Trane RTAC, Troubleshooting Manual

Page 1: ...er Cooled Chillers with the CH530 controls It is recommended that the service technician be familiar with the CH530 operation prior to servicing the microprocessor This bulletin is intended to serve as a supplement to the RTAC and RTHD IOMs the installation operation and maintenance manuel Subjects covered in this bulletin are intended to provide more comprehensive information for the RTAC and RTH...

Page 2: ...nditioning industry All technicians who handle refrigerants must be certified 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 mana...

Page 3: ...erter Fault Input 22 Troubleshooting the Inverter 22 Current Transformers 26 CT and Starter Compressor Current Input Checkout Procedure 27 Over Under Voltage 30 RTAC Chillers 30 Check out procedure for RTAC 30 Under Over Voltage Transformer Checkout 30 RTHD Chillers 31 Check out procedure for RTHD 31 Potential Transformer 31 Starter Module 33 Starter 34 X Line 34 Y Delta 34 YDelta Starter Sequence...

Page 4: ...mmunicating 57 Is the sensor reading accurately 58 Gas Pump RTHD Only 59 Gas Pump Checkout Procedure Unit Off 59 Gas Pump Checkout Procedure Unit On 60 Optical Sensor RTHD Only 61 Checkout Procedure 61 TechView Service Tool 62 Software Requirements 62 Hardware Requirements 62 Laptop requirements for CH530 63 The Download Process 63 Instructions for First Time Tracer CH530 Users 63 Using TechView 6...

Page 5: ...ID bus The communications bus is called the Inter Processor Communications The main processor is located in the human interfaces DynaView EZView Starter Module The starter module provides control of the compressor contactors when starting running and stopping the chiller Starter types include Across the Line RTAC Y Delta and Solid State RTHD The starter module provides protection of the compressor...

Page 6: ... RLC SVX05A EN CH530 OverviewCH530 Overview EXV stepper driver liquid level sensor input inverter interface pressure transducer The following is a graphic example of the CH530 architecture Figure 1 CH530 ...

Page 7: ...e around the unit and wired by stubs to a main trunk IPC bus The DynaView or EzView provides the user interface and the system main processor The main processor is the master of the chiller by collecting data status and diagnostic information and communicating commands to the other modules starter purge and the LLID bus The main processor also serves as the bus manager Functions of the bus manager...

Page 8: ...te a failure of the LED circuit or that the device is not programmed The LED circuit is designed to light the LED while the switch is active so the LED can be used to detect that power is supplied If the LED fails to light when a user attempts to activate the switch either loss of power or a hardware problem is indicated The LED software is designed to enter a special state to become selected when...

Page 9: ...our cable retainer tabs Push the cable into the connector to lock it beneath these tabs 3 Place the cover and wire over the base and hold in place Crimp the connector down using the Trane tool or a parallel jaw pliers It is important to apply equal pressure across the jaws of the pliers Figure 3 Cable and Connector Figure 4 Pliers ...

Page 10: ... in the connector Procedure for installing caps A cap must be installed on the bare end any time the is cut and or spliced 1 Always cut in parallel section of wire If cuts are made on twisted wire shorting of the wire pairs will occur An angle cut is necessary for the proper installation of the protective cap Refer to Figure 6 Right Wrong Figure 5 Finished Connector Figure 6 Wire ...

Page 11: ...p to be unverified Most of these kinds of failures must be tracked down manually A problem will usually fall in one of four scenarios Connect TechView and go into binding view One of the following scenarios should be present All LLIDs verified green smiling face s Suspect a communication problem It may be necessary to unbind and rebind some or all of the LLIDs All LLIDs not verified red frowning f...

Page 12: ...onnector or the LLID If only one LLID is not functioning suspect the LLID or the connector If problem is with multiple LLID suspect a problem with the LLID bus or a connector Chiller has multiple loss of communication diagnostics Using TechView go into binding view Are there devices that are not verified Refer to Section 3 Power supply checkout NO YES Reset diagnostics Check for 24 VAC at J2 1 and...

Page 13: ...onnector or the LLID If only one LLID is not functioning suspect the LLID or the connector If problem is with multiple LLID suspect a problem with the LLID bus or a connector Chiller has multiple loss of communication diagnostics Using TechView go into binding view Are there devices that are not verified Refer to Section 3 Power supply checkout NO YES Reset diagnostics Check for 24 VAC at J2 1 and...

Page 14: ...the output voltage is 22 8 to 25 2 VDC The input voltage should fall within the following values Table 2 list the values for the output voltage on the power supply If the green LED 1 is lit it implies that there is a good DC output voltage being produced by the board Output for terminals J1 J3 J4 J5 and J11 are the same The voltage output should be within 5 Power Supply Figure 8 Power Supply Table...

Page 15: ...p fuse X13110456020 on the power supply If this fuse is open LED 1 will not be on and there will not be any voltage out This fuse can be replaced The fuse is a medium time delay 3 0 amp 5X20mm Table 2 Output Voltage Terminals Voltage 1 24VDC 2 GND 3 COMM 4 COMM ...

Page 16: ... bound try to bind it If the sensor will not bind it could be a problem with the connector or the sensor itself Take a close look at the connector to make sure that all four wires are securely in place It may be necessary to remove the cap to check for broken or misplaced wires CAUTION Equipment Damage Possible All units built before October 1 2002 U02 used connectors that must be replaced if the ...

Page 17: ...l not bind replace the sensor Is the sensor reading accurately All temperature sensors on RTAC units are in thermal wells Cycle the chiller off prior to testing the sensor 1 Remove the sensor of concern from the well 2 Place the sensor while still connected to the LLID bus in an ice bath 3 Monitor the temperature on DynaView or TechView The temperature should approach 32 F 4 If the sensor is bound...

Page 18: ...e sensor itself Take a close look at the connector to make sure that all four wires are securely in place It may be necessary to remove the cap to check for broken or misplaced wires CAUTION Equipment Damage Possible All units built before October 1 2002 U02 used connectors that must be replaced if the cap is removed If the cap is removed on any of these units cut out the old connector and splice ...

Page 19: ...nnected to the LLID bus to a nitrogen source with a calibrated gauge 3 The pressure that is applied to the transducer must be steady state If the pressure is changing the test will not be accurate 4 Increase the pressure on the transducer 5 Monitor the pressure on DynaView or TechView The transducer measures in absolute pressure and then subtracts the local atmospheric pressure setting to display ...

Page 20: ... F without fan cycling without safety trips or other instabilities that would otherwise occur with fixed speed fans only Startup and Operation The MP provides an output one per circuit to control a contactor which delivers 3 phase power to the inverter s on that circuit The output energizes the contactor for the inverter s for that circuit at least 5 seconds prior to the first compressor start of ...

Page 21: ...4 5 F deadband above the condenser goal pressure which is set relative to the current Evaporator Pressure i e 60 PSID above it If variable speed fans are present then the air flow is modulated directly on the Desired New Air Flow calculated every 5 seconds When only fixed speed fans are present additional fans will not be staged on until the new Air Flow exceeds the next available fan step Figure ...

Page 22: ...ault Troubleshooting the Inverter The purpose of this troubleshooting section is to help technicians determine if the variable speed fan inverter the compressor module the fan contactor the fan motor or the interconnecting wiring is faulty WARNING Live Electrical Components During installation testing servicing and troubleshooting of this product it may be necessary to work with live electrical co...

Page 23: ... This will also be reflected as an L or W in digit 17 of the model number Go into Binding View and verify that the fan control LLIDs are bound 2 Verify that all inverter power and control signal wiring is correct for the affected circuit The wiring diagrams are found in RTAC SVX01C EN or on the inside of the unit fan control door Table 3 VFD Fault Conditions Fault Condition Number of Alarm LED fla...

Page 24: ...ore the compressor starts the contactor that would normally apply power to the inverter should pull in and the fan should run If the fan does not run check the line fuses and contactor contacts The fan will only run for approximately 30 seconds before the inverter fault will cause the contactor to drop out 5 Disconnect power from the unit and reconnect the inverter module At the same time check fo...

Page 25: ...be high line voltage A 10 high line voltage could cause a diagnostic trip The output frequency of the inverter is being internally limited to less than 50 of the signal speed commanded by the MP Excessive fan motor current high temperature or internal inverter failures could cause this to occur b There is an open circuit in the fault signal wiring somewhere between the inverter and the compressor ...

Page 26: ...seconds after transition even if it occurs immediately at start Additional two of the three current inputs also serve the Phase Rotation circuits If this circuit monitored immediately after start outputs an inconsistent value to the module due to loss of one or both of its inputs a diagnostic of either Phase Loss steady output or Phase Reversal Protection Lost varying output will occur with a maxi...

Page 27: ...r individual who has been properly trained in handling live electrical components perform these tasks Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury 1 Check incoming 3 phase power for voltage within 10 of nominal per Chiller nameplate Verify that unit size and voltage are set correctly using TechView 2 Check fo...

Page 28: ...ment Damage Current Transformers can be damaged and high voltages can result due to running the compressors without a suitable burden load for the CTs This load is provided by the Starter input Take care to properly reconnect the CT s Phoenix connector prior to attempted start of the compressors 5 Using a digital volt ohmmeter measure the resistance of the transformer s by probing the appropriate ...

Page 29: ...ps prove accurate reconnect the transformers to the Starter and re power the unit WARNING Live Electrical Components During installation testing servicing and troubleshooting of this product it may be necessary to work with live electrical components Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks Fa...

Page 30: ...l Components During installation testing servicing and troubleshooting of this product it may be necessary to work with live electrical components Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks Failure to follow all electrical safety precautions when exposed to live electrical components could resul...

Page 31: ...s The transformers will display of the magnitude of these voltages as well as under and over voltage protection if such is enabled Check out procedure for RTHD WARNING Live Electrical Components During installation testing servicing and troubleshooting of this product it may be necessary to work with live electrical components Have a qualified licensed electrician or other individual who has been ...

Page 32: ...ltage measurements listed Table 6 with respect to the displayed line to line voltage on DynaView or TechView is 3 of reading 14 4 290 14 9 300 15 4 310 15 9 320 16 3 330 16 8 340 17 3 350 17 8 360 18 3 370 18 8 380 19 3 390 19 8 400 20 3 410 20 8 420 21 3 430 21 8 440 22 3 450 22 8 460 23 3 470 23 8 480 24 3 490 24 8 500 25 3 510 25 7 520 26 2 530 26 7 540 27 2 550 27 7 560 28 2 570 Table 6 Starte...

Page 33: ... all the external wires to the J5 1 to 6 terminals Again measure the voltages in Table 7 If the voltages all fall within the acceptable range then there is most likely an error in the external wiring to the Starter module potential transformer inputs This includes the potential transformers themselves If any voltage is not within the acceptable range then there is most likely a problem with instal...

Page 34: ...ion Complete input is required to be wired at the starter module Y Delta Individual relays on the CH530 Starter module control the timing sequence for the Stop Start Short Transition and Run contactor closures During a motor start Prior to closing the Short contact the transition complete input is verified to be open otherwise an MMR diagnostic is generated The sequence of a Y Delta Start is shown...

Page 35: ...or Currents Starter Fault Type II When Currents Drop Below 85 RLA 1 5 Seconds Energize Transition Relay De Energize Shorting Relay Energize Run Contactor De Energize Transition Relay Confirm Transition Complete Input within 2 5 seconds Starter Did Not Transition Starting Compressor Max Accel Timer 6 to 64 Seconds Starting Compressor Starting Compressor Compressor Running Confirm Proper Compressor ...

Page 36: ...r for 500 Msec 1K1 Check for No Current Starter Fault type I Power Flow 36 RLC SVD05A EN Starter YDelta Starter Sequence Figure 15 Y Delta Starter Sequence Figure 16 Y Delta Starter Sequence L2 L3 1K1 1K1 1K1 1K2 1K2 1K4 1K4 1K4 R R R 1K2 1K3 1K3 L1 Starter De energized Power Flow ...

Page 37: ...low Check for No Current Starter Fault type II 1 Second 1K3 Remains Closed 1K1 L2 L3 1K1 1K1 1K1 1K2 1K2 1K4 1K4 1K4 R R R 1K2 1K3 1K3 L1 Power Flow Shorting Contactor 1K3 continues energized Energize Start Contactor 1K1 RLC SVD05A EN 37 Starter Figure 17 Y Delta Starter Sequence Figure 18 Y Delta Starter Sequence ...

Page 38: ... L2 L3 1K1 1K1 1K1 1K2 1K2 1K4 1K4 1K4 R R R 1K2 1K3 1K3 L1 Power Flow If 1 6 seconds after 1K1 closed no current was detected by all three CT s for the last 1 2 seconds then Starter Fault Type III is Displayed 38 RLC SVD05A EN Starter Figure 19 Y Delta Starter Sequence Figure 20 Y Delta Starter Sequence ...

Page 39: ... Flow When Maximum Phase Current Drops Less Than 85 of Nameplate RLA for 1 5 Seconds L2 L3 1K1 1K1 1K1 1K2 1K2 1K4 1K4 1K4 R R R 1K2 1K3 1K3 L1 Power Flow 1K4 Is Energized RLC SVD05A EN 39 Starter Figure 21 Y Delta Starter Sequence Figure 22 Y Delta Starter Sequence ...

Page 40: ...tiate Transition to Delta L2 L3 1K1 1K1 1K1 1K2 1K2 1K4 1K4 1K4 R R R 1K2 1K3 1K3 L1 Power Flow Power Flows Though Resistors 100 msec After 1K4 Closes Shorting Contactor 1K3 Opens 40 RLC SVD05A EN Starter Figure 23 Y Delta Starter Sequence Figure 24 Y Delta Starter Sequence ...

Page 41: ...Power Flow 260 msec After 2K3 Opens Run Contactor 2K2 Closes L2 L3 1K1 1K1 1K1 1K2 1K2 1K4 1K4 1K4 R R R 1K2 1K3 1K3 L1 Power Flow Delta configuration almost complete RLC SVD05A EN 41 Starter Figure 25 Y Delta Starter Sequence Figure 26 Y Delta Starter Sequence ...

Page 42: ... Test Transition Complete Contact closed and Open 1K4 De energizing Resistors L2 L3 1K1 1K1 1K1 1K2 1K2 1K4 1K4 1K4 R R R 1K2 L1 Power Flow Motor Running in Delta Configuration 42 RLC SVD05A EN Starter Figure 27 Y Delta Starter Sequence Figure 28 Y Delta Starter Sequence ...

Page 43: ...stem is not powered and when the solid state starter has an active fault It will be high voltage 115 VAC during normal operation of the solid state starter This input shall be ignored for five seconds following power up After the first five seconds if this input voltage is high a Starter Fault diagnostic shall be called out The sequence of a Solid State Start is shown in Figure 29 Refer to RTHD SV...

Page 44: ...s position of the slide valve is controlled by the slide valve load and unload solenoid valves The slide valve allows modulated capacity from about 25 to 100 of full load tonnage Since the piston must overcome static friction and force balances it can only be effectively moved while the compressor is running creating differential pressure To prevent starting at a partially loaded point the compres...

Page 45: ...steady state conditions they may not be energized at all To assure loading and unloading is occurring it may be necessary to make slight adjustments to the chilled water setpoint to force the action As the pulsed on time is potentially short it may be difficult to see especially if using a meter movement type voltmeter Use of a low wattage 115 VAC lamp may be of some help for a visual indication o...

Page 46: ...form these tasks Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury 1 Connect to unit with TechView Take manual control of the slide valve Change slide valve control from auto to manual Increase the slide valve duty cycle to load and decrease to unload 2 Connect a manifold gauge set to the schrader valve located at...

Page 47: ... should gradually decrease with each pulse sent to the unload solenoid Note The pressure behind the piston should be approximately suction pressure when the compressor is fully unloaded The RLA will be dependent on the application With the results from the above checkout procedure use Table 8 to determine the possible causes of the loading problem Operating properly Piston Pressure increase decrea...

Page 48: ...loader piston as it moves The position of the piston is controlled by two direct acting solenoid valves called the male load and male unload solenoid valves These valves add or vent pressure to the cylinder of the movable piston to position and modulate the amount of compressed vapor that can be bypassed back to suction With the female solenoid de energized internal female bypass valve open the mi...

Page 49: ...the schrader valve located at the side of the piston housing Refer to Figure 33 This schrader allows access to the back side of the step load piston and therefore will allow direct measurement of the pressure that actuates the step load valve 2 Observe the pressure during a compressor start Initially the pressure should drop to suction pressure The compressor will run unloaded for at least 45 seco...

Page 50: ...nd unloading is occurring it may be necessary to make slight adjustments to the chilled water setpoint to force the action As the pulsed on time is potentially short it may be difficult to see especially if using a meter movement type voltmeter Use of a low wattage 115 VAC lamp may be of some help for a visual indication of output triac operation When a triac is off about 3 VAC or less should be m...

Page 51: ...TB5 16 2TB5 16 Neutral Initially make sure that the Load toggle switch is open and the Unload toggle switch is closed 3 Connect a manifold gauge set to the schrader valve located at the end of the piston housing This schrader allows access to the pressure behind the male piston Refer to Figure 33 4 Re apply power to the unit and place the chiller in the stop mode Using techview lockout all compres...

Page 52: ...eclude proper Slide Valve operation Record the male piston pressure and compressor currents 2 Manually close and open the Load toggle switch to energize the Load Solenoid in 4 to 5 short pulses Each load pulse should be approximately one second in duration with approximately 10 seconds between pulses 3 Monitor the male pressure behind the piston and the amp draw of the unit Both should gradually i...

Page 53: ...se decrease remain constant Amp Draw remain constant remain constant remain constant Leaking load solenoid internal leak or leaking piston Piston Pressure increase may drop initially but will increase as soon as the unload is de energized increase Amp Draw increase may drop initially but will increase as soon as the unload is de energized increase Leaking unload solenoid Piston Pressure remain con...

Page 54: ...0 6386 steps command to the EXV via the LLIDs bus cable EXV Checkout Procedure Is the EXV bound and communicating Connect TechView and get into Binding View This will shut the chiller down Once in Binding View verify that the EXV is bound Note Please refer to Service Tool for questions concerning binding LLIDs and getting into Binding View If there are multiple LLIDs that are not verified go to IP...

Page 55: ...nd the EXV will not bind then replace the EXV Is the EXV functioning properly The EXV goes to the closed position at a normal shutdown There is a sight glass in the body of the valve to monitor EXV position Refer to Figure 35 1 Shut the chiller down 2 Lock out the circuit This can be done using DynaView under the setpoint tab or in TechView under the Compressor Service View Refer to Figure 36 With...

Page 56: ...56 RLC SVD05A EN Electronic Expansion Valve Figure 36 Compressor Service View RTAC Figure 37 Manual Override View RTHD ...

Page 57: ... a direct acting DC output voltage similar to that of a potentiometer Internal LLID This new level sensor is a capacitive based switch This switch is more reliable and has no moving parts It is less sensitive to foam and will provide consistent operation across the operating map This new sensor can be installed on existing chillers using an adapter There are 2 capacitor sensors in the copper tube ...

Page 58: ...Enable pump down the unit must be in the stopped mode to enable pump down This can be done from either DynaView Set Points tab or TechView Compressor Service View Pump down will be automatically terminated when the suction pressure reaches 5 psig If the ambient temperature is below 50 deg F the unit will do an operational pumpdown just before shut down This operational pumpdown is only active on u...

Page 59: ...ctly by the CH530 Gas Pump Checkout Procedure Unit Off To check the operation of the Gas Pump while the chiller is OFF do the following 1 Turn off chiller 2 Close front seat the angle valve downstream of the cold filter 3 Back seat valve and Install gauge Re open to read pressure 4 Close the angle valve on the condenser which supplies the Gas Pump 5 Make sure the gas pump solenoid valves are de en...

Page 60: ... J2 2 from the 1A6 Verify that the correct coil is de energized Or remove the electric coil from the drain valve to disable the valve and place a screwdriver or bolt shaft through the coil center to prevent overheating of the coil If the pressure holds to within 10 psi in 5 minutes the system is functioning normally 7 If the pressure fails to hold near condensing pressure there may be a solenoid v...

Page 61: ...lear prism therefore it is not necessary to recover refrigerant when removing the sensor 3 Place a mirror or white piece of paper from the face of the sensor 4 On the CH530 DynaView read the status of the oil loss sensor 5 The Oil Loss Level Sensor Status is on the reports tab under the compressor sub menu 6 Place a piece of black electrical tape directly on the face of the sensor After 10 seconds...

Page 62: ...resetting chiller diagnostics Low Level Intelligent Device LLID replacement and binding Main processor replacement and configuration modifications Setpoint modifications Service overrides TechView is available for download on Trane com at no cost Minimum Laptop requirements are listed below The version of TechView will be updated periodically and laptop requirements may change Please refer to Tran...

Page 63: ...pplications is available from the Tracer CH530 Main Processor Download page After downloading the TechView and main processor installation utility files the user must execute the utility files to actually install the programs on the PC Instructions for First Time Tracer CH530 Users 1 Create a folder called CH530 on your C drive You will select and use this folder in subsequent steps so that downlo...

Page 64: ...0 folder You will need to locate them to finish the installation process 10 To complete the installation process locate the installation utilities you downloaded into the CH530 folder If necessary use your PC s file manager to locate the downloaded files 11 Install the applications in the following order by double clicking on the install program and following the installation prompts Java Runtime ...

Page 65: ...laptop to the Main Processor using a RS232 serial cable Refer to Figure 38 2 A TechView icon has been placed on the computers desktop Double click on the icon to begin using TechView Click on Local Connection Figure 38 TechView Connection Figure 39 Connection Screen ...

Page 66: ...66 RLC SVD05A EN TechView Service Tool 3 Click on Help then About to find installed software versions Figure 40 Installed Software ...

Page 67: ...sary to rebuild the network image for Binding View to discover that it has been removed An unbound device stops communicating and allows a new device to be bound in its place It is good practice to turn the power off while detaching and attaching devices to the network Be sure to keep power on the service tool computer After power is restored to the network the reconnect function in Binding View r...

Page 68: ...ding procedure involves 1 Go into Binding View Figure 42 Binding View 2 Find the appropriate LLID on the frame or in the control panel 3 Click on bind 4 Select the desired LLID with the south pole of a magnet On panel mounted LLID this will be at the arrow Temperature sensors and Liquid level sensor will be at the dimple Transducers will be on top of the transducer body EXVs and will be at a reces...

Page 69: ...ht Refer to Figure 43 5 When the LED lights remove the magnet and click on Yes Refer to Table 44 on page 69 6 Confirm that binding took place The red face should have turned green Figure 43 Panel and Frame Mounted LLIDs Magnet LED Figure 44 Selecting a LLID to bind ...

Page 70: ... information has been confirmed Click on Bind and it should verify the device and turn the icon into a green smiling face The red frowning face marks a necessary device as it is set in the Configuration View that is unconfigured or is not communicating There are several reasons why a device may not be found The device has been added to the network bus but not yet bound The device configuration is ...

Page 71: ...RLC SVD05A EN 71 TechView Service Tool Figure 45 Unit Configuration View for an RTAC Unit ...

Page 72: ...72 RLC SVD05A EN TechView Service Tool Figure 46 Unit Configuration View for RTHD Unts ...

Page 73: ...RLC SVD05A EN 73 ...

Page 74: ...al Trane office or e mail us at comfort trane com Literature Order Number RLC SVD05A EN Date November 2005 Supersedes RTAC SVD01A EN Stocking Location Inland Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice ...