Trane CVGF 1000, Operation And Maintenance Manual

Page 1: ...Operation Maintenance Manual Gear Driven Centrifugal Water Cooled Liquid Chillers with CH530 Controls CVGF SVU02B E4 X39640691020 Unit Model CVGF 400 1000 Ton Units 50 and 60 Hz...

Page 2: ...ent damage Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions NOTICE Warnings and Cautions appear at appropriate sections throughout t...

Page 3: ...Warnings and Cautions General Information Unit Control Panel UCP Base Loading Control Algorithm Control System Components Machine Protection and Adaptive Unit Startup Unit Shutdown Periodic Maintenanc...

Page 4: ...ature History CVGF SVU02A E4 November 2002 This is a new manual About this manual Operation and maintenance information for models CVGF are covered in this manual This includes both 50 and 60 Hz CVGF...

Page 5: ...ration GBAS Generic Building Automation Interface GPM Gallons per minute HLUV High Lift Unloading Valve Hp Horsepower HVAC Heating Ventilating and Air Conditioning IE Internally Enhanced Tubes IPC Int...

Page 6: ...F unit back view Motor Unit nameplate Relief valves Oil cooler Economizer Condenser Two Stage Compressor Unit Mounted Starter Optional Relief Valves Unit Nameplate Control Panel CH530 Oil Pump Evapora...

Page 7: ...ters the evaporator at state point 1 Liquid refrigerant is vaporized to state point 2 as it absorbs heat from the system cooling load The vaporized refrigerant flows into the compressor first stage Co...

Page 8: ...small amount of refrigerant at an intermediate pressure labeled P1 Flashing some liquid refrigerant cools the remaining liquid to state point 8 Another benefit of flashing refrigerant is to increase...

Page 9: ...am Starter Condenser Motor Economizer Oil sump Pump Fixed orifice Distributor Evaporator Fixed orifice Strainer Fixed orifice Condenser sump Internal filter Compressor Inlet vanes High lift unloading...

Page 10: ...essor is two stage with high strength aluminum alloy fully shrouded impellers The impellers are tested at 25 percent over design operating speed The rotating assembly is dynamically balanced for vibra...

Page 11: ...rmation Figure 5 Compressor cross section view Motor rotor Motor shaft Bull gear Discharge end Suction end Motor terminal Motor housing Motor stator Pinion shaft Gear housing 2nd stage impeller Oil pu...

Page 12: ...r daily operation and one for periodic service appropriate information is readily accessible DynaView Human Interface For the operator day to day operational information is presented at the panel Up t...

Page 13: ...aring to Shut Down Shutting Down Starting Auto Waiting to Start Starting Compressor Running Running Running Limit Fast Restart or Satisfied Setpoint Stop Command or Diagnostic C o n f i r m e d S h u...

Page 14: ...on power up Apply Control Power Completing Self Test 12 Seconds Self Test Starting Application 20 30 Seconds Starting Application Note The variation in DynaView Power Up time is dependent on the numbe...

Page 15: ...Figure 8 Sequence of operation running Starter Status is Running Limit Mode Exit Limit Mode Starting Compressor Running Limit Running Running Modulate IGV for LWT control Running Modulate IGV for Limi...

Page 16: ...f delay complete Shutting down Shutting down Shutting down Close IGV 0 50 seconds Post Lube 1 minute De energize oil pump Confirm no oil pressure 5 minutes after oil pump is de energized De energize e...

Page 17: ...ure when oil differential pressure switch is open Satisfied setpoint Command IGV closed De energize compressor Confirm no oil pressure 5 minutes after oil pump is de energized De energize oil pump Clo...

Page 18: ...tor at 30 F 16 6 C or 105 F 40 5 C whichever is higher When enhanced oil temperature protection is enabled the oil temperature setpoint is fixed at 136 F 57 8 C The oil temperature control setpoint ra...

Page 19: ...ck validates the oil differential pressure before the oil pump is turned on This check in necessary in case the differential pressure switch is not operational Without this check the differential oil...

Page 20: ...ure is indicative of oil flow and active oil pump operation Significant fall in oil pressure is indicative of failure of the oil pump oil leakage or other blockage in the oil circuit Once oil flow has...

Page 21: ...ircuit diagram Starter Condenser Economizer Condenser Sump High Lift Unloading Valve HLUV Refrigerant Oil Motor Oil Cooler Strainer S F Distributor Evaporator Fixed Orifice Oil Sump Pump Internal Filt...

Page 22: ...ormation The UCP houses several other controls modules called panel mounted LLID Low Level Intelligent Device power supply terminal block fuse circuit breakers and transformer The IPC Interprocessor c...

Page 23: ...mperature These improvements keep chilled water flowing at a temperature closer to its setpoint Unit Control Panel UCP Tracer CH530 Chiller Controller Tracer CH530 s Main Processor DynaView is fast an...

Page 24: ...t the DynaView operator interface Such as evaporator and condenser water temperatures outdoor air temperature evaporator and condenser water pump control status and alarm relays external auto stop eme...

Page 25: ...layed The user operates the touch sensitive buttons by touching the button of choice The selected button is darkened to indicate it is the selected choice The advantage of touch sensitive buttons is t...

Page 26: ...to avoid complete light or complete dark which would potentially confuse an unfamiliar user to thinking the display was malfunctioning Persistent keys horizontal at the bottom of the display are those...

Page 27: ...ill be available to the user by selecting the additional information button double right arrow next to the top level operating mode These sub level modes are shown Table 1 The TOP LEVEL MODE is the te...

Page 28: ...n Auto Reset diagnostic Auto Unit determining if there is a need to run Waiting To Start Unit waiting for tasks required prior to compressor start to be completed Starting Compressor Unit is starting...

Page 29: ...t Time Inhibit MIN SEC 70 Waiting To Start Low Oil Temperature Inhibit 70 Oil Temperature Inhibit Temperature Waiting To Start Waiting For Starter To Start MIN SEC 70 Starting Compressor There is no s...

Page 30: ...d by options that can be scrolled to via the up or down arrows Description Chiller Operating Mode sub modes Evaporator Entering and Leaving Water Temperature Condenser Entering and Leaving Water Tempe...

Page 31: ...e to be manually reset through the Diagnostics alarm menu When reset they become historic and viewable via the TechView Performing a Reset All Active Diagnostics will reset all active diagnostics rega...

Page 32: ...f arbitration between the front panel BAS and external setpoints The chilled water reset status in the right most column will display one of the following messages Return Constant Return Outdoor None...

Page 33: ...isplayed in percent RLA Touching the double arrow to the left of the Active Current Limit Setpoint will take the user to the active current limit setpoint sub screen The active current limit setpoint...

Page 34: ...or Approach C or F Evaporator Water Flow Switch Status Flow or No Flow Condenser Report Items Units Condenser Entering Water Temperature C or F Condenser Leaving Water Temperature C or F Condenser Sat...

Page 35: ...ode Stopped Running 3 Amps L1 L2 L3 Amps 4 Volts AB BC CA Volts 5 Active Chiller Water Set Point F C 6 Active Current Limit Set Point 7 Refrigerant Type 134a 8 Compressor Starts 0 9 Compressor Running...

Page 36: ...ng Tab screens provides a user the ability to adjust settings justified to support daily tasks The layout provides a list of sub menus organized by typical subsystem Unit Control Panel UCP Settings sc...

Page 37: ...Units 1 Chilled Water Reset Constant Outdoor Return Disable Disable Percent 2 Return Reset Ratio Temperature 3 Return Start Reset Temperature 4 Return Maximum Reset Temperature 5 Outdoor Reset Ratio P...

Page 38: ...otes 3 Terminates with 10 minutes if inactivity 4 The Date and Time setup screen formats deviate slightly from the standard screens defined above See the time and date section for further details 5 En...

Page 39: ...ts of a setpoints list and the current value The operator selects a setpoint to change by touching either the description or setpoint value Doing this causes the screen to switch to the Analog Setting...

Page 40: ...th buttons only screen has no cancel or enter key do accept the new selection immediately Mode Override for Enumerated Settings is shown below Note Radio 1 and Radio 2 refer to touch sensitive buttons...

Page 41: ...ue setting An Auto or Manual selection is necessary set to the mode to override An Enter and Cancel Key will allow the user to Enter or Cancel the entry Mode Override for Analog Settings is shown belo...

Page 42: ...point screen with a 12 hour format is shown below The user must select Hour or Minute and then use the up or down arrows to adjust Adjusting hours will also adjust am and pm Note The 24 hour format se...

Page 43: ...o access to the DynaView screens including all reports all setpoints Auto Stop Alarms and Interlocks The password 159 is not programmable from either DynaView or TechView If the Display and Touch Scre...

Page 44: ...ally displayed while the current limit routine is active is suppressed while base loading Base loading can occur using Tracer or an external signal Tracer or an external signal Base Loading Current Se...

Page 45: ...e is configured The graphs in Figure 16 show the relationship between input and percent RLA While in base loading the active current limit setpoint is set to the Tracer or external base load setpoint...

Page 46: ...ding with external mA input and with external voltage input Base Loading with External mA Input RLA 100 90 80 70 60 50 40 30 20 4 6 8 10 12 14 16 18 20 mA RLA Base Loading using External Voltage Input...

Page 47: ...19 1A26 are standard and present in all configurations Other modules vary depending on machine optional devices Control System Components Control System Components Control Panel Internally mounted dev...

Page 48: ...it Mode or in Surge Mode the head relief request relay on the 1A9 J2 6 to J2 4 will be energized and can be used to control or signal for a reduction in the entering condenser water temperature This i...

Page 49: ...ignal 1 J2 2 Ground Standard Signal 2 Emergency stop J2 3 Binary Input Signal 2 J2 4 Ground 1F1 Standard not for field use 1F2 Standard not for field use 1T1 Standard not for field use 1Q1 Standard no...

Page 50: ...DRP Signal 1 J2 1 Output 1 J2 3 Ground 1A17 Optional Dual Analog Input Output Module 1A17 Optional Dual Analog Input Output Module 1A18 Optional Dual LV Binary input module 1A18 Optional Dual LV Binar...

Page 51: ...setting Temperature based On standard machines the Percent Condenser Pressure Indication Output is based on the Saturated Condenser Refrigerant and a temperature to pressure conversion is made If the...

Page 52: ...is typically set to 0 psi and will then correspond to 2 Vdc The Maximum Delta Pressure is typically set to 30 psi and corresponds to 10 Vdc The Minimum Delta Pressure Calibration setting has a range o...

Page 53: ...gnal 2 J2 4 Input 2 J2 6 Ground GBAS Signal 1 J2 2 Input 1 J2 3 Ground GBAS Signal 2 External Current limit Setpoint J2 5 Input 2 J2 6 Ground Figure 20 Voltage versus percent RLA Voltage versus Percen...

Page 54: ...its the maximum ECLS to 100 percent Module Characteristics 1A1 Power Supply Unit Control Power Supply Module Converts 27 Vac to 24 Vdc Power Input Voltage 23VRMS minimum 27VRMS Nominal 30VRMS maximum...

Page 55: ...rane IPC3 protocol 1A13 1A18 1A19 1A24 Dual Binary input module J2 1 Binary Input Signal 1 J2 2 Ground J2 3 Binary Input Signal 2 J2 4 Ground Binary Input Looks for a dry contact closure Low Voltage 2...

Page 56: ...ut a 200 Ohm load resistor is switched in 0 12 Vdc or 0 24 mA Analog Inputs CH530 accepts either a 2 10 Vdc or 4 20 analog input suitable for customer external control The type is determined at unit c...

Page 57: ...entering 4R6 Evaporator leaving 4R7 Condenser entering 4R8 Condenser leaving 4R9 Oil temperature 4R5 Outdoor air 4R13 Evaporator saturated refrigerant 4R10 Condenser saturated refrigerant 4R11 Probe...

Page 58: ...se 2F4 to terminal 2X1 1 starter panel to terminal 1X1 1 in the control panel From this point control voltage flows to 1 Circuit Breaker 1Q1 which provides power to the starter module 2A1 relay output...

Page 59: ...continuous seconds and condenser water flow verified within 4 minutes 15 seconds for the compressor start sequence to be initiated When less than 5 seconds remain before compressor start a starter tes...

Page 60: ...he opening of the shorting relay 2A1 J4 This places the compressor motor in the Delta configuration and the starter module waits to look for this transition for 2 35 seconds through the closure of the...

Page 61: ...lled water pump will continue to run while the Main processor module 1A22 monitors leaving chilled water temperature preparing for the next compressor motor start based on the differential to start se...

Page 62: ...ut down when a MPL is detected and will display a non latching diagnostic indicating the failure The oil pump will be run for the post lube time period when power returns The compressor and compressor...

Page 63: ...Starting Compressor Enforce Power Up Delay Timer Establish Condenser Water Flow 6 Second Minimum Close IGV 0 50 Seconds Command IGV Closed Energize Condenser Water Pump Relay Confirm Condenser Water F...

Page 64: ...oad Protection In the run mode a time trip curve is looked at to determine if a diagnostic should be called The starter LLID continuously monitors compressor line currents to provide running overload...

Page 65: ...allow the chiller to continue to run at a lower load to avoid tripping off using a diagnostic The Current Limit function uses a PID algorithm similar to the Leaving Water Temperature control that allo...

Page 66: ...ldown period After the compressor has been started the starting point of the filtered setpoint is initialized to the value of the Evaporator Leaving Water temperature and the percent RLA Minimum and M...

Page 67: ...ater freezing in the evaporator The cutout setpoint is factory set at 36 F 2 2 C however is adjustable with TechView The cut out strategy is illustrated in Figure 23 The Leaving Water Temperature Cut...

Page 68: ...iller to continue to run at a lower load instead of tripping off using HPC The Condenser Limit will be based on a pressure conversion from the Condenser Refrigerant Temperature sensor When limited by...

Page 69: ...heater is energized to raise the oil temperature Low oil temperature is indicative of refrigerant dilution in the oil Oil temperature is used to estimate this dilution since the oil temperature direc...

Page 70: ...ting of the oil and the bearings If the oil temperature is at or above the High Oil Temperature Cut out setpoint this diagnostic will be issued which will stop the compressor If Oil Temperature violat...

Page 71: ...ed The HLUV valve does not modulate the flow rate but rather is either open or closed Further the valve was sized to handle a mass flow sufficient to permit operation below 35 IGV position but not nec...

Page 72: ...it mode as stated below High Lift Unloading Limit Mode For a Gear Drive chiller the minimum IGV position is 60 of the Trigger IGV When the IGV movement is being limited to the 60 of the Trigger IGV po...

Page 73: ...the compressor one person will look at the rotor from the rear of the motor through the sight glasses to determine correct direction Looking at the sight glass the direction will be counter clockwise...

Page 74: ...t exceeds the start differential setpoint the unit enters the initiate in the start mode the oil pump and the condenser water pump are started If condenser water flow is not proven flow switch 5S2 doe...

Page 75: ...and evaporator are correct according to the pre commissioning procedures 10 Close all disconnect switches 11 Ensure the unit has been charged with the correct amount of refrigerant and oil and that th...

Page 76: ...ect switch 4 Drain the condenser piping and cooling tower if used 5 To drain the condenser remove the drain and vent plugs from the condenser headers 6 Once the unit is secured for winter the maintena...

Page 77: ...g temperatures 2 Current drawn by the compressor Amps 3 Oil level in the oil sump The oil level must be visible in the sight glass 4 Condenser pressure evaporator pressure 5 Unusual noise vibration an...

Page 78: ...ed that the services of a qualified water treatment specialist be engaged to determine what water treatment if any is required Trane assumes no responsibility for equipment failures which result from...

Page 79: ...nsitive electronic leak detector Set the scale to medium which corresponds to a 1 2 ounce 015l per year leak rate and probe all joints thoroughly Be sure and relieve the pressure in the unit before ev...

Page 80: ...isconnected to the oil heaters To remove the compressor oil attach an oil recovery and recharge hose or line to the oil sump drain valve located on the bottom of the oil sump See Figure 24 Attach the...

Page 81: ...or all CVGF units is 15 gallons 56 8 l of Trane OIL00037 Trane OIL00037 is R134a miscible oil in 1 gallon 3 785 l containers A 5 gallon 18 9 l container of Trane approved R134a oil is available Trane...

Page 82: ...to the oil sump drain valve located at the bottom of the oil sump See Figure 23 If possible evacuate the oil charging line to remove any non condensables and moisture This will require a shutoff valve...

Page 83: ...ilter cover could decrease the life of the compressor 7 Remove the oil filter and o ring 8 Install a new oil filter o ring and Roto Lock nylon seal 9 Replace the oil filter cover and torque the bolts...

Page 84: ...e oil pressure regulator is factory set to maintain oil pressure between 18 to 22 psid 124 151 kPa The unit will not start if the oil pressure is below 12 psid 82 kPa Adjusting the Oil Pressure Regula...

Page 85: ...ed previously 5 When the oil filter change is completed check the differential oil pressure and if it is below 18 psid 124 kPa adjust the oil pressure regulator to obtain a reading of between 18 to 22...

Page 86: ...cuum should not rise more than 100 microns 0 1 mm Hg per hour to a maximum of 500 microns 0 5 mm Hg over 12 hours If the vacuum rises above this either there is a leak or the unit has moisture present...

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Page 88: ...equipment referred to in this publication Soci t Trane Soci t Anonyme au capital de 41500 000 F Siege Social 1 rue des Am riques 88190 Golbey France Siret 306 050 188 00011 RSC Epinal B 306 050 188 N...