Trane PolyTherm ARTC-SVX005A-EN Installation And Maintenance Manual

Installation, Operation, and Maintenance

PolyTherm™ Simultaneous Chiller/Heater

SAFETY WARNING

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

February 2021

ARTC-SVX005A-EN

Introduction

Read this manual thoroughly before operating or servicing this unit.

Warnings, Cautions, and Notices

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

The three types of advisories are defined as follows:

WARNING

Proper Field Wiring and Grounding Required!

Failure to follow code could result in death or serious injury. All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state electrical codes.

WARNING

CAUTIONs

NOTICE

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

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

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

Important Environmental Concerns

Scientific research has shown that certain man-made chemicals can affect the earth’s naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handli ng of all refrigerants-including industry replacements for CFCs and HCFCs such as saturated or unsaturated HFCs and HCFCs.

Important Responsible Refrigerant Practices

Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified according to local rules. For the USA, the Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.

WARNING

Personal Protective Equipment (PPE) Required!

Failure to wear proper PPE for the job being undertaken could result in death or serious injury. Technicians, in order to protect themselves from potential electrical, mechanical, and chemical hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well as the instructions below:

• Before installing/servicing this unit, technicians MUST put on all PPE required for the work being undertaken (Examples; cut resistant gloves/sleeves, butyl gloves, safety glasses, hard hat/bump cap, fall protection, electrical PPE and arc flash clothing). ALWAYS refer to appropriate Safety Data Sheets (SDS) and OSHA guidelines for proper PPE.

• When working with or around hazardous chemicals, ALWAYS refer to the appropriate SDS and OSHA/GHS (Global Harmonized System of Classification and Labeling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection and handling instructions.

• If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other country-specific requirements for arc flash protection, PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASH CLOTHING. ENSURE ELECTRICAL METERS AND EQUIPMENT ARE PROPERLY RATED FOR INTENDED VOLTAGE.

WARNING

Follow EHS Policies!

Failure to follow instructions below could result in death or serious injury.

• All Trane personnel must follow the company’s Environmental, Health and Safety (EHS) policies when performing work such as hot work, electrical, fall protection, lockout/tagout, refrigerant handling, etc. Where local regulations are more stringent than these policies, those regulations supersede these policies.

• Non-Trane personnel should always follow local regulations.

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

Introduction

Trademarks

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

ARTC-SVX005A-EN 3

Table of Contents

Model Number Descriptions . . . . . . . . . . . . . . 6

Model Number and Coding . . . . . . . . . . . . . . . 7

Chiller/Heater Model and Serial Numbers 7

General Information . . . . . . . . . . . . . . . . . . . . . 8

Inspect and Report Damage . . . . . . . . . . . . . 8

Inspection of Delivered Equipment . . . . . 8

Warranty Issues . . . . . . . . . . . . . . . . . . . . . 8

Long Term Storage Requirements . . . . . . . 8

Factory Preparation . . . . . . . . . . . . . . . . . . 8

Customer Responsibilities . . . . . . . . . . . . . 9

Chiller Dimensions . . . . . . . . . . . . . . . . . . . . . 9

Handling of the Modules . . . . . . . . . . . . . . . 9

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

Chiller/Heater Clearances . . . . . . . . . . . . 11

Rigging, Lifting, and Moving

the Chiller/Heater . . . . . . . . . . . . . . . . . . . 12

Chiller/Heater and Description . . . . . . . . . . . 13

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

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

Component Description . . . . . . . . . . . . . . . 13

Evaporators, Condensers and Source/Sink

Heat Exchanger . . . . . . . . . . . . . . . . . . . . 13

Components Parts . . . . . . . . . . . . . . . . . . 14

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . 17

Preparation for Initial Startup . . . . . . . . . . 17

Request Initial Startup . . . . . . . . . . . . . . . 17

Installation Piping . . . . . . . . . . . . . . . . . . . . . . 20

Install Piping and External Components . 20

Initial Flushing of Piping . . . . . . . . . . . . . . . 20

Fill with Water/Glycol Solution . . . . . . . . 20

Connecting Module Couplings . . . . . . . . 21

Installation Electrical . . . . . . . . . . . . . . . . . . . . 22

Wiring and Piping . . . . . . . . . . . . . . . . . . . . 22

Connecting Module Power

and Control Wires . . . . . . . . . . . . . . . . . . . . 22

Service Access . . . . . . . . . . . . . . . . . . . . . 22

Chiller/Heater Module Main Power . . . . . 22

Module Control Wiring . . . . . . . . . . . . . . 22

Phase Monitor Installation . . . . . . . . . . . . 22

Power Interlock Switch . . . . . . . . . . . . . . .23

Operating Principles . . . . . . . . . . . . . . . . . . . . .24

Operating Procedures . . . . . . . . . . . . . . . . . . . .26

Operator Interface . . . . . . . . . . . . . . . . . . . . .26

Chiller/Heater Power Panels . . . . . . . . . . .26

Electronic Control . . . . . . . . . . . . . . . . . . . .27

Client and Server Controllers . . . . . . . . . .28

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

Microprocessor Functions . . . . . . . . . . . . .29

Password Protection . . . . . . . . . . . . . . . . .29

Operator Control . . . . . . . . . . . . . . . . . . . .29

How to Use the Touchscreen

Interface Panel . . . . . . . . . . . . . . . . . . . . . .29

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

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

Home Screen Features . . . . . . . . . . . . . . . . .31

Top Section Functions . . . . . . . . . . . . . . . .31

Project Name . . . . . . . . . . . . . . . . . . . . . . .32

Software Version . . . . . . . . . . . . . . . . . . . . 32

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

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

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

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

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

Admin Level . . . . . . . . . . . . . . . . . . . . . . . . 34

Log Out . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Modules Layout Screen . . . . . . . . . . . . . . . .34

Module Layout Screen Status Conditions 35

Module Indicators . . . . . . . . . . . . . . . . . . . . .36

Module En/Dis . . . . . . . . . . . . . . . . . . . . . .36

Module Status . . . . . . . . . . . . . . . . . . . . . .36

Module Cntrl Status . . . . . . . . . . . . . . . . . .36

Master Status . . . . . . . . . . . . . . . . . . . . . . .36

Lead Module . . . . . . . . . . . . . . . . . . . . . . . .37

Mode Status . . . . . . . . . . . . . . . . . . . . . . . .37

Heat Exchanger Indicators . . . . . . . . . . . . . .37

Refrigeration Indicators . . . . . . . . . . . . . . .37

4 ARTC-SVX005A-EN

Table of Contents

Solenoid ‘E’ . . . . . . . . . . . . . . . . . . . . . . . . 37

Solenoid ‘S’ . . . . . . . . . . . . . . . . . . . . . . . . 37

EX Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 37

D1/D2/S1/S2 . . . . . . . . . . . . . . . . . . . . . . . 37

Compressor Overview Screens . . . . . . . . . 38

Compressor 1 and Compressor 2 . . . . . . 38

Compressor En/Dis . . . . . . . . . . . . . . . . . . 38

Comp Status . . . . . . . . . . . . . . . . . . . . . . . 38

Communication . . . . . . . . . . . . . . . . . . . . 38

Module I/O Screens . . . . . . . . . . . . . . . . . . . 39

Analog Inputs . . . . . . . . . . . . . . . . . . . . . . 40

Analog Outputs . . . . . . . . . . . . . . . . . . . . 40

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . 40

Digital Outputs . . . . . . . . . . . . . . . . . . . . . 41

Expansion IO Screen . . . . . . . . . . . . . . . . 42

Active Alarms Screen . . . . . . . . . . . . . . . . . 42

Alarm History . . . . . . . . . . . . . . . . . . . . . . 43

Trend Screen . . . . . . . . . . . . . . . . . . . . . . . . 44

Cooling and Heating Demand . . . . . . . . . 44

Operator Tasks . . . . . . . . . . . . . . . . . . . . . . . 46

Normal Power Up . . . . . . . . . . . . . . . . . . . 46

Emergency Power Shutdown . . . . . . . . . . 47

Water Quality Guidelines . . . . . . . . . . . . . . 47

Monitor Water Quality . . . . . . . . . . . . . . . . . 47

Maintain Glycol Level . . . . . . . . . . . . . . . 47

Prevent Freezing . . . . . . . . . . . . . . . . . . . . 48

Controls Interface . . . . . . . . . . . . . . . . . . . . . . . 50

Chiller Controls . . . . . . . . . . . . . . . . . . . . . . . 50

Power Distribution . . . . . . . . . . . . . . . . . . 50

Touchscreen Interface Panel . . . . . . . . . . . 51

Microprocessor Control System . . . . . . . . 52

Master Microprocessor Controller . . . . . 52

Slave Microprocessor Controller . . . . . . 52

Microprocessor Controller Functions . . . 52

Thermal Capacity . . . . . . . . . . . . . . . . . . . . . 52

Electronic Controls . . . . . . . . . . . . . . . . . . 52

Sequence of Operations . . . . . . . . . . . . . . . . . 53

Description . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Chiller/Heater Performance Data . . . . . . . . . 54

Maintenance Procedures . . . . . . . . . . . . . . . . .55

Maintenance Strategy . . . . . . . . . . . . . . . . . .55

Power Disconnect Switch . . . . . . . . . . . . . . .55

Inspection and Maintenance Schedule . . .56

Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Annually . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Maintenance Tasks . . . . . . . . . . . . . . . . . . . .59

Inspection Methods . . . . . . . . . . . . . . . . . .59

Critical Cleaning Tasks . . . . . . . . . . . . . . . .59

Heat Exchanger Cleaning Procedure . . . .60

Compressor Tasks . . . . . . . . . . . . . . . . . . .60

Chiller/Heater Troubleshooting . . . . . . . . . . .62

General Approach to Fault Isolation . . . . . .62

Controller Diagnostic Codes . . . . . . . . . . . .62

Compressor Flash Codes . . . . . . . . . . . . . .62

Flash Code Description . . . . . . . . . . . . . . .62

Phase Monitor Protection . . . . . . . . . . . . . . .63

Symptoms and Solutions . . . . . . . . . . . . . . .63

Logical Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

High Voltage Logical Flow . . . . . . . . . . . . . .68

Control Logical Flow . . . . . . . . . . . . . . . . . . .68

Appendix A - Acronyms and Abbreviations 71

Acronym List . . . . . . . . . . . . . . . . . . . . . . . . . 71

Appendix B- Request for Initial Startup . . . .74

PolyTherm Chiller/Heater . . . . . . . . . . . . . . .74

Initial Start-up Agreement . . . . . . . . . . . . . .75

Appendix C - Active Alarm List . . . . . . . . . . . .76

Application . . . . . . . . . . . . . . . . . . . . . . . . . 76

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Auto Reset . . . . . . . . . . . . . . . . . . . . . . . . .76

Operator Reset . . . . . . . . . . . . . . . . . . . . . .76

Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Alarm Notes . . . . . . . . . . . . . . . . . . . . . . . .76

Alarm List . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

ARTC-SVX005A-EN 5

Model Number Descriptions

Digit 1— Brand

T = Trane

Digit 2 — Model Series

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

Digit 3, 4, 5— Condenser Type

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

Digit 6— Chilled Water System

P = Recirculating System, Tank and Pump M = Single Pass Chiller Unit (no tank and pump)

Digit 7— Cabinet Type

H = Horizontal Low Profile V = Vertical Upright

Digit 8, 9, 10, 11 — Chiller Capacity

0030 = 3 ton capacity 0300 = 30 ton capacity

Digit 12 — Refrigeration Circuits

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

Digit 13 — Voltage

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

Digit 14, 15 — Chiller Application

MM = Modular CP = Cold Plunge Process DW = Drinking Water and Filtration

Digit 16, 17 — Configuration 1

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

Digit 18, 19 — Configuration 2

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

Digit 20, 21, 22—Configuration 3

3HX = 3 Heat Exchanger (PolyTherm or Ecotherm) HP = Heat Pump HR = Heat Recovery FC = Integral Free Cooling

6 ARTC-SVX005A-EN

Model Number and Coding

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

Chiller/Heater Model and Serial Numbers

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

Table 1. Chiller/heater reference data

Mod u le Mode l N u m be r Se r i a l N um ber

Ma in

Figure 1. Typical PolyTherm chiller/heater nameplate

Model Coding Key

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

Note: Critical information for contacting Trane technical

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

ARTC-SVX005A-EN 7

General Information

Inspect and Report Damage

Upon delivery, inventory the shipment against the Trane bill of l adi ng t o ensure all modules and components have been received.

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

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

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

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

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

Inspection of Delivered Equipment

To report damage incurred in transit, complete the following:

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

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

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

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

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

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

7. Notify Trane customer service department (803-321-

1891) immediately. Trane will coordinate repairs with the owner and carrier. Do not attempt to make repairs locally without permission.

8 ARTC-SVX005A-EN

Warranty Issues

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

Long Term Storage Requirements

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

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

• The chiller/heater will not be placed into operation

for a period exceeding six months after leaving the Trane factory. That is, the initial start-up date will not occur within a six-month maximum dormancy window.

• The chiller/heater will be shipped using ocean

transit for all or part of the delivery process.

• Cold temperature storage conditions fall below

-20 °F (-29 °C).

• Ambient temperature storage conditions exceed

150 °F (66 °C).

Factory Preparation

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

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

• Placing silica gel packs in all electrical panels and

variable speed drive panels to prevent corrosion of electrical contacts and moisture from degrading sensitive controllers.

• Shrink-wrapping each chiller using polyethylene

film to limit environmental exposure and protect the chillers from damage during shipping.

• For multiple modular chiller system assemblies

shipped on a common skid, shrink wrap the entire skid rather than the individual modules.

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

Customer Responsibilities

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

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

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

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

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

General Information

WARNING

Proper Field Wiring and Grounding Required!!

Failure to follow code could result in death or serious injury.

All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state/natioanl electrical codes.

Handling of the Modules

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

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

Chiller Dimensions

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

Figure 3, p. 11, depending upon the rated tonnage of

and the chiller modules.

WARNING

Electrical Shock, Explosion, or Arc Flash Hazard!

Failure to follow these instructions could results in death or serious injury.

Install the product in an appropriate electrical/fire enclosure per local regulations. Do not install the product in hazardous or classified locations.

Do not use the product for life or safety applications.

Do not exceed the product ratings or maximum limits. Products rated only for basic insulation must be installed on insulated conductors.

Current transformer secondaries (current mode) must be shorted or connected to a burden at all times.

Unused openings for all circuit breakers, switches and wiring must be closed according to NEC requirements.

Remove all wire scraps, tools, replace all doors, covers and protective devices before powering the equipment.

Figure 2, p. 10

ARTC-SVX005A-EN 9

General Information

Figure 2. Chiller/Heater installation recommendations

10 ARTC-SVX005A-EN

General Information

Site Preparation and Clearances

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

Figure 3. Chiller/Heater bank dimensions for all configurations

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

Chiller/Heater Clearances

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

Minimum Clearances

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

Note: These clearances are general recommendations.

Mounting Rails

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

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

After setting and lubricating the mounting rails, begin installing the modules. All of the modules arrive with

Figure 4, p. 12.

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

labels on the electrical and control panel. Review the installation drawings to determine which is the first, master, module. Typically the master module also has the main power distribution panel attached to it.

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

NOTICE

Connection Leaks!

Incorrect installation of isolators could cause headers to link due to misalignment of connections. Do not install spring vibration isolators under individual modules.

ARTC-SVX005A-EN 11

General Information

Figure 4. Recommended chiller/heater clearances

Figure 5. Recommended chiller/heater module rigging

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

Rigging, Lifting, and Moving the Chiller/Heater

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

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

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

• Position lifting beams or spreader beams to prevent lifting straps from rubbing or contacting module side

12 ARTC-SVX005A-EN

panels or electrical boxes. Attach rigging bar on each end of module where 1 3/8 inch holes are provided.

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

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

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

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

Chiller/Heater and Description

Chiller/Heater Scope

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

Chiller/Heater Capacities

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

WARNING

Hazardous Voltage!

Failure to disconnect power before servicing could result in death or serious injury.

Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized. Verify that no power is present with a voltmeter.

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

Component Description

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

Tandem Compressors

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

continue to operate, to allow for variable flow and, on each

Evaporators, Condensers and Source/Sink Heat Exchanger

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

The return fluid piping from each evaporator and condenser includes an electronic valve for servicing each module individually while the remaining modules

ARTC-SVX005A-EN 13

condenser and source/sink heat exchanger operating as a condenser, to control head pressure. The fluid connections to each heat exchanger use roll grooved couplings for service convenience and ease of installation.

Chiller/Heater and Description

Condenser

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

Evaporator

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

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

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

Source/Sink Heat Exchanger

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

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

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

Components Parts

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

Frame

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

Cabinet

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

Strainers

A compact design suction diffuser with stainless steel 40 Mesh strainer is factory-installed on the branch line to each evaporator, condenser and source/sink heat exchanger inlet.

Isolation Valves

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

Reversing Valve

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

14 ARTC-SVX005A-EN

Chiller/Heater and Description

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

Refrigerant Piping

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

Electronic Expansion Valve

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

Flow Switch

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

Fluid Piping

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

CAUTION

Equipment Damage!

Failure to follow instructions could result in equipment damage. Do not jumper out the flow switch.

Refrigeration Controls

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

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

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

Low Pressure Bypass

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

ARTC-SVX005A-EN 15

Chiller/Heater and Description

Sight Glass

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

CAUTION

Equipment Damage!

Failure to remove moisture from system could cause corrosion within the chiller/heater components, and degrade performance.

Phase Monitor

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

16 ARTC-SVX005A-EN

Pre-Installation

Preparation for Initial Startup

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

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

Initial Startup

1. Close all drain valves and header purge valves.

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

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

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

WARNING

Hazardous Voltage!

Failure to disconnect power before servicing could result in death or serious injury.

12. Ensure refrigerant valves are open at the compressors.

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

14. Apply power to all modules in the chiller/heater.

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

16. Monitor and record all temperatures and refrigerant pressures.

Request Initial Startup

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

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

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

“Appendix B- Request for Initial Startup,” p. 74’)

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

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

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

Note: If Trane pumps are provided, check that each

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

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

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

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

CAUTION

Compressor Failure!

Failure to follow instructions below could result in catastrophic compressor failure. Do not operate with insufficient oil.

10. Connect phase monitor wiring, if required.

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

ARTC-SVX005A-EN 17

Pre-Installation

Table 2. Initial startup readiness checklist



Describe voltage service: Fused disconnect Non-fused disconnect • 50 cycle  60 cycle



Record rated power supply: __________volts_______ phase • Circuit breaker rating: _______



Record supply voltage on chiller nameplate: _________________



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



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



 Agrees with nameplate values? Voltages must be within 2%.

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



Check the box if all electrical connections inside each module electrical and control panel are tight. Ensure all



components inside each module are securely mounted and have not shifted during shipment.

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



Check the box if chiller/heater system includes any remote panels (city water switchover, remote control panel, or



customer supplied control devices). If so, voltage drops are likely to occur. Measure and record all control voltages:

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



remote panels.

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



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



List devices: ______________________________________________________________________________________

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



Check the box if voltage drops are detected.



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



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



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



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



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



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



Check the box if chilled water lines have been leak tested according to prestartup instructions.



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



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



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



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



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



Startup Readiness Dimension

18 ARTC-SVX005A-EN

Table 2. Initial startup readiness checklist (continued)

Pre-Installation



Check the box if source/sink chilled water lines have been leak tested according to prestartup instructions.



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



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



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



completed.

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



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



Check the box if all responsible installing contractors and sub-contractors have been notified to have



representatives available on site to provide technical support for the initial start-up procedure.

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



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



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

Startup Readiness Dimension

ARTC-SVX005A-EN 19

Installation Piping

Install Piping and External Components

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

Figure 6. Recommended PolyTherm chiller/heater piping

Important: An electronic expansion valve is a butterfly

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

Initial Flushing of Piping

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

Only cleaning liquids, acids, and detergents compatible with SAE Grade 316 stainless steel, copper, and carbon

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

steel should be used. Consult a professional water treatment specialist when in doubt.

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

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

Fill with Water/Glycol Solution

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

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

Level,” p. 47

concentration.

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

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

Note: Do not use a glycol feeder pump to fill the

to determine the appropriate glycol

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

“Maintain Glycol

20 ARTC-SVX005A-EN

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

Dowfrost

Important: Dowfrost inhibited propylene glycol-based

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

Dowfrost

Connecting Module Couplings

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

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

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

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

4. Lubricate the main header coupling gasket with an approved lubricant and re-install onto the rolled groove header pipe. Push the gasket fl ush with the pipe end to avoid damage when installing the next module.

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

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

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

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

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

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

11. Install the remaining modules using this procedure.

Installation Piping

ARTC-SVX005A-EN 21

Installation Electrical

Wiring and Piping

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

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

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

2. Insulate roll grooved connections after assembly.

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

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

Connecting Module Power and Control Wires

Chiller/Heater Module Main Power

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

Module Control Wiring

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

Figure 7. Typical controller network

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

Labeled control and communication cables are coiled inside each module and are connected to an Ethernet switch. The Ethernet cable tuns from the switch to each module’s microprocessor controller at the J30 connector.

Important: Electrical Hazards: Read before installing!

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

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

Service Access

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

Phase Monitor Installation

The chiller/heater is equipped with a phase monitor on the power distribution panel. It communicates with the master microprocessor controller in the master module electrical and control panel via the id9 terminal. Ensure that the wiring from the master microprocessor controller and terminal blocks to the phase monitor are connected and secure.

The phase monitor continuously monitors each of the three phases. The microprocessor receives input from the phase monitor indicating whether the voltage is within acceptable values. The phase monitor design protects against under-voltage, voltage unbalance, phase loss, and phase reversal.

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

22 ARTC-SVX005A-EN

Power Interlock Switch

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

WARNING

Hazardous Voltage!

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

Single Point Connections

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

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

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

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

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

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

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

Installation Electrical

ARTC-SVX005A-EN 23

Operating Principles

The PolyTherm Simultaneous Chiller/Heater is a state-ofthe-art six-pipe multipurpose system (See figure below) featuring independent water circuits to satisfy end user's requirements for heating and cooling year-round. It eliminates the need for duplicate equipment and significantly reduces space requirements by combining duties and reducing glycol requirements.

Figure 8. PolyTherm simultaneous chiller/heater

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

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

Figure 9. 30 and 40-ton PolyTherm dimensions

24 ARTC-SVX005A-EN

Operating Principles

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

Figure 10. 50 and 60-ton PolyTherm dimensions

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

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

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

p. 24

and Figure 10, p. 25.

Figure 9,

ARTC-SVX005A-EN 25

Operating Procedures

Operator Interface

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

Chiller/Heater Power Panels

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

Figure 11. Power distribution panel

Panel-Mounted Disconnect Switch

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

Power Distribution Panels

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

26 ARTC-SVX005A-EN

Operating Procedures

Cont r oll er Relay Exp an sion Boar d Cont r oll er

Elect ron ic Exp ansio n Valv e Cont r oll er

TB- 1 Ter m inal Block

TB- 2 Ter m inal Block

TB- 3 Ter m inal Block

TB- 4 Ter m inal Block

TB- 5 Ter m inal Block

Module Electrical and Control Panel

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

Figure 12. Module electrical panel

breakers and the microprocessor controller. See the figure below.

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

Figure 13, p. 27

Figure 13. Module control panel

Electronic Control

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

Figure 14, p. 28.

Figure 13, p. 27

ARTC-SVX005A-EN 27

Operating Procedures

Figure 14. Microprocessor controller

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

Client and Server Controllers

The distributed microprocessor control system enables all server modules to operate independently in the event that the client microprocessor controller fails. All chiller/heater safeties including temperature set point, refrigerant

Figure 15. Typical controller network

pressures, and freeze protection are preserved. The distributed microprocessor control programming only lacks the ability to rotate the lead compressors which typically occurs every 168 compressor operating hours.

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

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

28 ARTC-SVX005A-EN

Operating the Microprocessor

The touchscreen interface panel is ready to use when it is connected to the Ethernet switch and chiller/heater power is on. Upon initial startup, the status line will indicate that the chiller/heater is off. Pressing the ON-OFF button on the touchscreen interface panel turns the chiller/heater on and the touchscreen will indicate that it is powered on. Pressing the ON-OFFbutton effectively toggles the chiller/ heater ON and OFF.

Microprocessor Functions

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

Operating Procedures

forth) are written assuming the operator is using the touchscreen interface panel.

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

How to Use the Touchscreen Interface Panel

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

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

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

Figure 16. Touchscreen interface panel

Figure 16, p. 29)

NOTICE

Compressor Damage!

Failure to follow instructions could damage sensitive electronic components beyond repair.

To prevent arcing or surges of electrical current, do not use wires or cables to jump components or bypass the manufacturer's safety systems.

Password Protection

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

Operator Control

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

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

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

ARTC-SVX005A-EN 29

Operating Procedures

Touchscreen Interface Tutorial

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

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

Figure 17. Interface navigation scheme

Interface Menu Structure

Key interface screens are organized according to system, master module, and slave modules functions. See the below figure.

Home Screen

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

Modules Layout Screen

On the home screen, pressing the module layout button displays the modules layout screen ( screen is a graphical representation of the modules that are available in the chiller/heater.

Figure 21, p. 35). This

circuit, heat exchangers, compressors, and the module itself. There are two overview screens for each module. These screens are different for the master module and the slave modules.

Input/Output Screen

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

Trend Screens

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

Setup Screens

Overview Screens

Overview of main chiller/heater module refrigeration parameters and status of its components: refrigeration

30 ARTC-SVX005A-EN

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

Operating Procedures

Access to these screens is restricted to administrator level only.

Home Screen Features

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

Top Section Functions

Features in the top section include:

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

• The module access buttons display the overview screen for each module. These buttons provide access all chiller/heater modules screens individually. The

Home Screen

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

Module

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

number on the Mx button stands for the module number in the chiller/heater. Only modules that communicate directly with the touchscreen interface are viewable via the module access buttons.

• The software access button identifies the software version currently loaded

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

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

• The active alarm access button provides fast access to

a list of currently active system alarms

• The date/time displays the current settings of the

system isochronon

Software Icon

Log-in option

Module Layout

The software access button identifies the software version currently loaded.

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

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

ARTC-SVX005A-EN 31

Operating Procedures

Alarm

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

Date and Time

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

Figure 18. The home screen, ‘System Control’

Project Name

Figure 19. Interface software version pop-up window

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



Software Version

Pressing the Software Version button displays pop up window.

32 ARTC-SVX005A-EN

Operating Procedures

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

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

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

p. 32

• The fourth number indicates the beta software revision sequence.

Figure 19,

Middle Section Functions

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

• Chiller/heater temperature set points for cooling and heating

• Chiller/heater system cooling in and out water temperatures

• Chiller/heater system heating in and out water temperatures

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

• Chiller/heater system power on or power off status

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

Online

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

Evaporator / Condenser / Source

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

Cool / Heat / Simult

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

Bottom Section Functions

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

System On

This button powers the chiller/heater (and all its modules) on and off via a software switch. The button should be pressed for few seconds to power the chiller/heater.

Cool and Heat Demand Comp / %

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

Setup

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

ARTC-SVX005A-EN 33

Operating Procedures



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

Table 3. Log-in screens

Figure 20. User Log-in screen

Current Access Level

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



User Access Lev el



Tech Access Lev el

User Level

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

Tech Level

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

Admin Level

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

Adm in Acce ss Lev el

Log Out

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

Modules Layout Screen

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

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

Table 4, p. 35.

34 ARTC-SVX005A-EN

Figure 21. Modules layout screen showing four compressors on two modules

Operating Procedures

Module Layout Screen Status Conditions

Table 4. Module status conditions



Mod ule i n si m ult an eou s m o de ;

com pressors o n



Mod ule i n h ea t ing m ode ; com pressors o ff



Com pr ess or 1 is in a lar m a nd Com p re ssor 2 i s o n

On the home screen, pressing the alarm button displays the active alarms screen. See

Mod ul e t u r n ed of f b y ala r m an d un av ailable;

Figure 21, p. 35.

com pressors o ff



Mod ule in co ol in g m ode; com p resso r s of f



- Valv e LED is g r ee n = va lv e i s op en

- Valv e LED is gr ay = va lv e i s clo sed

ARTC-SVX005A-EN 35

I solatio n Val ves:

Refr igera t ion cir cu it in no r m al st a t e; bot h

com pressors o n



Refr ig er at io n ci rc uit in ala r m st a t e; co m pr ess or s

of f

Operating Procedures



Modules Overview Screens

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

Table 5. The overview screens

Mast er Ov er v iew 1 Scr een

Module Indicators

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

Module En/Dis

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

Module Status

Possible states indicating the module’s status include:

• Module ON - The module is ready to run

• OFF by Schedule - The module operates according to predefined schedule and is currently off as scheduled

• OFF by Digital Input - The module is turned off by the opened state of microprocessor controller DI1

• OFF by Keypad - The module is turned off by module EN/DIS button

• OFF by Alarm - The module is locked out by one of the major alarms.

• OFF by Master - The module is switching between control states master, slave, and stand-alone

• OFF by System - The module is turned off by one of the system off conditions.

• Man Mode - The module is in manual mode

On the home screen, pressing the M1 button displays the Module #1 (master module) overview 1 screen.

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



Sla ve Ov er v iew 1 Scr een

• Safety Mode - This display indicates the module is

running in one of the Safety Modes.

Module Cntrl Status

Possible options for each module include:

•Master Module

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

Note: Master Module is defined by its PLC IP address. So

in the chiller Master PLC IP address is always

192.168.1.11. All Slaves IP addresses go from

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

Master Status

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

• Master ON - All master module conditions are

satisfied by this module

• Waiting … - All master module conditions are

satisfied and the module is counting down the MASTER EN DELAY before attaining MASTER ON status.

• OFF by Cool Sensor - The chiller/heater cooling

temperature sensor has failed

36 ARTC-SVX005A-EN

Operating Procedures

• OFF by Heat Sensor - The chiller/heater heating temperature sensor has failed.

• OFF by No Slaves - The master microprocessor controller cannot communicate with any of the slave modules

• OFF by Exp IO Fault - A failure occurred in the master microprocessor controller IO expansion module which renders all system temperature sensors failed. All master status states 3 through 6 will cause all modules to run in the stand-alone mode. These failing conditions are avoided in normal master and slave operations.

Lead Module

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

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

• Master Online - This applies to slave microprocessor controllers only.

• LED Illuminated Green - The slave microprocessor controller is communicating with the master microprocessor controller

• LED Illuminated Gray - The slave microprocessor controller is not communicating with the master microprocessor controller

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

• Its evaporator and condenser EWT and LWT.

• Its cooling and heating and simultaneous mode.

• Its control temperature sensor selection.

The module runs temporarily in this mode until normal master and slave operation is restored.

• Slave Module - A module acts as a slave module when

• Its microprocessor controller has been assigned the

IP address from the slave address range.

• It is communicating with master module.

• The master module exists on the network. The

master microprocessor controller meets master module conditions.

Mode Status

There are six possible values:

• Simultaneous - The module is in simultaneous mode.

• Heating - The module is in heating mode.

• Cooling - The module is in cooling mode.

• Switching to Simult - The module is switching to

simultaneous mode.

• Switching to Heat - The module is switching to

heating mode.

• Switching to Cool - The module is switching to

cooling mode.

Heat Exchanger Indicators

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

Refrigeration Indicators

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

Solenoid ‘E’

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

Solenoid ‘S’

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

EX Valve

This indicates the position of electronic expansion valve.

D1/D2/S1/S2

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

Table 6. D1/D2 and S1/S2 values

Va lue Sim u ltan e ousl y Mode Coo l ing o n l y Mode H e a tin g o n ly M ode

Disch ar ge 1 (D1 ) Ope n Closed Ope n

Dischar ge 2 ( D2) Close d Open Closed

ARTC-SVX005A-EN 37

Operating Procedures

Table 6. D1/D2 and S1/S2 values (continued)

Va lue Sim u ltan e ousl y Mode Coo l ing o n l y Mode H e a tin g o n ly M ode

Disch ar ge 3 (D3 ) Ope n Ope n Closed

Dischar ge 4 ( D 4) Clo sed Closed Open

Compressor Overview Screens

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

Table 7. The overview screens 2



Mast er Ov er v iew 2 Scr een

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

Compressor 1 and Compressor 2

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

Compressor En/Dis

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

Comp Status

• Compressor Off - The compressor is off and can’t be turned on.

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

• OFF by Source Flow - The compressor is waiting for the Source Flow.

• OFF by Cond Flow - The compressor is waiting for Condenser Flow.

• OFF by Evap Flow - The compressor is waiting for the Evaporator Flow.

• OFF by Min Off - The compressor is cycling through safety Minimum Off Time.

• OFF by Switch - The compressor is off by HMI En button.



Slav e Ov erv i ew 2Scr een

• OFF by Alarm - The compressor is off by alarm.

• Running - The compressor is running.

• ON by Min On - The compressor is running and

cycling through safety Minimum On Time.

• Start Delayed - First Compressor - waiting for EXV to

open to preset position (70% by default); Second Compressor - cycling through Compressor Staging Delay.

• OFF by SST - The second compressor is off by too low

Saturated Suction Temperature.

• OFF by SDT - The second compressor is off by too

high Saturated Discharge Temperature.

Communication

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

Local Temp Cntrl

This indicator applies only if module is running in standalone mode:

• Cntrl Temp Hot / Cold - This is the local module’s hot

or chilled water temperature control sensors.

• Temp SP Hot / Cold - This is the local module’s

heating and cooling temperature control set points. This can only be adjusted by ‘tech’ or ‘admin’ access levels.

38 ARTC-SVX005A-EN

Operating Procedures

• Demand Hot / Cold - This is the local cooling and heating demand value in terms of the number of requested compressors.

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

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

• Temp Stage-Up Delay - When a compressor has been staged up, this delay must elapse before the next compressor can stage up.

• Temp Stage-Down Delay - When a compressor has been staged down, this delay must elapse before the next compressor can stage down.

Module I/O Screens

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

Table 8. Module input/output screens



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

The I/O menu is comprised of four screens for Master Module and three screens for Slave Module.

Both master and slave modules have Analog I/O (analog input and analog output), Digital I/O (digital input and digital output), and Expansion #2 I/O screens. The fourth screen Expansion #1 I/O applies to master module only.

Mast er I / O An alog Scr een



Mast er I / O Dig it al Scr ee n

ARTC-SVX005A-EN 39



Slav e I / O Ana lo g Screen

Slave I / O Dig it al Scr een

Operating Procedures



Table 8. Module input/output screens (continued)



Mast er I / O Exp an si on # 2 Scre en

Mast er I / O Exp an si on # 1 Scr een

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

• The ANALOG button displays the analog screen.

• The DIGITAL button displays the digital screen.

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

Analog Inputs

Slav e I /O Ex pan sio n # 2 Scr ee n

AI9

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

Analog Outputs

Analog output (AO) data includes these parameters:

AO1, AO2, AO3

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

AO5

This indicates compressor speed (optional). It is used in

AI1 – AI3, AI6 – AI8

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

case of VSD-controlled compressors.

Digital Inputs

AI4

This input indicates suction pressure.

Digital input (DI) data includes these parameters:

AI5

This input indicates discharge pressure.

40 ARTC-SVX005A-EN

Operating Procedures

Digital LEDs

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

Figure 22. Digital inputs

DI1 Remote On/Off

This activates a module on or off via digital input. If the master digital on-off input is enabled, toggling the DI1 on the master module will turn the entire chiller/heater on or off.

DI2, DI3, and DI4

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

DI7 and DI8

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

DI9 Phase Monitor

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

If the master phase monitor is enabled, the common power supply protection module is active for the chiller/ heater. Failure of the phase monitor will affect all modules in the chiller/heater. In this case, digital input is optional for the slave modules.

• Green LED This digital input is energized, the

connected device is closed.

• Gray LED This digital input is de-energized, the

connected device is open.

DO1, DO2 Comp On/Off

This digital output turns a compressor on and off.

DO3 Liq Line Solenoid ‘E’

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

DO4 Liq Line Solenoid ‘S’

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

DO6, DO7, DO8, DO9

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

DO10 General Alarm

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

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

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

DO11 Panel Heater / Fan (optional)

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

Digital Outputs

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

ARTC-SVX005A-EN 41

Operating Procedures

Expansion IO Screen

This screen controls analog inputs and digital requests.

There is an LED for each digital output that shows its state:

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

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

Expansion #1 (Master Only)

AI1 – AI6

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

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

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

Figure 23. Active alarms for the chiller/heater



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

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

Expansion #2

DI1-DI8

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

Active Alarms Screen

The active alarms screen lists all active (triggered) and non-active alarms in tabular form. See Figure above. Information presented in this screen in tabular form includes:

Select

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

Action

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

Status

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

• TRIGGERED (ACTIVE) / NOT ACKNOWLEDGED

• TRIGGERED (ACTIVE) / ACKNOWLEDGED

• NOT TRIGGERED / NOT ACKNOWLEDGED

• NOT TRIGGERED / ACKNOWLEDGED

Both active and non-active alarms can be acknowledged. When a non-active alarm is acknowledged, it can be reset, which immediately removes it from the active alarms list. When all non-active alarms have been acknowledged, only active alarms will remain on the list.

State

Name

This column displays the descriptive title each alarm.

42 ARTC-SVX005A-EN

This column displays the numeric value of each alarm.

Operating Procedures

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

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

Time

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

Description

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

Check / Uncheck All

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

Reset PLC

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

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

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

• The alarm can be reset when the reset PLC button is

pressed and the evaporator LWT is below the freezing alarm threshold. The freezing alarm threshold equals 36.0 °F (2.2 °C) by default.

• The LWT is below 36.0 °F (2.2 °C). The alarm cannot

be reset until the evaporator LWT exceeds 37.0 °F (2.8 °C).

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

PLC button clears the alarm.

A list of all chiller/heater alarms are found in

- Active Alarm List,” p. 76

“Appendix C

‘Hide Not Triggered’ Drop Down Menu

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

Ack

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

Reset

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

Save

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

Alarm History

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



ARTC-SVX005A-EN 43

Operating Procedures



Figure 24. Alarm history

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

p. 44

Figure 24,

Sort History Items

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

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

Duration

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

Time

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

Trend Screen

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

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

• Chilled water inlet and outlet temperatures.

• Hot water inlet and outlet temperatures.

• Cooling and heating demand.

Cooling and Heating Demand

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

Figure 25, p. 45.

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

Status

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

State

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

44 ARTC-SVX005A-EN



Figure 25. Cooling trend screen

Operating Procedures

Cooling Trend Screen

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

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

Figure 26. Time span selection options menu

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



ARTC-SVX005A-EN 45

Operating Procedures

Heating Trend Screen

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

Figure 27. Heat trend screen



Operator Tasks

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

NOTICE

Compressor Damage!

Failure to properly back-seat rotalock valves can cause compressor failure. Verify the circuit breakers on the module electrical panel are turned to OFF position prior to applying power.

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

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

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

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

Startup in the Installation section of this manual for instructions regarding that situation.

Normal Power Up

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

WARNING

Hazardous Voltage and Electrical Capacitor!

Failure to disconnect all power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects, before servicing.

Follow proper lockout/tagout procedures to ensure that electrical power cannot be accidentally energized. Always use PPE and a functional voltmeter when conducting service in this equipment.

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

the first-time initial startup for a newly installed chiller. See Preparation for Initial

46 ARTC-SVX005A-EN

Compressor Damage!

Failure to follow instructions below could result in catastrophic compressor failure. Do not operate with insufficient oil.

5. Verify that pressure and temperature switches are closed.

6. See recommended inspection interval in the maintenance section of this manual.

7. Restore power to all modules.

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

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

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

NOTICE

Operating Procedures

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

Emergency Power Shutdown

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

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

• Disconnect the primary power source from the

building that feeds electricity to the chiller/heater. This occurs in sudden emergencies (usually weather-related) or planned maintenance shutdowns.

• Press the panel disconnect switch on the exterior

door of the chiller/heater’s main power distribution panel, if so equipped.

• Move the circuit breaker switch to the OFF position

(CB-1 and CB-2) on the power distribution panel. This cuts power to all of the chiller/heater modules.

• Move the circuit breaker switch to the OFF position

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

• Press the SYSTEM ON button on the touchscreen

interface panel that is built into the power distribution panel door.

Note: Pressing the SYSTEM ON button on the

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

Water Quality Guidelines

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

Table 9. Water quality guidelines

Ele m en t / Com p o u n d /

Pr o p e r ty Va lue / U n i t

pH 7. 5 - 9. 0

Condu ct ivit y < 500 μS/ cm

Total Hardn ess 4. 5 - 8. 5 d H°

Free Chlor ine < 1.0 ppm

Am m onia ( NH

Sul phat e ( SO

Hydr ogen Car b on ate ( HCO

( HCO3-) / ( SO

( Ca + Mg ) / (HCO

Chlor id e ( Cl-) < 200 ppm

Notes:

1 . To t al Har dness/ corr osion : Wat er w it h h ig h h ar dnes s can cau se

cor r osi on pr ob le m s du e t o it s high ion con t en t ( Ca+ 2, Mg+ 2, Fe+ 2) wh ich als o m eans a h ig h e lec t r ica l con duct ivit y a nd a h ig h tot al di ssolv ed sol id ( TDS) . For t h is r ea son, to o h ig h h ardn ess v al u es sho u ld be avo id ed , n ot on ly du e t o high er r is k o f sca li ng, bu t a lso fo r cor rosi on risk . On t h e ot her h an d, soft w at er, b ut no t n ecessa ri ly cat io n ex chang e sof t en ed w ater, m ay in co n t rast hav e a lo w b u ff erin g cap aci t y a nd so be m ore c or r osiv e. I f t he ha r dn ess v al ue s ar e out side t he re com m ende d r an g e, ot her p ar ame t er s suc h as ox ygen con t en t , con du ct ivit y, and p H valu es sh ould b e con sider ed t o ev al uat e t h e cor rosi on risk .

2 . Fe3+ and Mn4 + a r e st rong ox idan t s an d m ay in creas e t h e risk for

local ize d corr osio n o n st ain less st ee ls i n com binat ion w it h b r azi n g m at eria l co pp er.

) < 0.5 ppm

) < 1 0 0 p p m

) 6 0 – 2 00 p pm

) > 1.5

) > 0.5

Monitor Water Quality

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

Note: Trane will not validate the chiller warranty if the

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

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

Table 10, p. 48 shows the capacity reduction and the

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

Maintain Glycol Level

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

Table 10, p. 48, for the

ARTC-SVX005A-EN 47

Operating Procedures

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

Table 10. Glycol performance impact factors

Ra n ge F a ct or Glycol Co n ce nt r a tion P e r cen t a g e s a n d Pe rfor ma nce I m pa ct

Prop y le ne Gly co l Con cent rat ion 30 % 40 % 50 %

Low est Am b ient Tem pera t u re 1 0 ° F ( -1 2 ° C) - 4 ° F (- 10 ° C) -20 ° F ( - 29 ° C)

Recom men d ed Min im um Leav ing Fluid Temp er at ure

Leav ing Temp er at ure

70 ° F ( 21 ° C) 0. 9 6 1. 2 7 0. 9 3 1. 4 3 0 . 9 1 1. 6 3

60 ° F ( 15. 6 ° C) 0. 9 5 1. 3 1 0.9 2 1.4 7 0. 9 0 1.68

55 ° F ( 13 ° C) 0. 9 5 1. 3 1 0. 9 2 1. 5 0 0 . 8 9 1. 7 3

50 ° F ( 10 ° C) 0. 9 4 1. 3 3 0. 9 1 1. 5 1 0 . 8 8 1. 7 5

Table 11, p. 49, provides

25 ° F ( - 4 ° C) 1 0 ° F (- 12 ° C) -10 ° F ( -23 ° C)

Capa city

Redu ct ion

Fact or

Pressu r e Drop

Fac to r

Capa city

Reduct ion

Fac to r

Pressur e D r op

Fac to r

Capacit y

Redu ct ion

Fact or

Pressur e D r op

Fac to r

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

NOTICE

Equipment Damage!

Failure to follow instructions below could result in permanent damage to pump and internal cooling surfaces. Do not use automotive antifreeze.

Note: If glycol-free solutions are mandated at the chiller

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

Heaters, heat tracing cable, and closed cell insulation can be installed on any exposed “wet” chiller components and tank and pump modules for protection against freezing in low ambient temperature and low refrigerant pressure conditions. However, the best freeze prevention is using the appropriate concentration of glycol. Trane does not warranty any component that fails due to freezing.

Prevent Freezing

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

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

In order to maintain a high quality glycol solution, the water used in the glycol mixture must have very few

Table 10, p. 48.

impurities. Impurities in the water can increase metal corrosion, aggravate pitting of cast iron and steel, reduce the effectiveness of the corrosion inhibitors, and increase the depletion rate of the inhibitor package.

To assure inhibitor effectiveness, the levels of chlorides and sulfates in the water should not exceed 25 ppm each. The total hardness in terms of calcium carbonate should be less than 100 ppm. For best long-term results, deionized or distilled water is recommended. Trane can provide concentrated solutions of Dowfrost, propylene glycol, or premixed solutions for use with the chiller.

NOTICE

Equipment Damage!

Failure to follow instructions below could result in permanent damage to pump and internal cooling surfaces. Do not use automotive antifreeze.

Propylene Glycol

Important: Glycol-based fluids provide such burst

protection in water solutions due to their low freezing points. As a glycol-based fluid cools below the solution’s freezing point, ice crystals begin to form, and the remaining solution becomes more concentrated in glycol. This ice/water/glycol mixture results in a flowable slush, and remains fluid, even as the temperature continues to cool. The fluid volume increases as this slush forms and the temperature cools, flowing into available expansion volume in the chiller/ heater. If the concentration of glycol is sufficient, no damage to the chiller/heater from fluid expansion should occur within the temperature range indicated in

Figure 28, p. 49. When liquids are cooled

they eventually either crystallize like ice or become increasingly viscous until they fail to flow and set up like glass. The first type of

48 ARTC-SVX005A-EN

Operating Procedures

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

correction factors are the “best informed estimates” for chillers with copper evaporators. The percentages may vary depending on the materials and alloys of the heat exchangers, total surface area, the amount of present or future fouling, and the brand of glycol used.

Table 11. Freeze and burst protection chart

W at e r / Gly co l

Te m pe r at u r e Fr e e z e Pr o t e ct ion Bur st Pr o t e ct ion

20 ° F ( - 7 ° C) 18 % gly co l m ixt u r e 12 % gly col m i x t ure

10 ° F ( - 12 ° C) 29 % gly co l m ixt u r e 20 % gly col m i x t ure

0 ° F ( -17. 8 ° C) 36 % gly co l m ixt u r e 24 % gly col m i x t ure

- 10 ° F ( -23 ° C) 42% g ly co l m ixt u r e 28 % g ly co l m ixt u r e

- 20 ° F ( -29 ° C) 46% g ly co l m ixt u r e 30 % g ly co l m ixt u r e

flow.

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

The precise concentration of glycol for a particular chiller/ heater is affected by several key factors such as ambient temperature extremes, entering and leaving water temperatures, and chiller/heater size. A chiller’s optimum glycol concentration is modified by these considerations as reflected in above

Table 10, p. 48. These capacity

Storage Provisions

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

Figure 28. Water/Glycol concentration freezing points (in degrees fahrenheit)

ARTC-SVX005A-EN 49

Controls Interface

Chiller Controls

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

Figure 29. PolyTherm chiller/heater master module control panel

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

Power Distribution

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

Figure 29, p. 50.

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

Hazardous Voltage!

Failure to disconnect power before servicing could result in death or serious injury.

Disconnect all electric power, inlcuding remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot e inadvertently energized. Verify that no power is present with a voltmeter.

Main Power Distribution

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

WARNING

Figure 30. PolyTherm power distribution panel

50 ARTC-SVX005A-EN

Controls Interface

Panel Disconnect

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

Figure 31. PolyTherm master module high voltage

module). The disconnect switch must be turned to the off position before the panel can be opened for service.

Module Electrical Panel

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

Figure 32. PolyTherm slave module high voltage

Touchscreen Interface Panel

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

ARTC-SVX005A-EN 51

Controls Interface

Figure 33. PolyTherm chiller/heater touchscreen

interface panel

Microprocessor Control System

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

Master Microprocessor Controller

A microprocessor controller is used to control tasks and automate functions. One microprocessor controller is designated the master controller. All others are called slave controllers. The master microprocessor controller rotates the lead compressors every 168 system operating hours. The master controller reads all analog and fault port values from the slave controllers and passes these values to the Building Automation System (BAS). This controller must have the optional BAS card installed to connect to a building automation system.

Figure 34. PolyTherm chiller/heater controller

Microprocessor Controller Functions

The microprocessor provides the following functions and alarms:

• Adjustable fluid temperature set point

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

• Reset temperature control set point based on decreased load

• High and low fluid temperature alarm set points

• Fluid inlet and outlet temperature

• Suction and discharge refrigeration pressures on each refrigeration circuit

• Compressor run status

• Current alarm status

• Demand load

• Compressor run hours

• Running count of compressor starts

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

• Remote start-stop input

• Dry contact for general alarm

Thermal Capacity

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

Electronic Controls

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

Principles,” p. 24

touchscreen interface.

for a complete description of the

“Operating

Slave Microprocessor Controller

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

52 ARTC-SVX005A-EN

Figure 34, p. 52.

Sequence of Operations

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

Description

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

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

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

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

ARTC-SVX005A-EN 53

Chiller/Heater Performance Data

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

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

Figure 1, p. 7.

Table 12. PolyTherm chiller/heater example specifications

Chil le r/ H e a t e r ( Fou r 3 0- t o n M odule s ( TP W CCMV 0 30 0T3 -MM - H R-3 H X )

Evap or a t or Type: Brazed plat e Flui d: Wat er

Conde nser : Bra zed plat e Flui d: Wat er

Sou r ce/ Sin k Hx: Brazed pl at e Flu id : 30% Glycol

Coo lin g M o d e

Load Sou r ce/ Sin k H eat Exch an g er

EFT = 5 5 ° F (13 ° C) LFT = 4 5 ° F ( 7 ° C) EFT = 6 5 ° F ( 18 ° C) LFT = 7 7 ° F ( 25 ° C)

Flow Rat e: 600 gpm Flow Rat e: 6 5 0 gp m

Pressu r e D rop : 3. 8 p si Pressure Dr op : 4. 2 psi

Cool in g Capa cit y: 3, 4 8 0,00 0 bt u/ h r ( 290 t ons)

Hea t ing M o d e

Load Sou r ce/ Sin k Heat Ex ch an ger

EFT = 1 00 ° F ( 38 ° C) LFT = 1 2 0 ° F ( 49 ° C) EFT = 6 0 ° F ( 16 ° C) LFT = 5 0 ° F ( 10 ° C)

Flow Rat e: 300 gpm Flow Rat e: 4 2 4 gp m

Pressu r e D rop : 1. 6 p si Pressure Dr op : 2. 4 psi

Cool in g Capa cit y: 2, 9 6 8,00 0 Bt u / hr ( 870 kW)

Sim u l t a n e ous H ea t i n g a nd Co oli n g M ode

Load ( Col d) Load ( Ho t )

EFT = 5 5 ° F (13 ° C) LFT = 4 5 ° F ( 7 ° C) EFT = 1 0 0 ° F ( 38 ° C) LFT = 1 2 0 ° F ( 49 ° C)

Flow Rat e: 476 gpm Flow Rat e: 3 4 6 gp m

Pressu r e D rop : 2. 7 p si Pressure Dr op : 2. 0 psi

Cool in g Capa cit y: 2, 3 8 0,00 0 Bt u / hr ( 198 . 3 t ons)

Heat in g Capa cit y: 3, 4 8 0,00 0 Bt u / hr ( 1,0 1 0 k W)

Key : Bt u/ hr = Br it ish Th er m al Uni t s per hour ; EFT = Ent eri ng Fluid Tempe ra t ure; gp m = ga ll on s per m inu t e; Hx = Hea t ex chan ger ; kW = k il ow at t ; LFT = Leav ing Fluid Temp er at ur e; p si = po u nds per squa r e in ch .

54 ARTC-SVX005A-EN

Maintenance Procedures

Maintenance Strategy

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

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

Figure 35. An approach to chiller/heater maintenance

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

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

Power Disconnect Switch

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

ARTC-SVX005A-EN 55

PPE for Arc/Flash Required!

Failure to wear appropriate PPE could result in death or serious injury.

To avoid being injured, technicians MUST put on all necessary Personal Protective Equipment (PPE), in accordance with NFPA70E for arc/flash protection, PRIOR to entering the panel.

WARNING

Maintenance Procedures

maintaining a operational log and conducting weekly,

NOTICE

Compressor Damage!

Failure to follow instructions could damage sensitive electronic components beyond repair.

To prevent arcing or surges of electrical current, do not use wires or cables to jump components or bypass the manufacturer's safety systems.

Inspection and Maintenance Schedule

Proactive measures should be taken to prevent potential problems with the chiller/heaters. These include

Table 13. Recommended chiller/heater service intervals

Ta s k Fr e q u e n cy

Visu ally insp ect the chi ll er / heater Dai ly

Log pr essur e a n d t emperat u r es Dai ly

I n sp ect t ou ch scr een i nt er f ace p an el for al ar m hist ory Daily

Clean st raine r s on t h e in l et wat er pip e Mon t h ly

Check t he com presso r o il leve l si gh t gla ss Mon t h ly

Confirm t he gl ycol con cent rat io n Mon t h ly

Confirm t he ref rig er at ion pressu r es Mon t h ly

Check t he refrig er at ion l iq u id li ne sig h t gl ass Mon t h ly

I n spect r ef r igerant pr essure s an d t empera t u re set poin t s Qua rt er ly

I n spect sup er h ea t ( 1 0 ° F to 12 ° F [ 5° C t o 6° C] ) an d sub - co ol in g t empera t u r es ( 10° F to 15° F [ 5 ° C t o 8° C] )

I n spect t h e evapo rat or ent ering an d l eav ing eva por at or t em perat u r e Qua r t er ly

Collect w at er/ glycol m i x t u r e sa m ple f or a nal y sis Qua rt er ly

I n spect cr an k ca se h eat er s and ob ser ve pr oper ope rat ion Qua rt er ly

I n spect w at er pi ping f or si gn s of leak s Quar t er ly

I n spect refr iger an t pip in g f or o il or ref r ig er ant lea ks Qua r t er l y

Obser v e r ef r ige rat i on op era t ing pr essur es Quar t erl y

Confi rm m o t or am p er ag e d raw an d v o lt age Qua rt er ly

Confirm chiller /h ea t er sup er h ea t an d su b - coolin g Qua rt er ly

Check f or w orn or b urne d co ntact ors Qua rt er ly

I n spect al l elect rica l co nn ect io ns an d f uses Ann u al ly

I n spect ea ch com pre ssor f or r efr igera nt p r essures, ov er h ea t in g , o il lea k s Ann u al ly

I n spect com presso r t erm inal s for pi t t ing , cor r osion, and loose con nect ions Ann u al ly

I n spect com p resso r oil leve l Ann u al ly

Confirm an d r ecord com presso r am p er age d raw an d v olt age Ann u al ly

Com p ar e w at er / gly col flow a ga in st design sp ecif ica t ion s Ann u al ly

Tight en com pre ssor r o t al ock n ut s Ann u al ly

quarterly, and annual inspections of the chiller/heater. See below table.

Daily

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

• Log pressures and temperatures.

• Visually inspect the unit.

• Inspect touchscreen display for alarms.

• Inspect modules for obvious leaks

• Listen for any atypical noises or vibrations.

Qua rt er ly

Federal Clean Air Act

Important: Responsible refrigerant practices are

important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be properly certified. The Federal Clean Air Act prescribes procedures

recycling of refrigerants and the equipment that must be used in maintenance procedures involving potential leakage of HVAC refrigerants. State and local governments may have additional requirements that must be followed to responsibly handle HVAC refrigerants.

for handling, reclaiming, recovering, and

56 ARTC-SVX005A-EN

Maintenance Procedures

Weekly

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

• Inspect touchscreen interface panel for alarm status

and additions to the alarm history. (Do not clear alarms as this is a very important performance record if troubleshooting problems arise.)

• Listen for excessive vibrations or motor noise. This

usually signals a loose brace or section of piping.

• Measure all refrigerant static pressure on any idle

circuits. Record any significant changes or reductions in pressure.

• Clean strainers weekly during initial weeks after

initial start up until water quality has been reliably established. Thereafter, inspect and clean strainers at least monthly.

Monthly

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

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

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

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

NOTICE

Equipment Damage!

Failure to remove moisture from system could cause corrosion within the chiller/heater components and degrade performance.

Perform vacuum evacuation of system to remove moisture.

Eventually, dry compressor starts could occur causing premature compressor failure. This may indicate that some oil has been lost from a previous refrigerant leak repair. The compressor data label indicates the correct oil type and quantity with which it should be filled.

Note: A flashlight may be required to see the oil churning

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

CAUTION

Compressor Damage!

Failure to follow instructions below could result in catastrophic compressor failure. Do not operate with insufficient oil.

6. Check the glycol concentration using a refractometer.

NOTICE

Compressor Damage!

Failure to following instructions below could result in extensive compressor damage.

Verify that suction pressure is sufficient. Secure the circuit or module offline until status can be examined in detail.

7. Check the refrigeration pressures.

8. For R410A refrigerant, low pressure refrigeration gauge should read 120 to 160 psi and high pressure refrigeration gauge should read 300 to 500 psi.

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

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

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

Important: For R134A, suction pressures below 25 psi

can cause extensive damage to a compressor.

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

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

5. Low oil sight glass conditions could signify an undercharged chiller that lacks proper refrigerant velocity to return oil to the compressor sump.

ARTC-SVX005A-EN 57

Equipment Damage!

Failure to remove moisture from system could cause corrosion within the chiller/heater components and degrade performance.

Perform vacuum evacuation of system to remove moisture.

NOTICE

Maintenance Procedures

Note: Bubbles in the sight glass do not necessarily

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

Quarterly

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

1. Inspect refrigerant pressures and temperature set points.

2. Inspect chiller/heater superheat and sub-cooling. System superheat should be 10 °F to 12 °F (55 °C to 6 °C). System sub-cooling should be 10+ °F (5.5+ °C).

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

4. Inspect strainers.

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

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

7. Inspect crankcase heaters for proper operation.

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

9. Inspect refrigerant piping circuit for signs of oil or refrigerant leakage. Conduct ‘sniffer test’ to find refrigerant leaks.

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

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

a. Verify that the pressure controls (low pressure and

high pressure switches) are ‘cutting in’ and ‘cutting out’ at the appropriate pressures.

b. Verify refrigerant charge by recording the

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

c. Observe head pressure for signs of improper

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

12. Check compressor motor amperage draws and voltage supplies and maintain a record of those values. Verify that they are within the name plate rating. Also, check

for voltage imbalance. The chiller/heater’s phase monitor will open if the voltage imbalance exceeds 4%.

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

Annually

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

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

WARNING

Hazardous Voltage!

Failure to disconnect power before servicing could result in death or serious injury.

2. Inspect fuses to ensure they are undamaged and functioning and are of the correct amperage rating.

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

WARNING

Refrigerant under High Pressure!

Failure to follow instructions below could result in an explosion which could result in death or serious injury or equipment damage.

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

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

5. Inspect that the oil level is visible in each compressor and not discolored or bubbled. Annual oil samples

58 ARTC-SVX005A-EN

should be taken to be analyzed for destructive acids, corrosive materials, or metal deposits.

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

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

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

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

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

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

12. Inspect entire plumbing system for leaks.

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

14. Inspect crankcase heaters to verify proper operation.

15. Sample refrigerant to analyze for moisture or acid.

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

Maintenance Tasks

The maintenance tasks described herein present the basic, minimal, steps required to successfully complete a task. Local policies and protocols may require more elaborate procedures with additional checks and inspections. Freely substitute in those cases where local procedures are more elaborate and complete than the procedures listed in this manual.

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

Inspection Methods

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

Table 13, p. 56.

Maintenance Procedures

WARNING

Hazardous Voltage!

Failure to disconnect power before servicing could result in death or serious injury.

Critical Cleaning Tasks

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

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

Strainer Cleaning Procedure

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

NOTICE

Equipment Damage!

Failure to follow instructions could result in damage to the equipment. Do not operate without strainers in place.

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

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

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

may be equipped with an electronic valve that must be manually locked in the closed position.

3. Remove the insulation to expose the roll grooved blind end cap or service cap on the end of the strainer housing. Utilize a short section of hose to connect to the valve on the end cap to relieve pressure and capture fluid. (Dispose of or re-utilize water/glycol mixture according to local protocols.)

ARTC-SVX005A-EN 59

Maintenance Procedures

CAUTION

Risk of High Pressure Solution!

Failure to relieve pressure gradually could result in minor to moderate injury and water damage to equipment.

Water/glycol mixture can be under considerable hydraulic pressure in the strainer housing. Escaping solution can thoroughly saturate equipment and personnel. Close isolation valves fully. Relieve pressure using a boiler valve. Use extreme care to slowly remove the end cap and release pressure gradually.

4. Inspect the gasket and service cap for abrasions, tears, excessive dirt, or deterioration. Replace gasket if necessary.

Figure 36. Chiller strainer

5. Remove the strainer from the housing.

6. Clean the strainer inside and out using a soft natural bristle brush and tap water.

7. Clean the interior of the end cap (or service cap), and the gasket using a soft natural bristle brush and tap water. Apply a light coating of lubrication to the gasket.

8. Re-install the strainer in the housing (large end first). Replace the gasket and end cap and tighten coupling collar securely.

9. Ensure the water/glycol make-up system is operational to replenish the water/glycol mixture lost during the cleaning process.

10. Energize power to the module containing the strainer by turning power ON at the breaker and/or disconnect.

Heat Exchanger Cleaning Procedure

Fouling of the heat exchangers will result in a gradual decline in performance of the chiller/heater.

1. Isolate each heat exchanger using the isolation valves.

2. Back flush using the city water supply forced to a drain.

3. A brazed-plate heat exchanger is cleaned by back washing which is forcing a cleansing water/glycol mixture backwards through it at higher than normal pressures.

4. Flushing should take place across a maximum 30 Mesh screen filter/strainer with frequent screen cleaning to remove the debris from the chiller/heater. Flushing should continue until the screen is clean. After detergent and chemical cleaning, flush the piping for a minimum of one hour with fresh water to remove any remaining cleaning compounds.

Compressor Tasks

PolyTherm Chiller/Heater has been designed for ease of maintenance access. When properly positioned within a machine room or space, Trane compressors can be quickly

60 ARTC-SVX005A-EN

removed for repair or replacement. (See

and Clearances,” p. 11

Remove Tandem Compressors

Verify that power is disconnected from the chiller/heater.

WARNING

Hazardous Voltage!

Failure to disconnect power before servicing could result in death or serious injury.

There are two different methods for removing the tandem compressors, depending on the space in which the chiller/ heater is installed and the available space overhead or behind the module:

Remove Through the Roof Panel: Where there is a minimum of 48 inches of overhead clearance, remove the

“Site Preparation

Maintenance Procedures

eight fasteners attaching the roof panel to the module. Position a lifting device over the tandem compressors.

Remove Through the Side C Top Panel: Where there is a minimum of 36 inches of rear clearance, remove the fasteners attaching the upper Side C panel to the module. Position supports on the middle level framing sufficient to slide the tandem compressors out the rear.

1. Close the suction and discharge rotalock valves (if so equipped). Firmly front-seat both rotalock valves clockwise.

Note: Do not over-tighten as a rotalock valve can become

difficult to loosen if over-tightened.

2. Recover the refrigerant from the high and low sides of the compressor using a suitable vacuum recovery machine and clean recovery cylinder.

3. Detach the refrigeration lines from the compressor suction and discharge stubs. Reconnect rotalock valves.

4. Evacuate the compressor using the connections on the suction and discharge stubs to 500 microns or lower (250 to 500 micron range is ideal).

5. Disconnect the compressor power lines and all associated power leads.

6. Observe the oil level in each compressor via the sight glass and confirm the oil level is below the oil line connector opening.

7. Disconnect and cap the threaded oil line on each compressor.

8. Remove the four mounting bolts holding each compressor to the middle frame.

9. Position a lifting device (top removal) or support bracing (rear removal) and ensure there is sufficient clearance as the compressors are moved.

10. Remove the compressors from the module by lifting or sliding.

3. Install the rotalock nuts on the compressor suction and discharge connections. The recommended torque is 80 lbf for 2-inch and larger and 60 lbf for rotalock nuts smaller than 2-inch. Tighten with a narrow spud wrench.

4. Evacuate the compressors using the connections on the suction and discharge stubs to 500 microns or lower (250 to 500 micron range is ideal).

5. Attach compressor power lines, all associated power leads, and safeties in the compressor electrical box.

6. Re-connect the threaded oil line on each compressor.

7. Observe the oil level in each compressor via the sight glass and confirm the oil level is visible.

8. Open all rotalock valves (if so equipped) until fully back-seated counterclockwise.

NOTICE

Valve Damage!

Applying excessive force when fully opening an isolation valve could cause valve damage. The valve could bind in the fully open position and prevent proper service isolation.

9. Restore power to the module containing the compressor by turning the circuit breakers CB-1 and CB-2 to the ON position.

10. Observe the newly installed tandem compressors to verify that all connections have been seated and tightened correctly.

Install Tandem Compressors

Verify that power is disconnected from the chiller/heater.

WARNING

Hazardous Voltage!

Failure to disconnect power before servicing could result in death or serious injury.

1. Position the tandem compressors into the chiller/ heater using the same method used for removal.

2. Position the compressors in position and attach to the frame with eight mounting bolts, washers, and nuts. Tighten nuts with 1/2-inch socket and wrench.

ARTC-SVX005A-EN 61

Chiller/Heater Troubleshooting

General Approach to Fault Isolation

Trane manufactures chillers with embedded fault detection and diagnostics in each module’s controller that offers continuous dedicated monitoring to record and report faults as they occur in real time allowing repairs to be performed in a timely manner.

Various faults occurring in a building’s HVAC system can lead to unnecessary energy consumption and poor thermal comfort for a building’s occupants. Fault detection and isolation plays a significant role in monitoring, maintaining, and repairing chillers to improve operator safety and minimize operating costs.

Fault detection is recognizing that a problem has occurred, even if the root cause is not yet known. Fault isolation is the process of reducing potential causes to determine the most likely source of chiller failure

Controller Diagnostic Codes

Compressors used in Trane systems are highly automated with digital capability to record and report a range of operating parameters and critical events. This technology can be employed to assist in troubleshooting compressor faults and potential corrective action.

Compressor Flash Codes

The technology in the Trane compressor will communicate an abnormal system condition through a unique flash code:

ALERT LED (Yellow): The ALERT LED will flash a number of times consecutively, pause and then repeat the process. The number of consecutive flashes, defined as the flash code, correlates to a specific anomaly or abnormal condition.

TRIP/LOCK LED (Red): indicates either a TRIP or LOCK condition.

• TRIP is indicated by a solid illumination of the LED. This means the compressor is not running and demand is present at the module.

• LOCK is indicated by a flashing LED correlating to a lock condition in which the module will prevent the compressor from starting.

Flash Code Description

Compressors will report a range of flash codes when specific critical events occur. See the following table.

CODE 1 – Long Run Time: The module will flash yellow one time when the compressor operates for longer than 18 continuous hours. This is an alert code only and the module will not lockout the compressor for this condition. (This code is inactive for heat pumps.)

CODE 2 – Compressor (Pressure) Trips: The module will flash yellow two times when the compressor operates from 12 seconds to 15 minutes followed by a trip condition lasting longer than 7 minutes. When four consecutive or ten total code 2 events are recorded, the module will lockout the compressor and flash red two times.

CODE 3 – Pressure Switch Cycling: The module will flash yellow three times when the compressor operates from 12 seconds to 15 minutes followed by a trip condition lasting between 35 seconds to 7 minutes. When four consecutive or ten total CODE 3 events are recorded, the module will lockout the compressor and flash red three times.

CODE 4 – Locked Rotor Trip: The module will flash yellow four times when the compressor trips within 12 seconds of operation and does not reset and start within 35 seconds. When ten consecutive CODE 4 events are recorded the module will lockout the compressor and flash red four times.

CODE 5 – Compressor (Moderate Run) Trip: The module will flash yellow five times when the compressor has operated between 15 minutes and 18 hours, followed by a compressor trip lasting longer than 7 minutes. When four consecutive or ten total CODE 5 events are recorded, the module will lockout the compressor and flash red five times.

CODE 6 – Open Start Circuit: The module will lockout the compressor and flash red six times if the module detects a demand signal in the Y terminal and current in the R winding of the compressor, but no current is detected in the s winding of the compressor for 2 seconds.

CODE 7 – Open Run Circuit: The module will lockout the compressor and flash red seven times if the module detects a demand signal in the Y terminal and current in the S winding of the compressor, but no current is detected in the R winding of the compressor for 2 seconds.

CODE 8 – Welded Contactor: The module will flash yellow eight times if it has detected line currents in the S and R windings and demand is absent for 15 seconds.

CODE 9 – Low Voltage: The module will flash nine times if the module supply voltage drops below 17 Vac for 2 seconds. The module will prevent the compressor from starting until adequate voltage is established.

CODE 10 – Over-Current Protection: When the current at the PORT terminal is greater than 2A for 40 milliseconds, the module will flash a CODE 10. The red LED will flash 10 times with the yellow LED remaining OFF. This event will cause a lockout of the compressor and indicates that the module is mis-wired or the contactor coil is shorted to ground.

The following table assists in explaining the alarm codes that appear in the remote interface panel in the event of an alarm. The alarm history is accessed by pressing the alarm log key. See the following table.

62 ARTC-SVX005A-EN

Table 14. Compressor fault code summary

Chiller/Heater Troubleshooting

Ale r t Cod e

Nor m al Run Solid Gre en

COD E 1

Yel l o w Fl a s h 1

COD E 2

Yel l o w Fl a s h 2

COD E 3

Yel l o w Fl a s h 3

COD E 4

Yel l o w Fl a s h 4

COD E 5

Yel l o w Fl a s h 5

COD E 6

Red Flash 6

COD E 7

Red Flash 7

COD E 8

Yel l o w Fl a s h 8

COD E 9

Yel l o w Fl a s h 9

COD E 1 0

Red Flash 1 0

Nor m al o perat i on , no alar m st at us. N/ A N/ A

Long run ti m e. Com pre ssor i s run ning for m or e t han 18 hour s at fu ll load. (CO D E 1 is d is ab le d i n h ea t pu m p m ode.)

Com pr essor pr essu re tr ip. Com pr essor r uns fo r 1 2 secon ds t o 15 m inu tes fol low ed by a com presso r trip con dit ion last in g long er t h an 7 m inu t es.

Pressu r e sw it ch cyc lin g. Com pr esso r ru ns f or 1 2 secon ds to 1 5 m i nu tes fo llo wed b y a com presso r t rip last in g 35 secon ds to 7 m inu t es.

Lock ed rot or. Com presso r t rip s w it hin a com pre ssor r u n tim e of 1 2 se cond s an d does n ot st art w it hin 3 5 seco nds.

Com p resso r m od er at e r un t r ip. Com pressor ru n s fo r 15 m inutes t o 1 8 ho urs foll ow ed by a com pressor tr ip l ast in g l ong er t h an 7 m inu t es.

Open st art circui t . Mod u le h as d etect ed Y or Y 1 , an d cur r ent in t he R w in d in g of the com pre ssor a nd no cu r ren t in t he S w in d in g o f t he com presso r fo r 2 secon d s.

Ope n r un ci rcu it. Modu le ha s de tect ed Y or Y1 , and cur rent in t he S wi ndi ng of t he com pre ssor and no cu rren t in t he R w in d in g o f t he com presso r f or 2 secon ds.

Weld ed cont act or. Modu le h as d ete cted li ne curr ent s i n R an d S w ind ings, and Y or Y1 is at 0 Vac f or 15 seco n ds.

Low v olt age . Mo dul e h as det ect ed a 2 4 Va c su pply v olt ag e b elow 1 7 Vac ± 1 Vac for 2 se conds.

Ove r cur r en t pro t ect ion. PRO T t erm inal h as ab ov e a 2 A inp u t fo r m ore t han 40 m il li secon ds.

Ale r t

Con d i t i on

Phase Monitor Protection

If the chiller/heater fails to power up, eliminate electrical phase issues by inspecting the phase monitor device located in the power distribution panel.

When all voltages are acceptable and the phase sequence is correct the output relay is energized and the LED glows green. Under-voltages and unbalanced voltages must be sensed for a continuous trip delay period before the relay de-energizes. Reset is automatic upon correction of the fault condition. The output relay will not energize if a fault condition is sensed as power is applied. The LED flashes red during the trip delay, then glows red when the output de-energizes. The LED flashes green/red if phase reversal is sensed.

Table 15. Phase monitor LED diagnostic codes

LED D isp lay I n d ica t ion

Glowin g g r ee n: All v o lt ages are acce pt able a nd pha se se quen ce i s cor rect .

Flash in g re d: Trip d ela y pr io r t o deen erg izi ng . Glow ing r ed: Out pu t h as been deen er g ized up on f au l t de t ect io n .

Lock o u t

Le v e l

N/ A N/ A

4x c ons ecut i ve, 1 0 x t ot al

4x consecu t ive , 1 0 tot a l

10 x con se cu t iv e

4x c ons ecut i ve, 1 0 x t ot al

1 occurre nce

N/ A N/ A

1 occurre nce

Lock o u t

I ndi cat ion

Red : Flash 2

Red : Flash 3

Red : Flash 4

Red : Flash 5

Red : Flash 6

Red : Flash 7

Red : Flash 10

If the phase monitor fails to energize (the LED glows red) check wiring of all three phases, voltage, and phase sequence. If phase sequence is incorrect, the LED flashes green/red. To correct this, swap any two line voltage connections at the mounting socket. No further adjustment should be required.

Symptoms and Solutions

This section lists the most common troubleshooting symptoms and the closest potential solution for each. This is not an exhaustive listing of all potential causes or resolutions, but represents the best direction in which to initiate a solution.

Note: An anti-short cycle timer is included in the master

microprocessor controller to prevent the compressors from starting until the delay has elapsed. The microprocessor also provides minimum compressor run timers. Take these fixed timer parameters into consideration when conducting a fault isolation process.

Flash ing red a nd green : Phase re ver sal is d et ected.

No pow er t o ph ase m onit or.

ARTC-SVX005A-EN 63

Chiller/Heater Troubleshooting

1 . Sy m pt o m : Co m pr e sso r w ill not st a rt

Po ssible Cause s Po t e nt i a l So lu t i o n s

Circuit b reake rs are in th e OFF p osit ion Moves ci rcuit br eak ers to th e ON posit ion in t he po wer dist rib ut ion pa nel

Temp er at ur e con t r ol not in dem and Set point has been re ach ed or st ill w it hin b an d

Diff er ent ia l p r essur e swit ch op en due con d en ser f lo w swit ch op en Condenser sid e loss of f lo w ; clean st raine r

Refr ige ran t lo w p r essu r e sw i t ch op en

Hig h pr essu re sw it ch op en Low f low rat e; ch eck f or di rt y o r clog ged s tr ain er. Requ ir es a m an ua l res et

Flow sw it ch d efect ive Repla ce FS- 1 an d FS- 2 sw itch

Com presso r o ver lo ad op en ed

No h ig h v o lt age po w er t o co n t act or

Phase m oni t or open or t rip ped Ov er or u nde r 4 % t o 8% ; lo ss of le g

2 . Sy m pt o m : Co m pr e sso r fa ils t o co n t inu e r unn ing

Po ssible Cause s Po t e nt i a l So lu t i o n s

Com p r esso r no t po w er ed Assure all cir cuit bre ak er s ar e in t h e ON p osi t ion

Circuit bre ak er s op en Check cir cu it s an d m otor w in din g f or sh ort s or gr ounds

Trip ped cir cu i t br eake r Reset b reaker s af t er f aul t is cor r ect ed

I n vest i gat e f or p ossib le ov erload in g

Elect rical ov eram p br eak er t r ip p ed Repai r or rep lace

Def ect iv e co nt act or or coil Det er mine t ype a nd cause. Correct f au lt bef o re r ep la cin g p arts.

Syst em shut down b y saf et y d ev ices

Liq ui d l in e solen oi d w ill no t op en

Mot or el ect rica l t r o ubl e Replace t and em com presso r s

Low refr igera nt lev el o r l ow pr essur e eve nt h as o ccu rre d fou r t im es and locke d out the ci r cu it

Allow m o t or to coo l an d reset ; high am p l oa d/ floo dback ; loose con nect i on , or lo w re fri ger an t ch ar g e

Check b r eake rs; en er g ize f r om po w er di st ribut ion p an el an d m odule ele ct r ical p an el; check ON/ OFF but t on in t ouchscreen in t erface

Ove rload s ar e aut o-r eset. Mo nit o r t o assure t he ov er l oa d d oe s no t r eoccu r

Repai r, r ep lace, or cor r ect saf et y i ssu e ( for e x am ple, n o f lo w, low pr essur e)

Chec k coil f or op en cir cui t, s hor t ci rcu it , or b ur nou t . Rep lace coi l o r ent i re valv e, if needed

3 . Sy m pt o m : Co m pr e sso r h a s e x cess ive n oise or v ibra t i o n

Po ssible Cause s Po t e nt i a l So lu t i o n s

Floodi ng of r ef r ig era nt i nt o cr an k ca se

I m pro per di sch a r ge pi pin g sup p or t Repai r as n ecessar y. Relocat e, ad d , o r rem ove sup p or ts

I m proper o r w orn com pre ssor su p po r t s Repla ce su p po r t s

Wor n com pressor Repla ce t a ndem com presso r s

Low fl ui d f low a cross h eat exchan ger; clo gged st rain er. Ch eck settin g of ex pa nsio n v al v e

4 . Sy m pt o m : Co m pr e sso r cy cle s t oo shor t

Po ssible Cause s Po t e nt i a l So lu t i o n s

Temp er at ure di ffe ren t ial set t oo lo w ( 4 ° F (22 ° C) m inim um )

Err at ic w at er t h er m ostat dev ice Rep la ce t herm ost at assem b ly.

I n suff icie nt e vap or at or w at er fl ow Adj ust fl ow rat e or clea n st rain er.

Ram p/ set t em perat ure set po in t. D ef au lt 5 ° F r aise u p accor din gly wit h low l oad s.

5 . Sy m pt o m : Com pr e ssor o il le v e l in si g h t gla ss lo w

Po ssible Cause s Po t e nt i a l So lu t i o n s

Low ref r ig er ant cha rge Ch eck for lea ks an d r epair. Ad d re friger an t t o p r op er cha rge

Leak in r ef r igerant line Rep ai r l ea k ; add r ef r ig er ant

6 . Sy m pt o m : Low r e frig e r at ion su ct i o n pre ssur e

Po ssible Cause s Po t e nt i a l So lu t i o n s

Lack of r ef r ig er ant Check f or lea ks. Rep ai r an d a dd ch ar g e

Evap or a t or f ou led Clea n ch em ically

64 ARTC-SVX005A-EN

Chiller/Heater Troubleshooting

6 . Sy m pt o m : Low r e frig e r at ion su ct i o n pre ssur e ( con t i n u e d )

Po ssible Cause s Po t e nt i a l So lu t i o n s

Low wat er f low I ncr ease f lo w ra t e

Cond en si ng t em per at ure t oo l ow Check so urce wat er m odu la t io n v alv e an d t em perat u r e

Low wat er t emp er at ur e Raise se t po in t and in cr ea se f lo w ; che ck desig n spe cif i cat ion

Low di sch arg e p r essur e Check for r ef r ig er ant lea k

Exp an sion valv e m alf unctio ni n g

Com pressor ser v ic e valve s close d Ope n ser v ice valve ( if so e qui pped) cou n t erclo ck w is e co m p le t el y

Clog ged liqu id li n e f ilt er - drier Repla ce l iq u id li ne filt er - d r ier o r cor e

Excessiv e gl ycol con cent rat ion Dr ain, r ef il l ( d ei on ized w ater ) , ret est

Liqui d l in e solen oi d r est r ict ed or fa ult y Repla ce so le noid valve coil

I n suff icie nt chi ll ed wat er f lo w Adj ust fl ow r at e acro ss evapo rat or

Rest rict ed w a t er / gly co l lin e Clean st r ain er s; ch eck m an ual a nd el ect ron ic exp ansion v alves

Wat er /g lycol m ixt ure con t am ina t ed

Evap or at or clog ge d or f oul ed

7 . Sy m pt o m : H igh r e f r i g e r a t ion su ct ion p r e ssur e

Po ssible Cause s Po t e nt i a l So lu t i o n s

Exp an sion v al v e ope n ed t oo fa r close d Re- ad j u st t o 1 0 ° C t o 1 2 ° C

Excessiv e r efr i ge ran t char ge

Ent er ing w ater t em perat u r e ex ce ssive Failing t an dem com pressor s; ch eck d esig n sp ecif icat ion s

I ncr ease su ct ion pr essu re; su ct ion t empera t u re pr essur e; ch eck f or pr op er su per h eat ; che ck el ect ro ni c ex p ans ion v alv e re pla ce if ne cessa ry ; cab ling t o st eppi ng m oto r; con t act Trane tech n ica l su p po r t

I nt en si ve cle an u p eff ort n eeded t o ident ify sou r ce o f co nt am inat ion; ex t er nal f il t er may be req uir ed

Reverse flu sh w ith ap propriat e ch em ical so lu t ions f ol lo w in g a ppr ove d pr ocedur es

Creat es h igh pr essur e alarm s; r eco ver ex cess re fri ger an t ; w eigh in cor r e ct ch arge a s in d icat ed o n da t a p la t e

8 . Sy m pt o m : Low r efrig e ra n t d isch ar g e pr e ss u r e

Po ssible Cause s Po t e nt i a l So lu t i o n s

Suct io n sh u t of f va lv e p art ially closed Open v al ve

I n suff icie nt r e fri ger an t in ch il ler/ heat er Check f or le ak s. Repair a nd ad d R4 1 0A or R13 4 A as n ee de d

Low su ct ion p r essure Se e lo w p r essure below

Sou r ce h ea t ex ch an ger m odu lat ing va lv e n ot p r op erl y ad j u st ed or n ot fu n ct ion in g

Refer t o OEM m anu fact urer m anu al fo r d efa ult set t in g s; check Y1 ele ct r i cal ou t p ut J6

9 . Sy m pt o m : H igh r e f r ige r an t d isch a rge pre ssur e

Po ssible Cause s Po t e nt i a l So lu t i o n s

Syst em ov erchar g ed w it h r efr i ge ran t Rem ov e e x ces s ref r ig era nt

Non - co ndensab les in chi ll er / hea t er Pu rge n on- cond en sabl es accor ding t o app r ov ed pr ocedu r es

Rest rict ed by p ass l in e Check v al ves obst ruct ed ; fl ush l in e; b lo w ou t li ne wit h d r y n it r og en ga s

Dischar ge shut of f v al v e par t ially clo sed Open va lv e

Liq ui d l in e solen oi d v al v e coil Check v al v e; r ep la ce i f d ef ect iv e

1 0 . S y m pt o m : Lo w ch i lle d w at er t e m pe r a tu r e

Po ssible Cause s Po t e nt i a l So lu t i o n s

Temp er at ure set poin t set adj ust ed t oo low

Wat er f low ra t e t hro ug h ev ap or a t or t o o lo w Cle an st r ai ne r ; che ck pu m p, an d d if f er ent ial pr essur e se t t in g s

Syst em con t r ols m alfu n ct ion in g Check and r ep lace t em perat u r e sensor s if necessary

Reset tem per atu re set po in t t o corr ect d esign spe cifi cat ion s (lo w r etur n tem pera tures)

1 1 . S y m pt om : H i g h ch ill e d w at e r t em per a t u re

Po ssible Cause s Po t e nt i a l So lu t i o n s

Refr igera t io n cir cu it s no t cooli n g

Check elect r on ic e x pa nsio n v al v e for ex cessiv e f low ; ad j u st or r ep la ce elect r on i c ex pan sio n v alv e

ARTC-SVX005A-EN 65

Chiller/Heater Troubleshooting

1 1 . Sy m pt om : H i gh ch ill e d w at e r tem per a t u r e ( co n t i n u e d )

Po ssible Cause s Po t e nt i a l So lu t i o n s

Load hig he r t han cap aci t y of chiller /h ea t er Refer t o chi ll er / hea t er design specifi cat ions

Low ref r ig er ation ch arg e Cond u ct leak ch eck on r ef r igera t ion syst em

Temp er at ur e sen sor n ot p r operly in st a ll ed Check t hat sen sor i s pr oper ly i nst al led in w el l

Fouled e vapor at or Rever se f lush ev apora t or; ch eck st rainer f or d eb r is

Excessiv e f low thr oug h ev ap orat or Reverse flush eva por at or; che ck st rain er for deb ris; ch eck pum p, valv es

1 2 . Co m pr e sso r t h e r ma l p r o t e ct o r sw it ch o p e n ( ov e r l o a d i n g )

Po ssible Cause s Po t e nt i a l So lu t i o n s

Elect rica l m alfu n ct ion

Opera t ing be yon d d esig n con di t ion s All oca t e ch ille r / heat er f or use wit hin o per at ing cap ac it y. Add eq uip m ent

Dischar g e valve part ially shu t Open v al ve

Liq ui d f lo odb ack Adj ust e lect r on ic ex pansio n v alv e, in cr ease flow, or raise set po in t

Com presso r s ov er am pin g Correct r ef r ig er an t charge; check e lect r ica l co nn ect io ns

1 3 . S y m pt om : N o low v o lt a g e ( 2 4 Va c)

Po ssible Cause s Po t e nt i a l So lu t i o n s

Cont rol cir cu it fu se o pe n Check f u se p r on g con t act p oin t s; r ep la ce f use Phase m oni t or o pen ed or t r ip p ed Replace t ran sf or mer, T 1 or T 2 prim ary or secon dar y fu se b lo w n

No prim ary voltag e on T 1 or T 2 Check b r ea ker s, fu se s; check po w er su pply specif icat ion s

Check co nt act ors f or dam age; ch eck w iri ng f or lo ose con n ect ions; re place co m pre sso r s

1 4 . S y m pt om : Fl o w sw it ch o p e n

Po ssible Cause s Po t e nt i a l So lu t i o n s

I n suff icie nt w a t er f low Ch eck st rain e r f or d eb r is; clean st raine r

Swit ch def ect ive Repla ce f low sw it ch

1 5 . S y m pt om : El e ct ronic e xpan si on v alv e supe r h e a t t oo h i gh

Po ssible Cause s Po t e nt i a l So lu t i o n s

Wat er/ g ly col t em pe rat u r e t oo w ar m Low ref r ig er ant l ev el; adj ust c hil ler / hea te r ref ri ger an t char ge as re qui re d

Obst ruct ed fi lt er dry er Repla ce f ilt er d r y er

Low ref r ig er ant cha rge Ad j ust r efr iger an t as p er dat a pl at e

I m pro pe r ly set sup erh e at v al ve set tin g Rese t va lv e set t ings t o fact ory speci ficat io ns

1 6 . Ele ct r o n i c e x p a n s ion v a l v e su p e r he a t t o o lo w

Po ssible Cause s Po t e nt i a l So lu t i o n s

Suct io n t e m p er at ure sen sor n ot pr operly locat ed

I m pro pe r ly set sup erh e at v al ve set tin g Rese t va lv e set t ings t o fact ory speci ficat io ns

Low fl ow I ncr ease flo w o r clean st r aine r

Chec k i f se cur ed t o pipe or in sula ted ; che ck sen sor posi ti on o n p ipe at 48- 10- 2 o’cl ock p osit ion s

1 7 . Sy m pt o m : Co n t act or/ r e l a y in ope r a t ive

Po ssible Cause s Po t e nt i a l So lu t i o n s

Coil sho r t ed or op en Repla ce co ntact or

Mech an ical parts br oke n o r j am med Replace assem bly

Coil sho r t ed or op en Repla ce co ntact or

Cont acts br oke n o r j am m ed Repla ce co nt act or

Cont acts pit t ed or bu r n ed Re pl ace con t act or

No 2 4 Vac t o co il Check f or l oose w ir ing. Rep lace secon d ar y fuse t o T2 t r an sf or mer

Bad rela y o n m icro processor co nt roller Repla ce m icro pr ocessor con t r ol ler

66 ARTC-SVX005A-EN

Chiller/Heater Troubleshooting

1 7 . S y m pt o m : Fr ee z e pr ot e ct ion safe t y a ct ivat e d

Po ssible Cause s Po t e nt i a l So lu t i o n s

Temp er atur e set point too low Reset ab ov e f r ee zin g t em perat u r e at evapor at or or disch a rge

Low wat er f lo w Remov e r estrict ions; incr ease fl ow ; cl ean st rain er

Low su ct ion p r essure See ‘l ow su ct i on pr essu r e’

ARTC-SVX005A-EN 67

Logical Flow

High Voltage Logical Flow

The PolyTherm Simultaneous Chiller/Heater is available in a range of voltage/amperage/phase configurations to meet the demands of a worldwide market. The high voltage configuration for a chiller/heater module is listed on each module’s name plate. The chiller/heater is

Figure 37. PolyTherm chiller/heater control wiring (master module)

designed to operate with high voltage power supplied to the unit at all times.

Control Logical Flow

The chiller/heater uses low voltage for controller and sensor circuits.

68 ARTC-SVX005A-EN

Figure 38. Expansion board wiring (master module)

Figure 39. Expansion valve wiring

Logical Flow

ARTC-SVX005A-EN 69

Logical Flow

Water/Glycol Mixture Logical Flow

Trane recommends using a water/glycol mixture instead of an all water fluid. The water/glycol mixture is used within a closed system as shown in the below figure.

Figure 40. PolyTherm chiller/heater piping installation diagram

70 ARTC-SVX005A-EN

Appendix A - Acronyms and Abbreviations

All acronyms and abbreviations used in this manual, on the chiller controllers, and on module indicators and gauges are listed in the following tables.

Acronym List

All acronyms and abbreviations in this publication are listed in the following table, with their full spellings and expansions.

Table 16. Acronyms and Abbreviations

I tem Ex pansion

41 0 A R41 0A

Ack Ack now le dg ed

Ack ed Ackn ow ledge d

ACWS Aut omat i c Cit y Wat er Swit cho ver

Add r Add r ess

AHRI Air - Con d it ionin g, Heat ing a nd Ref rig er ation I nst it ut e

AL ala r m

Alm Alar m

Alr m s alarm s

Anl g Analog

AO1 ana lo g out put on e

API Ap plicat ion Progra m Int erf ace

Aval Avai l ab le

BAS Bu ild in g Aut oma t ion Syst em

Bd boar d

bt u Br i t ish t her m al unit

CCelsius

C1 Circu i t 1

C2 Circu i t 2

CB Cir cu it Bre ak er

CE Conf orm ance Eur op ean

ckt cir cu it

CL cool

Cnt r l, Con t r l Con t r oller

Com m Com muni cat ion

Com p, Com ps

Cool Dem an d Cooling Dem and

Com pen s Com pen sat ion

COND, Cond con d en ser

CSA Canad ian St anda r ds Associat ion

CSV Com ma- Separ at ed Valu es

DB Dr y Bul b

DB Dist r ib ut io n Bloc k

DifPr D if f er ent ial Pressure

Dis Disab le d

Dish Discha r ge

Dist urb D ist rib ut io n

Com p r essor, Com presso r s

Table 16. Acronyms and Abbreviations (continued)

I te m Exp a n sion

Dly D el ay

DP Dif f er ent ial Pressure

DTC Danf oss Turb ocor Com pre ssors I nc.

ECM Elect rically Com mu t ated Motor

EER Ener gy Eff iciency Rat ing

EMC Elect rom agnet i c Com pat ib il it y

EMI Elect rom agnet ic I n t er feren ce

En Enab le d

EPC Ext end ed Perfor m ance Com presso r

Err Err or

Evap Evapo rat or

Evap Fl Eva por at or Flow

EVC Elect ron ic [ exp ansion ] Valv e Cont roller

EVD Exp an si on Valve Dr iv er

EX Exp ansion

Ex Va l v e Ex p a n sio n Val ve

Exp Export

EXP1 Ex pa nsio n Bo ar d 1

Ext ern Ex t er n al

EXV Elect r on ic [ e xpa nsion] Valve

FFahrenheit

FLA Full Load Am per es

FLC Full Lo ad Cur r en t

FREECOOL Fr ee Cool in g

FRI Frid ay

FTP Fil e Tran sf er Pr ot ocol

gp m ga ll on s p er m inut e

GUI Gra ph ical User I nter face

Hea t De m and He at ing D em and

HFC Hy dr o flu or ocar b on

HG Ho t Gas

HH. MM. SS Tim e: Hour.Min u t e. Secon d

HMI Hum an Mach ine I nt er f ace

Hot gas1 Hot Gas 1

HP Hig h Pressu r e

HPS Hig h Pressur e Sw itch

HT h ea t

HVAC Heat ing , Vent ilat i on , an d Ai r- Con di t ion in g

I / O I npu t / Out put

I D I n sid e D ia m et er

I den t I den t ifi cat ion

I EEE I n st i t u t e of Elect r ical a nd Ele ct r oni c Eng ine er s

I GBT Insu l at e d Gate Bip olar Tran si st o r

I GV Inl et Guide Vane

I m p I m por t

I m plem I m p le m ent ati on

ARTC-SVX005A-EN 71

Appendix A - Acronyms and Abbreviations

Table 16. Acronyms and Abbreviations (continued)

I tem Ex pansio n

I n In ch

I NFO I nform at ion

I n t I nt eg rat ion

I P I ndu st r y Pack

I so Isolat ion

LA Low Am bient

lbf f oo t po und s

LBV Load Balan ce Valve

LED Lig ht- Em it tin g Diode

Lgt h Lengt h

LI FO Last I n Fir st Out

Liq Liqu id

LLS Liqui d Li ne Sol en oid

LP Low Pressure

LPPD Low Pressure Pum p Down

LPS Low Pressu r e Sw it ch

LRA Lock ed Rot or Am per es

m m inu t e

Max Max im um

Mem Mem ory

Min Min im um

MON Mond ay

m s milliseco nd

Mx Mod u le 1 t hro ugh x

NEMA Nationa l Elect r ica l Ma nuf act ure r s Asso cia t ion

NFPA Nat ion al Fire Protect ion Associ at ion

NTC Neg at i ve Temp er atur e Coeffi cie nt

Num Num ber

OA Out side Am bien t

OAT Outsid e [ am bien t ] Ai r Tem p er at ure

OD Ou t side D iam et er

Opn Op en

OS Operat in g Syst em

P Process

Para ms Par am eter s

PASV Pa ssive File Transf er Pro t ocol

PD Pressur e D if f er ent ial

PE Prot ect ive Ear t h

PLC Pro gr a m m able Log ic Con t r oller

PMD Panel Mo unt ed Discon n ect

POE Poly olest er Oi l

Pos Posi t ion

pp m pa rt s pe r m il li on

Pres pr essur e

psi pou nds p er squa r e in ch

Pum pDown Pum p Dow n

Pum pMod Pum p Mo dul e

PWM Pul se W id t h Mod ulation

Table 16. Acronyms and Abbreviations (continued)

I te m Exp a n sion

Pwrup St g Up Power Up St age Up

REFRI G Ref r igera t ion

Rem Off Rem ot e Of f

RMA Retur n ed Mer ch and ise Au t hor izat ion

RmpD n Ram p Down

Rot Rot at ion

rp m rev olu t io ns per m inu t e

RP Redu nd ant Pum p

ssecond

S1, S2 Sw it ch # 1, Sw it ch # 2

SAT Sa t urda y

SDT Sa t ura t ed Di sch ar g e Tem pe rat u r e

Sim ult Sim u lt aneo u s

SL Ser v ice Lin e

Sof t So ft war e

SP Set Point

SQ. Sq uar e

Src So urce

SSS So li d St ate Star t er

SST Sat u r at ed Su ct ion Tem perat u r e

St ar t Pt Stat in g Point

Suct Suct ion

SUN Sun day

Sy s Sy ste m

Sy sCh EWT Syst e m Chi ll ed En t erin g Wat er Tem per at u r e

Sy sCh LWT Sy st e m Chi ll ed Le av ing Wat er Tem per at ur e

SysHot EWT Sy st em Hot Ent ering Wat er Temp era t ure

SysHotLWT Syst em Hot Leav ing Wat er Tempe rat u r e

Te m p Te m p e r a t u r e

Tem p Di ff - Tem perat u r e Dif fer en t ial ( m i nus)

Tem p Di ff + Tem per at ure Diff ere nt ia l ( p lu s)

TEMPS Tem p er at ure s

THU Thu r sd ay

TT Tw i n Tu r b in e

TUE Tuesday

TXV The rm al Exp an si on Valv e

U1, U2 bin ary 1 , bi nar y 2

UL Under w r it ers Labora t ories

UV Ult r av i ol et

VAC Volt s, Alt e rna t ing Cur r ent

Var Va ri ab le

Var iab Var ia bl e

VDC Volt s, Dire ct Cur r ent

Ver. Ve rs ion

VFD Var i ab le Fr eq u en cy Dr ive

WED Wed n esd ay

Y1, Y2 ana lo g o ut put : y 1 = cond en se r, y 2 = ev ap or at or

Y4 analog ou t put

72 ARTC-SVX005A-EN

Table 16. Acronyms and Abbreviations (continued)

I tem Ex pansio n

YY.MM. DD Dat e: Year. Mon t h . Day

Appendix A - Acronyms and Abbreviations

ARTC-SVX005A-EN 73

Appendix B- Request for Initial Startup

PolyTherm Chiller/Heater

As part of a continuous commitment to quality, initial startup of this chiller/heater by a factory certified technician may be purchased from Trane. No initial startup will be scheduled without a Request for Initial Startup form completed and on file with the Trane customer service department. Submitting this form indicates that all critical work described on the form has been completed. To prevent additional charges for aborted startups, the following items must be completely functional and operating and this form signed and returned to Trane at least 10 working days prior to the scheduled initial startup date.

Chiller/Heater Initial Start-up Data

Model Number: Master Module Serial Number:

Primary Contact Name: Primary Contact Phone:

Primary Contact FAX: Primary Contact Mobile:

Name of Chiller Site:

Physical Location of Chiller:

Requested Date for Initial Start-up:

Requested Time for Initial Start-up:

Mandatory Initial Startup Requirements

Ma n d a t o r y Ta sk s

All modules are installed with minimum clearances exceeded on all sides.

Refrigeration gauges are indicating equal pressures.

Chilled water lines from chiller to customer’s equipment are permanently connected.

Chilled water lines have been flushed clean of mud, slag, and other construction debris.

All chilled water line filters and strainers are clean.

Chilled water lines have been leak tested according to prestart instructions.

Chiller reservoir (if included) is at operating level with correct water/glycol mixture.

High voltage wiring is installed, tested, and functional.

All water, refrigeration, electrical, and control connections between chiller modules are completed.

All control wiring between modular chillers is installed, tested, and functional.

Control wiring is complete, including any remote interface panel or special-purpose module wiring.

Automatic City Water Switchover (if included) is installed, flushed, and leak-tested.

Condenser, if applicable, is installed, piped, wired, and leak-tested.

All responsible installing contractors and sub-contractors are notified to have representatives available on site to provide technical support for the initial start-up procedure.

Full load shall be available for chiller on the initial start-up date.

Da t e

Com plet e d

I ni t ial e d

Com pl e t e

74 ARTC-SVX005A-EN

Appendix B- Request for Initial Startup

Initial Start-up Agreement

By signing this form, you agree the chiller is ready for initial startup. It is understood that, if the chiller is not ready for initial startup due to site problems, the initial startup will be aborted at the discretion of the designated start-up technician. Payment for an aborted startup will be forfeited. Rescheduled initial startups are subject to any additional costs that may have been incurred by the technician. An approved purchase order or payment in advance will be required to reschedule an aborted initial startup.

Name (Printed): ____________________________________ Date: ________________________

Signature: ___________________________ Company __________________________________

ARTC-SVX005A-EN 75

Appendix C - Active Alarm List

All active alarms are reported on the Active Alarms screen.

Application

Shows if alarm applies to master microprocessor controller, slave microprocessor controller, or both.

Type

This is the alarm type; either an automatic reset or a manual reset performed by the operator.

Auto Reset

An alarm automatically resets itself once the condition triggering the alarm is resolved, so it will change from active to non-active automatically.

Operator Reset

When the alarm condition is resolved, the alarm still needs to be manually reset using the RESET PLC button.

OPERATOR RESET is always required for major alarms or alarms that cause module shut-down or lock-out, signifying that intervention is required.

Action

The action taken by the microprocessor controller logic to avoid alarm or keep it from damaging equipment.

Table 17. Touchscreen interface active alarm states

Warning

This is an informative alarm; no action is required.

Alarm Notes

• Alarm covers special cases that can occur on the active alarms screen are listed below.

• * – if the EWT is selected as the cooling or heating temperature control sensor.

• ** – if the LWT is selected as the cooling or heating temperature control sensor.

• *** – If the EWT is selected as cooling or heating temperature control sensor and the module is running in stand-alone mode.

• **** – If the LWT is selected as cooling or heating temperature control sensor and the module is running in stand-alone mode.

• ***** – If both compressors are in lock-out, that will in turn lock out the module.

Alarm List

All alarm states that can appear on the Active Alarms screen are listed in the following table:

Ala r m Ap p lica t i on Type Act ion

Sla ve 1 c om mu n icat ion l ost Clie nt Aut o Rese t War nin g

Sla ve 2 c om mu n icat ion l ost Clie nt Aut o Rese t War nin g

Sla ve 3 c om mu n icat ion l ost Clie nt Aut o Rese t War nin g

Sla ve 4 c om mu n icat ion l ost Clie nt Aut o Rese t War nin g

Sla ve 5 c om mu n icat ion l ost Clie nt Aut o Rese t War nin g

Sla ve 6 c om mu n icat ion l ost Clie nt Aut o Rese t War nin g

Sla ve 7 c om mu n icat ion l ost Clie nt Aut o Rese t War nin g

Sla ve 8 c om mu n icat ion l ost Clie nt Aut o Rese t War nin g

Sla ve 9 c om mu n icat ion l ost Clie nt Aut o Rese t War nin g

Syst em Chilled LWT t oo hig h Clien t Au t o Rese t War n in g

Syst em Hot LWT t oo l ow Cl ient Au t o Reset War n in g

WRONG MASTER ROTATION CONTROL PARAMETERS

BMS OFFLINE Client Au t o Reset War n ing

cpCOe UI 1 SENSOR FAI LURE Client Aut o Reset Sw i t ch es Cli en t m odule and slave m o du les in St and - alone Mod e *

cpCOe UI 2 SENSOR FAI LURE Client Aut o Reset Sw i t ch es Cli en t m odule and slave m o du les in St and - alone Mod e *

cpCOe UI 3 SENSOR FAI LURE Client Aut o Reset Sw i t ch es Cli en t m odule and slave m o du les in St and - alone Mod e *

cpCOe UI 4 SENSOR FAI LURE Client Aut o Reset Sw i t ch es Cli en t m odule and slave m o du les in St and - alone Mod e *

cpCOe UI 5 SENSOR FAILURE Clien t Aut o Reset War n in g

cpCOe UI 6 SENSOR FAILURE Clien t Aut o Reset War n in g

cpCOe UI 7 SENSOR FAI LURE Client Au t o Reset Sw i t ch es t o I nt er n al Cool in g set point if ‘ Ext ernal ‘ is se le ct ed

cpCOe UI 8 SENSOR FAI LURE Client Au t o Reset Sw i t ch es t o I nt er n al Cool in g set point if ‘ Ext ernal ‘ is se le ct ed

cpCOe OFFLI NE ALARM Client Auto Reset Sw i t ch es Cli en t m odule and sla ve m o du les in st a nd - alone m od e

Clie nt Aut o Reset Warn i ng

76 ARTC-SVX005A-EN

Appendix C - Active Alarm List

Table 17. Touchscreen interface active alarm states (continued)

Ala r m Ap p lica t i on Type Act ion

cpCOe W RONG CONFIG Alar m Clien t Au t o Reset War nin g

UI 1 SENSOR FAILURE Clien t / Ser v er Auto Reset Sh u t s dow n local cooling con t r ol * * *

UI 2 SENSOR FAILURE Clien t / Ser v er Auto Reset Sh u t s dow n local cooling con t r ol * * *

UI 3 SENSOR FAILURE Clien t / Ser v er Auto Reset Sh u t s dow n local h eat i ng cont rol * * *

UI 4 SENSOR FAILURE Clien t / Ser v er Aut o Reset Sh ut s do w n m odu le if ‘LP Alar m Mode = Sen so r’

UI 5 SENSOR FAI LURE Client / Serv er Aut o Reset Shu t s d ow n m o du le

UI 6 SENSOR FAI LURE Clien t / Ser ver Aut o Reset Shu t s d ow n local h eat in g con t r ol * * * *

UI 7 SENSOR FAILURE Client / Ser v er Au t o Reset Warn ing

UI 8 SENSOR FAI LURE Cli en t / Ser v er Aut o Reset Lo ck s ou t m odul e if it is r unn ing in heat ing m ode

UI 9 SENSOR FAILURE Client / Ser v er Au t o Reset Warn ing

UI 1 0 SENSOR FAILURE Clien t / Ser v er Au t o Reset Warn i ng

UI 1 2 SENSOR FAILURE Clien t / Ser v er Au t o Reset Warn i ng

COMPRESSOR 1 WARNI NG Clie nt / Se r v er Au t o Rese t War n ing

COMPRESSOR 1 FAI LURE Clie nt / Se r v er Au t o Rese t Sh ut s dow n com pr ess or 1

COMPRESSOR 1 FAILURE Clien t / Ser v er Au t o Reset Sh ut s do w n com pre ssor 1 * * * * *

COMPRESSOR 1 CORESENSE FAI LURE Client / Se r v er Au t o Reset Sh ut s dow n com pr essor 1

COMP 1 CORESENSE COMM UNI CATI ON LOST

COMPRESSOR 2 WARNI NG Clie nt / Se r v er Au t o Rese t War n ing

COMPRESSOR 2 FAI LURE Clie nt / Se r v er Au t o Rese t Sh ut s dow n com pr ess or 2

COMPRESSOR 2 FAILURE Clien t / Ser v er Au t o Reset Sh ut s do w n com pre ssor 2 * * * * *

COMPRESSOR 2 CORESENSE FAI LURE Client / Se r v er Au t o Reset Sh ut s dow n com pr essor 2

Com p 2 CORESENSE COMM UNI CATI ON LOST

EVD OFFLINE Clie nt / Se r v er Au t o Rese t War n ing

EVD SYSTEM ALARM Clien t / Ser v er Aut o Reset Wa r n in g

EVD DRI VER A ALARM Clien t / Ser ver Aut o Reset War n in g

EVD DRI VER B ALARM Clien t / Ser v er Aut o Reset Wa rni ng

EVAPORATOR FREEZI NG ALARM Clien t / Ser v er Op era t or Reset Lock s o ut m odu le

SOURCE FREEZ I NG ALARM Clien t / Ser v er Oper a t or Reset Lock s out m od ule

PHASE MON I TOR ALARM Client / Ser v er Au t o Reset Lock s ou t m od u le

EVAPORATOR FLOW ALARM Clien t / Ser v er Opera t or Reset Locks o ut m od u le

CONDENSOR FLOW ALARM Client / Serv er Op er at or Reset Lock s ou t m odule

SOURCE FLOW ALARM Cli en t / Ser v er Oper ator Reset Lock s ou t m o du le

CONDENSOR LWT TOO LOW Cli en t / Serve r Aut o Reset War n in g

EVAPORATOR LWT TOO HI GH Cl ient / Se r v er Au t o Rese t War n ing

HP ALARM Client / Serv er Op er at or Reset Lock s ou t mod ule

HP SWI TCH ALARM Client / Serv er Aut o Reset Locks o ut m od u le

LP ALARM Client / Server Oper at or Reset Sh u t s d ow n m odu le

LP Lock out ALARM Client / Ser ver Operat o r Reset Lo ck s ou t m odul e

ERROR I N THE NUMBER OF RETAIN MEMORY WRI TI NGS

ERROR in RETAIN MEMORY WRI TI NGS Client / Serve r Oper at or Reset Warni ng

WRONG TEMPERATURE CONTROL PARAMETERS

WRONG LOCAL ROTATI ON CONTROL PARAMETERS

MASTER COMMUNI CATI ON LOST Se r v er Au t o Reset Swit che s sla v e m odu le t o st and - al one m od e

I NCOMPLETE SAFETY CYCLE Clien t / Serve r Aut o Reset War n in g

cpCOe # 2 OFFLINE ALARM Cli en t / Ser v er Au t o Rese t Sw it ches m ast er an d slave m od u le s in st an d - al on e m ode

Client / Ser ver Aut o Reset Shu t s down co m p r essor 1

Client / Ser ver Aut o Reset Shu t s down co m p r essor 2

Client / Serve r Op era t or Reset Warni ng

Clie nt / Se r v er Au t o Reset War ning

ARTC-SVX005A-EN 77

Appendix C - Active Alarm List

Table 17. Touchscreen interface active alarm states (continued)

Ala r m Ap p lica t i on Type Act ion

cpCOe # 2 WRONG CONFI G ALARM Clien t / Ser ver Aut o Reset Lock s o ut m odu le

Valv e D1 OPENI NG FAILURE Clie nt / Serve r Operat o r Reset Lo ck s ou t m odul e

Valv e D1 CLOSI NG FAILURE Client / Serv er Op er a t or Reset Lock s out m od ule

Valv e D2 OPENI NG FAILURE Clie nt / Serve r Operat o r Reset Lo ck s ou t m odul e

Valv e D2 CLOSI NG FAILURE Client / Serv er Op er a t or Reset Lock s out m od ule

Valv e S1 OPENING FAILURE Clien t / Ser v er Oper at or Reset Lock s ou t m odule

Valv e S1 CLOSI NG FAI LURE Clien t / Ser v er Oper ator Reset Lock s ou t m odul e

Valv e S2 OPENING FAILURE Clien t / Ser v er Oper at or Reset Lock s ou t m odule

Valv e S2 CLOSI NG FAI LURE Clien t / Ser v er Oper ator Reset Lock s ou t m odul e

78 ARTC-SVX005A-EN

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