Trane Manhattan Gen II, Installation, Operation And Maintenance Manual

Page 1: ...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 e...

Page 2: ...hazardous situation which if not avoided could result in minor or moderate injury It could also be used to alert against unsafe practices NOTICE Indicates a situation that could result in equipment o...

Page 3: ...arks All trademarks referenced in this document are the trademarks of their respective owners WARNING Follow EHS Policies Failure to follow instructions below could result in death or serious injury A...

Page 4: ...ion 20 Power Interlock Switch 20 Module Control Wiring 20 Operating Principles 21 Operating Procedures 22 Operator Interface 22 Chiller Power Panels 22 Electronic Control 23 Client and Server Controll...

Page 5: ...troller Tasks 57 Chiller Troubleshooting 58 General Approach to Fault Isolation 58 Controller Diagnostic Codes 58 Compressor Diagnostic Codes 59 CoreSense Flash Codes 59 CoreSense Flash Code Descripti...

Page 6: ...ller 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 Compr...

Page 7: ...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 Model Number Criticalinfor...

Page 8: ...ained by a water treatment professional familiar with the materials of construction and operation of the equipment The chiller modules arrive fully charged with refrigerant As required under Federal r...

Page 9: ...t point on the plates creating complex channels This allows fluid to come into close proximity of the cold refrigerant separated only by channel plates tthat enable heat from one fluid to be transferr...

Page 10: ...Confirm the oil level is correct in each compressor Note If Trane pumps are provided check that each pump s overload setting matches the nameplate amperage of the pumps as described previously Bump p...

Page 11: ...nction boxes located between the chiller 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...

Page 12: ...chnical support for the initial start up procedure Check the box if full load will be available for chiller on the initial start up date Touchscreen Interface Panel Record version and date of software...

Page 13: ...esponsibility will be made and the carrier will authorize repairs in the event of admission of fault 7 Notify Trane customer service department immediately Trane will coordinate repairs with the owner...

Page 14: ...een checked by a qualified structural engineer to support the weight of the fluid filled modules and the connective piping to and from the chiller Installations must account for minimum service access...

Page 15: ...Installation Mechanical ARTC SVX002A EN 15 Figure 2 Recommended chiller clearances...

Page 16: ...ubbing or contacting module side panels or electrical boxes Do not use cables chains or any other type of metalized strapping to lift a module Do not push a chiller module while directly in contact wi...

Page 17: ...ng isolators or rubber in shear isolator pads must be installed under the structural steel mounting rails After setting each module remove front or rear access panels to improve access to components w...

Page 18: ...1 Mix the concentrate of propylene glycol in a tank or drum for transfer into the chiller Use Table 7 p 40 Glycol Performance Impact Factors to assist in determining the appropriate glycol concentrati...

Page 19: ...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 roll grooved couplings Star...

Page 20: ...at the mounting socket No further adjustment should be required Power Interlock Switch Some Manhattan Gen II Chiller systems are optionally equipped with a panel mounted disconnect switch installed o...

Page 21: ...ixture is cooled via a compact brazed plate evaporator An externally adjustable thermal expansion valve meters the proper flow of refrigerant to the evaporator where it evaporates and the heat in the...

Page 22: ...ides power to the individual electrical components in that module Panel Mounted Disconnect Switch Some Manhattan Gen II Chiller systems are optionally equipped with a panel mounted disconnect switch i...

Page 23: ...on through built in BMS2 port 4 Modbus IP Modbus router is used 5 LonWorks LonWorks router is used Client and Server Controllers The distributed microprocessor control system enables all server module...

Page 24: ...ons involving temperatures pressures set points alarms operating schedules and elapsed operating hours This touchscreen interface panel is located inside the control panel The touchscreen interface is...

Page 25: ...res 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 Interface Menu Struct...

Page 26: ...Operating Procedures 26 ARTC SVX002A EN Home Screen Features Figure 12 HMI home screen...

Page 27: ...ll limited Beyond user tech can adjust cooling heating setpoints turn separate modules on off and has access to some machine basic temperature control settings described below Password is tech2 admin...

Page 28: ...e Compressor Status ModulesAvail Setup Numberofmodulesavailable for Client Server temperature control and number of modules set up for Client Server temperature control Modules Online Number of chille...

Page 29: ...ation valves and the module overall See figure below Module Layout Screen Status Conditions Each module picture is a set of images that show real time color coded state of compressor refrigeration cir...

Page 30: ...tle each alarm Source Value This column displays the numeric value of each alarm If an alarm has a Source Value 1 it can only be reset with the RESET button when the condition triggering the alarm has...

Page 31: ...ed in the upper right portion of the screen resets the active alarms in the client microprocessor so they could be further acknowledged or reset on the touchscreen interface Only those alarms for whic...

Page 32: ...larms states apply to alarm history screen TRIGGERED NOT ACKNOWLEDGED TRIGGERED ACKNOWLEDGED Tag Value This is the same as Source Value for active alarms Modules Overview Screens Each module controlle...

Page 33: ...conditions are satisfied and module is counting down a delay before acquiring Client ON status 3 OFFbySensor Systemcoolingorheatingtemperature sensor failed 4 OFF by no Servers Client PLC communicate...

Page 34: ...running due to safety Minimum On Time 10 ON by Pumpdown Compressor has been called off but keeps running due to Pump down sequence Comp X Speed Can be displayed in different units 1 Volts If PLC analo...

Page 35: ...eed compressor s hard wired control signal Digital Inputs Digital input DI data includes these parameters Digital LEDs There is an LED for each digital input that indicates its current state For all i...

Page 36: ...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 AI11 Expansion...

Page 37: ...time axis scrolling 8 Button is used to pause resume real time trending Operator Tasks Before operating the unit ensure that all compressor refrigeration service valves are fully back seated countercl...

Page 38: ...on 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...

Page 39: ...e for the effects on the chiller when operating with other glycol concentrations This table shows the capacity reduction and the pressure drop that occurs when higher concentrations of glycol are used...

Page 40: ...ne glycol or premixed solutions for use with the chiller Propylene Glycol Glycol based fluids provide such burst protection in water solutions due to their low freezing points As a glycol based fluid...

Page 41: ...t propylene glycol and Dowtherm ethylene glycol branded products Consult your local supplier or engineering contractor for more precise recommendations Storage Provisions The chiller controls are desi...

Page 42: ...erator Control and Monitoring Each system is provided with a touchscreen interface panel that is used to turn the chiller ON and OFF adjust set points clear alarms and perform detailed set up of the m...

Page 43: ...nd Control Panel From the power distribution panel power is fed to the individual chiller modules and connects to each module s electrical and control panel See above figure Electrical Controls The Ma...

Page 44: ...at the evaporator outlet The sensor bulb should be located at the 4 o clock or 8 o clock positions on the pipe for the most accurate pressure measurement Ensure that the closed cell insulation covers...

Page 45: ...e leaving temperature of the chilled water glycol mixture maintaining a minimum flow of water through the evaporator and keeping debris out of the air cooled condenser In applications where it is desi...

Page 46: ...oint minus 1 F 0 5 C a compressor will de energize in the reverse of the sequence by which it came on 10 This process occurs throughout the operating range of the chiller 11 The microprocessor will ro...

Page 47: ...ond module will energize This operation continues with all subsequent chiller modules as needed based on system demand 12 On a decrease in system demand and flow such that the leaving water glycol mix...

Page 48: ...uid Temperature 85 F 29 C Leaving Fluid Temperature 44 F 7 C Leaving Fluid Temperature 95 F 37 3 C Evaporator Pressure Drop 4 4 psi Condenser Pressure Drop 3 1 psi Maximum Operating Pressure 650 psi r...

Page 49: ...d 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...

Page 50: ...ended chiller service intervals Task Frequency Visually inspect the chiller Daily Log pressure and temperatures Daily Inspect touchscreen interface panel for alarm history Weekly Clean strainers on th...

Page 51: ...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 requi...

Page 52: ...urned contacts on motor starters Replace contacts if in doubt It is recommended to replace contactors every 5 6 years Annually The annual chiller maintenance inspection is critical to the long term pe...

Page 53: ...evaporator cleaning On multiple module chillers Trane provides service isolation valves on each evaporator to isolate each strainer for cleaning without disrupting the operation of any remaining modul...

Page 54: ...as the valve can become difficult to loosen if over tightened 2 Recover the remaining refrigerant charge from the compressor using a suitable recovery machine and a clean recovery cylinder that is pre...

Page 55: ...rdous fluids 6 Loosen the four bolts that attach the pump base to the frame with the appropriate size wrench or socket 7 Remove the pump 8 Disconnect the piping stubs from the suction and discharge co...

Page 56: ...and discharge piping Capture any escaping fluids encountered during the pump change out process Notes Always use a second counter wrench when performingplumbingtasks to firmly hold the fittingsor join...

Page 57: ...verifythatthepowertothe chiller is disconnected 1 Remove all quick connect black plugs and the one orange plug power supply 24 Vac 2 The PLC logic controller is DIN rail mounted Once plugs are removed...

Page 58: ...o Shuts down Circuit 1 2 Compressor 1 2 Offline Auto Shuts down compressor 1 2 Compressor 1 2 Warning Auto Warning Condenser Flow Alarm User Shuts down Circuits Circuit 1 in Constant Flow systems Cond...

Page 59: ...ompressor 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 sec...

Page 60: ...led in heat pump mode N A N A CODE 2 Yellow Flash 2 Compressor pressure trip Compressor runs for 12 seconds to 15 minutes followed by a compressor trip condition lasting longer than 7 minutes 4x conse...

Page 61: ...LED blinking No power Green POWER Power supply on the board OK Green POWER Blinking Drive in an alarm state Blinking for one second Drive selected on the control panel when multiple drives are connec...

Page 62: ...e 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 client mi...

Page 63: ...ssible Causes Potential Solutions Defective capacity control Repair or replace module Unloader mechanism defective Replace unloader Faulty thermostat gauge or broken capillary tube Replace thermostat...

Page 64: ...alarms reclaim excess refrigerant and verify proper sub cooling and superheat High water temperature Low refrigerant charge failing compressor check design specifications 9 Symptom Low refrigerant dis...

Page 65: ...ow voltage 24 Vac Possible Causes Potential Solutions Control circuit fuse open Check fuse prong contact points replace fuse Phase monitor opened or tripped Check for correct voltages Transformer T1 d...

Page 66: ...ischarge Low water flow Remove restrictions Increase HP Low suction pressure See low suction pressure Code hex Fault Aux code Cause What to do 1080 Backup Restore timeout Panel or PC tool has failed t...

Page 67: ...er supply imbalance 3181 Wiring or earth fault Programmable fault 31 23 Wiring or earth fault Incorrect input power and motor cable connection ie input power cable is connected to drive motor connecti...

Page 68: ...ectors on the control unit is stuck or disconnected Check auxiliary fan s and connection s Replace fan if faulty Make sure the front cover of the drive module is in place and tightened Reboot the cont...

Page 69: ...epresentative 64B2 User set fault Loading of user parameter set failed because requested set does not exist set is not compatible with control program drive was switched off during loading Ensure that...

Page 70: ...ck that braking cycle meets allowed limits 7184 Brake resistor wiring Brake resistor short circuit or brake chopper control fault Check brake chopper and brake resistor connection Ensure brake resisto...

Page 71: ...lt parameter 32 37 Supervision 4 signal 80B4 Signal supervision Editable message text Programmable fault 32 46 Supervision 5 action Fault generated by the signal supervision function 5 Check the sourc...

Page 72: ...rately Check that no operation limits prevent the completion of the ID run Restore parameters to default settings and try again Check that the motor shaft is not locked FF81 FB A force trip A fault tr...

Page 73: ...presents the simplified logical flow block diagrams for the principal systems in the Manhattan Gen II Water Cooled Modular Chiller Control Logical Flow The chiller uses low voltage for controller and...

Page 74: ...age amperage phase configurations to meet the demands of a worldwide chiller market The high voltage configuration for a chiller module is listed on each module s name plate The chiller is designed to...

Page 75: ...nt refrigeration circuits per module using scroll compressors See below figure The thermal capacity of the chiller modules is dependent on the leaving temperature of the chilled water maintaining a mi...

Page 76: ...EN 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 below figure Figure...

Page 77: ...e Controller EXP1 Expansion Board 1 EXV Electronic expansion Valve F Fahrenheit FLA Full Load Amperes FLC Full Load Current FREECOOL Free Cooling FRI Friday gpm gallons per minute GUI Graphical User I...

Page 78: ...Saturday SDT Saturated Discharge Temperature SP Set Point SSS Solid State Starter SST Saturated Suction Temperature StartPt Stating Point SUN Sunday Sys System Temp Temperature TEMPS Temperatures THU...

Page 79: ...nitialed Complete All chiller modules are installed with minimum clearances available from all sides Refrigeration gauges are indicating equal pressures Chilled water lines from chiller to customer s...

Page 80: ...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...

Page 81: ......

Page 82: ...hout notice We are committed to using environmentally conscious print practices Trane by Trane Technologies NYSE TT a global climate innovator creates comfortable energy efficient indoor environments...