Trane CVHH, Installation, Operation And Maintenance Manual

Page 1: ...d 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 a...

Page 2: ...ection 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 mu...

Page 3: ...HA 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 A...

Page 4: ...zed to perform start up and warranty of Trane products will perform or have direct on site technical supervision of the disassembly and reassembly work The installing contractor must notify Trane or a...

Page 5: ...and Vents 22 Strainers 22 Required Flow Sensing Devices 22 Evaporator and Condenser Water Piping 25 Water Piping Connections 26 Waterbox Locations 26 Grooved Pipe Coupling 27 Flange Connection Adapter...

Page 6: ...Cooling Cycle 67 Oil and Refrigerant Pump 68 Motor Cooling System 70 Tracer AdaptiView Display 70 RuptureGuard 71 EarthWise Purge 71 How a Purge System Works 71 Start up and Shut down 75 Chiller Seque...

Page 7: ...Installation 98 Discussion 98 Procedure 98 Reassembly 99 Torque Requirements 99 Bolt Tightening Sequence for Waterboxes 101 Evaporator Waterbox Covers 101 Condenser Waterbox Covers 101 Heat Recovery...

Page 8: ...umber when calling for service or during parts identification Service Model Number The service model represents the unit as built for service purposes It identifies the selections of variable unit fea...

Page 9: ...required to identify internal and external compressor parts The model number begins with CCHH and the nameplate is located on the foot of the volute Note The serial number space on the compressor name...

Page 10: ...igit 32 Special Options Digit 33 Water Flow Control Digit 34 Chilled Water Reset Digit 35 Control Heat Recovery Auxiliary Temperature Sensors Digit 36 Industrial Chiller Package INDP Digit 37 Control...

Page 11: ...are covered or plugged to prevent contamination during shipment and handling Figure 3 p 14 shows an illustration of a typical unit and its components As soon as the unit arrives at the job site inspec...

Page 12: ...nal only Terminal lugs Ground connection s Jum per bars BAS wiring optional IPC wiring AFD and remote m ounted starters only Control voltage wiring AFD and remote mounted starters only Oil pum p inter...

Page 13: ...plastic coverings Do not remove any plastic coverings Do not remove any plastic cov erings Do not charge the chiller with refrigerant I f additional refrigerant is on site follow manufactures storage...

Page 14: ...unit is always designated as the front side of the unit Figure 3 Typical Simplex CVHH CenTraVac chiller 1 Suction Elbow 2 Compressor 3 Terminal Box 4 Control Panel 5 Condenser 6 Motor Housing 7 Econo...

Page 15: ...2 cm 3 feet Use a housekeeping pad to provide better service clearances refer to submittal for more information Per NEC Article 110 Unit mounted starters from 0 600V require a 107 cm 42 inch clearance...

Page 16: ...166 1087 428 91 36 325 128 200L 200L 272 107 472 186 1217 479 86 34 282 111 200L 20HL 272 107 472 186 1217 479 94 37 333 131 200L 220L 272 107 472 186 1219 480 94 37 305 120 220L 220L 305 120 472 186...

Page 17: ...the lifting cables are in place attach a safety chain or cable between the first stage casing of the compressor and the lifting beam Important There should not be tension on this safety cable the cabl...

Page 18: ...18 then push or pull the unit across a smooth surface Should the chiller be on a shipping skid it is not necessary to remove the skid from the chiller before moving it into place If removal of the com...

Page 19: ...Spring isolators should be considered whenever chiller installation is planned for an upper story location Base isolator placement is shown in Figure 7 also refer to Table 3 Spring isolators typically...

Page 20: ...t on the isolator s lower housing refer to Figure 8 6 Check the clearance on each isolator If this dimension is less than 6 35 mm 1 4 in on any isolator use a wrench to turn the adjusting bolt one com...

Page 21: ...lign with the punch mark use full length shims to raise one end of the chiller until the water level at each end of the tube aligns with the punch marks at both ends of the chiller 5 Once the unit is...

Page 22: ...connection the openings are 19 05 mm 3 4 in 2 If necessary for the application install pressure relief valves at the drain connections on the evaporator and condenser waterboxes To do so add a tee wi...

Page 23: ...4 turns Note When installed the tip of the ifm efector sensor probe must be at least 2 54 cm 1 in away from any pipe wall Placing the tip of the probe at the center of the pipe is preferred 3 Install...

Page 24: ...vaporator and condenser proof of flow switches are required These switches are used with control logic to confirm flow prior to starting a unit and to stop a running unit if flow is lost For trouble s...

Page 25: ...tions arrange the water piping so that the water supply enters the shell at the lower connection and exits from the top connection Operational problems may result if this piping is not correct Some sh...

Page 26: ...aporator or condenser can be switched end for end to obtain the desired piping arrangement If removal of waterboxes is necessary refer to Waterbox Removal and Installation p 98 If the waterboxes on an...

Page 27: ...re not provided for CVHH units with 2068 4 kPa or 300 psig waterboxes that have 356 mm 14 in and larger piping connections All flange to flange assembly bolts must be provided by the installer Bolt si...

Page 28: ...use gasket to pinch Figure 17 Modifying 300 psig or 21 bar flange adaptors for flat faced flange application Remove to mate to flat faced flanges Figure 18 Typical Victaulic flange gasket configuratio...

Page 29: ...r of bolts to a snug tightness following the numerical sequence for the appropriate bolt pattern as shown below Next sequentially tighten the remaining half of the bolts in numerical order Pressure Te...

Page 30: ...ased on ASHRAE Standard 15 ASHRAE Standard 15 provides specific requirements for the discharge piping that allows pressure relief devices to safely vent refrigerant to the atmosphere if over pressuriz...

Page 31: ...flange bore Hand tighten all bolts assuring equal pressure Use a torque wrench set to 196 6 N m 145 ft lb with a 24 mm socket Tighten bolts in a star pattern one half turn each to maintain even press...

Page 32: ...relief line requirements NOTICE Proper Refrigerant Vent Line Termination Failure to properly terminate a refrigerant vent line could result in equipment damage Improperly terminating a refrigerant ve...

Page 33: ...Piping CVHH SVX001A EN 33 Figure 19 Illustrates rupture disk location cross section of rupture disk Note Pipe connection is 3 in NPT Rupture disk Suction connection Gasket Outside pipe assembly Cap B...

Page 34: ...ormed within the valve body Provisions such as installing a set of flanges see Figure 22 or other disconnect means must be made in the discharge vent piping This will allow the piping downstream of th...

Page 35: ...41 0 034 900 1200 130M 130M 0 932 0 412 0 346 0 141 0 034 900 1200 160M 200M 1 022 0 461 0 386 0 141 0 034 900 1200 200L 220L 1 222 0 575 0 473 0 141 0 034 900 1200 220L 220L 1 284 0 637 0 473 0 141 0...

Page 36: ...elief device kPa P0 0 15 P atmospheric pressure Figure 23 Rupture disk vent pipe sizing SI units for use with Table 8 p 35 Note This figure provided as a reference is based on ASHRAE Standard 15 Vent...

Page 37: ...L 200L 156 8 75 4 57 1 19 8 4 5 1500 1700 220L 220L 169 9 83 6 62 1 19 8 4 5 900 1200 100M 10HM 127 0 48 4 55 7 18 5 4 5 900 1200 130M 13HM 138 2 54 0 61 3 18 5 4 5 900 1200 160M 20HM 150 2 60 5 66 8...

Page 38: ...P atmospheric pressure Figure 24 Rupture disk vent pipe sizing IP units for use with Table 9 p 37 Note This figure provided as a reference is based on ASHRAE Standard 15 Vent line size is typically d...

Page 39: ...er insulation is completed Important Do not insulate the motor housing unit wiring or sensor modules Insulation Thickness Requirements Factory applied insulation All low temperature surfaces are cover...

Page 40: ...arine waterboxes wrap waterbox shell insulation with strapping and secure strapping with seal 4 Apply 50 8 mm 2 in wide black tape on overlap joints Where possible apply 7 6 cm 3 in wide strip of 9 7...

Page 41: ...24 Vac 210 mA power from the 1T3 power supply located in the chiller control panel Wiring and Port Descriptions Figure 26 illustrates the UC800 controller ports LEDs rotary switches and wiring termina...

Page 42: ...machine LLIDs IPC3 Tracer bus 19 200 baud IPC3 Bus used for Comm4 using TCI or LonTalk using LCI C 5 Power 210 mA at 24 Vdc and ground terminations same bus as item 4 Factory wired 6 Not used 7 Marqu...

Page 43: ...ion Controls CVHH SVX001A EN 43 Figure 28 Control panel Tracer AdaptiView main unit assembly showing low voltage and higher voltage areas for proper routing of field wiring 30 Volt Maximum 30 120 Volt...

Page 44: ...Tracer AdaptiView display is horizontal Note Review Adjusting the Tracer AdaptiView Display Arm p 45 prior to attaching the display as some adjustments may be required prior to attaching the display...

Page 45: ...loosen tighten or indicators Joint 3 has a 6 mm hex screw controlling the tension on a gas spring which allows the Tracer AdaptiView display to tilt up and down Joints 1 and 2 are covered by a plastic...

Page 46: ...c and connection information Do not modify or cut enclosure to provide electrical access Removable panels have been provided and any modification should be done away from the enclosure If the starter...

Page 47: ...ures to ensure the power cannot be inadvertently energized For variable frequency drives or other energy storing components provided by Trane or others refer to the appropriate manufacturer s literatu...

Page 48: ...t pump neutral 2X8 25 1X1 16 Starter to Oil Refrigerant Pum p Junction Box Starter Panel Term inals Oil Refrigerant Pum p Junction Box Low Voltage 3 Phase Pump Power 2X8 21 2X8 22 2X8 23 4X4 1 4X4 2 4...

Page 49: ...5X12 10 1K23 J6 1 Transition com plete 5X12 14 1K23 J12 2 Solid State Starter Fault c 5X12 12 5X12 11 1K13 J2 2 1K13 J2 1 Low Voltage Circuits less than 3 0 Vac Starter Panel Term inals Unit Control P...

Page 50: ...p 47 Wires lugs and fuses breakers are sized based on National Electric Code NEC NFPA 70 and UL 1995 Maxim um Lead Length Meters Feet 8 1627 5339 10 1023 3357 12 643 2112 14 404 1328 16 254 835 17 201...

Page 51: ...supply wiring in accordance with NEC and local guidelines using the RLA value stamped on the chiller nameplate and transformer load on L1 and L2 Confirm that wire size iscompatible with lug size stat...

Page 52: ...ustomer is required to follow all local national and or IEC codes for installation Service personnel must use proper PPE for servicing and should also use proper lockout tagout procedures during servi...

Page 53: ...abling The customer is required to provide an overcurrent protective device upstream of all starters and drives in accordance with IECstandards and or any applicable local and national codes Service p...

Page 54: ...or circuit are NOT inside of the starter For the low voltage CPTR option the single phase 4kVA transformer feeds the 120 V control power to all of the controls The three phase line power feeds a motor...

Page 55: ...IP2X PFCCs must be wired one of two ways as shown as explained in the following Option 1 and Option 2 NOTICE Motor Damage Failure to wire PFCCs into the starter correctly could cause misapplication of...

Page 56: ...points are downstream of the current transformers route the PFCC leads through the current transformers as shown in the following figure This ensures that the overloads register both line and capacito...

Page 57: ...onduits 2 Remote mounted starter 3 Unit control panel 4 IPC Circuit conduit less than 30V and CT PT wiring for starters by others Note Must enter the low voltage Class 2 portion of the unit control pa...

Page 58: ...ided on each motor terminal stud use the factory supplied Belleville washers on the wire lug connections Figure 32 illustrates the junction between a motor terminal stud and terminal lug Torque for th...

Page 59: ...al for proper operation Separate low voltage less than 30V refer to Table 13 p 48 wiring from the 115V wiring by running each in its own conduit When routing the IPC circuit out of the starter enclosu...

Page 60: ...ing RLA LRA etc In all cases of non Trane supplied starters the Trane Engineering Specification for UC800 Starter By Others available through your local Trane office must be followed in order to ensur...

Page 61: ...wire sizing by the installer must be made in accordance with the National Electric Code or any other applicable codes Three terminals are provided on the chiller for the connection of power to the mo...

Page 62: ...shaft Note 6 0kV and 6 6kV motors on 6800 or 6800L frames see compressor model number for motor frame use the same motor terminals as the 10kV 13 8kV motors The motor terminal on a 10 13 8kV motor has...

Page 63: ...ary Input Norm ally Open External Hot Water Control Enable Input 1K8 J2 3 to 4 Binary Input Norm ally Open External Ice Machine Control Enable Input 1K9 J2 1 to 2 Binary Input Norm ally Open External...

Page 64: ...g evaporator water temperatures When a secondary flow sensing device is used remove the factory jumper and install its contacts between 1X1 5 to 1K26 4 this places the secondary flow sensing device in...

Page 65: ...module 2 Motor winding temperature 1 3 Motor winding temperature 2 4 Motor winding temperature 3 5 Oil pump discharge pressure transducer 6 Oil tank pressure transducer 7 Evaporator water differential...

Page 66: ...16 cm 6 in between low voltage 30V and high voltage circuits Failure to do so could result in electrical noise that may distort the signals carried by the low voltage wiring including the IPC Optiona...

Page 67: ...rigerant then passes through an orifice plate and into the economizer The economizer reduces the energy requirements of the refrigerant cycle by eliminating the need to pass all gaseous refrigerant th...

Page 68: ...il pressure regulating valve designed to maintain a net oil pressure of 137 9 to 165 5 kPad 20 to 24 psid It is then filtered and sent to the braze plate heat exchanger oil cooler located above the oi...

Page 69: ...ctors 9 525 mm 0 375 in OD 16 Liquid refrigerant to economizer 6 Oil return to tank 17 Liquid refrigerant to evaporator 7 Oil tank 18 Evaporator 8 Oil cooler braze plate heat exchanger 19 Oil reclaim...

Page 70: ...The refrigerant pump is located on the front of the oil tank motor inside the oil tank The refrigerant pump inlet is connected to the well at the bottom of the condenser The well design ensures prefe...

Page 71: ...nser pressure lowers the chillers efficiency and capacity A purge system is required on low pressure centrifugal chillers It is a device that is externally mounted on the chiller Its purpose is to rem...

Page 72: ...and fan 3 Pressure relief device fusible plug 4 Pump out solenoid valve 5 Automatic expansion valve 6 Carbon tank 7 Carbon tank temperature sensor 8 Carbon tank heater 9 Exhaust solenoid valve 10 Pum...

Page 73: ...losed float switch is open for more than 20 minutes the purge controls will turn off the refrigeration system and generate a non latching diagnostic Purge Liquid Level Too High Warning If the float sw...

Page 74: ...ting If the limit temperature is reached the system shuts down and a Purge Carbon Regen Temperature Limit Exceeded diagnostic is generated Sensors The following sensors are used to enable control comm...

Page 75: ...s a state chart with the arrows and arrow text depicting the transitions between states Descriptions The text in the circles are the internal software designations for each state The first line of tex...

Page 76: ...76 Based on the Restart Inhibit function and the Differential to Start setpoint the oil and refrigerant pump is energized and the oil vent line valve is closed to the minimum position The oil pressure...

Page 77: ...water pump will continue to run while the main processor module monitors leaving chilled water temperature preparing for the next compressor motor start based on the differential to start setpoint Fi...

Page 78: ...or based on entering evaporator fluid temperature The control panel will not permit the Ice Building mode to be entered again until the unit is switched to the non ice building mode and back into the...

Page 79: ...ration ice building stopped to ice to ice building complete Ice Making Command 1 Front Panel 2 Tracer 3 External Input Evap Entering Water Temp Falls Below the Ice Termination Setpoint Auto Run Inhibi...

Page 80: ...ter setpoint Heating is the primary mission and cooling is a waste product or is a secondary mission This type of operation requires an endless source of evaporator load heat such as well or lake wate...

Page 81: ...for CE application only Important Before servicing disconnect all power sources and allow at least 30 minutes for capacitors to discharge All electrical enclosures unit or remote are IP2X WARNING Live...

Page 82: ...during start up unit operation will be locked out and a manual reset is required before the start up sequence can begin again If the fault condition has not cleared the control panel will not permit r...

Page 83: ...ge is on the high pressure or low pressure side of the chiller Decrease energy usage by running the purge refrigeration circuit only when needed to remove non condensables rather than running it conti...

Page 84: ...run 60 minutes without any pump out The purge control reviews the historical data and determine the Pumpout Time with the chiller On Pumpout Time from last 24 hours daily average over last 7 days whi...

Page 85: ...Procedure Chiller Compressor On Figure 48 p 84 illustrates this process Submodes You can view up to six purge submodes from the Purge Settings screen The available purge submodes are Refrigeration Cir...

Page 86: ...increases The purge controller monitors the compressor suction temperature and cycles or stops the pump out depending on the temperature that is present The 1 4 hp air cooled condensing unit of the re...

Page 87: ...temperature sensor serves as the feedback to this control algorithm The compressor suction temperature pump out initiate and pump out terminate values are calculated by the purge control and are a fu...

Page 88: ...with standard pump out compressors operation at low chiller condenser saturation temperatures may result in a system vacuum greater than the pump out compressor can overcome If the chiller experience...

Page 89: ...nity when the chiller is shut down and no pump out minutes have accumulated for the previous 60 minutes 4 If there is no opportunity to regenerate as indicated by Rules 1 2 and 3 and the carbon capaci...

Page 90: ...t 7 Days Indicates the average daily pump out time for the last 168 hours a moving 168 hour window Enables a comparison of present pump out times to past averages and can be another indication of the...

Page 91: ...ure to disconnect power and discharge capacitors before servicing could result in death or serious injury Disconnect all electric power including remote disconnects and discharge all motor start run c...

Page 92: ...level in the chiller oil sump using the two sight glasses provided in the oil sump head When the unit is operating the oil level should be visible in the lower sight glass Complete logs on a daily bas...

Page 93: ...d be performed immediately to find and fix the leaks Measure the compressor motor winding resistance to ground a qualified service technician should conduct this check to ensure that the findings are...

Page 94: ...lectrical enclosures unit or remote are IP2X Weekly Maintenance Perform thefollowing maintenance procedureon a weekly basis Figure 52 Purge operation under typical and leak conditions WARNING Contain...

Page 95: ...several filter drier assembly changes may be required before a satisfactory moisture level is achieved A reoccurring or persistent wet indication is a sign of possible chiller air or water infiltrati...

Page 96: ...d loose material from smooth bore tubes To clean other types of tubes including internally enhanced types consult a qualified service organization for recommendations WARNING Hazard of Explosion Failu...

Page 97: ...mal treated and clean condenser water inspect the coating system within three months Only when initial inspections show no problems are present should subsequent maintenance intervals be increased Sac...

Page 98: ...icable manufacturing location 2 The rated lifting capacity of the lifting shackle must meet or exceed the published weight of the waterbox Verify the waterbox weight from the latest published literatu...

Page 99: ...95 21 8 0 858 130 Evaporator 1034 2 kPa 150 psi NA NA 347 766 11 9 0 469 NA NA 292 645 11 9 0 469 645 1423 21 8 0 858 Evaporator 2068 4 kPa 300 psi 431 950 11 9 0 469 NA NA 320 705 11 9 0 469 NA NA 69...

Page 100: ...kPa 150 psi 1247 2750 21 8 0 858 NA NA NA NA NA NA NA NA 22H Heat Recovery Condenser 1034 2 kPa 150 psi 1747 3853 21 8 0 858 NA NA NA NA NA NA NA NA Table 24 CVHH waterbox weights continued Shell Size...

Page 101: ...side Then apply final torque to each bolt in sequential order Condenser Waterbox Covers Condenser waterbox covers use a similar procedure to that which is used for the evaporator waterbox covers Use...

Page 102: ...llation completion verification before Trane start up is scheduled and for reference during the Trane start up Where the form or check sheet also exists outside of this publication as standalone liter...

Page 103: ...piping prior to the chiller commissioning by Trane service personnel The contractor is responsible for any foreign material left in the unit 2 Piping Chilled water piping connected to Condenser and he...

Page 104: ...al ventilation Does the installation have properly placed and operating audible and visual refrigerant alarms If it is required by local code is a self contained breathing apparatus available 11 Ow ne...

Page 105: ...Report Pre Start Operations Verify nitrogen holding charge Calibrate the high pressure cutout control HPC Meg compressor motor Check condenser installation Check evaporator installation Check electric...

Page 106: ...erator is working properly and moves without binding Dry run test starter non AFD Remove separate source power and reconnect wiring Preparation for Start up Relieve nitrogen holding charge Confirm pro...

Page 107: ...test tubes every three years Evaporator Inspect for fouling and scaling in tubes Check operation of evaporator water flow sensing device Factory recommendation to eddy current test tubes every three y...

Page 108: ...ate factory installed gantries After the first month of operation inspect Heresite or Belzona coated waterboxes after first month thereafter inspect as needed Inspect anodes Inspect and lubricate hing...

Page 109: ...iff Press Oil Tank Tem p IGV Position Outboard Bearing Pad Temperature 1 Outboard Bearing Pad Temperature 2 Outboard Bearing Pad Temperature 3 Motor RLA L1 L2 L3 Amps L1 L2 L3 Volts AB BC CA Power KW...

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Page 111: ...lio of advanced controls and HVAC systems comprehensive building services and parts For more information visit www Trane com Trane has a policy of continuous product and product data improvement and r...