39. PolyTherm chiller/heater piping installation diagram

used within a closed system as shown in the following figure.

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Page 74

Appendix A. Acronyms and Abbreviations

All acronyms and abbreviations used in this manual, on the chiller controllers, and on module indicators and gauges are listed in the following tables.

Acronym List

All acronyms and abbreviations in this publication are listed in the following table, with their full spellings and expansions.

Table 17. Acronyms and abbreviations

Item

410A R410A

Ack

Acked

ACWS

Addr Address

AHRI

AL alarm

Alm Alarm

Alrms alarms

Anlg Analog

AO1

API

Aval Available

BAS

Bd board

btu British thermal unit

C Celsius

C1 Circuit 1

C2 Circuit 2

CB Circuit Breaker

ckt circuit

CL cool

Cntrl, Contrl

Comm Communication

Comp, Comps Compressor, Compressors

CoolDemand

Acknowledged

Automatic City Water Switchover

Air-Conditioning, Heating and Refrigeration Institute

analog output one

Application Program Interface

Building Automation System

Conformance European

Controller

Cooling Demand

Expansion

Table 17. Acronyms and abbreviations (continued)

Item

Compens Compensation

COND, Cond

CSA Canadian Standards Association

CSV

DB Distribution Block

DifPr Differential Pressure

Dis Disabled

Dish

Disturb Distribution

Dly Delay

DP Differential Pressure

DTC

ECM

EER

EMC

EMI

En Enabled

EPC

Err Error

Evap Evaporator

EvapFl Evaporator Flow

EVC

EVD

Ex Valve

Exp Export

EXP1

Extern External

EXV

F Fahrenheit

FLA

FLC Full Load Current

FREECOOL

FRI

FTP File Transfer Protocol

condenser

Comma-Separated Values

Dry Bulb

Discharge

Danfoss Turbocor Compressors Inc.

Electrically Commutated Motor

Energy Efficiency Rating

Electromagnetic Compatibility

Electromagnetic Interference

Extended Performance Compressor

Electronic [expansion] Valve Controller

Expansion Valve Driver

Expansion

Expansion Valve

Expansion Board 1

Electronic [expansion] Valve

Full Load Amperes

Free Cooling

Friday

Expansion

A–1

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AAccrroonnyymmss aanndd AAbbbbrreevviiaattiioonnss

Table 17. Acronyms and abbreviations (continued)

Item

gpm gallons per minute

GUI

HeatDemand

HFC

HG Hot Gas

HH.MM.SS Time: Hour.Minute.Second

HMI Human Machine Interface

Hotgas1

HPS

HT heat

HVAC

I/O

ID Inside Diameter

Ident Identification

IEEE

IGBT

IGV Inlet Guide Vane

Imp Import

Implem Implementation

In Inch

INFO Information

Int

Iso Isolation

LA Low Ambient

lbf

LBV Load Balance Valve

LED

Lgth Length

LIFO Last In First Out

Liq Liquid

LLS

LP Low Pressure

LPPD

LPS Low Pressure Switch

LRA

m minute

Graphical User Interface

Heating Demand

Hydrofluorocarbon

Hot Gas 1

High Pressure

High Pressure Switch

Heating, Ventilation, and Air-Conditioning

Input/Output

Institute of Electrical and Electronic Engineers

Insulated Gate Bipolar Transistor

Integration

Industry Pack

foot pounds

Light-Emitting Diode

Liquid Line Solenoid

Low Pressure Pump Down

Locked Rotor Amperes

Expansion

Table 17. Acronyms and abbreviations (continued)

Item

Max Maximum

Mem

Min Minimum

MON

ms millisecond

NEMA National Electrical Manufacturers Association

NFPA National Fire Protection Association

NTC

Num Number

OA Outside Ambient

OAT

OD Outside Diameter

Opn Open

P Process

Params Parameters

PASV Passive File Transfer Protocol

PD Pressure Differential

PE Protective Earth

PLC

PMD Panel Mounted Disconnect

POE

Pos Position

ppm parts per million

Pres

psi pounds per square inch

PumpDown Pump Down

PumpMod Pump Module

PWM Pulse Width Modulation

Pwrup Stg Up Power Up Stage Up

REFRIG

RemOff Remote Off

RMA Returned Merchandise Authorization

RmpDn Ramp Down

Rot Rotation

rpm revolutions per minute

Memory

Monday

Module 1 through x

Negative Temperature Coefficient

Outside [ambient] Air Temperature

Operating System

Programmable Logic Controller

Polyolester Oil

pressure

Refrigeration

Redundant Pump

Expansion

ARTC-SVX005B-EN

A–2

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AAccrroonnyymmss aanndd AAbbbbrreevviiaattiioonnss

Table 17. Acronyms and abbreviations (continued)

Item

s second

S1, S2 Switch #1, Switch #2

SAT

SDT

Simult Simultaneous

SL Service Line

Soft Software

SP Set Point

SQ. Square

Src Source

SSS Solid State Starter

SST

StartPt

Suct Suction

SUN

Sys System

SysChEWT System Chilled Entering Water Temperature

SysChLWT System Chilled Leaving Water Temperature

SysHotEWT System Hot Entering Water Temperature

SysHotLWT System Hot Leaving Water Temperature

Temp Temperature

Saturday

Saturated Discharge Temperature

Saturated Suction Temperature

Stating Point

Sunday

Expansion

Table 17. Acronyms and abbreviations (continued)

Item

Temp Diff - Temperature Differential (minus)

Temp Diff + Temperature Differential (plus)

TEMPS

THU

TT Twin Turbine

TUE

TXV

U1, U2 binary 1, binary 2

UL Underwriters Laboratories

UV Ultraviolet

VAC

Var Variable

Variab Variable

VDC

Ver. Version

VFD

WED

Y1, Y2

YY.MM.DD

Temperatures

Thursday

Tuesday

Thermal Expansion Valve

Volts, Alternating Current

Volts, Direct Current

Variable Frequency Drive

Wednesday

analog output: y1 = condenser, y2 = evaporator

analog output

Date: Year.Month.Day

Expansion

A–3

ARTC-SVX005B-EN

Page 77

Appendix B. Request for Initial Startup PolyTherm Chiller/Heater

critical work described on the form has been completed. To prevent additional charges for aborted startups, the following items must be completely

As part of a continuous commitment to quality, initial startup of this chiller by a factory-certified technician may be purchased from Trane. No initial startup will be scheduled without a Request for Initial Startup form completed and on file with the Trane customer service

functional and operating and this form signed and returned to Trane at least 10 working days prior to the scheduled initial startup date.

CChhiilllleerr//HHeeaatteerr IInniittiiaall SSttaarrttuupp DDaattaa

department. Submitting this form indicates that all

Model Number:

Primary Contact Name: Primary Contact Phone:

Primary Contact FAX: Primary Contact Mobile:

Name of Chiller Site:

Physical Location of Chiller:

Requested Date for Initial Start-up: Requested Time for Initial Start-up:

Primary Module Serial Number:

MMaannddaattoorryy IInniittiiaall SSttaarrttuupp RReeqquuiirreemmeennttss

Mandatory Tasks Date Completed

All chiller modules are installed with minimum clearances available from all sides.

Refrigeration gauges are indicating equal pressures.

Chilled water lines from chiller to customer’s equipment are permanently connected.

Chilled water lines have been flushed clean of mud, slag, and other construction debris.

All chilled water line filters and strainers are clean.

Chilled water lines have been leak tested according to prestart instructions.

Chiller reservoir (if included) is at operating level with correct water/glycol mixture.

High voltage wiring is installed, tested, and functional.

All water, refrigeration, electrical, and control connections between chiller modules are completed.

All control wiring between modular chillers is installed, tested, and functional.

Control wiring is complete, including any remote interface panel or special-purpose module wiring.

Automatic City Water Switchover (if included) is installed, flushed, and leak-tested.

Condenser, if applicable, is installed, piped, wired, and leak-tested.

All responsible installing contractors and sub-contractors are notified to have representatives available on site to provide technical support for the initial start-up procedure.

Full load shall be available for chiller on the initial start-up date.

Initialed

Complete

Initial Startup Agreement

By signing this form, you agree the chiller is ready for initial startup. It is understood that, if the chiller is not

ARTC-SVX005B-EN

ready for initial startup due to site problems, the initial startup will be aborted at the discretion of the designated startup technician. Payment for an aborted startup will be forfeited. Rescheduled initial startups are subject to any additional costs that may have been incurred by the technician. An approved purchase

B–1

Page 78

RReeqquueesstt ffoorr IInniittiiaall SSttaarrttuupp

order or payment in advance will be required to reschedule an aborted initial startup.

Name (Printed): ____________________________________

Signature: _________________________________________ Company: __________________________________

Date: ______________________________________

B–2

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Page 79

Appendix C. Active Alarm List

All active alarms are reported on the Active Alarms screen.

Application

Shows if alarm applies to primary microprocessor controller, secondary microprocessor controller, or both.

Type

This is the alarm type; either an automatic reset or a manual reset performed by the operator.

Auto Reset

An alarm automatically resets itself once the condition triggering the alarm is resolved, so it will change from active to non-active automatically.

Operator Reset

When the alarm condition is resolved, the alarm still needs to be manually reset using the RREESSEETT PPLLCC button.

OOPPEERRAATTOORR RREESSEETT is always required for major alarms or alarms that cause module shut-down or lockout, signifying that intervention is required.

Action

The action taken by the microprocessor controller logic to avoid alarm or keep it from damaging equipment.

Warning

This is an informative alarm; no action is required.

Alarm Notes

• Alarm covers special cases that can occur on the active alarms screen are listed below.

• * – If the EWT is selected as the cooling or heating temperature control sensor.

• ** – If the LWT is selected as the cooling or heating temperature control sensor.

• *** – If the EWT is selected as cooling or heating temperature control sensor and the module is running in stand-alone mode.

• **** – If the LWT is selected as cooling or heating temperature control sensor and the module is running in stand-alone mode.

• ***** – If both compressors are in lock-out, that will in turn lock out the module.

Alarm List

All alarm states that can appear on the Active Alarms screen are listed in the following table:

Table 18. Touchscreen interface active alarm states

Alarm

Secondary 1 communication lost Primary Auto Reset Warning

Secondary 2 communication lost Primary Auto Reset Warning

Secondary 3 communication lost Primary Auto Reset Warning

Secondary 4 communication lost Primary Auto Reset Warning

Secondary 5 communication lost Primary Auto Reset Warning

Secondary 6 communication lost Primary Auto Reset Warning

Secondary 7 communication lost

Secondary 8 communication lost Primary Auto Reset Warning

Secondary 9 communication lost Primary Auto Reset Warning

System Chilled LWT too high Primary Auto Reset Warning

System Hot LWT too low Primary Auto Reset Warning

WRONG PRIMARY ROTATION CONTROL PARAMETERS

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Application Type

Primary Auto Reset Warning

Action

C–1

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AAccttiivvee AAllaarrmm LLiisstt

Table 18. Touchscreen interface active alarm states (continued)

Alarm

BMS OFFLINE Primary Auto Reset Warning

cpCOe UI1 SENSOR FAILURE Primary Auto Reset Switches Primary module and secondary modules in

cpCOe UI2 SENSOR FAILURE Primary Auto Reset Switches Primary module and secondary modules in

cpCOe UI3 SENSOR FAILURE Primary Auto Reset Switches Primary module and secondary modules in

cpCOe UI4 SENSOR FAILURE Primary Auto Reset Switches Primary module and secondary modules in

cpCOe UI5 SENSOR FAILURE Primary Auto Reset Warning

cpCOe UI6 SENSOR FAILURE Primary Auto Reset Warning

cpCOe UI7 SENSOR FAILURE Primary Auto Reset

cpCOe UI8 SENSOR FAILURE Primary Auto Reset

cpCOe OFFLINE ALARM Primary Auto Reset Switches Primary module and secondary modules in

cpCOe WRONG CONFIG Alarm Primary Auto Reset Warning

UI1 SENSOR FAILURE Primary / Secondary Auto Reset Shuts down local cooling control ***

UI2 SENSOR FAILURE Primary / Secondary Auto Reset Shuts down local cooling control ***

UI3 SENSOR FAILURE Primary / Secondary Auto Reset Shuts down local heating control ***

UI4 SENSOR FAILURE Primary / Secondary Auto Reset

UI5 SENSOR FAILURE Primary / Secondary Auto Reset Shuts down module

UI6 SENSOR FAILURE Primary / Secondary Auto Reset Shuts down local heating control ****

UI7 SENSOR FAILURE Primary / Secondary Auto Reset Warning

UI8 SENSOR FAILURE Primary / Secondary

UI9 SENSOR FAILURE Primary / Secondary Auto Reset Warning

UI10 SENSOR FAILURE Primary / Secondary Auto Reset Warning

UI12 SENSOR FAILURE Primary / Secondary Auto Reset Warning

COMPRESSOR 1 WARNING

COMPRESSOR 1 FAILURE Primary / Secondary Auto Reset Shuts down compressor 1

COMPRESSOR 1 FAILURE Primary / Secondary Auto Reset Shuts down compressor 1 *****

COMPRESSOR 1 CORESENSE FAILURE Primary / Secondary Auto Reset Shuts down compressor 1

COMP 1 CORESENSE COMMUNICATION LOST

COMPRESSOR 2 WARNING Primary / Secondary Auto Reset Warning

COMPRESSOR 2 FAILURE

COMPRESSOR 2 FAILURE Primary / Secondary Auto Reset Shuts down compressor 2*****

COMPRESSOR 2 CORESENSE FAILURE Primary / Secondary Auto Reset Shuts down compressor 2

Comp 2 CORESENSE COMMUNICATION LOST

EVD OFFLINE Primary / Secondary Auto Reset Warning

Application Type

Stand-alone Mode *

Switches to Internal Cooling set point if ‘External' is selected

stand-alone mode

Shuts down module if ‘LP Alarm Mode = Sensor’

Auto Reset

Primary / Secondary

Primary / Secondary Auto Reset Shuts down compressor 1

Primary / Secondary

Primary / Secondary Auto Reset Shuts down compressor 2

Auto Reset Warning

Auto Reset

Locks out module if it is running in heating mode

Shuts down compressor 2

Action

C–2

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Page 81

Table 18. Touchscreen interface active alarm states (continued)

AAccttiivvee AAllaarrmm LLiisstt

Alarm

EVD SYSTEM ALARM Primary / Secondary Auto Reset Warning

EVD DRIVER A ALARM Primary / Secondary Auto Reset Warning

EVD DRIVER B ALARM Primary / Secondary Auto Reset Warning

EVAPORATOR FREEZING ALARM Primary / Secondary Operator Reset Locks out module

SOURCE FREEZING ALARM

PHASE MONITOR ALARM Primary / Secondary Auto Reset Locks out module

EVAPORATOR FLOW ALARM Primary / Secondary Operator Reset Locks out module

CONDENSOR FLOW ALARM Primary / Secondary Operator Reset Locks out module

SOURCE FLOW ALARM Primary / Secondary Operator Reset Locks out module

CONDENSOR LWT TOO LOW Primary / Secondary Auto Reset Warning

EVAPORATOR LWT TOO HIGH Primary / Secondary Auto Reset Warning

HP ALARM Primary / Secondary Operator Reset Locks out module

HP SWITCH ALARM Primary / Secondary Auto Reset Locks out module

LP ALARM Primary / Secondary Operator Reset Shuts down module

LP Lockout ALARM Primary / Secondary Operator Reset Locks out module

ERROR IN THE NUMBER OF RETAIN MEMORY WRITINGS

ERROR in RETAIN MEMORY WRITINGS Primary / Secondary Operator Reset Warning

WRONG TEMPERATURE CONTROL PARAMETERS

WRONG LOCAL ROTATION CONTROL PARAMETERS

PRIMARY COMMUNICATION LOST Secondary Auto Reset Switches secondary module to stand-alone mode

INCOMPLETE SAFETY CYCLE Primary / Secondary Auto Reset Warning

cpCOe #2 OFFLINE ALARM Primary / Secondary Auto Reset Switches primary and secondary modules in stand-

cpCOe #2 WRONG CONFIG ALARM

Valve D1 OPENING FAILURE Primary / Secondary Operator Reset Locks out module

Valve D1 CLOSING FAILURE Primary / Secondary Operator Reset Locks out module

Valve D2 OPENING FAILURE Primary / Secondary Operator Reset Locks out module

Valve D2 CLOSING FAILURE Primary / Secondary Operator Reset Locks out module

Valve S1 OPENING FAILURE Primary / Secondary Operator Reset Locks out module

Valve S1 CLOSING FAILURE Primary / Secondary Operator Reset Locks out module

Valve S2 OPENING FAILURE Primary / Secondary Operator Reset Locks out module

Valve S2 CLOSING FAILURE Primary / Secondary Operator Reset Locks out module

Application Type

Primary / Secondary

Primary / Secondary Operator Reset Warning

Primary / Secondary Auto Reset Warning

Primary / Secondary

Operator Reset

Auto Reset

Locks out module

alone mode

Locks out module

Action

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NNootteess

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NNootteess

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Page 84

Trane creates com fortable, energy efficient indoor en viron m ents f or com m er cial applications. For mor e inform ation, please visit tr ane.com o r ameri canstandardair .com.

Arcti c designs co st-efficient leading-edg e chillers and applied solution s to m eet individual cust omer needs—from large, m ediu m to small er-scale system s. For m o re inform atio n, please visit ww w .arcti cchiller group .com.

Trane has a po li cy o f conti nu ous pro du ct an d pr od uct data im pr ov ement an d r eserv es the rig ht to change desi gn and specif icat io ns w it ho ut notice. W e are co m mitt ed t o using env ir onmen tal ly consciou s pr int pr acti ces.

ARTC-SVX005B-EN 15 Dec 2021

Super sedes A RTC-SVX005A -EN (Feb 2021)