Trane Tracer CH535 User Manual

User Guide
Tracer CH535 Chiller Controller on models CGAX/CXAX
CG-SVU007C-GB
Original instructions
Table of Contents
General information .......................................................................................... 4
Tracer CH535 Presentation ................................................................................5
Tracer CH535 Hardware ..................................................................................... 7
Tracer CH535 Extention Hardware ................................................................... 8
Tracer CH535 module connections Terminals .................................................. 9
Alarms .............................................................................................................. 10
User interface display ......................................................................................15
2 © 2016 Trane
3
General information
Foreword
These instructions are given as a guide to good practice in the installation, operation and periodic maintenance by the user of TRACER CH535 chiller controller.
They do not contain the full service procedures necessary for the continued successful operation of this equipment. The services of a qualified service technician should be employed, through the medium of a maintenance contract with a reputable service company.
Warranty
Warranty is based on the general terms and conditions of the constructor. The warranty is void if the equipment is modified or repaired without the written approval of the constructor, if the operating limits are exceeded, or if the control system or the electrical wiring is modified. Damage due to misuse, lack of maintenance, or failure to comply with the manufacturer’s instructions, is not covered by the warranty obligation. If the user does not conform to the rules of “Maintenance”, it may entail cancellation of warranty and liabilities by the constructor.
Reception
When the unit arrives on site, check it has not been damaged in any way during transport. If damage is observed, or even merely suspected, notify the carrier within 24 hours by registered letter. Notify the local Trane Sales office at the same time. The unit should be totally inspected within 3 days of delivery. If damage is observed, notify the last carrier by registered letter and notify the local sales office.
General information
About this manual
Cautions appear at appropriate places in this instruction manual. Your personal safety and the proper operation of this machine require that you follow them carefully. The constructor assumes no liability for installations or servicing performed by unqualified personnel.
4
Important note: This document describes all the functions available on TRACER CH535 with software version 1.x and explains how to program it. Certain parameters must only be modified by qualified personnel. Before changing any parameter, always check that the change does not affect the good and safe operation of the equipment. Operation must always stay within the catalogued limits.
Tracer CH535 is a programmable microprocessor electronic controller dedicated to handle safe and optimized operation of the scroll compressor chiller, series Conquest, only cooling (CGAX) and heat pumps (CXAX).
Module description
Figure 1 – Programmable microprocessor electronic controller
Tracer CH535 Presentation
A = pLAN Address selection key
B = pLAN Address display
C = Power Supply Presence LED
D = Overcharge LED
E = Fieldbus/BMS on port J26 micro switch
F = USB host (master ) port
G = USB slave (device) port
Each controller is provided with connectors for the inputs/output and the pLAN address display, which has a button and a LED for setting the pLAN address.
5
Tracer CH535 Presentation
LED
Tracer CH535 provides 6 LEDs:
• 1 yellow LED indicating that the device is powered;
• 1 red LED indicating an overload on the +VDC (J2-5)
terminal;
• 4 LEDs indicating valve status:
Flashing LEDs mean the valve is moving; steadily-on LEDs mean the valve is completely open or closed.
Table 1 – LED descriptions
LED Colour Description
A Yellow Close A (connector J27)
B Green Open A (connector J27)
C Yellow Close B (connector J28)
D Green Open B (connector J28)
Micro switches
Four micro switches are provided to configure port J26 as a Fieldbus or BMS port. They must not be modified (Fieldbus mandatory).
USB ports
There are 2 USB ports which can be accessed after removing the cover:
• A “host” USB port for connecting pen drives;
• A “slave” USB port for direct connection to the USB
port of a computer on which pCOManager is installed, which can be used to upload the application program, commissioning the system, etc.
Serial ports
Table 2 – Serial port descriptions
Serial Type/connectors Features
Built into main board
• HW driver: asynchronous half duplex RS485 pLAN
Serial ZERO pLAN/J10, J11
Serial ONE BMS 1 Serial Card
Serial TWO Field Bus 1 Serial Card
Serial THREE BMS 2 / J25
Serial FOUR Field Bus 2 / J26
• Not optically isolated
• Connectors: telephone jack + 3-pin plug-in connector
− For standard display connection
• Not built into main board
• HW driver: not present
• Can be used with all the BMS expansion cards of the
Tracer CH535 family
− For Modbus, BACnet, LonTalk, Web connections
• Not built into main board
• HW driver: not present
• Can be used with all Fieldbus expansion cards of the
Tracer CH535 family
− Not used
• Built into main board
• HW driver: asynchronous half duplex RS485 slave
• Optically-isolated/non-optically-isolated serial
• 3-pin plug-in connector
− For Deluxe display connection
• Built into main board
• HW driver: asynchronous half duplex RS485 Master or Slave
(see par. 3.2)
• J26: optically isolated/not optically isolated
• 3-pin plug-in connector
For Tracer CH535 ext connections
6
Tracer CH535 Hardware
Built-In driver module connections terminals
Figure 2 – Built-in driver terminal locations
10
11
J11 pLAN
J10
13 14
12
C4
C1
C1
C4
NO1
J12
NO4
NO2
NO3
J13
J25
BMS2
C7
NO5
NO6
4 3 2 1
J26
FBus2
NO7C7NO8
J14
15
C8
J15
C9
132
J27
NO9
NC8
C9
NO10
NO11
J16
NO12
4
C13
C12
J17
NC12
132
NC13
NO13
J18
4
J28
16 17
18
20
22 24
drac SMBdrac suBdleiF
J1
J24 J2 J3
G
G0
1
REF
U1U2U3
GND
+5 V
+Vterm
2 3 3 3 8
U4
GNDU5GND
GND
+VDC
4
5
J4
VG
VG0Y1Y2Y3Y4
7 8
6
J5
ID1
ID2
ID3
ID4
ID5
ID6
J30
C D
A
B
VBAT
G0
G
ID7
J6
ID8
IDC1
U6U7U8
VREF
GND
S1S2S3S4DI1
J7
GND
ID9
ID10
ID11
ID12
IDC9
1 = Power Supply connection (G (+) , GO (-) )
2 = +Vterm: additional terminal power supply
-VREF power supply for rasiometric probes
3 = Universal Input / Outputs
4 = +VDC: power supply for active probes
5 = pLAN address setup key, secondary display LED
6 = VG: power supply voltage A for options
VG0: power supply for optically isolated analog output at 0 Vac/Vdc
7 = Analog ouputs
8 = ID: digital inputs at low voltage
9 = ID..: digital inputs at low voltage
IDH..: digital inputs at high voltage
10 = pLAN telephone connector for terminal/download application programme
11 = pLAN removable connector
12 = Reserved
13 = Reserved
14 = Reserved
15 = Relay digital outputs
21
driver
23
J29
DI2
IDC13
ID14
ID14H
ID13H
ID13
J8
9
7
Tracer CH535 Extention Hardware
Figure 3 – CH535 extention terminal locations
8
C1
C2
NC1
NO1
7
NC2
NO2
B1
B2
GND
+Vdc
+5VRef
C4
C3
NC4
NC3
NO3
NO4
B3
B4
GND
+Vdc
+5VRef
4
ID1
ID2
ID4
ID3
IDC1
VG
G
G0
1
Y1
VG0
2
5
6
T+
T-
GND
3
1 = Power Supply connection (G (+), G0 (-))
2 = Optically-isolated analog output, 0 to 10 V
3 = RS485 network connector (GND, T+, T-)
4 = Optically-isolated digital inputs, at 24 Vac/Vdc
5 = Yellow power LED and 3 indicator LEDs
6 = Serial address
7 = Analog inputs and power to probes
8 = Relay digital outputs
8
Tracer CH535 module connections Terminals
TRACER CH535 offers customer the possibility to use inputs or outputs in order to:
• use an external water setpoint reset using an analog input (option),
• use an auxiliary setpoint (option),
• connect a remote on/off of the circuit/unit (standard),
• connect a remote Cooling/Heating switch (standard),
• return a circuit fault (option),
• receive unit capacity percent (option).
Note: External water setpoint based on an external signal input (0-20mA or 4-20mA), it will be possible to offset the active setpoint from 0°C to 20°C. This function can be used in conjunction with the automatic setpoint reset function.
1
Water setpoint
5
Ambient
2 3
temperature
4
Table 3 – External demand limit setpoint allowances
Nb of CMP allowed
Percent
0.0% 0 1 1 1
25.0% 5 1 1 2
33.3% 6.66 1 2 2
50.0% 10 2 2 3
66.7% 13.34 2 3 3
75.0% 15 2 3 4
100.0% 20 2 3 4
Percent
20.0% 4 1 1 1
40.0% 8 1 1 2
46.7% 9.33 1 2 2
60.0% 12 2 2 3
73.4% 14.67 2 3 3
80.0% 16 2 3 4
100.0% 20 2 3 4
Current
0-20mA
Current
4-20mA
Simplex
Duo
Simplex
Duo
Simplex
Trio
Nb of CMP allowed
Simplex
Trio
Duplex
Duplex
1 = Leaving water temperature setpoint
2 = Minimum value
3 = Maximum value
4 = Reset = 20°C
5 = Active setpoint
Note: External demand limit setpoint based on an external signal input (0-20mA or 4-20mA), it will define the number of compressors allowed to start.
9
Alarms
Alarms display and resetting
A fault on a unit will be shown through the user interface or through 2 digital outputs, one for each refrigerant circuit. The alarms are divided into 3 categories:
Warning: Shows that something is wrong on the unit but unit can be kept in operation. A message is displayed on the user interface screen. These messages are not recorded in the history list.
Fault with automatic reset: when the cause of the fault disappears, the fault is cancelled and unit operation will return to normal. The messages displayed on the user interface screen disappear but are recorded in the history list of faults. The fault is relayed through the digital output if I/O parameter is set to show a circuit fault.
Fault with manual reset: when the cause of the fault disappears, a manual reset is required to restart the unit. The messages displayed on the user interface screen disappear and are recorded in the history list of faults. The fault is relayed through the digital output if I/O parameter is set to show a circuit fault.
Should an alarm occur,
Pressing to Table 6 for possible messages)
When alarm message is displayed press the default if necessary.
once will display the alarm message (refer
will be lit in red.
to reset
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Table 4 - Status, Warning and Alarm messages
Message
1 No Alarm - Unit On See unit status on Main display
2 Alarm Water Pump1 Manual Unit On Defective water pump 1
3 Alarm Water Pump2 Manual Unit On Defective water pump 2
4 User Ckt1 Stop - Circuit 1 Off Circuit 1 Disable by Settings (via keyboard)
5 User Ckt2 Stop - Circuit 2 Off Circuit 2 Disable by Settings (via keyboard)
6 Ext. Ckt1 Stop - Circuit 1 Off Circuit 1 Off by Digital Input (Duplex units)
7 Ext. Ckt2 Stop - Circuit 2 Off Circuit 2 Off by Digital Input (Duplex units)
8 Rem. Ckt1 Stop - Circuit 1 Off Circuit 1 Disable by Supervision
9 Rem. Ckt2 Stop - Circuit 2 Off Circuit 2 Disable by Supervision
10 Clock Unit Stop - Unit Off Unit Off by Program (Hourly, Weekly)
11 Operator Stop - Unit Off Unit Off by Operator (via keyboard)
12 Phase Fault Auto Unit Off Phase Loss or Phase Reversal
13 Warning Ckt1 LP Limit Auto Circuit 1 Limit
14 Warning Ckt2 LP Limit Auto Circuit 2 Limit
15 Warning Ckt1 HW Limit Auto Circuit 1 Limit
16 Warning Ckt2 HW Limit Auto Circuit 2 Limit
17 Warning Ckt1 HP Limit Auto Circuit 1 Limit
18 Warning Ckt2 HP Limit Auto Circuit 2 Limit
19 Warning Ckt1 HT Limit Auto Circuit 1 Limit
20 Warning Ckt2 HT Limit Auto Circuit 2 Limit
21 Warning Ckt1 CIPD Limit Auto Circuit 1 Limit
22 Warning Ckt2 CIPD Limit Auto Circuit 2 Limit
Warning Low SuperHeat
23
ckt1
Warning Low SuperHeat
24
ckt2
Alarm Outside Air Temp
25
Cooling: Too Low Cooling mode: below -10°C (default value)
Heating: Out of Range
26 Ckt1 Defrost - Unit On Defrost on Circuit 1
Reset
Type
Auto Circuit 1 Off Super Heat on circuit 1 is below low limit (2°C)
Auto Circuit 2 Off Super Heat on circuit 2 is below low limit (2°C)
Auto Unit Off
Unit Status Description
Suction pressure on circuit 1 is below the setpoint (1.5barG).
Suction pressure on circuit 2 is below the setpoint (1.5barG).
Leaving water temperature is above the setpoint (Default value: 25°C).
Leaving water temperature is above the setpoint (Default value: 25°C).
Discharge pressure on circuit 1 is above the setpoint (Default value: 43.1barG).
Discharge pressure on circuit 2 is above the setpoint (Default value: 43.1barG).
Discharge temperature on circuit 1 is above the setpoint (Default value: 128°C).
Discharge temperature on circuit 2 is above the setpoint (Default value: 128°C).
Compressor Involute Pressure Differential on circuit 1 is above 22.2barG or above 18.6barG during 25min.
Compressor Involute Pressure Differential on circuit 2 is above 22.2barG or above 18.6barG during 25min.
Ambient temperature is out of range for unit operation:
Heating mode: below -15°C (default value) or above 29°C.
Alarms
11
Alarms
Message
27 Ckt2 Defrost - Unit On Defrost on Circuit 2
28 Alarm Loss of Water Flow Auto Unit Off
29 Alarm Air Sensor Auto Unit Off
30 Alarm Water In Sensor Auto Unit Off
31 Alarm Water Out Sensor Auto Unit Off
32 Alarm HT Sensor Ckt1 Auto Circuit 1 Off
33 Alarm HP Sensor Ckt1 Auto Circuit 1 Off
34 Alarm HT Sensor Ckt2 Auto Circuit 2 Off
35 Alarm HP Sensor Ckt2 Auto Circuit 2 Off
36 Alarm PHR LWT Sensor Auto Unit On
37 Alarm PHR EWT Sensor Auto Unit On
Alarm Ext. Water SP
38
Signal
Alarm Ext. Demand Limit
39
SP Signal
40 Alarm Fan1 fault Ckt1
41 Alarm Fan1 fault Ckt2
42 Alarm LP Ckt1 Fault
43 Alarm LP Ckt2 Fault
44 Alarm Comp. 1A Fault Manual CMP 1A Off CMP 1A is faulty
45 Alarm Comp. 1B Fault Manual CMP 1B Off CMP 1B is faulty
46 Alarm Comp. 1C Fault Manual CMP 1C Off CMP 1C is faulty
47 Alarm Comp. 2A Fault Manual CMP 2A Off CMP 2A is faulty
48 Alarm Comp. 2B Fault Manual CMP 2B Off CMP 2B is faulty
Reset
Type
Auto Unit On
Auto Unit On
Auto /
Manual
Auto /
Manual
Auto /
Manual
Auto /
Manual
Unit Status Description
Circuit 1 On
(Off if only one
fan)
Circuit 2 On
(Off if only one
fan)
Circuit 1 Off
Circuit 2 Off
Lossofwaterowformorethan1sec.Pump
restarts by a manual unit mode changeover
Faulty sensor, out of range -30..+80°C (short circuit or open circuit)
Faulty sensor, out of range -30..+80°C (short circuit or open circuit)
Faulty sensor, out of range -30..+80°C (short circuit or open circuit) (short circuit or open circuit)
Faulty sensor, out of range -30..+150°C (short circuit or open circuit)
Faulty sensor, out of range 1..46Bar (short circuit or open circuit)
Faulty sensor, out of range -30..+150°C (short circuit or open circuit)
Faulty sensor, out of range 1..46Bar (short circuit or open circuit)
Faulty sensor, out of range -30..+80°C (short circuit or open circuit)
Faulty sensor, out of range -30..+80°C (short circuit or open circuit)
Faulty signal, out of range 0..20mA or 4..20mA
followingconguration
Faulty signal, out of range 0..20mA or 4..20mA
followingconguration
The 1st fan on the circuit 1 is faulty
The 1st fan on the circuit 2 is faulty
Suction pressure on circuit 1 is below the setpoint. Manual reset after 3 faults within 1 hour
Suction pressure on circuit 2 is below the setpoint. Manual reset after 3 faults within 1 hour
12
Alarms
Message
Warning Comp.1A
49
Maintenance
Warning Comp.1B
50
Maintenance
Warning Comp.1C
51
Maintenance
Warning Comp.2A
52
Maintenance
Warning Comp.2B
53
Maintenance
54 Alarm HT Ckt 1 Fault Manual Circuit 1 Off High Discharge Temperature Fault on Ckt1
55 Alarm HT Ckt 2 Fault Manual Circuit 2 Off High Discharge Temperature Fault on Ckt2
Alarm CMP Involute Press
56
Diff Ckt 1
Alarm CMP Involute Press
57
Diff Ckt 2
Alarm Low Sat Suction
58
Temp Ckt 1
Alarm Low Sat Suction
59
Temp Ckt 2
Alarm Low SuperHeat
60
Ckt1
Alarm Low SuperHeat
61
Ckt2
Alarm Low water
62
temperature
63 Alarm HP Ckt1 Fault Manual Circuit 1 Off High Pressure Cut-Out circuit 1
64 Alarm HP Ckt2 Fault Manual Circuit 2 Off High Pressure Cut-Out circuit 2
Alarm Ckt 1 Fault (1st
65
fan or all CMP)
Alarm Ckt 2 Fault (1st
66
fan or all CMP)
67 Alarm Unit Fault Manual Unit Off
68 AlarmspCOe5ofine Auto Unit On pCOextension5isofine
Alarms pCOe 5 Analog
69
input 1
Alarms pCOe 5 Analog
70
input 2
Alarms pCOe 5 Analog
71
input 3
Alarms pCOe 5 Analog
72
input 4
Reset
Type
Manual Unit On
Manual Unit On
Manual Unit On
Manual Unit On
Manual Unit On
Manual Circuit 1 Off
Manual Circuit 2 Off
Manual Circuit 1 Off Low Suction Saturated Temperature Fault on Ckt1
Manual Circuit 2 Off Low Suction Saturated Temperature Fault on Ckt2
Manual Circuit 1 Off
Manual Circuit 2 Off
Manual Unit Off
Manual Circuit 1 Off
Manual Circuit 2 Off
Auto Unit On pCOextension5 is in default on Analog input #1
Auto Unit On pCOextension5 is in default on Analog input #2
Auto Unit On pCOextension5 is in default on Analog input #3
Auto Unit On pCOextension5 is in default on Analog input #4
Unit Status Description
Compressor running hours above the threshold
denedinunitconguration.Eachcompressor
start is equal to 3 running hours.
High CMP Involute Pressure Differential Fault on Ckt1
High CMP Involute Pressure Differential Fault on Ckt2
Low Super Heat warning on circuit 1 occurred three times in one hour
Low Super Heat warning on circuit 2 occurred three times in one hour
LWT < antifreeze or INT (antifreeze­EWT)<=10°Cxsecond
Simultaneous faults on compressors 1A and 1B (1A, 1B and 1C for units #36, #39 and #45) or Fan 1 Fault Ckt1 for units #7 to #20, #35 and #40.
Simultaneous faults on compressors 2A and 2B or Fan 1 Fault Ckt2 for units #7 to #20, #35 and #40.
Simultaneous faults on Ckt1 and Ckt2 on duplex units
13
Alarms
Message
Alarms pCOe 5 IO
73
mismatch
74 Alarm Drive Fault Manual Unit Off Variable Primary Flow Drive fault
Alarm Low Differential
75
Pressure ckt1
Alarm Low Differential
76
Pressure ckt2
Warning Cutout Supp
77
Heating
78 Warning LRTC limit ckt1 Auto Circuit 1 Limit Low Refrigerant Temperature cut-out on circuit 1
79 Warning LRTC limit ckt2 Auto Circuit 2 Limit Low Refrigerant Temperature cut-out on circuit 2
EVD EVO EXV synchro
80
Please wait
Reset
Type
Auto Unit On pCOextension5 is in default on Analog input #4
Auto Circuit 1 Off
Auto Circuit 2 Off
Auto Unit On
Auto Unit Off Expansion Valve is currently initiating
Unit Status Description
Low Differential Pressure on circuit 1 (High Pressure - Low Pressure)
Low Differential Pressure on circuit 2 (High Pressure - Low Pressure)
Information that Supplemental Heating is in cut out
14
User interface display
Figure 4 – LCD Display
Table 5 – Button functions
Button Description Backlighting Function
• Pressed together with UP and power supply allows the
1 Alarm White / Red
2 Prg White / Yellow Access to sub-menus
3 Esc White Return to high level
4 Up White
5 Enter White Conrmvalue
6 Down White
2 + 5 Language White
controller address to be changed
• Pressed together with ENTER accesses the BIOS page
• Pressed together with DOWN or ENTER allows the terminal
address to be changed
• Increase value
• Pressed together with UP and ENTER allows the terminal
address to be changed
• Decrease value
• Pressed together PRG and ENTER allows the terminal
language to be changed
Note: In addition to the menu definition, the setting range (within parenthesis or bold for discrete data) and the default value (underlined) of each parameter are indicated:
15
User interface display
Figure 5 - Deluxe touchscreen display
Button Description Function
1 Alarm
3 Esc Return to Main screen
7 Reports
8 Data Graph Graphicalcolordataloggingdisplayongraphs.4predenedgraphsavailable.
9 Settings AdjustmentofUnitsetpoints,parameter,conguration,scheduling.
10 Language Toggle through different display languages.
11 Auto/Stop Toggle unit in AUTO or OFF mode.
12 Back Return to previous windows
13 Brightness Toggle through 3 level of back light brightness levels.
16
Display status of unit component. Multiple pages toggle up/down possible through arrow button located on bottom right side of the screen
User interface display
Access to sub-menus
Access using the “Prg” key
Data display sub-menu
Settings sub-menu
Daily/weekly program sub-menu
Unit configuration sub-menu (accessible to Trane technicians only, not accessible to end users)
The sub-menu will be selected using the Up and Down keys and selected using the Enter button.
Data display menu
Show status and values of:
Temperature sensors
Pressures sensors
Compressors
Fans
Pump package
Expansion valve
Auxiliary heat
Operating modes
Setpoints
Setting menu
Show status and allows modification of:
Local and auxiliary setpoints
Setpoint offset
Operating modes
Circuit manual lockout
Clock menu
Show status and allows modification of:
Actual date and time adjustment
Scheduling
Figure 6 – Scheduling
Monday Tuesday Wednesday Thursday Friday Saturday Sunday
Weekly schedule Start ------------ ------------ ------------ Stop
Unit Status Unit ON Unit ON Unit ON Unit ON Unit ON Unit OFF Unit OFF
00:00 03:00 06:00 09:00 12:00 15:00 18:00 21:00 00:00
Daily Schedule Start ------------ ------------ ------------ Stop
Unit Status Unit OFF Unit OFF Unit ON Unit ON Unit ON Unit ON Unit ON Unit OFF Unit OFF
Example of scheduling where unit is running from Monday to Friday in a time frame from 6:00 to 18:00
17
User interface display
Exemple of hourly scheduling
00:00 03:00 06:00 09:00 12:00 15:00 18:00 21:00 00:00
Zone #1 “Start
Zone #2 “Start
Zone #3 “Start
Zone #4 “Start
“Unit active
cooling setpoint”
15°C 15°C 10°C 7°C 7°C 7°C 10°C 15°C 15°C
CSP 10°C”
CSP 7°C”
CSP 10°C”
CSP 15°C”
Example of hourly setpoint scheduling where unit is delivering 15°C water during the night and 7°C during peak period of the day (from 9:00 to 15:00). Occupied zone from 6:00 to 21:00.
Configuration menu
Shows and allows modification of unit configuration with 2 user levels (Local technician and Trane service technician):
Local technician (by default password = 0005) allows to:
Show status display version application
Modification of pump timers, freeze protection and other limits
Force defrost cycle
Show status of digital and analog inputs/outputs,
Manual override of expansion valve.
Modification of local technician password.
18
User interface display
19
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CG-SVU007C-GB November 2016 Supersedes CG-SVU007B-GB_0915
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