Trane CVGF-SVU02B-E4, CVGF 400, CVGF 1000 Operation And Maintenance Manual

Operation
Maintenance Manual

Gear-Driven Centrifugal
Water-Cooled Liquid
Chillers with CH530
Controls

CVGF-SVU02B-E4

X39640691020

Unit Model
CVGF 400-1000 Ton Units
(50 and 60 Hz)

CVGF-SVU02B-E4

© 2005 American Standard Inc. All rights reserved.

Warnings and
Cautions

Warnings and Cautions

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

designed to alert personnel to
conditions that could result in
equipment damage.

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

NOTICE: Warnings and Cautions appear at appropriate sections throughout this manual.
Read these carefully.



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

in death or serious injury.



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

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

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

accidents.

CVGF-SVU02B-E4

3

Contents

Warnings and Cautions

General Information

Unit Control Panel (UCP)

Base Loading Control Algorithm

Control System Components

Machine Protection and Adaptive

Unit Startup

Unit Shutdown

Periodic Maintenance

2

4

22

44

47

62

73

76

77

CVGF-SVU02B-E4

4

Model Number

Refer to the Installation Manual.

Product Description Block

A typical Product Description
Block is shown in the Installation
Manual.

Unit Nameplate

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

Note: Trane starters are
identified by a separate model
number found on the starter.

Literature History

CVGF-SVU02A-E4
(November 2002)

This is a new manual.

About this manual

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

Carefully review this information
and follow the instructions given
to successfully operate and
maintain a CVGF unit.

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

General
Information

CVGF-SVU02B-E4

5

Commonly Used
Abbreviations

For convenience, a number of
abbreviations are used
throughout this manual. These
are listed alphabetically below,
along with a translation of each:

ASME = American Society of
Mechanical Engineers

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

BAS = Building Automation
System

CDBS = Condenser Bundle Size

CDSZ = Condenser Shell Size

CH530 = Tracer CH530 Controller.

CWR = Chilled Water Reset

CWR’ = Chilled Water Reset
Prime

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

DV = DynaView

™

Clear Language
Display, also know as the Main
Processor (MP)

ELWT = Evaporator Leaving
Water Temperature

ENT = Entering Chilled Water
Temperature

EXOP = Extended Operation

GBAS = Generic Building
Automation Interface

GPM = Gallons-per-minute

HLUV = High Lift Unloading
Valve.

Hp = Horsepower

HVAC = Heating, Ventilating, and
Air Conditioning

IE = Internally-Enhanced Tubes

IPC = Interprocessor
Communication

LCD = Liquid Crystal Display

LED = Light Emitting Diode

General
Information

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

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

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

MP = Main Processor

PFCC = Power Factor Correction
Capacitor

PID = Proportional Integral
Derivative

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

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

ODT = Outdoor Temperature

OPST = Operating Status
Control

RLA = Rated Load Amps

RTD = Resistive Temperature
Device Tracer CH530= Controls
Platform used on this Chiller

TRMM = Tracer
Communications

UCP = Unit Control Panel

CVGF-SVU02B-E4

6

Figure 2. Component location for typical CVGF unit (back view)

Motor

Unit nameplate

Relief valves

Oil cooler

Economizer

Condenser

Two-Stage Compressor

Unit-Mounted Starter (Optional)

Relief Valves

Unit Nameplate

Control Panel CH530

Oil Pump

Evaporator

General
Information

Figure 1. General CVGF unit component

CVGF-SVU02B-E4

7

Cooling Cycle

The refrigeration cycle of the
CVGF chiller can be described
using the pressure-enthalpy
diagram shown in Figure 3. Key
state points are indicated and
will be referred to in the
following discussion. A
schematic of the system
showing refrigerant flow is given
in Figure 4.

Evaporator - A liquid vapor
refrigerant mixture enters the
evaporator at state point 1.
Liquid refrigerant is vaporized to
state point 2 as it absorbs heat
from the system cooling load.
The vaporized refrigerant flows
into the compressor first stage.

Compressor first stage ­Refrigerant vapor is drawn from
the evaporator into the first
stage compressor. The first stage
impeller accelerates the vapor
increasing its temperature and
pressure to state point 3.

General
Information

Figure 3. P-H chart

P

Pc

P

1

Pe

5

8

1

RE

RE

1

Evaporator

Economizer

Condenser

4
Compressor
2nd stage

3
Compressor
1st stage

2

H

CVGF-SVU02B-E4

8

Compressor second stage ­Refrigerant vapor leaving the
first stage compressor is mixed
with cooler refrigerant vapor
from the economizer. This
mixing lowers the enthalpy of
the vapor entering the second
stage. The second stage
impeller accelerates the vapor,
further increasing its
temperature and pressure to
state point 4.

Condenser - Refrigerant vapor
enters the condenser where the
system cooling load and heat of
compression are rejected to the
condenser water circuit. This
heat rejection cools and
condenses the refrigerant vapor
to a liquid at state point 5.

Economizer and refrigerant
orifice system - Liquid

refrigerant leaving the
condenser at state point 5 flows
through the first orifice and
enters the economizer to flash a
small amount of refrigerant at
an intermediate pressure
labeled P1. Flashing some liquid
refrigerant cools the remaining
liquid to state point 8.

Another benefit of flashing
refrigerant is to increase the
total evaporator Refrigeration
Effect from RE’ to RE. The
economizer provides around 4
percent energy savings
compared to chillers with no
economizer.

To complete the operating cycle,
liquid refrigerant leaving the
economizer at state point 8
flows through a second orifice.
Here refrigerant pressure and
temperature are reduced to
evaporator conditions at state
point 1.

An innovative design feature of
the CVGF chiller is maximizing
the evaporator heat transfer
performance while minimizing
refrigerant charge requirements.
This is accomplished by the
Trane-patented falling film
evaporator design. The amount
of refrigerant charge required in
CVGF is less than that in
comparably sized chillers of
flooded evaporator design.

General
Information

CVGF-SVU02B-E4

9

General
Information

Figure 4. Refrigerant flow diagram

Starter

Condenser

Motor

Economizer Oil sump

Pump

Fixed
orifice

Distributor

Evaporator

Fixed
orifice

Strainer

Fixed
orifice

Condenser
sump

Internal filter

Compressor

Inlet
vanes

High lift
unloading
valve
(HLUV)

Gears

Bearings

Oil cooler

Refrigerant Flow

S

F

ST

2

ST

1

CVGF-SVU02B-E4

10

Compressor Description

The CVGF compressor consists
of three distinct sections: the
two-stage centrifugal
compressor, the motor, and the
gear box with integral oil sump.
See Figure 5.

Compressor

The centrifugal compressor is
two-stage with high-strength
aluminum alloy fully shrouded
impellers. The impellers are
tested at 25 percent over design
operating speed. The rotating
assembly is dynamically
balanced for vibration of less
than 5.1 mm/sec (0.2 ips peak
velocities) at nominal operating
speeds. The control system
affords 20 to 100 percent
capacity modulation by
electrically actuated guide vanes
upstream of each impeller.

General
Information

CVGF-SVU02B-E4

11

General
Information

Figure 5. Compressor cross-section view

Motor rotor

Motor shaft

Bull gear

Discharge end

Suction
end

Motor terminal

Motor
housing

Motor stator

Pinion shaft

Gear housing

2nd stage
impeller

Oil pump

1st stage
impeller

Oil
sump

CVGF-SVU02B-E4

12

Drive Train

The drive train consists of
helical bull and pinion gears.
Gear tooth surfaces are case
hardened and precision ground.
The one-piece impeller shaft is
supported by hydrodynamic
thrust and radial bearings.

Motor

The motor is a hermetic, liquid
refrigerant cooled, two-pole,
low-slip squirrel cage induction
motor. A radial hydrodynamic
bearing and duplex angular
contact ball bearings support
the rotor assembly. Winding­embedded sensors provide
positive thermal protection.

Controls Overview

Controls Operator Interface

Information is tailored to
operators, service technicians
and owners. When operating a
chiller, there is specific
information you need on a day­to-day basis such as setpoints,
limits, diagnostic information,
and reports.

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

By providing two different tools,
one for daily operation and one
for periodic service, appropriate
information is readily
accessible.

DynaView™Human Interface

For the operator, day-to-day
operational information is
presented at the panel. Up to
seven lines of data (English or SI
units) are simultaneously
displayed on the touch-sensitive
screen. Logically organized
groups of information such as
chiller modes of operation,
active diagnostics, settings and
reports put information
conveniently at your fingertips.
See Operator Interface Section
for details.

TechView™ Chiller

For the service technician or
advanced operator all chiller
status, machine configuration
settings, customizable limits,
and up to 60 active or historic
diagnostics are displayed
through the TechView

™

interface. Using TechView™, a
technician can interact with an
individual device or a group of
devices for advanced
troubleshooting. LED lights and
their respective TechView

™

indicators visually confirm the
viability of each device. Any PC
that meets the system
requirements may download the
service interface software and
Tracer CH530 updates. For more
information on TechView™visit
your local Trane Service
company, or The Trane
Company’s website at
www.trane.com.

General
Information

CVGF-SVU02B-E4

13

General
Information

Figure 6. CVGF sequence of operation overview

Stopped

Stopped

Run Inhibit

Power Up

Stopping

Preparing to Shut

Down Shutting

Down

Starting

Auto

Waiting to Start

Starting

Compressor

Running

Running

Running - Limit

Fast Restart or Satisfied Setpoint

Stop Command or Diagnostic

Confirm

ed Shutdow

n

Confirm

ed Start

Stop Command

Diagnostic

Start Command

Diagnostic Reset

CVGF-SVU02B-E4

14

General
Information

Figure 7. Sequence of operation: power up

Apply

Control

Power

Completing Self Test

(12 Seconds)

Self Test

Starting Application

(20-30 Seconds*)

Starting

Application

*Note: The variation in DynaView Power Up time is dependent on the number of
installed options.

Last Mode

Such as
Auto or

Stopped

as shown

CVGF-SVU02B-E4

15

General
Information

Figure 8. Sequence of operation: running

Starter Status is
“Running”

Limit Mode

Exit Limit Mode

Starting
Compressor

Running

- Limit Running

Running

Modulate IGV for
LWT control

Running

Modulate IGV for
Limit control

Modulate IGV for
LWT control

CVGF-SVU02B-E4

16

Figure 9. Immediate shutdown to stopped or run inhibit

General
Information

Running

Immediate shutdown non-latching diagnostic

Immediate shutdown latching diagnostic

Panic stop

Run Inhibit

Stopped

Post lube complete

Run Inhibit or
Stopped

Post lube and evaporator
pump off delay complete

Shutting down Shutting down Shutting down

Close IGV
(0-50 seconds)

Post Lube:
(1 minute)

De-energize oil pump

Confirm no oil pressure*
5 minutes after oil pump is de-energized

De-energize evaporator
water pump relay

Evaporator pump off
delay not performed for
immediate shutdown

De-energize
compressor

Confirm no compressor currents 8
seconds after compressor is de­energized

De-energize condenser
water pump

*Note: No oil pressure when oil differential pressure switch is open.

CVGF-SVU02B-E4

17

General
Information

Figure 10. CVFG sequence of operation: satisfaction setpoint

Running

Preparing shutdown Shutting down Shutting down

*Note: No oil pressure when oil differential pressure switch is open.

Satisfied setpoint

Command IGV closed

De-energize compressor

Confirm no oil pressure*
5 minutes after oil pump
is de-energized

De-energize oil pump

Close IGV
(0-50 seconds)

Post lube
(1 minute)

Auto

Confirm no compressor
currents within 30 seconds

De-energize condenser
water pump relay

Enforce all running mode
diagnostics

CVGF-SVU02B-E4

18

Oil Management

The primary purpose of Oil
Management is to ensure
appropriate and sufficient
lubrication to the bearings
during compressor operation
and to minimize refrigerant
dilution in the oil.

The Oil Management system
performs safety checks and
manages the operation of the Oil
Pump and the Oil Heater. The
sensor inputs used for these
purposes are the Differential Oil
Switch, and the Oil Temperature.

Two oil heater outputs exist, that
should always operate
simultaneously, for example,
both on or both off.

Note: The Oil Pump and the Oil
Heater are never energized at the
same time.

Low Oil Temperature Start
Inhibit Setpoint default is: 95° F.

When enhanced oil protection is
enabled, the low oil temperature
start inhibit is the saturated
evaporator at 30°F (16.6°C) or
105°F (40.5°C), whichever is
higher.

When enhanced oil temperature
protection is enabled, the oil
temperature setpoint is fixed at
136°F (57.8°C).

The oil temperature control
setpoint range is settable from:
100 to 160°F (37.8 to 71.1°C)

Essential Modes

The Oil-Management has the
following modes:

1. Low Temperature Start Inhibit:

The oil temperature is at or
below the low oil temperature
start inhibit setpoint. The heater
is energized to raise the oil
temperature. See Low
Temperature Start Inhibit section
for information about Enhanced
Oil Temp Protection.

This mode is indicated to the
user.

2. Idle: The oil pump is off. The
oil temperature is maintained
by the heater, at the control­temperature setpoint +/- 2.5°F
(1.4°C).

3. Pre-lube: The oil pump
lubricates the bearing for 30
seconds before the
compressor starts.

This mode is indicated to the
user.

4. Running: The oil pump
continues to lubricate the
bearings when the compressor
is running.

General
Information

CVGF-SVU02B-E4

19

5. Post-lube: The oil pump
lubricates the bearings for 60
seconds after the compressor
is stopped to ensure bearings
remain lubricated as the
compressor coasts to a stop.

If a start command is issued
while in post-lube, a quick restart
will be performed.

The post-lube mode is indicated
to the user on DynaView™and
TechView™.

6. Manual: The oil pump can be
commanded on and off in a
manual mode.

Oil Temperature Control

The oil heater is used to
maintain the oil temperature
within +/- 2.5°F (4.5°C) of the oil
temperature control setpoint.
The oil heater is commanded off
when the oil pump is
commanded on.

Oil Differential Pressure
Check

The Oil Differential Pressure
Check validates the oil
differential pressure before the
oil pump is turned on. This check
in necessary in case the
differential pressure switch is
not operational. Without this
check, the differential oil
pressure feedback is gone. This
check is made after post-lube is
complete to verify that the
differential pressure has
dropped to indicate no oil flow.

Here are the details:

•

CH530 verifies that the
pressure switch is reading no
differential pressure with the
oil pump off before proceeding
with pre-lube.

•

CH530 displays a mode
Waiting for Low Oil Differential
Press.

•

The check is made if oil pump
is off and before it is turned on.

•

CH530 allows five minutes for
the differential oil pressure
switch to open.

•

This check is performed on
power up or reset also. If a
MPL occurred or power up was
within the post-lube time, oil
pump is running so do not do
the check.

General
Information

CVGF-SVU02B-E4

20

Protective Diagnostics and
their description

Differential Oil Pressure Overdue

is a latching diagnostic that can
come up while the unit is in pre­lube.

The differential pressure switch
status is used instead of the Low
Differential Oil Pressure Cutout
setpoint.

Low Differential Pressure Cutout

is a latching diagnostic that can
come up while the unit is
running. Oil pressure is
indicative of oil flow and active
oil pump operation. Significant
fall in oil pressure is indicative of
failure of the oil pump, oil
leakage, or other blockage in the
oil circuit.

Once oil flow has been
established, if the differential
pressure switch indicates there
is not oil pressure for 2 seconds,
this diagnostic will be issued.

Unexpected Differential Oil
Pressure is a latching diagnostic

that can come up while the unit
is idle and is implemented to
recognize and ensure that the
pressure switch is operational
and that it is open for a period of
five minutes.

General
Information

CVGF-SVU02B-E4

21

General
Information

Figure 11. Oil circuit diagram

Starter

Condenser

Economizer

Condenser

Sump

High Lift

Unloading

Valve (HLUV)

Refrigerant

Oil

Motor

Oil Cooler

Strainer

S

F

Distributor

Evaporator

Fixed Orifice

Oil Sump

Pump

Internal Filter

Bearings

Gears

ST 1

ST 2

Compressor

Fixed Orifice

CVGF-SVU02B-E4

22

Control Panel Devices and
Unit Mounted Devices

Unit Control Panel (UCP)

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

The UCP houses several other
controls modules called panel
mounted LLID (Low Level
Intelligent Device), power
supply, terminal block, fuse,
circuit breakers, and transformer.
The IPC (Interprocessor
communication) bus allows the
communications between LLID’s

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

Unit Control
Panel (UCP)

Figure 12. Control panel

CVGF-SVU02B-E4

23

Whenever the controller senses
a situation that might trigger a
protective shutdown, it focuses
on bringing the critical
parameter back into control.
When the parameter is no longer
critical, the controller switches
its objective back to controlling
the chilled water temperature, or
to another more critical
parameter should it exist.

Variable water flow through the
evaporator

Chilled water systems that vary
water flow through chiller
evaporators have caught the
attention of engineers,
contractors, building owners,
and operators. Varying the water
flow reduces the energy
consumed by pumps, while
requiring no extra energy for the
chiller. This strategy can be a
significant source of energy
savings, depending on the
application. With its faster and
more intelligent response to
changing conditions, Tracer
CH530 reliably accommodates
variable evaporator water flow
and its effect on the chilled water
temperature. These
improvements keep chilled
water flowing at a temperature
closer to its setpoint.

Unit Control
Panel (UCP)

Tracer CH530 Chiller
Controller

Tracer CH530’s Main Processor,
DynaView™, is fast and keeps
the chiller online whenever
possible. Smart sensors collect
three rounds of data per second,
55 times the data collection
speed of its predecessor. Each
device (a sensor) has its own
microprocessor that
simultaneously converts and
accurately calibrates its own
readings from analog to digital.

Because all devices are
communicating digitally with
the DynaView™, there is no need
for the main processor to
convert each analog signal one
at a time. This distributed logic
allows the main processor to
focus on responding to
changing conditions in the load,
the machine, its ancillary
equipment, or its power supply.
Tracer CH530 constantly
receives information about key
data parameters, temperatures
and currents. Every five seconds
a multiple objective algorithm
compares each parameter to its
programmed limit. The chiller’s
Adaptive Control™capabilities
maintain overall system
performance by keeping its peak
efficiency.

CVGF-SVU02B-E4

24

DynaView

™

presents three menu
tabs across the top which are
labeled “MAIN, REPORTS, and
SETTINGS”.

The Main screen provides an
overall high level chiller status
so the operator can quickly
understand the mode of
operation of the chiller.

The Chiller Operating Mode will
present a top level indication of
the chiller mode (Auto, Running,
Inhibit, Run Inhibit, and so forth)
The “additional info” icon will
present a subscreen that lists in
further detail the subsystem
modes.

The MP contains non-volatile
memory both checking for valid
set points and retaining them on
any power loss. System data
from modules (LLID) can be
viewed at the DynaView

™

operator interface. Such as
evaporator and condenser water
temperatures, outdoor air
temperature, evaporator and
condenser water pump control,
status and alarm relays, external
auto-stop, emergency stop, and
evaporator and condenser water
flow switches.

Unit Control
Panel (UCP)

The DynaView™(DV) Operator
Interface contains the Main
Processor (MP) which
communicates commands to
other modules, collecting data,
status and diagnostic
information from the other
modules over the IPC (Inter
Processor Communications)
link. The Main Processor
software controls water flows by
starting pumps and sensing
flow inputs, establishes a need
to heat or cool, performs pre­lube, performs post-lube, starts
the compressor, performs water
temperature control, establishes
limits, and pre-positions the
inlet guide-vanes.

Figure 13. DynaView™main processor

CVGF-SVU02B-E4

25

Unit Control
Panel (UCP)

Main screen content can be
viewed by selecting the up or
down arrow icons. The Main
screen is the default screen.After
an idle time of 30 minutes.

DynaView™(DV) is the operator
interface of the Tracer CH530
control system utilized on the
CTV machines. The DynaView

™

enclosure is 9.75" (24.8 cm)
wide, 8” (20.3 cm) high and 1.6”
(4.1 cm) deep. The DynaView

™

display is approximately 4” (10.2
cm) wide by 3” (7.6) high.
Features of the display include a
touch screen and long life LED
backlight. This device is capable
of operating in 0 - 95 percent
relative humidity (non­condensing). The enclosure
includes a weather tight
connection means for the RS232
TechView™connection.

Touch screen key functions are
determined completely in the
software and change depending
upon the subject matter
currently being displayed. The
user operates the touch sensitive
buttons by touching the button
of choice. The selected button is
darkened to indicate it is the
selected choice. The advantage
of touch sensitive buttons is that
the full range of possible choices
as well as the current choice is
always in view.

Up or down arrow buttons are
used to allow a continuously
variable setpoint, such as
leaving water setpoint. The value
changes by touching the up or
down arrows.

Action buttons are buttons that
appear temporarily and provide
the operator with a choice such
as Enter or Cancel. The operator
indicates his choice by touching
the button of choice. The system
then takes the appropriate action
and the button typically
disappears.

DynaView™consists of various
screens, each meant to serve a
unique purpose of the machine
being served. Tabs are shown
row across the top of the display.
The user selects a screen of
information by touching the
appropriate tab. The folder that
is selected will be brought to the
front so it’s contents are visible

CVGF-SVU02B-E4

26

Unit Control
Panel (UCP)

The main body of the screen is
used for description text, data,
setpoints, or keys (touch
sensitive areas) The double up
arrows cause a page by page
scroll either up or down. The
single arrow causes a line by
line scroll to occur. At the end of
the screen, the appropriate scroll
buttons will disappear.

The bottom of the screen is the
persistent area. It is present in all
screens and performs the
following functions. The left
circular area is used to reduce
the contrast and viewing angle
of the display. The right circular
area is used to increase the
contrast and viewing angle of
the display. The contrast control
will be limited to avoid complete
“light” or complete “dark”,
which would potentially confuse
an unfamiliar user to thinking
the display was malfunctioning.

Persistent keys, horizontal at the
bottom of the display, are those
keys that must be available for
operation regardless of the
screen currently being displayed.
These keys are critical for
machine operation. The Auto
and Stop keys will be presented
as radio buttons within the
persistent key display area. The
selected key will be dark. The
chiller will stop when the Stop
key is touched, entering the stop
sequence. Pressing the
“Immediate Stop” button will
cause the chiller to stop right
away.

The AUTO and STOP, take
precedence over the ENTER and
CANCEL keys. (While a setting is
being changed, AUTO and STOP
keys are recognized even if
ENTER or CANCEL has not been
pressed. Selecting the Auto key
will enable the chiller for active
cooling.

CVGF-SVU02B-E4

27

The machine-operating mode
indicates the operational status
of the chiller. A subscreen with
additional mode summary
information will be provided.
When the user scrolls down the
screen the Machine Operation
Mode will remain stationary

On DynaView™, the user will be
presented with a single line of
text that represents the ‘top­level’ operating state of the
machine. These top-level modes
are shown in the Table 1.
Additional information (if it
exists) regarding the machine
operating state will be available
to the user by selecting the
“additional information” button
(double right arrow) next to the
top-level operating mode. These
sub-level modes are shown
Table 1.

The TOP LEVEL MODE is the text
seen on the single top level
chiller system operating mode
line. The SUB LEVEL MODE is
the text seen on the operating
mode sub-menu. The operating
mode sub-menu may have up to
six (6) lines of text displayed.

The BAS CODE is the code that
will be sent via COMM4/5 to the
Tracer Summit system as the
chiller system mode. Note that
each top level mode may contain
multiple sub level modes. In
general, the BAS CODE will
reflect the top level mode and
not the sub level mode.

Unit Control
Panel (UCP)

Figure 14.

CVGF-SVU02B-E4

28

Unit Control
Panel (UCP)

Table 1. A general description of the top level modes is show in the following table.

Top Level Mode Description

Stopped Unit inhibited from running and will require user action to go to Auto.
Run Inhibit Unit inhibited from running by Tracer, External BAS, or an Auto Reset diagnostic.
Auto Unit determining if there is a need to run.
Waiting To Start Unit waiting for tasks required prior to compressor start to be completed.
Starting Compressor Unit is starting compressor.
Running Compressor is running with no limits in effect.
Running – Limit Compressor is running with limit in effect.
Preparing To Shutdown Unit is closing inlet guide vanes prior to compressor shutdown.
Shutting Down Compressor has been stopped and unit is performing shutdown tasks.

Figure 15.

CVGF-SVU02B-E4

29

Unit Control
Panel (UCP)

Reference

Top Level Mode Sub Level Mode BAS Code

SYSTEM RESET

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

Motor Temperature / Inhibit Temperature
Waiting To Start Restart Time Inhibit: MIN:SEC 70
Waiting To Start Low Oil Temperature Inhibit: 70

Oil Temperature / Inhibit Temperature
Waiting To Start Waiting For Starter To Start: MIN:SEC 70
Starting Compressor There is no sub mode displayed 72
Running There is no sub mode displayed 74
Running Surge 74
Running Base Loaded 74
Running Current Control Soft Loading 74
Running Capacity Control Soft Loading 74
Running – Limit Current Limit 75
Running – Limit Phase Unbalance Limit 75
Running – Limit Condenser Pressure Limit 75
Running – Limit Evaporator Temperature Limit 75
Running – Limit Minimum Capacity Limit 75
Running – Limit Maximum Capacity Limit 75
Preparing To Shutdown Closing IGV IGV Position % 7E
Shutting Down Post-Lubrication Time: MIN:SEC 7E
Shutting Down Evaporator Pump Off Delay: MIN:SEC 7E
Shutting Down Condenser Pump Off Delay: MIN:SEC 7E

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

configuration validity screens will be present.

CVGF-SVU02B-E4

30

Unit Control
Panel (UCP)

Main Screen

The main screen provides an
overall view of the chiller
performance in addition to the
main and sub operating modes.
The table below indicates other
items found , when specified by
options, that can be scrolled to
via the up or down arrows.

Description

Chiller Operating Mode (>>sub modes)
Evaporator Entering and Leaving Water Temperature
Condenser Entering and Leaving Water Temperature
Active Chilled Water Setpoint (>>source)
Active Current Limit Setpoint (>>source), If enabled
Active Base Loading Setpoint (>>source), If enabled
Average Line Current
Approximate Chiller Capacity, If option installed
Software Version

CVGF-SVU02B-E4

31

Unit Control
Panel (UCP)

Diagnostic Screen

The diagnostic screen is
accessible by touching the
Alarms enunciator.

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

Machine shutdowns can be of
two types:

Latching (MMR) require
corrective action and manual
reset.

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

Up to ten active diagnostics can
be displayed if required.

The reason for all diagnostics
must be determined and
corrected. Do not reset and
restart the chiller as this can
cause a repeat failure. Contact
local Trane Service for assistance
as necessary.

After corrective action, the chiller
can be reset or restarted. In the
case of a diagnostic type, the
chiller will have to be manually
reset through the Diagnostics
alarm menu.

When reset they become historic
and viewable via the TechView

™

.

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

A Manual Override indicator
(shares space with the Alarms
key) alerts the operator to the
presence of a manual override.
An Alarm will take precedence
over the manual override, until
the reset of active alarms. The
manual override indicator would
reappear if such an override
exists.

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

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

The languages for DynaView

™

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

CVGF-SVU02B-E4

32

Unit Control
Panel (UCP)

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

The Active Chilled Water
Setpoint the result of arbitration
between the front panel, BAS,
and external setpoints.

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

The left column text “Front
Panel”, “BAS”, “External”,
Chilled Water Reset, and “Active
Chilled Water Setpoint” will
always be present regardless of
installation or enabling those
optional items. In the second
column “- - - -” will be shown if
that option is Not Installed,
otherwise the current setpoint
from that source will be shown.

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

CVGF-SVU02B-E4

33

Unit Control
Panel (UCP)

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

CVGF-SVU02B-E4

34

Unit Control
Panel (UCP)

Reports Evaporator Report Items Units

Evaporator Entering Water Temperature °C or °F
Evaporator Leaving Water Temperature °C or °F
Evaporator Saturated Refrigerant Temperature °C or °F
Evaporator Refrigerant Pressure Psia or kPa
Evaporator Approach °C or °F
Evaporator Water Flow Switch Status Flow or No Flow

Condenser Report Items Units

Condenser Entering Water Temperature °C or °F
Condenser Leaving Water Temperature °C or °F
Condenser Saturated Refrigerant Temperature °C or °F
Evaporator Refrigerant Pressure Temperature °C or °F
Condenser Refrigerant Pressure Psia or kPa
Condenser Approach Temperature °C or °F
Condenser Water Flow Switch Status Flow or No Flow
Outdoor Air Temperature, If installed °C or °F

Reports

CVGF-SVU02B-E4

35

Unit Control
Panel (UCP)

Compressor Report Items Units

Compressor Starts: ###
Compressor Running Time: Hour and minute
Oil Differential Pressure Switch Open or Closed
Oil Tank Temperature °C or °F
Vanes Position Percent open
Vanes Position Steps Steps

Motor Report Items Units

Percent RLA L1 L2 L3 Percent RLA
Amps L1 L2 L3 Amps
Volts AB, BC, CA Vac
Power Consumption, If installed xxx kW
Load Power Factor, If installed xx
Winding Temperature A °C or °F
Winding Temperature B °C or °F
Winding Temperature C °C or °F

ASHRAE Chiller Log Units

1. Current Time / Date HH:MM AM / PM MMM DD YYYY

2. Chiller Mode Stopped / Running

3. Amps L1 L2 L3 Amps

4. Volts AB BC CA Volts

5. Active Chiller Water Set Point F/ C

6. Active Current Limit Set Point %

7. Refrigerant Type 134a

8. Compressor Starts 0

9. Compressor Running Time 0:00

10. Oil Tank Temperature F/ C

11. Evaporator Entering Water Temperature F/ C

12. Evaporator Leaving Water Temperature F/ C

13. Evaporator Saturated Refrigerant Temperature F/ C

14. Evaporator Saturated Refrigerant Pressure PSIG / kPa

15. Evaporator Approach Temperature F/ C

16. Evaporator Water Flow Switch Status Flow / No Flow

17. Condenser Entering Water Temperature F/ C

18. Condenser Leaving Water Temperature F/ C

19. Condenser Saturated Refrigerant Temperature F/ C

20. Condenser Refrigerant Pressure PSIG / kPa

21. Condenser Approach Temperature F/ C

22. Condenser Water Flow Switch Status Flow / No Flow

CVGF-SVU02B-E4

36

Setting Tab screens provides a
user the ability to adjust settings
justified to support daily tasks.
The layout provides a list of sub­menus, organized by typical
subsystem.

Unit Control
Panel (UCP)

Settings screen for standard CVGF:

CVGF-SVU02B-E4

37

Unit Control
Panel (UCP)

Chiller

Description Units notes

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

2. Front Panel Chilled Water Setpoint Temperature 1

3. Front Panel Current Limit Setpoint Percent 2

4. Front Panel Base Load Command On or Auto

6. Front Panel Base Load Setpoint Percent

6. Differential to Start Temperature

7. Differential to Stop Temperature

8. Setpoint Source (none, use front panel, override BAS), none default

Feature Settings

Description Units

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

2. Return Reset Ratio Temperature

3. Return Start Reset Temperature

4. Return Maximum Reset Temperature

5. Outdoor Reset Ratio Percent

6. Outdoor Start Reset Temperature

7. Outdoor Maximum Reset Temperature

8. External Chilled Water Setpoint (Enable, Disable), Disable

9. External Current Limit Setpoint (Enable, Disable), Disable

10. External Base Loading Setpoint (Enable, Disable), Disable

Notes:

1. Temperatures will be adjustable to 0.1 degree F or C. The Main Processor provides the minimum and maximum allowable value.

2. Adjustable to the nearest whole number percent. The Main Processor provides the minimum and maximum allowable value.

CVGF-SVU02B-E4

38

Unit Control
Panel (UCP)

Mode Overrides
Description Units Default Monitor Value Notes

1. Compressor Control Signal (Auto, Manual) Auto Percent Vane Position
[0-100] )

7

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

2) Override Time Remaining 3

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

2) Override Time Remaining 3

4. Oil Pump (Auto, On), Auto 1) Differential pressure

2) Override Time Remaining 3

5. Clear Restart Inhibit Timer

Display Settings
Description Units Notes

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

2. Date “mmm dd, yyyy” 4

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

4. Time of Day HH:mm 4

5. Keypad and Display Lockout (Enable, Disable), Disable 5

6. Display Units (SI, English), English

7. Pressure Units Absolute / Guage

8. Language (English, Selection 2, Selection 3), English 6

Notes:

3. Terminates with 10 minutes if inactivity.

4. The Date and Time setup screen formats deviate slightly from the standard screens defined above. See the time and date section for further details.

5. Enables a DynaView

™

Lockout screen. All other screens timeout in 30 minutes to this screen when enabled. The DynaView™Lockout Screen displays

a 0-9 keypad to permit the user to exit the lockout with a fixed password (1x5 x 9 + Enter). See lockout section for further details.

6. Language choices are dependent on what has been setup in the Main Processor. Language selections will include English and two alternate as

loaded by TechView

™

. Language shall always be the last setting listed on the Display Settings menu. This will allow a user to find language selection

if looking at an unrecognizable language.

7. Manual Compressor Control allows an operator to override the Auto Control and manually control the compressor while in operation. This is not

active during Stop mode.

Evaporator Leaving Water
Temperature

CVGF-SVU02B-E4

39

Unit Control
Panel (UCP)

Each Settings subscreen consists
of a setpoints list and the current
value. The operator selects a
setpoint to change by touching
either the description or setpoint
value. Doing this causes the
screen to switch to the Analog
Settings subscreen shown
below.

{

Note: Spin buttons used to
change setpoint value.

CVGF-SVU02B-E4

40

Unit Control
Panel (UCP)

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

Mode Override for Enumerated Settings is shown below:

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

CVGF-SVU02B-E4

41

Unit Control
Panel (UCP)

The mode override analog setting subscreen is similar but offers an
Auto or Manual radio button and value setting. An Auto or Manual
selection is necessary set to the mode to override. An Enter and
Cancel Key will allow the user to Enter or Cancel the entry.

Mode Override for Analog Settings is shown below:

The date setpoint screen for setting up the is shown below: The user
must select Day, Month, or Year and then use the up or down arrows
to adjust.

CVGF-SVU02B-E4

42

Unit Control
Panel (UCP)

The time setpoint screen with a 12 hour format is shown below: The
user must select Hour, or Minute and then use the up or down
arrows to adjust. Adjusting hours will also adjust am and pm.

Note: The 24 hour format setpoint screen is similar with the am and
pm not shown.

CVGF-SVU02B-E4

43

Unit Control
Panel (UCP)

The DynaView™Display Touch
Screen Lock screen is shown
below. This screen is used if the
Display and Touch Screen Lock
feature is enabled. 30 minutes
after the last key stroke this
screen will be displayed and the
Display and Touch Screen will be
locked out until “159 Enter” is
entered.

Until the proper password is
entered there will be no access
to the DynaView™screens
including all reports, all
setpoints, Auto, Stop, Alarms,
and Interlocks. The password
“159” is not programmable from
either DynaView™or TechView™.

If the Display and Touch Screen
Lock feature is disabled, the
following screen will be
automatically shown if the MP
temperature is below 32°F (0°C)
and it has been 30 minutes after
the last key stroke. Note: the
main processor is equipped with
an on-board temperature sensor
which enables the ice protection
feature.

1 2 3

4 5 6

7

8 9

Enter Cancel

DISPLAY AND TOUCH SCREEN ARE LOCKED

ENTER “159 Enter” TO UNLOCK

CVGF-SVU02B-E4

44

If the chiller approaches full
current, the evaporator
temperature drops too low, or
the condenser pressure rises too
high, Tracer CH530 Adaptive.
Control logic limits the loading
of the chiller to prevent the
chiller from shutting down on a
safety limit. These limits may
prevent the chiller from reaching
the load requested by the Base
Loading signal.

Base Loading Control is basically
a variation of the current limit
algorithm. During base loading,
the leaving water control
algorithm provides a load
command every 5 seconds. The
current limit routine may limit
the loading when the current is
below setpoint. When the
current is within the deadband of
the setpoint the current limit
algorithm holds against this
loading command.

If the current exceeds the
setpoint, the current limit
algorithm unloads.

The “Capacity Limited By High
Current” message normally
displayed while the current limit
routine is active is suppressed
while base loading.

Base loading can occur using
Tracer or an external signal.

Tracer or an external signal Base
Loading: Current Setpoint
Range: (20 - 100) percent RLA.
Base Loading requires Tracer
Summit and an optional Tracer
Communications Module (LLID)

Base Loading Control
Algorithm

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

Industrial process applications
might use this feature to impose
a specific load on the facility’s
electrical system.

Cogeneration plants might use
this feature to balance the
system’s heating, cooling and
electrical generation. All chiller
safeties and adaptive control
functions are in full effect when
Base Loading control is enabled.

Base Loading
Control Algorithm

CVGF-SVU02B-E4

45

Tracer Base Loading

The Tracer commands the chiller
to enter the base load mode by
setting the base load mode
request bit ON. If the chiller is
not running, it will start
regardless of the differential to
start. While the unit is running in
base loading, it will report that
status back to the Tracer. When
the Tracer removes the base
load mode request, the unit will
continue to run, using the
normal chilled water control
algorithm, and will turn off, only
when the differential to stop has
been satisfied.

External Base Base Loading

The CH530 accepts 2 inputs to
work with external base loading.
The binary input is at 1A18
Terminals J2-1 and J2-2
(Ground) which acts as a switch
closure input to enter the base
loading mode. The second input,
an analog input, is at 1A17
terminals J2-2 and J2-3 (Ground)
which sets the external base
loading setpoint, and can be
controlled by either a 2-10Vdc or
4-20mA Signal. At startup the
input type is configured.

The graphs in Figure 16 show
the relationship between input
and percent RLA. While in base
loading the active current limit
setpoint is set to the Tracer or
external base load setpoint,
providing that the base load
setpoint is not equal to 0 (or out
of range). If it is out of range, the
front panel current limit setpoint
is used. During base loading, all
limits are enforced with the
exception of current limit.
DynaView™displays the
message “Unit is Running Base
Loaded.”

An alternative and less radical
approach to Base Loading
indirectly controls chiller
capacity. Artificially load the
chiller by setting the chilled
water setpoint lower than it is
capable of achieving. Then,
modify the chiller’s load by
adjusting the current limit
setpoint. This method provides
greater safety and control
stability in the operation of the
chiller because it has the
advantage of leaving the chilled
water temperature control logic
in effect.

The chilled water temperature
control logic responds quicker to
dramatic system changes, and
can limit the chiller loading prior
to reaching an Adaptive Control
limit point.

Base Loading
Control Algorithm

CVGF-SVU02B-E4

46

Base Loading
Control Algorithm

Figure 16. Base loading with external mA input and with external voltage input

Base Loading with External mA Input

%RLA

100

90

80

70

60

50

40

30

20

46 8101214161820

mA

—— %RLA

Base Loading using External Voltage Input

%RLA

100

90

80

70

60

50

40

30

20

46 8101214161820

Volts

—— %RLA

CVGF-SVU02B-E4

47

The Control Panel Devices table
corresponds to the same device
designators. Optional controls
are present when a specific
optional controls package is
specified. Optional controls
packages are: OPST Operating
Status, GBAS Generic Building
Systems, EXOP Extended
operation, and TRMM Tracer
communications. 1A1, 1A4, 1A5,
1A6, 1A9, 1A13, 1A19, 1A26 are
standard and present in all
configurations. Other modules
vary depending on machine
optional devices.

Control System
Components

Control System Components

Control Panel Internally mounted
devices

For visual identification Internal
Control Panel mounted devices
are identified by their respective
schematic designation number.
Control panel items are marked
on the inner back panel in the
control panel (Figure 17).

Figure 17. Control panel components layout

OPTIONAL

OPTIONAL

OPTIONAL

OPTIONAL

OPTIONAL

OPTIONAL

OPTIONAL

OPTIONAL

OPTIONAL

CVGF-SVU02B-E4

48

Chilled and Condenser Water
Flow Interlock Circuits

Proof of chilled water flow for
the evaporator is made by the
closure of flow switch 5S1 and
the closure of auxiliary contacts
5K1 on terminals 1X1-5 and 1A6­J3-1 and J3-2. Proof of
condenser water flow for the
condenser is made by the
closure of flow switch 5S2 and
the closure of auxiliary contacts
5K2 on terminals 1X1-6 and 1A6­J2-1 and J2-2.

Head Relief Request Output

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

Maximum Capacity Relay

When the chiller has been
operating at maximum capacity
for over a 10 minute (TechView

™

adjustable) time period this relay
will activate. Also upon being
less than maximum capacity for
10 minutes, this relay will
deactivate. This is located at
LLID 1A9-J2-1 and J2-3.

Compressor Running Relay

Relay activates while the
compressor is running.

Control System
Components

CVGF-SVU02B-E4

49

Control System
Components

Control Panel Devices
Standard Devices

Controls Field Connection

Description Package Purpose Point Terminals

1A1 Power Supply Standard #1 Converts 24 vac to 24 Vdc not for field use

Standard High Pressure Cutout not for field use

Standard Relay #1 Chilled water pump J2-1 NO, J2-2 NC,

(Relay #1) J2-3 common

Standard Relay #2 Condenser water pump control J2-4 NO, J2-5 NC,

(Relay #2) J2-6 common

Standard Input 1 Condenser Flow Input J3-2 Condenser water

flow switch

Standard Input 2 Evaporator Flow Input J2-2 Chilled water

flow switch

Standard Relay #1 Maximum Capacity Relay J2-1 NO, J2-2 NC,

J2-3 common

Standard Relay #2 Head Relief Request Relay J2-4 NO, J2-5 NC,

J2-6 common

Standard Relay #3 Oil Pump J2-7 NO, J2-8 NC,

J2-9 common

Standard Signal #1 J2-3 Binary Input Signal #1,

J2-4 Ground

Standard Signal #1 External Auto Stop, J2-1 Binary Input Signal #1,

J2-2 Ground

Standard Signal #2 Emergency stop J2-3 Binary Input Signal #2,

J2-4 Ground

1F1 Standard not for field use

1F2 Standard not for field use

1T1 Standard not for field use

1Q1 Standard not for field use

1Q3 Standard not for field use

1X1 Terminal Block Standard

1A4 Quad High Voltage
Input

1A19 Standard Dual LV
Binary input module

1A5 Quad Relay
Output modules
1A5 Quad Relay
Output modules
1A6 Dual High Voltage
Input
1A6 Dual High Voltage
Input
1A9 Standard Quad
Relay Output Status
1A9 Standard Quad
Relay Output Status

1A9 Standard Quad
Relay Output Status

1A13 Dual LV Binary
input module

1A13 Dual LV Binary
input module

Oil Differential Pressure
Switch

LLID Power Supply Transformer
Primary Circuit protection

Oil Pump Motor Branch Circuit
protection
Control Panel Power
Transformer ; 120:24Vac
Circuit Breaker Compressor
Motor Controller Control Power
Branch Circuit
Circuit Breaker – Module [­LLID] Power Supply Branch
Circuit
Control Panel Terminal Block,
Flow switch connections

1X1-5 Chilled water flow
switch input
1X1-6 Condenser water flow
switch input

CVGF-SVU02B-E4

50

EXOP Extended Operation Option
The following modules (1A17, 1A18) are provide when this control package is specified.

EXOP Signal #1 J2-2 Input #1,

J2-3 Ground

EXOP Signal #2 Refrigerant monitor inputs J2-5 Input #2,

J2-6 Ground

EXOP Signal #1 External Base Loading J2-1 Binary Input Signal #1,

Enable or Disable input, points J2-2 Ground

EXOP Signal #2 External Hot Water Control J2-3 Binary Input Signal #2,

Enable or Disable input J2-4 Ground

Refrigerant Monitor Input 1A17

Analog type input 4-20ma input signal to the 1A17 J2-5 to J2-6 (ground). This represents 0-100 ppm.

TRMM TRM4 TRM5 (Tracer Comm 4, Comm 5 interface)

TRM4 / TRM5 Tracer Communications J2-1 COMM+, J2-2 COMM -J2-3,

COMM +J2-4, COMM -,

CDRP (Condenser Refrigerant Pressure Output) (1A15)

CDRP Signal #2 J2-4 Output #2, J2-6 Ground

CDRP Signal #1 J2-1 Output #1, J2-3 Ground

1A17 Optional Dual Analog
Input/Output Module

1A17 Optional Dual Analog
Input/Output Module
1A18 Optional Dual LV Binary
input module
1A18 Optional Dual LV Binary
input module

External Base Loading
Setpoint input

1A14 Optional
Communication
Interface Module

1A15 Optional Dual Analog
Input/output Module

Condenser Refrigerant
Pressure output

Control System
Components

OPST Operation Status Option
Relay output module 1A8 provide relay outs as shown:

OPST Relay #1 MAR Alarm Relay, J2-1 NO, J2-2 NC,

(Non-Latching) J2-3 common

OPST Relay #2 Limit Warning Relay, J2-4 NO, J2-5 NC,

J2-6 common

OPST Relay #3 MMR Alarm Relay J2-7 NO, J2-8 NC,

(Latching) J2-9 common

OPST Relay #4 Compressor running relay J2-10 NO, J2-11 NC,

J2-12 common

1A8 Optional Quad Relay
Output Status
1A8 Optional Quad Relay
Output Status
1A8 Optional Quad Relay
Output Status
1A8 Optional Quad Relay
Output Status

1A15 Optional Dual Analog
Input/output Module

Percent RLA Compressor
Output

CVGF-SVU02B-E4

51

CDRP Refrigerant Pressure
Output Option 1A15:

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

This output is located at 1A15­J2-4(+) to J2-6 (ground)

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

A) Condenser Pressure Output.

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

Temperature based

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

If the Condenser Saturated
Temperature goes out of range
due to an open or short, a
pressure sensor diagnostic will
be called and the output will also
go to the respective out of range
value. That is, for an out of range
low on the sensor, the output
will be limited to 2.0 Vdc. For an
out of range high on the sensor,
the output will be limited to 10.0
Vdc.

Control System
Components

Figure 18.

CAP

10 vdc

2 vdc

0 PSIA

0 Percent

HPC in PSIA

100 Percent

CVGF-SVU02B-E4

52

Control System
Components

Figure 19. Delta pressure setting

B) Refrigerant Differential Pressure
Indication Output:

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

The “Minimum Delta Pressure“
is typically set to 0 psi and will
then correspond to 2 Vdc. The
“Maximum Delta Pressure “ is
typically set to 30 psi and
corresponds to 10 Vdc.

The Minimum Delta Pressure
Calibration setting has a range of
0-400 psid (0-2758 kPa) in
increments of 1 psid (1kPa). The
Maximum Delta Pressure
Calibration setting has a range of
1-400 psid (7-2758 kPa) in
increments of 1 psid (1kPa). The
condenser refrigerant pressure is
based on the Condenser
Refrigerant Temperature sensor.
The evaporator refrigerant
pressure is based on the
Saturated Evaporator Refrigerant
Temperature Sensor.

10 vdc

2 vdc

Minimum Delta

Pressure Setting

Maximum Delta

Pressure Setting

CVGF-SVU02B-E4

53

Percent RLA Output

2 to 10 Vdc corresponding to 0
to 120% RLA. With a resolution
of 0.146%. The Percent RLA
Output is polarity sensitive.

The following graph illustrates
the output:

Control System
Components

GBAS (Generic Building Automation System)

GBAS Signal #1 Percent RLA Compressor Output J2-1 Output #1, J2-3 Ground

GBAS Signal #2 J2-4 Input #2, J2-6 Ground

GBAS Signal #1 J2-2 Input #1, J2-3 Ground

GBAS Signal #2 External Current limit Setpoint J2-5 Input #2, J2-6 Ground

Figure 20. Voltage versus percent RLA

Voltage versus Percent RLA

Voltage

Percent RLA

1A15 Optional Dual
Analog Input/output
Module
1A15 Optional Dual
Analog Input/output
Module

1A16 Optional Dual
Analog Input/output
Module
1A16 Optional Dual
Analog Input/output
Module

Condenser Rerigerant Pressure
or Evaporator/Condenser
differential

Chilled Water Reset input, or
External Chiller Water Setpoint

CVGF-SVU02B-E4

54

External Chilled Water Setpoint
(ECWS)

The External Chilled Water
Setpoint allows the chilled water
setpoint to be changed from a
remote location. The External
Chilled Water Setpoint is found
on 1A16 J2-2 to J2-3 (ground).
2-10 Vdc and 4-20 mA
correspond to a 0 to 65°F (-17.8
to 18.3°C) CWS range.

External Current Limit Setpoint

The External Current Limit is an
option that allows the current
limit setpoint to be changed
from a remote location. The
External Limit Setpoint is found
on 1A16 J2-5 to J2-6 (ground),
2-10 Vdc and 4-20 mA each
correspond to a 40 to 120
percent RLA range. CH530 limits
the maximum ECLS to 100
percent.

Module Characteristics

1A1, Power Supply :

Unit Control Power Supply
Module Converts 27 Vac to 24
Vdc.

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

Frequency: 50-60 Hz

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

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

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

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

Binary Input Signal #1 J2-1 to 2

Binary Input Signal #2 J3-1 to 2

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

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

14-26 AWG with a maximum of
two 14 AWG

Power, 24 +/- 10 percent Vdc, 20
mA maximum. Trane IPC3
protocol. J1-1 +24Vdc, J1-2
Ground, J1-3 COMM +, J1-4
COMM -

Control System
Components

CVGF-SVU02B-E4

55

1A5, 1A8, 1A9 Quad Relay Output
Status:

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

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

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

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

Relay Outputs: at 120 Vac: 7.2
Amps resistive, 2.88 Amps pilot
duty, 1/3 HP, 7.2 FLA, at 240 Vac:
5 Amps general purpose 14-26
AWG, two 14 AWG Maximum
Power, 24

±10 percent Vdc, 100 mA
maximum. Trane IPC3 protocol.

1A13, 1A18, 1A19, 1A24 Dual
Binary input module:

J2-1 Binary Input Signal #1, J2-2
Ground, J2-3 Binary Input Signal
#2, J2-4 Ground

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

14 - 26 AWG with a maximum of
two 14 AWG

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

1A14 Communication interface
Module

Power, 24 ± 10 percent Vdc, 50
mA maximum. Trane IPC3
protocol.

Control System
Components

1A14 Communication Polarity

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

CVGF-SVU02B-E4

56

1A15, 1A16, 1A17, Dual Analog
Input/output Module;

Analog Output: The Analog
Output is a voltage only signal.
2-10 Vdc at 22mA

J2: 14 - 26 AWG with a
maximum of two 14 AWG

J2-1 Output #1 to J2-3 (ground),
J2-4 Output #2 to J2-6 (ground).

CH530 provides a 2-10 Vdc
analog signals as Outputs. The
Output’s maximum source
capability is 22mA. The
maximum recommended length
to run this signal is included in
the table below.

Analog Input:

The analog input can be
software switched between a
voltage input or a current input.
When used as a current input a
200 Ohm load resistor is
switched in.

0-12 Vdc or 0-24 mA Analog Inputs

CH530 accepts either a 2-10 Vdc
or 4-20 analog input suitable for
customer external control. The
type is determined at unit
commissioning during feature
installation.

J2: 14-26 AWG with a maximum
of two 14 AWG

J2-2 Input #1 to

J2-3 (ground).

J2-5 Input #2 to

J2-6 (ground).

Power, 24 +/- 10 percent Vdc, 60
mA maximum, Trane IPC3
protocol.

Control System
Components

Maximum Length to Run external Output signals

Gauge Ohms per Foot Length (Feet) Length (Meters)

14 0.00 2823 1062.7 324
16 0.004489 668.3 203.8
18 0.007138 420.3 128.1
20 0.01135 264.3 80.6
22 0.01805 166.3 50.7
24 0.0287 104.5 31.9
26 0.04563 65.7 20
28 0.07255 41.4 12.6

Note: the above table is for copper conductors only.

CVGF-SVU02B-E4

57

Note: If the chiller is operating in
a limit mode (current limit,
condenser limit, evaporator
limit, and so forth), the limit
operation has priority over all
DynaView™manual modes of
operation.

On each CH530 power-up, the
inlet guide vanes are driven full
closed to recalibrate the zero
position (steps) of the Stepper
motor vane actuator.

Motor Temperature Sensor
Module

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

Temperature Sensors

Evaporator entering 4R6
Evaporator leaving 4R7
Condenser entering 4R8
Condenser leaving 4R9
Oil temperature 4R5
Outdoor air 4R13
Evaporator saturated refrigerant
4R10
Condenser saturated refrigerant
4R11

Probe Operating Temperature
Range -40 to 121°C

Accuracy± 0.250°C over the
range - 20 to 50°C ± 0.50°C over
the range -40 to 121°C

Starter Module

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

The starter module is present in
all starter selections. This
includes Wye Delta, Across the
Line, and Solid State whether
remote unit mounted or supplied
by others. The starter module
provides the logic to provide the
motor protection for current
overload, phase reversal, phase
loss, phase imbalance, and
momentary power loss.

Control System
Components

CVGF-SVU02B-E4

58

Electrical Sequence

This section will acquaint the
operator with the control logic
governing chillers equipped with
Tracer CH530 control systems.

Note: The typical wiring
diagrams are representative of
standard units and are provided
only for general reference. They
may not reflect the actual wiring
of your unit. For specific
electrical schematic and
connection information, always
refer to the wiring diagrams that
shipped with the chiller.

With the supply power
disconnect switch or circuit
breaker (2Q1 or 2K3) on, 115-volt
control power transformer 2T5
and a 15-amp starter panel fuse
(2F4 ) to terminal (2X1-1) starter
panel to terminal 1X1-1 in the
control panel. From this point,
control voltage flows to:

1. Circuit Breaker 1Q1 which
provides power to the starter
module (2A1) relay outputs
and the High Pressure Cutout
switch (4S1).

2. Circuit Breaker 1Q3 which
provides power to
Transformer (1T1) which steps
down the 115 Vac to 24 Vac.
This 24 Vac then powers the
24 Vdc power supply 1A1, and
1A2 if present. The 24 Vdc is
then connected to all modules
using the IPC Bus providing
module power. 1Q3 also
provides power to the
external chiller water proof of
flow device connected
between terminal block
1X1-5 to 1A6-J3-2, and
condenser water proof of flow
device connected at 1X1-6 to
1A6-J2-2.

3. The DynaView

™

display
module 1A22, receives 24 Vdc
power from the IPC bus.

Control System
Components

CVGF-SVU02B-E4

59

CH530 and Wye-Delta
Starter Control Circuits
(Sequence of Operation)

Logic Circuits within the various
modules will determine the
starting, running, and stopping
operation of the chiller. When
operation of the chiller is
required the chiller mode is set
at ‘‘Auto.” Using customer­supplied power, the chilled water
pump relay (5K1) is energized by
the 1A5 Module output at 1A5­J2-4, and chilled water flow must
be verified within 4 minutes 15
seconds by the 1A6 module. The
main processors logic decides to
start the chiller based on the
differential to start setpoint. With
the differential to start criteria
met module 1A5 then energizes
the condenser water pump relay
(5K2) using customer-supplied
power at 1A5 J2-1.

Based on the restart inhibit
function and the differential to
start setpoint, oil pump (4M3)
will be energized by 1A9 module
(1A9-J2-7). The oil pressure
switch must be closed for 30
continuous seconds and
condenser water flow verified
within 4 minutes 15 seconds for
the compressor start sequence
to be initiated.

When less than 5 seconds
remain before compressor start,
a starter test is conducted to
verify contactor state prior to
starting the compressor. The
following test or start sequence
is conducted for “Wye-Delta”
starters:

1. Test for transition complete
contact open (1A23X or
2A1-J12-2) –160 to 240 msec.
An MMR diagnostic will be
generated if the contact is
closed.

2. Delay time - 20 msec.

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

4. Delay time - 200 msec.
(Opens 2K1).

5. Close shorting contactor,
(2K3) and check for no current
(1A23 or 2A1 J4-1) for one
second. If currents are
detected the MMR diagnostic
‘‘Starter Fault Type II’’ is
generated. (Starter Integrity
test)

6. If no diagnostics are
generated in the above tests,
the stop relay (2A1- J10) is
closed for two seconds and
the start relay (2A1-J8) is
closed to energize the start
contactor (2K1).

Control System
Components

CVGF-SVU02B-E4

60

The shorting contactor (2K3)

has already been energized
from (F) above. The
compressor motor (4M1) starts
in the “Wye” configuration, an
auxiliary contact (2K1-AUX)
locks in the start contactor
(2K1) coil.

7.After the compressor motor
has accelerated and the
maximum phase current has
dropped below 85 percent of
the chiller nameplate RLA for

1.5 seconds, the starter
transition to the “Delta”
configuration is initiated.

8.The transition contactor (2K4)
is closed through relay 2A1-J2,
placing the transition resistors
(2R1, 2R2, and 2R3) in parallel
with the compressor motor
windings.

9.The shorting contactor (2K3) is
opened through the opening
of relay 2A1-J4 100 msec after
the closure of the transition
relay 2A1-J2.

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

2.35 seconds through the
closure of the transition
complete contacts 2K2- AUX
at module 2A1-J12 input.

11. The starter module must now
confirm closure of the
transition complete contact
(2K2- AUX) within 2.32 to

2.38 seconds after the run
relay (2A1-J6) is closed.
Finally, the transition relay
(2A1-J2) is opened de­energizing the transition
contactor (2K4) and the
compressor motor starting
sequence is complete.

An MMR diagnostic will be
generated if the transition
complete contacts (2K2-AUX) do
not close.

Now that the compressor motor
(4M1) is running in the “Delta”
configuration, the inlet guide
vanes will modulate, opening
and closing to the chiller load
variation by operation of the
stepper vane motor actuator
(4M2) to satisfy chilled water
setpoint. The chiller continues to
run in its appropriate mode of
operation: Normal, Softload,
Limit Mode, and so forth

Control System
Components

CVGF-SVU02B-E4

61

Control System
Components

If the chilled water temperature
drops below the chilled water set
point by an amount set as the
“differential to stop” setpoint, a
normal chiller stop sequence is
initiated as follows:

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

2. After the 50 seconds has
elapsed, the stop relay (2A1­J10) and the condenser water
pump relays (1A5-J2) open to
turn off. The oil pump motor
(4B3) will continue to run for 1
minute post-lube while the
compressor coasts to a stop.
The chilled water pump will
continue to run while the
Main processor module
(1A22) monitors leaving
chilled water temperature
preparing for the next
compressor motor start based
on the “differential to start”
setpoint.

If the <STOP> key is pressed on
the operator interface, the chiller
will follow the same stop
sequence as above except the
chilled water pump relay (1A5­J2) will also open and stop the
chilled water pump after the
chilled water pump delay timer
has timed out after compressor
shut down.

If the “Immediate Stop” is
initiated, a panic stop occurs
which follows the same stop
sequence as pressing the
<STOP> key once except the
inlet guide vanes are not
sequence closed and the
compressor motor is
immediately turned off.

CVGF-SVU02B-E4

62

Machine Protection and
Adaptive Control

Momentary Power Loss (MPL)
Protection

Momentary power loss detects
the existence of a power loss to
the compressor motor and
responds by initiating the
disconnection of the compressor
motor from the power source.

Power interruptions of less than
30 line-cycles are defined as
momentary power losses. Tests
have shown that these short­term power interruptions can be
damaging to the motor and
compressor if the chiller is
reconnected to the line while the
motor and line phases do not
match. The chiller will be shut
down when a MPL is detected
and will display a non-latching
diagnostic indicating the failure.

The oil pump will be run for the
post-lube time period when
power returns. The compressor
and compressor motor are
protected from damage from
large torques and inrush
currents resulting from
reconnecting the compressor
motor to the power source
following a momentary loss of
power.

MPLs greater than 2 or 3 cycles
are detected resulting in unit
shut down. Disconnection from
the line is initiated within 6 line­cycles of the power loss. MPL
protection is active anytime the
compressor is in the running
mode. (The transition complete
input has been satisfied.)

Note: MPL is defaulted to
enabled however can be
disabled, if required using
TechView™.

Machine Protection
and Adaptive

CVGF-SVU02B-E4

63

Figure 21. CVGF sequence of operation: momentary power loss, (DynaView™and starter module

remain

powered)

Momentary Power
Loss Detected

Momentary Power Loss Cleared
and Need to Cool

Shutting Down

Waiting to Start

Running

Starting

Compressor

Enforce Power Up Delay Timer

Establish Condenser Water Flow

(6 Second Minimum)

Close IGV (0-50 Seconds)

Command IGV Closed

Energize Condenser
Water Pump Relay

Confirm Condenser Water Flow Within 4
minutes 15 seconds (6 Second Filter)

Enforce Restart Inhibit Timer (30 Minutes)

De-Energize
Compressor

Confirm No Compressor Currents
Within 0-30 Seconds

De-Energize Condenser
Water Pump Relay

Machine Protection and
Adaptive

CVGF-SVU02B-E4

64

Machine Protection and
Adaptive

Current Overload
Protection

Motor currents are continuously
monitored for over current
protection and locked rotor
protection. This protects the
chiller from damage due to
current overload during starting
and running modes but is
allowed to reach full load amps.
This overload protection logic is
independent of the current limit.
The overload protection will
ultimately shut the unit down
anytime the highest of the three
phase currents exceeds the time
trip curve. A manual reset
diagnostic describing the failure
will be displayed.

Overload protection for the
motor starts based on the
maximum time to transition
permitted for a particular motor.

Running Overload Protection

In the run mode, a time trip
curve is looked at to determine if
a diagnostic should be called.
The starter LLID continuously
monitors compressor line
currents to provide running
overload and locked rotor
protection.

Overload protection is based on
the line with the highest current.
It triggers a manually resettable
diagnostic shutting down the
compressor when the current
exceeds the specified time trip
curve. The compressor overload
time trip curve is expressed as a
percent of the RLA of the
compressor and is not
adjustable:

Overload Must Hold = 102
Percent RLA.

Overload Must Trip in 20 (+0 -3)
seconds = 112 Percent RLA

(Note the above gives a nominal
20 seconds must trip point of
107 Percent RLA.)

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

The time trip curve is as follows:

Figure 22. Overload time trip versus percent RLA

Nominal Triptime
(Sec)

Minimum Triptime
(Sec)

Maximum Triptime
(Sec)

CVGF-SVU02B-E4

65

Current Limit Protection

Current Limit Protections exist to
avoid motor current overload
and damage to the compressor
motor during starting and
running.

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

Compressor motor current is
continuously monitored and
current is controlled using a
limit function to prevent running
into overload diagnostic trips.
The current limit control logic
attempts to prevent the motor
from shutting down on a
diagnostic trip by limiting
compressor current draw
relative to an adjustable current
limit DynaView

™

CLS.

This setpoint can also be
lowered to provide electrical
demand limiting on the unit as
required. This could also be set
to allow the chiller to continue to
run at a lower load to avoid
tripping off using a diagnostic.

The Current Limit function uses
a PID algorithm (similar to the
Leaving Water Temperature
control) that allows the chiller to
run at the CLS. At machine
startup, or with any setpoint
change the new current limit
setpoint reached after the
filtered setpoint time elapses.
The minimum current limit
setpoint is default set to 40
percent RLA (20-100 percent).
The filtering time default is set
to 10 minutes (0-120 minutes);
however these can be altered
using the TechView™. This
filtered setpoint allows for stable
control if the Current Limit
setpoint is adjusted during a run.

Phase Loss Protection

Loss of phase detection protects
the chiller motor from damage
due to a single-phasing
condition. The controls will shut
down the chiller if any of the
three phase currents feeding the
motor are lost. The shutdown
will result in a latching
diagnostic indicating the failure.

Reverse Rotation
Protection

This function protects the
compressor from damage
caused by being driven in the
reverse direction. Incorrect
phase rotation detection results
in a manually resettable
diagnostic. Phase Reversal
protection default is set to
enable, however can be disabled
using TechView™.

Machine Protection and
Adaptive

CVGF-SVU02B-E4

66

Differential to Start or Stop

The Differential to Start setpoint
is adjustable from 1 to 10°F (0.55
to 5.5°C) and the Differential to
Stop setpoint adjustable from 1
to 10°F (0.55 to 5.5°C). Both
setpoints are with respect to the
Active Chilled Water Setpoint.
When the chiller is running and
the Leaving Water Temperature
(LWT) reaches the Differential to
Stop setpoint the chiller will go
through its shutdown sequence
to Auto. Reference Figure 10.

SoftLoading

Softloading stabilizes the startup
control during the initial chiller
pulldown. Soft loading is used to
bring the building loop
temperature from its start value
to the Chilled Water or Hot Water
Setpoint in a controlled manner.
Without soft loading, the chiller
controls will load the chiller
rapidly and use the full chiller
capacity to bring the loop
temperature to setpoint.
Although the start temperature
of loop may have been high, the
actual system load may be low.
Thus, when the setpoint is met
the chiller must unload quickly
to the system load value. If it is
not able to unload quickly
enough, the supply water
temperature will drop below
setpoint and may even cause the
chiller to cycle off. Soft loading
prevents the chiller from going
to full capacity during the
pulldown period. After the
compressor has been started,
the starting point of the filtered
setpoint is initialized to the value
of the Evaporator Leaving Water
temperature and the percent
RLA.

Minimum and Maximum
Capacity Limit

A Minimum Capacity can be set
to limit the unloading ability of
the compressor forcing
differential stop to be reached
cycling the chillers. Minimum
capacity limit will be displayed
when in this limit mode. This
indicates when the chiller is
running fully unloaded. Similarly
a maximum capacity can be set
to limit normal chilled water
temperature control. The
maximum capacity relay is
energized which is a signal used
by generic BAS systems to start
another chiller.

The minimum (default at 0
percent) and maximum (default
at 100 percent) capacity are
adjustable using TechView™.

There are three independent
Softload setpoints:

• Capacity Control Softload Time
default is to 10 minutes and
settable from 0-120 minutes.
This setting controls the time
constant of the Filtered Chilled
Water Setpoint.

• Current Limit Control Softload
Time default is 10 minutes and
settable from 0-120 minutes.
This setting controls the time
constant of the Filtered Current
Limit Setpoint.

• Current Limit Softload Starting
Percent default is 40 percent
RLA and settable from 20-100
percent. This setting controls
the Starting point of the
Filtered Current Limit Setpoint.

Note: TechView

™

provides

access to these three setpoints.

Machine Protection and
Adaptive

CVGF-SVU02B-E4

67

Evaporator Limit

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

Evaporator limit could occur
with an initial pulldown of a loop
temperature where the
condenser is colder than the
evaporator (inverted start), and
the evaporator refrigerant
temperature may drop below the
LRTC. This limit prevents the
unit from shutting down on a
diagnostic during this type of
pulldown. Another example is a
chiller that is low on refrigerant
charge. It will run with low
evaporator refrigerant
temperatures. This limit allows
the chiller to continue to run at a
reduced load.

Evaporator Limit uses the
Evaporator Refrigerant
Temperature sensor in a PID
algorithm (similar to the Leaving
Water Temperature control) that
allows the chiller to run at the
LRTC + 2 degree F (1.1°C).

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

Leaving Water Temperature
Cut-out

Leaving water temperature
cutout is a safety control that
protects the chiller from damage
caused by water freezing in the
evaporator. The cutout setpoint
is factory set at 36°F (2.2°C)
however is adjustable with
TechView™. The cut-out strategy
is illustrated in Figure 23.

The Leaving Water Temperature
Cut-out Setpoint is
independently adjustable from
the chilled water setpoint.
Shutdown of the compressor
due to violation of the Leaving
Water Temperature Cut-out
results in an automatically
resettable diagnostic (MAR). The
DynaView™Operating Mode
indicates when the Leaving
Water Temperature Cut-out
Setpoint conflicts with the
chilled water temperature
setpoint by a message on the
display. The Leaving Water
Temperature Cutout Setpoint
and chilled water setpoint, both
active and front panel, are
separated by a minimum of

1.7°F (0.94°C). (See Cut-out
Strategy Figure 23.) When either
difference is violated, the CH530
does not permit the above
differences to be violated and
the display exhibits a message
to that effect and remains at the
last valid setpoint. After violation
of the Leaving Water
Temperature Cut-out Setpoint
for 30°F (16.7°C) seconds the
chiller will shutdown and
indicate a diagnostic.

Low Refrigerant
Temperature Cut-out

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

Machine Protection and
Adaptive

CVGF-SVU02B-E4

68

Figure 23. Cutout strategy

Machine Protection and
Adaptive

Condenser Limit

Condenser pressure is
continuously monitored to
provide a limit function that
prevents High Pressure Cutout
(HPC) trips. This protection is
called Condenser Refrigerant
Pressure Limit, or High Pressure
Limit. A fully loaded compressor,
operating at high Evaporator
Leaving Water Temperature
(ELWT) and high condenser
temperatures causes high
condenser pressures. The
purpose of this limit is to avoid
HPC trips by allowing the chiller
to continue to run at a lower
load instead of tripping off using
HPC.

The Condenser Limit will be
based on a pressure conversion
from the Condenser Refrigerant
Temperature sensor. When
limited by this action,
“Condenser Pressure Limit” will
be displayed as a sub-operating
mode.

The Condenser Limit Setpoint is
factory set (93 percent of HPC),
however can be changed using
TechView

™

.

Chilled-Water Set Point

Differential to stop

adjustment range

X degrees minimum differential

Y degrees minimum
differential

Evaporator leaving-water
temperature cutout

Evaporator refrigerant
temperature cutout

Hold

Evaporator
limit

Integrate to trip

Evaporator limit set point

Limit loading

Unload

2°F (1.1°C)

0.5°F (0.28°C)

2.5°F (1.36°C)

CVGF-SVU02B-E4

69

Restart Inhibit

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

Restart Inhibit Function Using
Time Base

This method uses straight start­to-start timer to determine when
to allow the next start. A Restart
Inhibit Start-to-Start Time
setpoint is used to set the
desired start-to-start time.

Default is 20 minutes and can be
altered using the TechView

™

. A
time based restart inhibit
function is used if the Restart
Inhibit Type is set to ‘Time’ using
TechView™or if the motor
winding temperatures are
determined to be invalid.

Note: When the start is inhibited
by the restart inhibit function,
the time remaining will be
displayed along with the restart
inhibit mode. There is no ‘free’
start on a power up of the MP
since a real time clock is used to
determine when the next start
will be allowed based on the
start time of the previous start.

Low Oil Temperature Start Inhibit

When oil temperature is at or
below the low oil temperature
start inhibit setpoint (80­140°F/26.7-60°C), the heater is
energized to raise the oil
temperature.

Low oil temperature is indicative
of refrigerant dilution in the oil.
Oil temperature is used to
estimate this dilution since the
oil temperature directly
corresponds to amount of
refrigerant dilution in the oil. It is
required that oil contains
minimal refrigerant in it. This is
accomplished by boiling the
refrigerant out of the oil by
maintaining a high enough oil
temperature.

If enhanced oil temperature
protection is disabled or below a
given Low Oil Temperature
Inhibit setting (default 95°F/35°C)
the compressor cannot be
started. This is an inhibit mode
and will be reported to the
operator interface.

The oil heater is energized in an
attempt to raise the oil
temperature over this inhibit
temperature setpoint. The
compressor is inhibited from
starting until the oil temperature
is raised 5°F (2.7°C) or more
degrees above this setpoint.

The Low Oil Temperature Start
Inhibit is tested on every start
unless a quick restart is being
performed during post-lube.

If the Enhanced Oil Temperature
Protection setting is enabled, the
Low Oil Temperature Start
Inhibit value is 136°F (57.8°C).

If the Enhanced Oil Temperature
Protection setting is not enabled,
the Low Oil Temperature Start
Inhibit value is settable with the
Low Oil Temperature Start
Inhibit Setpoint using the
TechView™.

Machine Protection and
Adaptive

CVGF-SVU02B-E4

70

Oil Temperature Control

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

If the oil temperature is at or
below the Low Oil Temperature
Cutout setpoint, this diagnostic
will be issued and stops the
compressor. This diagnostic is
ignored for the first 10 minutes
of compressor run. After that, if
the oil temperature falls below
this cutout temperature for more
than 60 consecutive seconds this
diagnostic is issued.

Low Oil Temperature Cutout

If the oil temperature is at or
below the Low Oil Temperature
Cutout, for more than 60
consecutive seconds this
diagnostic will be issued
stopping the compressor.

This diagnostic does not take
affect during the first 10 minutes
of compressor run.

High Oil Temperature Cutout

This is a latching diagnostic
resulting in an immediate
shutdown. Default Setpoint
value: 165°F (73.9°C)
Implemented to avoid
overheating of the oil and the
bearings.

If the oil temperature is at or
above the High Oil Temperature
Cut-out setpoint this diagnostic
will be issued, which will stop
the compressor. If Oil
Temperature violates this
temperature cut-out for more
than 120 seconds, this diagnostic
is issued.

Manual Oil Pump Control

The oil pump control accepts
commands to turn on the oil
pump. The manual oil pump
choices will be “Auto” or “On.”
When the oil pump is
commanded “On,” it will revert
to “Auto” in 10 minutes, and is
adjustable at DynaView

™

or

TechView™.

Controls Chilled Water Reset
(CWR)

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

When the CWR function is based
on return water temperature, the
CWR feature is standard. When
the CWR function is based on
outdoor air temperature, the
CWR feature is an option
requiring an outdoor
temperature sensor.

The type of CWR is selected in
the Operator Interface settings
Menu along with the Reset Ratio,
Start Reset Setpoint, and the
Maximum Reset Setpoint.

Machine Protection and
Adaptive

CVGF-SVU02B-E4

71

High Lift Unloading (500 Ton
Family Only)

High Lift Unloading Valve directs
discharge gases from the
condenser through a solenoid
valve directly into the
economizer. From the
economizer, this gas then flows
to the second stage compressor
where the economizer normally
is connected. The purpose of
HLUV is to increase the gas flow
rate through the second stage
compressor. Bypass gas is
allowed to occur using an inline
normally closed solenoid valve.
The high lift unloading function
is dependent on the lift (where
lift is defined as the difference
between Condenser Saturated
Refrigerant Temperature and the
Evaporator Saturated Refrigerant
Temperature) and on chiller load.
When the high lift unloading
mode is entered, the High Lift
Unloading valve is opened and
the inlet guide vane close travel
is limited.

The HLUV valve does not
modulate the flow rate, but
rather is either open or closed.
Further, the valve was sized to
handle a mass flow sufficient to
permit operation below 35% IGV
position but not necessarily to
0%. The valve was sized to
permit substantial but
incomplete unloading and yet
was kept as small as practicable
to minimize power requirements
with HLUV operation.

Not all CVGF chillers require the
bypassing of condenser gas. In
some tonnages, the High Lift
Unloading Valve and copper
lines do not exist. The LLID (1A9)
with the High Lift Unloading
relay always exists.

Note: There is noticeable noise,
due to gas flow, when the high
lift unloading valve is open.

Functional Description

The following equation
determines action of the high lift
unloading function:

Trigger IGV% = 0.98 * Lift + -

0.065 * CPIM + C

Where Lift is defined as
Condenser Saturated Refrigerant
Temperature minus Evaporator
Saturated Refrigerant
Temperature in °F. The CPIM is
the average impeller diameter in
inches times 100.

Machine Protection and
Adaptive

CVGF-SVU02B-E4

72

High Lift Unloading Solenoid

The normally open contact of a CH530 control relay powers the normally closed high lift unloading valve
solenoid with the following logic:

Function
De-energized De-energized Closed No condenser gas bypass
Energized Energized Open Bypass condenser gas

Machine Protection and
Adaptive

LLID Relay

State

High Lift Unloading

Valve Solenoid

High Lift

Unloading Valve

The high lift unloading valve
opens if the compressor is
running and the IGV position is
at or below the Trigger IGV% line
– 5%. The high lift unloading
valve closes when the IGV
position reaches the Trigger
IGV% + 5% or the compressor
shuts down.

Note that this 5% is of the full
IGV travel range of 100%. Also
note that operation of the high
lift unloading valve is
independent of the high lift
unloading limit mode as stated
below.

High Lift Unloading Limit Mode

For a Gear Drive chiller, the
minimum IGV position is 60% of
the Trigger IGV%. When the IGV
movement is being limited to the
60% of the Trigger IGV% point,
the high lift unloading limit
submode is displayed.

Compressor Start Up

At compressor startup, the
chiller is initialized as to not be
in high lift unloading. The rules
to enter high lift unloading mode
are as stated above. Also at
startup, sufficient time should be
allowed so that an accurate
Trigger IGV% may be calculated.
Here non-saturated conditions
exist right away resulting in
unstable temperature
measurements.

Manual Capacity Control

This is the Compressor Control
Signal mode override in
DynaView™. Here high lift
unloading solenoid valve
operation, 60% of the Trigger
IGV% and displaying of the high
lift unloading limit submode is
obeyed.

Chiller Shutdown

The high lift unloading valve is
normally closed (de-energized).
There is no check performed to
ensure the valve is closed without
using TechView™.

CVGF-SVU02B-E4

73

Pre-Commissioning Bump
Start Procedure

Note: The following procedure is

a requirement prior to the first
start of the chiller. Failure to
complete may result in damage
to the compressor and void the
warranty.

Procedure

1. Complete all control settings.

2. Ensure water flows in the
condenser and evaporator are
correct according to the pre­commissioning procedures.

3. Ensure the unit has been
charged with the correct
amount of refrigerant and oil
and that the oil is the proper
operating temperature.

4. Complete a phase rotation test
if the voltage is less than 600
volts.

The following checks require
TWO personnel to complete.
During the bump start of the
compressor, one person will look
at the rotor from the rear of the
motor through the sight glasses
to determine correct direction.
Looking at the sight glass, the
direction will be counter­clockwise. Do not check the
rotation of the motor after the
start sequence has completed as
the indication may be incorrect.

5. With the voltage applied to the
mains on the starter, place the
chiller in Auto mode.

6. After the pre-lube is complete,
let the starter energize the
motor, permitting a start.

7. After three seconds, activate
the emergency stop by
pressing the Immediate Stop
button at the CH530 twice in
quick succession. During this
three second period, the rotor
should be seen to rotate in a
counter-clockwise direction.

8. If the direction is incorrect, the
3 phases must be isolated
from the power source and
two legs swapped to obtain
the correct direction.

Unit
Startup

CVGF-SVU02B-E4

74

Unit Startup

Unit Start-Up Procedures

Daily Unit Start-Up

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

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

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

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

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

5. Check the current limit
setpoint and readjust it, if
necessary, in the chiller
settings menu.

6. Press <AUTO>.

Next, the CH530 checks the
leaving evaporator water
temperature and compares it to
the chilled water setpoint. If the
difference between these values
is less than the start differential
setpoint, cooling is not needed.

If the CH530 determines that the
difference between the
evaporator leaving water
temperature and chilled water
setpoint exceeds the start
differential setpoint, the unit
enters the initiate in the start
mode, the oil pump and the
condenser water pump are
started. If condenser water flow
is not proven (flow switch 5S2
does not close) within 4 minutes
15 seconds, the unit is locked out
on a MMR Diagnostic.

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

When less than 5 seconds
remain on the restart inhibit, the
pre-start test is conducted on Y­Delta starters. If faults are
detected, the unit’s compressor
will not start, and a MMR
Diagnostic will be generated.

Note: Whenever the CH530
detects a MMR diagnostic
condition during start-up, unit
operation is locked out, and
manual reset is required before
the start-up sequence can begin
again. If the fault condition has
not cleared, CH530 will not
permit restart.

When the cooling requirement is
satisfied, the CH530 originates a
“Shutting down” signal. The
inlet guide vanes are driven
closed for 50 seconds, and the
unit enters a 1 minute post-lube
period. The compressor motor
and condenser water pump
starter are de-energized
immediately, but the oil pump
continues to run during this 3
minute interval; the evaporator
pump will continue to run. Once
the post-lube cycle is done, the
unit returns to auto mode.

Unit
Startup

CVGF-SVU02B-E4

75

Seasonal Unit Start-Up

Note: The following procedure is

a requirement prior to the first
start of the chiller. Failure to
complete may result in damage
to the compressor and void the
warranty.

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

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

3. Vent and fill the cooling tower,
if used, as well as the
condenser and piping. At this
point, all air must be removed
from the system (including
each pass). Then close the
vents in the condenser water
boxes.

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

5. If the evaporator was
previously drained, vent and
fill the evaporator and chilled
water circuit. When all air is
removed from the system
(including each pass), close
the vent valves in the
evaporator water boxes.

6. Lubricate the external vane
control linkage as needed.

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

8. Complete all control settings.

9. Ensure water flows in the

condenser and evaporator are
correct according to the pre­commissioning procedures.

10. Close all disconnect

switches.

11. Ensure the unit has been

charged with the correct
amount of refrigerant and oil
and that the oil is the proper
operating temperature.

12. Complete a phase rotation

test if the voltage is less than
600 volts.

13. Perform instructions listed in

“Unit Start-up” section



WARNING

Live Electrical
Components!

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

CAUTION

Refrigerant Loss May
Occur:

To avoid excessive unit refrigerant
pressure above the relief valve
setting, follow these
recommended procedures:

• Do not run the pump for more
than 30 minutes after chiller shut­down.

Failure to avoid excessive
operation of the evaporator
water pump with Chiller off
may cause loss of refrigerant
charge.

• If the chilled water loop is used
for heating.

• Ensure that the evaporator is
isolated from the hot water loop
before changing over to the
heating mode.

Unit
Startup

CVGF-SVU02B-E4

76

Unit Shutdown

Unit Shutdown Procedures

Daily Unit Shutdown

Note: Refer to Start-Run

Shutdown sequence (Figure 9).

1. Press <STOP>.

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

Seasonal Unit Shutdown

CAUTION

Refrigerant in Oil Pump

Damage may occur

The control power disconnect
must remain closed to allow oil
sump heater operation. Failure to
do this will allow refrigerant to
condense in the oil pump.

3. Open all disconnect switches
except the control power
disconnect switch.

4. Drain the condenser piping
and cooling tower, if used.

5. To drain the condenser,
remove the drain and vent
plugs from the condenser
headers.

6. Once the unit is secured for
winter, the maintenance
procedures described under
“Annual Maintenance” in the
Periodic Maintenance section
of this manual should be
performed by authorized
Trane service technicians.



WARNING

Refrigerant Discharge
Hazard!

DO NOT ALLOW CHILLER TO
INCREASE IN TEMPERATURE OR
PRESSURE WHILE THE UNIT IS
OFF.

Continuous running of pumps
while the chiller is off can increase
the temperature or pressure and
will result in premature release of
refrigerant causing bodily harm
and possible death to anyone in
contact with refrigerant discharge

Unit
Shutdown

CVGF-SVU02B-E4

77

Periodic Maintenance

Overview

Use of a periodic maintenance
program is important to ensure
the best possible unit
performance and efficiency.

Daily Maintenance Checks

Check the chiller’s evaporator
and condenser pressures, and
discharge oil pressure.

IMPORTANT: IT IS HIGHLY
RECOMMENDED THAT THE
OPERATING LOG BE
COMPLETED ON A DAILY BASIS.

Check the oil level in the chiller oil
sump using the two sight glasses
provided in the oil sump head.
When the unit is operating, the oil
level should be visible in the lower
sight glass.

Weekly Checks

Check the following after the
machine has been in operation for
at least 30 minutes:

1. Chilled water and condenser

water entering and leaving
temperatures.

2. Current drawn by the

compressor (Amps).

3. Oil level in the oil sump. The oil

level must be visible in the sight
glass.

4. Condenser pressure, evaporator

pressure.

5. Unusual noise, vibration, and so

forth

It is strongly recommended that
unit readings and observations are
recorded on a weekly log sheet.

The acceptance of a warranty claim
may depend on this.

Annual Checks

The yearly maintenance should be
performed by an authorized Trane
service technician. It should include
weekly checks.

1. Check setting and operation of
all controls and safety devices.

2. Leak test the entire machine for
refrigerant leaks.

3. Check starter contactors for wear
and replace if required.

4. Check motor winding insulation.

5. Check motor amps draw.

6. Perform an oil analysis.

7. Perform vibration analysis.

8. Check and adjust the water flow

9. Check and adjust interlocks.

10. Clean condenser tubes.

Periodic
Maintenance

CVGF-SVU02B-E4

78

Condenser cleaning

Water available for cooling
condensers frequently contains
minerals that collect on the
condenser tube walls as carbonate
scale. Scale accumulation rate will
be increased by high condensing
temperatures and water with a
high mineral content.

Cooling towers, when used, may
collect dust and form material
that will deposit in the
condenser tubes forming sludge.

Scale and sludge formation is
indicated by high condensing
temperatures and large
differences between condensing
and leaving water temperatures.

To maintain maximum efficiency,
the condenser must remain free
of scale and sludge. Even a very
thin coating on the tube surface
may greatly decrease condenser
heat transfer capacity. Two
methods for cleaning condenser
tubes are mechanical and
chemical.

CAUTION

Proper Water Treatment!

The use of untreated or improperly
treated water in a CenTraVac may
result in scaling, erosion,
corrosion, algae and or slime
conditions. It is recommended that
the services of a qualified water
treatment specialist be engaged to
determine what water treatment,
if any, is required. Trane assumes
no responsibility for equipment
failures which result from
untreated or improperly treated
water, or saline or brackish water.

The mechanical method
removes sludge and loose
material from the condenser
tubes. Working a round nylon or
bristle brush attached to a rod, in
and out of the tubes loosens the
sludge. After cleaning, flush the
tubes with clean water.

The chemical method removes
scale deposits. The standard
condenser water circuit consists
of copper, steel and cast iron.
Any reliable water treatment
company will be able to
recommend a cleaning solution
for the job.

Note: Trane assumes no
responsibility if deterioration of
the unit is due to inadequate
water treatment.

Evaporator cleaning

The evaporator is part of a
closed water circuit and should
not accumulate an appreciable
amount of scale or sludge.
However, if cleaning should be
required, use the same methods
outlined for cleaning the
condenser.

Note: Trane assumes no
responsibility if deterioration of
the unit is due to inadequate
water treatment.

Periodic
Maintenance

CVGF-SVU02B-E4

79

Controls checkout and
adjustments

Controls are checked and
calibrated during run-in of the
unit prior to shipment. Any
adjustments should be made
exclusively by authorized Trane
service technician.

It is strongly recommended to
have proper functioning and
setpoints of all controls checked
once per year.

Control settings

For control calibration and
check-out, contact an authorized
Trane service technician.

Trouble Analysis

See the Diagnostic List for
trouble shooting information.
The diagnostic must be
analyzed, corrections made by
qualified personnel and the
latching diagnostic reset before
the chiller can be returned to
operation.

Diagnostic Codes

A Latching diagnostic will shut
down the machine or a part of
the machine if so indicated. A
latching diagnostic will require a
manual reset to restore
operation. A Non-latching
diagnostic will shut down the
machine or a part of the machine
if so indicated. A non-latching
diagnostic will automatically
reset when the condition causing
the diagnostic goes away. If a
diagnostic is informative only,
no machine action is taken
except to load a diagnostic code
into the last diagnostic register.
Unless otherwise stated, all
active diagnostics will be lost on
loss of power.

Leak Testing Procedure

To leak-test the CVGF, weigh a
one-pound charge of trace gas
and bring the pressure up to a
maximum of 75 psig (517 kPa)
using dry nitrogen. This pressure
has been found to be adequate
to find leaks in a CVGF when
using a sensitive electronic leak
detector. Set the scale to
“medium” which corresponds to
a 1/2-ounce (.015l) per year leak
rate and probe all joints
thoroughly. Be sure and relieve
the pressure in the unit before
evacuation or leak repair. Local
codes take precedence when
conducting evacuation.

WARNING



Hazard of Explosion!

Use only dry nitrogen with a
pressure regulator for pressurizing
unit. Do not use acetylene, oxygen
or compressed air or mixtures
containing them for pressure
testing. Do not use mixtures of a
hydrogen containing refrigerant
and air above atmospheric
pressure for pressure testing as
they may become flammable and
could result in an explosion.
Refrigerant, when used as a trace
gas should only be mixed with dry
nitrogen for pressurizing units.
Failure to follow these
recommendations could result in
death or serious injury or
equipment or property-only
damage.

Taking an Oil Sample

To obtain an accurate oil sample,
the chiller must be operating for
a minimum of 30 minutes. An
approved oil sample cylinder for
R134a should be used. Make
sure the upstream oil filter
isolation angle valve is
completely backseated in order
to close the 1/4 inch Schrader
valve port. Attach a low loss
hose or line with a Schrader
valve depressor to the oil
sampling 1/4 inch Schrader valve
located on the upstream oil filter
isolation valve.

Attach the other end of the hose
or the line to the oil-sampling
cylinder. Evacuate the cylinder
and hose or line to remove any
non-condensables or moisture.
Open the valve on the sample
cylinder. Turn the upstream oil
isolation angle valve stem
approximately one turn
clockwise to allow oil under
pressure to enter the sample
cylinder.

Periodic
Maintenance

CVGF-SVU02B-E4

80

Weigh the cylinder as the oil is
being transferred and shut off
the cylinder valve when the
desired weight of oil has been
transferred. Backseat the angle
valve to shut off oil flow and
remove the hose from the
Schrader valve. Be sure to
replace the Schrader and angle
valve cap and secure them when
sampling is complete. Recover
the oil and refrigerant from the
oil sample hose or line with an
approved R134a recovery unit.

When oil analysis indicates the
need to change the oil (high
acidity, moisture, and so forth),
use the following procedure for
removing the oil.

Removing Compressor Oil

Make sure the unit is not running
and the power has been
disconnected to the oil heaters.
To remove the compressor oil,
attach an oil recovery and
recharge hose or line to the oil
sump drain valve located on the
bottom of the oil sump (See
Figure 24. Attach the refrigerant
vapor return hose or line of the
recovery unit to the condenser
service valve. Open the oil sump
drain valve and condenser
service valve and activate the oil
recovery process according to
the operation specifications of
the recovery unit. After all the oil
has been recovered and residual
R134a refrigerant vapor returned
to the condenser, shut the oil
drain valve and condenser
service valve off and secure the
caps to both valves.

Periodic
Maintenance

Figure 24. CVGF compressor oil system component locations

Oil filter isolation valves

1/4” Schrader valve

Oil level sightglasses

Oil heater - 500 w

Oil sump drain valve

Oil Heater - 500 w

Oil filter cover

CVGF-SVU02B-E4

81

Periodic
Maintenance

Trane recommends subscribing
to an oil analysis program to
determine the condition of the
oil rather than changing the oil
on a periodic basis. This
program will reduce the chiller’s
lifetime oil consumption and
minimize refrigerant emissions.
The oil analysis should be
performed by a qualified
laboratory, experienced in
refrigerant and oil chemistry,
and the servicing of Trane
centrifugal chillers.

Oil Charging Procedure

Use appropriate oil as specified:

USA Europe
Oil 0037 Oil 021E
Oil 0049 Oil 0020E

CAUTION

OIL CONTAMINATION

Due to the hygroscopic properties
of POE oil, all oil must be stored in
metal containers. The oil will
absorb water if stored in a plastic
container.

Oil Charging

CVGF units ship factory charged
with 15 gallons (56.8 l) of oil and
a 5 psig (34 kPa) @ 70 °F (20°C)
dry nitrogen holding charge.

Note: The correct oil charge for
all CVGF units is 15 gallons (56.8
l) of Trane OIL00037 (Trane
OIL00037 is R134a miscible oil in
1-gallon (3.785 l) containers). A 5
gallon (18.9 l) container of Trane
approved R134a oil is available
(Trane OIL00049). As with
mineral oil, if water is in the
system it will react with the oil to
form acids. Use the following
table to determine the
acceptability of the oil.

Unit Charged With Refrigerant

1. Decant the oil from the
shipping container into the
cylinder of an oil recovery and
recharge unit per the unit
operation instructions (15
gallons (56.8 l) required).

2. A vacuum of at least 500
microns must be attained and
an oil temperature of at least
122°F (50°C) maintained to
remove existing moisture. A
standing vacuum rise test
should be performed after the
distillation process is
complete to insure the oil has
completely outgassed any
moisture or non-condensibles.
A vacuum rise of less than 100
microns (0.1 mm Hg) in a 2
hour period indicates the oil is
ready for transfer.

Moisture content

Acid Level

POE Oil
Properties

Acceptable
Levels

less than
300 ppm

less than

0.5 TAN (mg
KOH/g)

CVGF-SVU02B-E4

82

3. Attach the oil transfer hose of
the recovery unit oil pump to
the oil sump charging and
drain valve and evacuate.

4. Open the oil charging valve on
the bottom of the oil tank of
the CVGF and operate the oil
recovery and recharge unit oil
pump to charge the oil into
the tank.

5. When the oil is at the center of
the upper sight glass, stop the
transfer of oil.

6. Energize the oil heaters.

7. At the control panel, go to the
Service Tests menu and scroll
down to the “oil pump”
screen. Turn the oil pump on
in manual mode and let it run
for several minutes. This will
charge the oil lines and oil
cooler with oil.

8. After shutting the oil pump
off, check the oil level in the
sump sight glasses. The level
should be between the center
of the upper glass and center
of the lower sight glass. Float
balls are installed in each sight
glass to allow easy level
determination.

9. If the oil level is below the
center of the lower sight glass,
charge oil into the sump as
outlined in step 4.

10. Close the oil sump drain
valve and remove the oil
charging line.

11. Reinstall the oil drain valve
cap and tighten securely.

Unit in a Vacuum.

1. Connect one end of an oil
charging line to an oil supply
(15 gallons (56.8 l) total
required) and the other end to
the oil sump drain valve
located at the bottom of the
oil sump (See Figure 23). If
possible, evacuate the oil
charging line to remove any
non-condensables and
moisture. This will require a
shutoff valve on the oil supply
side of the line and an access
valve located on the line itself.

2. Open the oil sump drain valve
and allow the vacuum to draw
the oil into the sump until the
upper sight glass ball is
located in the center of the
upper sight glass.

3. Close the oil sump drain valve
and remove the oil charging
line. Reinstall the oil drain
valve cap and tighten
securely.

4. Make sure the oil heaters are
energized and the oil is up to
temperature (greater than
122°F (50°C)).

5. Continue pulling a vacuum on
the unit to remove any
residual moisture or non­condensables, which may
have been introduced during
the oil charging. A vacuum of
at least 500 microns (0.5 mm
Hg) should be attained before
blanking off the vacuum
pump. A vacuum rise test
should be performed to insure
all non-condensables and
moisture have been removed
from the system before
charging the unit with
refrigerant 134a. The vacuum
level should not rise by more
than 100 microns (0.1 mm Hg)
in a 2 hour period.

6. After charging the unit with

refrigerant, operate the oil
pump in the manual mode as
outlined in step 7 in the
preceding procedure and
follow that procedure if
additional oil is required to
bring the level between the
center of the two sight
glasses.

Periodic
Maintenance

CVGF-SVU02B-E4

83

Replacing the Oil Filter

The oil filter should not be
changed unless absolutely
required due to plugging, which
will shut the chiller off on low oil
pressure or if the oil is required
to be changed. To replace the oil
filter, use the following
procedure:

1. Be sure the chiller is in the
Stop mode.

2. Locate the two oil filter
isolation valves (See Figure

24).

3. Connect an approved
refrigerant recovery unit for
R134a to the 1/4 inch Schrader
valve on the oil filter inlet
isolation valve to allow
removal of oil and refrigerant
from the oil filter cavity.

4. Close both isolation valves.

5. Recover the refrigerant and oil
out of the oil filter cavity.

6. Remove the oil filter cover by
removing the bolts and
loosening the Roto-Lock
connector on the outlet oil
filter isolation valve.

Note: When removed, do not
allow any contaminants to get
on the oil filter cover. Re­installing a contaminated oil
filter cover could decrease the
life of the compressor.

7. Remove the oil filter and o­ring.

8. Install a new oil filter, o-ring,
and Roto-Lock nylon seal.

9. Replace the oil filter cover and
torque the bolts and Roto­Lock connector. The cover is
torqued to 19 lb-ft (2.62 N-m)
and the Roto-Lock to 90 lb-ft
(12.44 N-m).

10. Evacuate the oil filter cavity
by attaching a deep vacuum
pump to the 1/4 inch
Schrader valve and pulling at
least a 500 micron (0.5 mm
Hg) vacuum. Do a standing
vacuum rise test to
determine if any leaks are
present. If leak free, remove
the vacuum pump from the
valve.

11. Replace the Schrader valve
cap and tighten.

12. Open both isolation valves.

13. On the DynaView

™

display,
select Settings, Mode
overrides and select Oil
Pump. Start and run the oil
pump in manual mode to
charge the oil filter with oil.
Allow the pump to run for
several minutes and shut the
oil pump off by going back
to the Auto mode at the
control panel.

14. Check the oil level in the
sump and if it is below the
center of the lower sight
glass, add oil by following
the oil charging procedure
outlined previously.

Periodic
Maintenance

CVGF-SVU02B-E4

84

Oil Sump Heaters

The CVGF uses two 500 watt
heaters to maintain the oil sump
temperature at 136°F (57.7°C).
These heaters are located in the
lower oil sump casting, one on
each side of the oil sump cover,
and can be serviced without
removing the refrigerant or oil,
since the heaters are not located
in the oil sump itself but in the
casting (See Figure 24).

The CH530 will not allow the
chiller to start unless the oil
sump temperature is at least
30°F (16°C) above saturated
evaporator temperature, or at
least 105°F (58°C), whichever is
higher. The oil sump comes
factory insulated and must
remain insulated to allow the oil
temperature to maintain 136°F
(57.7°C) while the unit is off.

The oil heaters are only
energized during the unit “off”
cycle to maintain oil
temperature for startup. During
the run cycle, the oil sump
heaters are de-energized and the
oil temperature may vary
depending on load and
operating conditions. The unit
will trip on a latching diagnostic
of high oil temperature if the oil
exceeds 165°F (74°C).

Oil Pressure Protection

A differential oil pressure switch
provides protection for the CVGF
should the oil pressure fall
below safe operating levels for
any reason. This switch opens at
9 psid (62kPa) and closes at 12
psid (82 kPa). The oil pressure
regulator is factory set to
maintain oil pressure between
18 to 22 psid (124-151 kPa). The
unit will not start if the oil
pressure is below 12 psid (82
kPa).

Adjusting the Oil Pressure
Regulating Valve

The oil pressure regulator
should be calibrated to maintain
18 to 22 psid during
commissioning. In the event that
the oil pressure switch will not
close to allow unit
startup, the following diagnostic
procedure should be followed:

1. With the unit and the oil pump
off, connect a pressure gauge
to the service valve after the
oil filter and another gauge to
the Schrader valve located
next to the oil pressure switch
capillary on the oil sump. (An
optional method is to use a
differential pressure gauge
instead of two separate
gauges.)

2. On the DynaView

™

display,
select Settings, Mode
overrides and select Oil Pump.
Place oil pump in manual
mode. Check the oil pressure
gauge readings and calculate
the differential oil pressure by
subtracting the oil sump
pressure reading from the
discharge oil pressure
reading.

If the differential pressure is
between 18 to 22 psid (124­151 kPa), the oil pressure
regulating valve should not be
adjusted. If the oil pressure
switch is not closed at
pressures above 12 psid
(82kPa), the switch is defective
and should be replaced. If the
switch is closed the unit will
not start due to a low oil
pressure diagnostic. If the
differential oil pressure cannot
be achieved, the oil pump
may be running backwards.

Periodic
Maintenance

CVGF-SVU02B-E4

85

3. To reverse the oil pump motor
rotation, two leads must be
swapped on the oil pump
motor contactor. Be sure to
remove all power from the
unit before doing any
electrical wiring changes.

Note: Be sure to perform the
Bump Start test to determine
proper compressor rotation
before operating the chiller.

If the differential oil pressure
measured is below 12 psid (82
kPa), the oil filter may be
plugging or the regulator may
need adjustment.

4. Then check the pressure drop
across the oil filter, connect a
gauge to the service valve
before the oil filter and
another gauge to the service
valve after the oil filter.
Subtract the pressure reading
taken from after the oil filter
from the gauge before the oil
filter to obtain the pressure
drop. If the pressure drop is
excessive (more than 8 psid
(54 kPa)), shut the oil pump off
and replace the oil filter per
the procedure outlined
previously.

5. When the oil filter change is
completed, check the
differential oil pressure and if
it is below 18 psid (124 kPa),
adjust the oil pressure
regulator to obtain a reading
of between 18 to 22 psid (124­151 kPa).

If the pressure drop across the
filter is not excessive, but the
oil differential pressure is
below 18 psid, adjust the oil
pressure regulating valve to
obtain 18 to 22 psid (124-151
kPa) oil pressure. To increase
pressure, remove the oil
pressure regulator cap and
screw the regulator stem in a
clockwise direction. Be sure to
replace the cap and tighten
when adjustment is complete.

6. Remove the pressure gauges
when all diagnostic work is
complete. Be sure and replace
and secure any valve caps
which were removed.

CVGF Oil Pump

The oil pump for the CVGF is a
positive displacement, direct
drive pump, three phase motor.
The motor must be phased
correctly to provide positive
differential oil pressure. This
pump and motor is located
within the oil sump and can not
be serviced without recovering
the refrigerant and removing the
oil from the machine.

Periodic
Maintenance

CVGF-SVU02B-E4

86

Refrigerant Charge

If a low refrigerant charge is
suspected, first determine the
cause of lost refrigerant. Once
the problem is repaired follow
the procedures below for
evacuating and charging the
unit.

WARNING

Hazardous Voltage!

Disconnect all electric power,
including remote disconnects
before servicing. Follow proper
lockout/tagout procedures to
ensure the power can not be
inadvertently energized. Failure to
disconnect power before servicing
could result in death or serious
injury.

Evacuation and Dehydration

1. Disconnect ALL power while
evacuating the system.

2. Connect the vacuum pump to
the 5/8” flare connection on
the bottom of the evaporator.

3. Remove all of the moisture
from the system to insure a
leak free unit. Pull the system
down below 500 microns (0.5
mm Hg).

4. After the unit is evacuated,
perform a standing rise test
for at least an hour. This
vacuum should not rise more
than 100 microns (0.1 mm Hg)
per hour to a maximum of 500
microns (0.5 mm Hg) over 12
hours. If the vacuum rises
above this, either there is a
leak or the unit has moisture
present.

Note: If oil is in the system, this
test is more difficult. The oil is
aromatic and will give off vapors
that will raise the pressure of the
system. Check for oil
temperature >122°F (50°C).

Refrigerant Charging

Once the system is leak and
moisture free, use the 5/8” flare
connections at the bottom of the
evaporator and side of
condenser to add refrigerant
charge. See Unit Nameplate for
correct refrigerant charge
amounts.

Add the refrigerant charge as a
vapor until the system pressure
is above 29.4 psi (203 kPa) or
Temperature is above 34°F (1°C).
Liquid refrigerant may be added
once these conditions are
achieved.

CAUTION

Possible Freeze-up

Water can freeze during charging.
Circulate water during charging to
prevent freezing.

Caution

Charge vapor in the unit
until:

• System pressure is above 29.4
psig (203 kPa )

• The saturation temperature of
R134a is above 34°F (1°C)

Periodic
Maintenance

Literature Order Number

File Number

Supersedes

Stocking Location

Trane has a policy of continuous product and product data improvement and reserves the right to
change design and specifications without notice. Only qualified technicians should perform the
installation and servicing of equipment referred to in this publication.

Société Trane – Société Anonyme au capital de 41500 000 F – Siege Social: 1 rue des Amériques –
88190 Golbey – France – Siret 306 050 188-00011 – RSC Epinal B 306 050 188
Numéro d’identification taxe intracommunanutaire: FR 83 3060501888

Trane
A business of American Standard Companies
www.trane.com

For more information contact your local Trane office
or e-mail us at [e-mail]

CVGF-SVU02B-E4

SL-RF-CTV-CVGF-SVU02B-E4-0205

CVGF-SVU02A-E4-1202

China