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Operation Maintenance Manual: Gear-Driven Centrifugal Water-Cooled Liquid Chillers With CH530 Controls
Operation Maintenance Manual: Gear-Driven Centrifugal Water-Cooled Liquid Chillers With CH530 Controls
Maintenance Manual
Gear-Driven Centrifugal
Water-Cooled Liquid
Chillers with CH530
Controls
Unit Model
CVGF 400-1000 Ton Units
(50 and 60 Hz)
X39640691020 CVGF-SVU02B-E4
Warnings and
Cautions
NOTICE: Warnings and Cautions appear at appropriate sections throughout this manual.
Read these carefully.
WARNING – Indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION – Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe practices.
Periodic Maintenance 77
CVGF-SVU02B-E4 3
General
Information
4 CVGF-SVU02B-E4
General
Information
Commonly Used DTFL = Design Delta-T at Full LLID = Low Level Intelligent
Abbreviations Load (for example, the Device (Sensor, Pressure
difference between entering and Transducer, or Input/output UCP
For convenience, a number of leaving chilled water module)
abbreviations are used temperatures)
throughout this manual. These MAR = Machine Shutdown Auto
are listed alphabetically below, DV = DynaView™ Clear Language Restart (Non-Latching where
along with a translation of each: Display, also know as the Main chiller will restart when
Processor (MP) condition corrects itself.)
ASME = American Society of
Mechanical Engineers ELWT = Evaporator Leaving MMR = Machine Shutdown
Water Temperature Manual Restart (Latching where
ASHRAE = American Society of chiller must be manually reset.)
Heating, Refrigerating and Air ENT = Entering Chilled Water
Conditioning Engineers Temperature MP = Main Processor
BAS = Building Automation EXOP = Extended Operation PFCC = Power Factor Correction
System GBAS = Generic Building Capacitor
CDBS = Condenser Bundle Size Automation Interface PID = Proportional Integral
GPM = Gallons-per-minute Derivative
CDSZ = Condenser Shell Size
HLUV = High Lift Unloading PSID = Pounds-per-Square-Inch
CH530 = Tracer CH530 Controller. (differential pressure)
Valve.
CWR = Chilled Water Reset PSIG = Pounds-per-Square-Inch
Hp = Horsepower
CWR’ = Chilled Water Reset (gauge pressure)
Prime HVAC = Heating, Ventilating, and
Air Conditioning ODT = Outdoor Temperature
IE = Internally-Enhanced Tubes OPST = Operating Status
Control
IPC = Interprocessor
Communication RLA = Rated Load Amps
LCD = Liquid Crystal Display RTD = Resistive Temperature
Device Tracer CH530= Controls
LED = Light Emitting Diode Platform used on this Chiller
TRMM = Tracer
Communications
UCP = Unit Control Panel
CVGF-SVU02B-E4 5
General
Information
Two-Stage Compressor
Condenser
Relief Valves
Evaporator
Oil Pump
Unit Nameplate
Motor
Unit nameplate
Relief valves
Oil cooler
Economizer
6 CVGF-SVU02B-E4
General
Information
Pc Condenser
5 4
Compressor
2nd stage
P1 Economizer 3
8
Compressor
1st stage
1 Evaporator 2
Pe
RE
1
RE
CVGF-SVU02B-E4 7
General
Information
Compressor second stage - Economizer and refrigerant To complete the operating cycle,
Refrigerant vapor leaving the orifice system - Liquid liquid refrigerant leaving the
first stage compressor is mixed refrigerant leaving the economizer at state point 8
with cooler refrigerant vapor condenser at state point 5 flows flows through a second orifice.
from the economizer. This through the first orifice and Here refrigerant pressure and
mixing lowers the enthalpy of enters the economizer to flash a temperature are reduced to
the vapor entering the second small amount of refrigerant at evaporator conditions at state
stage. The second stage an intermediate pressure point 1.
impeller accelerates the vapor, labeled P1. Flashing some liquid An innovative design feature of
further increasing its refrigerant cools the remaining the CVGF chiller is maximizing
temperature and pressure to liquid to state point 8. the evaporator heat transfer
state point 4. Another benefit of flashing performance while minimizing
Condenser - Refrigerant vapor refrigerant is to increase the refrigerant charge requirements.
enters the condenser where the total evaporator Refrigeration This is accomplished by the
system cooling load and heat of Effect from RE’ to RE. The Trane-patented falling film
compression are rejected to the economizer provides around 4 evaporator design. The amount
condenser water circuit. This percent energy savings of refrigerant charge required in
heat rejection cools and compared to chillers with no CVGF is less than that in
condenses the refrigerant vapor economizer. comparably sized chillers of
to a liquid at state point 5. flooded evaporator design.
8 CVGF-SVU02B-E4
General
Information
Starter
Internal filter
F
Compressor
Inlet
High lift Gears ST vanes
ST
unloading Motor 2 1
valve Bearings
Condenser
(HLUV)
Fixed
Oil cooler orifice
Condenser
sump S
Strainer
Fixed
orifice
Distributor
Refrigerant Flow
Evaporator
CVGF-SVU02B-E4 9
General
Information
10 CVGF-SVU02B-E4
General
Information
Motor rotor
Motor shaft
Discharge end
Bull gear
Motor stator
Pinion shaft
Gear housing
2nd stage
impeller
1st stage
impeller
Oil
sump
CVGF-SVU02B-E4 11
General
Information
12 CVGF-SVU02B-E4
General
Information
Stopped
Power Up
Stopped
Run Inhibit
n
w
St
do
ar
ut
tC
Sh
om
ia
ed
gn
m
irm
os
an
tic
d
nf
Co
Re
se
t
Stopping Starting
Fast Restart or Satisfied Setpoint Auto
Preparing to Shut Waiting to Start
Down Shutting Starting
Down Stop Command or Diagnostic Compressor
St
op
t
ar
Co
St
m
D
ed
m
ia
irm
an
gn
d
os
nf
Co
tic
Running
Running
Running - Limit
CVGF-SVU02B-E4 13
General
Information
Self Test
Completing Self Test
(12 Seconds)
Starting Application
(20-30 Seconds*) Application
Starting
Last Mode
Such as
Auto or
Stopped
as shown
14 CVGF-SVU02B-E4
General
Information
Starting
Running - Limit Running Running Running
Compressor
CVGF-SVU02B-E4 15
General
Information
Run Inhibit or
Running Shutting down Shutting down Shutting down
Stopped
De-energize evaporator
Evaporator pump off water pump relay
delay not performed for
immediate shutdown
De-energize
compressor
De-energize condenser
water pump
*Note: No oil pressure when oil differential pressure switch is open.
16 CVGF-SVU02B-E4
General
Information
Satisfied setpoint
Confirm no compressor
currents within 30 seconds
De-energize condenser
water pump relay
CVGF-SVU02B-E4 17
General
Information
Oil Management Low Oil Temperature Start This mode is indicated to the
Inhibit Setpoint default is: 95° F. user.
The primary purpose of Oil
Management is to ensure When enhanced oil protection is 2. Idle: The oil pump is off. The
appropriate and sufficient enabled, the low oil temperature oil temperature is maintained
lubrication to the bearings start inhibit is the saturated by the heater, at the control-
during compressor operation evaporator at 30°F (16.6°C) or temperature setpoint +/- 2.5°F
and to minimize refrigerant 105°F (40.5°C), whichever is (1.4°C).
dilution in the oil. higher. 3. Pre-lube: The oil pump
The Oil Management system When enhanced oil temperature lubricates the bearing for 30
performs safety checks and protection is enabled, the oil seconds before the
manages the operation of the Oil temperature setpoint is fixed at compressor starts.
Pump and the Oil Heater. The 136°F (57.8°C). This mode is indicated to the
sensor inputs used for these The oil temperature control user.
purposes are the Differential Oil setpoint range is settable from:
Switch, and the Oil Temperature. 4. Running: The oil pump
100 to 160°F (37.8 to 71.1°C) continues to lubricate the
Two oil heater outputs exist, that bearings when the compressor
should always operate Essential Modes is running.
simultaneously, for example, The Oil-Management has the
both on or both off. following modes:
Note: The Oil Pump and the Oil 1. Low Temperature Start Inhibit:
Heater are never energized at the
same time. The oil temperature is at or
below the low oil temperature
start inhibit setpoint. The heater
is energized to raise the oil
temperature. See Low
Temperature Start Inhibit section
for information about Enhanced
Oil Temp Protection.
18 CVGF-SVU02B-E4
General
Information
5. Post-lube: The oil pump Oil Temperature Control Here are the details:
lubricates the bearings for 60 The oil heater is used to
seconds after the compressor maintain the oil temperature
• CH530 verifies that the
pressure switch is reading no
is stopped to ensure bearings within +/- 2.5°F (4.5°C) of the oil differential pressure with the
remain lubricated as the temperature control setpoint. oil pump off before proceeding
compressor coasts to a stop. The oil heater is commanded off with pre-lube.
If a start command is issued when the oil pump is
while in post-lube, a quick restart commanded on. • CH530 displays a mode
Waiting for Low Oil Differential
will be performed. Press.
Oil Differential Pressure
The post-lube mode is indicated
to the user on DynaView™ and
Check • The check is made if oil pump
is off and before it is turned on.
TechView™. The Oil Differential Pressure
6. Manual: The oil pump can be
Check validates the oil • CH530 allows five minutes for
differential pressure before the the differential oil pressure
commanded on and off in a oil pump is turned on. This check switch to open.
manual mode. in necessary in case the
differential pressure switch is
• This check is performed on
power up or reset also. If a
not operational. Without this MPL occurred or power up was
check, the differential oil within the post-lube time, oil
pressure feedback is gone. This pump is running so do not do
check is made after post-lube is the check.
complete to verify that the
differential pressure has
dropped to indicate no oil flow.
CVGF-SVU02B-E4 19
General
Information
Protective Diagnostics and Low Differential Pressure Cutout Once oil flow has been
their description is a latching diagnostic that can established, if the differential
come up while the unit is pressure switch indicates there
Differential Oil Pressure Overdue running. Oil pressure is is not oil pressure for 2 seconds,
is a latching diagnostic that can indicative of oil flow and active this diagnostic will be issued.
come up while the unit is in pre- oil pump operation. Significant
lube. Unexpected Differential Oil
fall in oil pressure is indicative of Pressure is a latching diagnostic
The differential pressure switch failure of the oil pump, oil that can come up while the unit
status is used instead of the Low leakage, or other blockage in the is idle and is implemented to
Differential Oil Pressure Cutout oil circuit. recognize and ensure that the
setpoint. pressure switch is operational
and that it is open for a period of
five minutes.
20 CVGF-SVU02B-E4
General
Information
Starter
Internal Filter
F Compressor
Gears
Motor ST 2 ST 1
High Lift Condenser Bearings
Unloading
Valve (HLUV)
Oil Cooler
Condenser
Sump S
Strainer
Fixed Orifice
Refrigerant
Distributor
Oil
Evaporator
CVGF-SVU02B-E4 21
Unit Control
Panel (UCP)
Control Panel Devices and The UCP houses several other and the main processor. Unit
Unit Mounted Devices controls modules called panel mounted devices are called
mounted LLID (Low Level frame mounted LLID’s and can
Unit Control Panel (UCP) Intelligent Device), power be temperature sensors or
Safety and operating controls supply, terminal block, fuse, pressure transducers. These and
are housed in the unit control circuit breakers, and transformer. other functional switches
panel, and the starter panel. The The IPC (Interprocessor provide analog and binary inputs
UCP ‘s operator interface and communication) bus allows the to the control system.
main processor is called the communications between LLID’s
DynaView™ and is located on the
UCP door. (See Operators
interface section for detailed
information)
Figure 12. Control panel
22 CVGF-SVU02B-E4
Unit Control
Panel (UCP)
Tracer CH530 Chiller Whenever the controller senses Variable water flow through the
Controller a situation that might trigger a evaporator
protective shutdown, it focuses Chilled water systems that vary
Tracer CH530’s Main Processor, on bringing the critical water flow through chiller
DynaView™, is fast and keeps parameter back into control. evaporators have caught the
the chiller online whenever When the parameter is no longer attention of engineers,
possible. Smart sensors collect critical, the controller switches contractors, building owners,
three rounds of data per second, its objective back to controlling and operators. Varying the water
55 times the data collection the chilled water temperature, or flow reduces the energy
speed of its predecessor. Each to another more critical consumed by pumps, while
device (a sensor) has its own parameter should it exist. requiring no extra energy for the
microprocessor that chiller. This strategy can be a
simultaneously converts and significant source of energy
accurately calibrates its own savings, depending on the
readings from analog to digital. application. With its faster and
Because all devices are more intelligent response to
communicating digitally with changing conditions, Tracer
the DynaView™, there is no need CH530 reliably accommodates
for the main processor to variable evaporator water flow
convert each analog signal one and its effect on the chilled water
at a time. This distributed logic temperature. These
allows the main processor to improvements keep chilled
focus on responding to water flowing at a temperature
changing conditions in the load, closer to its setpoint.
the machine, its ancillary
equipment, or its power supply.
Tracer CH530 constantly
receives information about key
data parameters, temperatures
and currents. Every five seconds
a multiple objective algorithm
compares each parameter to its
programmed limit. The chiller’s
Adaptive Control™ capabilities
maintain overall system
performance by keeping its peak
efficiency.
CVGF-SVU02B-E4 23
Unit Control
Panel (UCP)
The DynaView™ (DV) Operator The MP contains non-volatile DynaView™ presents three menu
Interface contains the Main memory both checking for valid tabs across the top which are
Processor (MP) which set points and retaining them on labeled “MAIN, REPORTS, and
communicates commands to any power loss. System data SETTINGS”.
other modules, collecting data, from modules (LLID) can be The Main screen provides an
status and diagnostic viewed at the DynaView™ overall high level chiller status
information from the other operator interface. Such as so the operator can quickly
modules over the IPC (Inter evaporator and condenser water understand the mode of
Processor Communications) temperatures, outdoor air operation of the chiller.
link. The Main Processor temperature, evaporator and
software controls water flows by condenser water pump control, The Chiller Operating Mode will
starting pumps and sensing status and alarm relays, external present a top level indication of
flow inputs, establishes a need auto-stop, emergency stop, and the chiller mode (Auto, Running,
to heat or cool, performs pre- evaporator and condenser water Inhibit, Run Inhibit, and so forth)
lube, performs post-lube, starts flow switches. The “additional info” icon will
the compressor, performs water present a subscreen that lists in
temperature control, establishes further detail the subsystem
limits, and pre-positions the modes.
inlet guide-vanes.
24 CVGF-SVU02B-E4
Unit Control
Panel (UCP)
Main screen content can be Touch screen key functions are Action buttons are buttons that
viewed by selecting the up or determined completely in the appear temporarily and provide
down arrow icons. The Main software and change depending the operator with a choice such
screen is the default screen.After upon the subject matter as Enter or Cancel. The operator
an idle time of 30 minutes. currently being displayed. The indicates his choice by touching
DynaView™ (DV) is the operator user operates the touch sensitive the button of choice. The system
interface of the Tracer CH530 buttons by touching the button then takes the appropriate action
control system utilized on the of choice. The selected button is and the button typically
CTV machines. The DynaView™ darkened to indicate it is the disappears.
enclosure is 9.75" (24.8 cm) selected choice. The advantage DynaView™ consists of various
wide, 8” (20.3 cm) high and 1.6” of touch sensitive buttons is that screens, each meant to serve a
(4.1 cm) deep. The DynaView™ the full range of possible choices unique purpose of the machine
display is approximately 4” (10.2 as well as the current choice is being served. Tabs are shown
cm) wide by 3” (7.6) high. always in view. row across the top of the display.
Features of the display include a Up or down arrow buttons are The user selects a screen of
touch screen and long life LED used to allow a continuously information by touching the
backlight. This device is capable variable setpoint, such as appropriate tab. The folder that
of operating in 0 - 95 percent leaving water setpoint. The value is selected will be brought to the
relative humidity (non- changes by touching the up or front so it’s contents are visible
condensing). The enclosure down arrows.
includes a weather tight
connection means for the RS232
TechView™ connection.
CVGF-SVU02B-E4 25
Unit Control
Panel (UCP)
The main body of the screen is The bottom of the screen is the Persistent keys, horizontal at the
used for description text, data, persistent area. It is present in all bottom of the display, are those
setpoints, or keys (touch screens and performs the keys that must be available for
sensitive areas) The double up following functions. The left operation regardless of the
arrows cause a page by page circular area is used to reduce screen currently being displayed.
scroll either up or down. The the contrast and viewing angle These keys are critical for
single arrow causes a line by of the display. The right circular machine operation. The Auto
line scroll to occur. At the end of area is used to increase the and Stop keys will be presented
the screen, the appropriate scroll contrast and viewing angle of as radio buttons within the
buttons will disappear. the display. The contrast control persistent key display area. The
will be limited to avoid complete selected key will be dark. The
“light” or complete “dark”, chiller will stop when the Stop
which would potentially confuse key is touched, entering the stop
an unfamiliar user to thinking sequence. Pressing the
the display was malfunctioning. “Immediate Stop” button will
cause the chiller to stop right
away.
The AUTO and STOP, take
precedence over the ENTER and
CANCEL keys. (While a setting is
being changed, AUTO and STOP
keys are recognized even if
ENTER or CANCEL has not been
pressed. Selecting the Auto key
will enable the chiller for active
cooling.
26 CVGF-SVU02B-E4
Unit Control
Panel (UCP)
The machine-operating mode The TOP LEVEL MODE is the text The BAS CODE is the code that
indicates the operational status seen on the single top level will be sent via COMM4/5 to the
of the chiller. A subscreen with chiller system operating mode Tracer Summit system as the
additional mode summary line. The SUB LEVEL MODE is chiller system mode. Note that
information will be provided. the text seen on the operating each top level mode may contain
When the user scrolls down the mode sub-menu. The operating multiple sub level modes. In
screen the Machine Operation mode sub-menu may have up to general, the BAS CODE will
Mode will remain stationary six (6) lines of text displayed. reflect the top level mode and
On DynaView™, the user will be not the sub level mode.
presented with a single line of
text that represents the ‘top-
level’ operating state of the
machine. These top-level modes
are shown in the Table 1.
Additional information (if it
exists) regarding the machine Figure 14.
operating state will 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.
CVGF-SVU02B-E4 27
Unit Control
Panel (UCP)
Table 1. A general description of the top level modes is show in the following table.
Top Level Mode Description
Stopped Unit inhibited from running and will require user action to go to Auto.
Run Inhibit Unit inhibited from running by Tracer, External BAS, or an 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 compressor.
Running Compressor is running with no limits in effect.
Running – Limit Compressor is running with limit in effect.
Preparing To Shutdown Unit is closing inlet guide vanes prior to compressor shutdown.
Shutting Down Compressor has been stopped and unit is performing shutdown tasks.
Figure 15.
28 CVGF-SVU02B-E4
Unit Control
Panel (UCP)
Reference
Top Level Mode Sub Level Mode BAS Code
SYSTEM RESET Boot & Application software part number, self-test, and
configuration validity screens will be present. NA
Stopped Local Stop 00
Stopped Panic Stop 00
Stopped Diagnostic Shutdown – Manual Reset 00
Run Inhibit Tracer Inhibit 100
Run Inhibit External Source Inhibit 100
Run Inhibit Diagnostic Shutdown – Auto Reset 100
Auto Waiting For Evaporator Water Flow 58
Auto Waiting For A Need To Cool 58
Auto Waiting For A Need To Heat 58
Auto Power Up Delay Inhibit: MIN:SEC 58
Waiting To Start Waiting For Condenser Water Flow 70
Waiting To Start Establishing Oil Pressure 70
Waiting To Start Pre-Lubrication Time: MIN:SEC 70
Waiting To Start Motor Temperature Inhibit: 70
Motor Temperature / Inhibit Temperature
Waiting To Start Restart 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 sub mode displayed 72
Running There is no sub mode displayed 74
Running Surge 74
Running Base Loaded 74
Running Current Control Soft Loading 74
Running Capacity Control Soft Loading 74
Running – Limit Current Limit 75
Running – Limit Phase Unbalance Limit 75
Running – Limit Condenser Pressure Limit 75
Running – Limit Evaporator Temperature Limit 75
Running – Limit Minimum Capacity Limit 75
Running – Limit Maximum Capacity Limit 75
Preparing To Shutdown Closing IGV IGV Position % 7E
Shutting Down Post-Lubrication Time: MIN:SEC 7E
Shutting Down Evaporator Pump Off Delay: MIN:SEC 7E
Shutting Down Condenser Pump Off Delay: MIN:SEC 7E
CVGF-SVU02B-E4 29
Unit Control
Panel (UCP)
Main Screen
The main screen provides an
overall view of the chiller
performance in addition to the
main and sub operating modes.
The table below indicates other
items found , when specified 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 Temperature
Active Chilled Water Setpoint (>>source)
Active Current Limit Setpoint (>>source), If enabled
Active Base Loading Setpoint (>>source), If enabled
Average Line Current
Approximate Chiller Capacity, If option installed
Software Version
30 CVGF-SVU02B-E4
Unit Control
Panel (UCP)
CVGF-SVU02B-E4 31
Unit Control
Panel (UCP)
The active chilled water setpoint The chilled water reset status, in
is the setpoint that is currently in the right most column, will
use. It will be displayed to 0.1 display one of the following
degrees Fahrenheit or Celsius. messages: Return, Constant
Touching the double arrow to Return, Outdoor, None
the left of the Active Chilled The left column text “Front
Water Setpoint will take the user Panel”, “BAS”, “External”,
to the active chilled water Chilled Water Reset, and “Active
setpoint arbitration sub-screen. Chilled Water Setpoint” will
The Active Chilled Water always be present regardless of
Setpoint the result of arbitration installation or enabling those
between the front panel, BAS, optional items. In the second
and external setpoints. column “- - - -” will be shown if
that option is Not Installed,
otherwise the current setpoint
from that source will be shown.
The “Back” button provides
navigation back to the chiller
screen.
32 CVGF-SVU02B-E4
Unit Control
Panel (UCP)
CVGF-SVU02B-E4 33
Unit Control
Panel (UCP)
Reports
34 CVGF-SVU02B-E4
Unit Control
Panel (UCP)
CVGF-SVU02B-E4 35
Unit Control
Panel (UCP)
36 CVGF-SVU02B-E4
Unit Control
Panel (UCP)
Chiller
Description Units notes
1. Front Panel Control Type (Chilled Water, Hot Water), Chilled Water default
2. Front Panel Chilled Water Setpoint Temperature 1
3. Front Panel Current Limit Setpoint Percent 2
4. Front Panel Base Load Command On or Auto
6. Front Panel Base Load Setpoint Percent
6. Differential to Start Temperature
7. Differential to Stop Temperature
8. Setpoint Source (none, use front panel, override BAS), none default
Feature Settings
Description 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 Percent
6. Outdoor Start Reset Temperature
7. Outdoor Maximum Reset Temperature
8. External Chilled Water Setpoint (Enable, Disable), Disable
9. External Current Limit Setpoint (Enable, Disable), Disable
10. External Base Loading Setpoint (Enable, Disable), Disable
Notes:
1. Temperatures will be adjustable to 0.1 degree F or C. The Main Processor provides the minimum and maximum allowable value.
2. Adjustable to the nearest whole number percent. The Main Processor provides the minimum and maximum allowable value.
CVGF-SVU02B-E4 37
Unit Control
Panel (UCP)
Mode Overrides
Description Units Default Monitor Value Notes
1. Compressor Control Signal (Auto, Manual) Auto Percent Vane Position
[0-100] )
Evaporator Leaving Water 7
Temperature
2. Evaporator Water Pump (Auto, On), Auto 1) Evaporator Flow status
2) Override Time Remaining 3
3. Condenser Water Pump (Auto, On), Auto 1) Condenser Flow status
2) Override Time Remaining 3
4. Oil Pump (Auto, On), Auto 1) Differential pressure
2) Override Time Remaining 3
5. Clear Restart Inhibit Timer
Display Settings
Description Units Notes
1. Date Format (“mmm dd, yyyy”, “dd-mmm-yyyy”),
2. Date “mmm dd, yyyy” 4
3. Time Format (12-hour, 24-hour), 12-hour
4. Time of Day HH:mm 4
5. Keypad and Display Lockout (Enable, Disable), Disable 5
6. Display Units (SI, English), English
7. Pressure Units Absolute / Guage
8. Language (English, Selection 2, Selection 3), English 6
Notes:
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. Enables a DynaView™ Lockout screen. All other screens timeout in 30 minutes to this screen when enabled. The DynaView™ Lockout Screen displays
a 0-9 keypad to permit the user to exit the lockout with a fixed password (1x5 x 9 + Enter). See lockout section for further details.
6. Language choices are dependent on what has been setup in the Main Processor. Language selections will include English and two alternate as
loaded by TechView™. Language shall always be the last setting listed on the Display Settings menu. This will allow a user to find language selection
if looking at an unrecognizable language.
7. Manual Compressor Control allows an operator to override the Auto Control and manually control the compressor while in operation. This is not
active during Stop mode.
38 CVGF-SVU02B-E4
Unit Control
Panel (UCP)
{
Note: Spin buttons used to
change setpoint value.
CVGF-SVU02B-E4 39
Unit Control
Panel (UCP)
40 CVGF-SVU02B-E4
Unit Control
Panel (UCP)
The date setpoint screen for setting up the is shown below: The user
must select Day, Month, or Year and then use the up or down arrows
to adjust.
CVGF-SVU02B-E4 41
Unit Control
Panel (UCP)
The time setpoint 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 setpoint screen is similar with the am and
pm not shown.
42 CVGF-SVU02B-E4
Unit Control
Panel (UCP)
1 2 3
4 5 6
7 8 9
Enter Cancel
CVGF-SVU02B-E4 43
Base Loading
Control Algorithm
Base Loading Control If the chiller approaches full If the current exceeds the
Algorithm current, the evaporator setpoint, the current limit
temperature drops too low, or algorithm unloads.
This feature allows an external the condenser pressure rises too
controller to directly modulate The “Capacity Limited By High
high, Tracer CH530 Adaptive.
the capacity of the chiller. It is Current” message normally
Control logic limits the loading
typically used in applications displayed while the current limit
of the chiller to prevent the
where virtually infinite sources routine is active is suppressed
chiller from shutting down on a
of evaporator load and while base loading.
safety limit. These limits may
condenser capacity are available prevent the chiller from reaching Base loading can occur using
and it is desirable to control the the load requested by the Base Tracer or an external signal.
loading of the chiller. Two Loading signal. Tracer or an external signal Base
examples are industrial process
Base Loading Control is basically Loading: Current Setpoint
applications and cogeneration
a variation of the current limit Range: (20 - 100) percent RLA.
plants.
algorithm. During base loading, Base Loading requires Tracer
Industrial process applications the leaving water control Summit and an optional Tracer
might use this feature to impose algorithm provides a load Communications Module (LLID)
a specific load on the facility’s command every 5 seconds. The
electrical system. current limit routine may limit
Cogeneration plants might use the loading when the current is
this feature to balance the below setpoint. When the
system’s heating, cooling and current is within the deadband of
electrical generation. All chiller the setpoint the current limit
safeties and adaptive control algorithm holds against this
functions are in full effect when loading command.
Base Loading control is enabled.
44 CVGF-SVU02B-E4
Base Loading
Control Algorithm
Tracer Base Loading External Base Base Loading An alternative and less radical
approach to Base Loading
The Tracer commands the chiller The CH530 accepts 2 inputs to
indirectly controls chiller
to enter the base load mode by work with external base loading.
capacity. Artificially load the
setting the base load mode The binary input is at 1A18
chiller by setting the chilled
request bit ON. If the chiller is Terminals J2-1 and J2-2
water setpoint lower than it is
not running, it will start (Ground) which acts as a switch
capable of achieving. Then,
regardless of the differential to closure input to enter the base
modify the chiller’s load by
start. While the unit is running in loading mode. The second input,
adjusting the current limit
base loading, it will report that an analog input, is at 1A17
setpoint. This method provides
status back to the Tracer. When terminals J2-2 and J2-3 (Ground)
greater safety and control
the Tracer removes the base which sets the external base
stability in the operation of the
load mode request, the unit will loading setpoint, and can be
chiller because it has the
continue to run, using the controlled by either a 2-10Vdc or
advantage of leaving the chilled
normal chilled water control 4-20mA Signal. At startup the
water temperature control logic
algorithm, and will turn off, only input type is configured.
in effect.
when the differential to stop has The graphs in Figure 16 show
been satisfied. The chilled water temperature
the relationship between input
control logic responds quicker to
and percent RLA. While in base
dramatic system changes, and
loading the active current limit
can limit the chiller loading prior
setpoint is set to the Tracer or
to reaching an Adaptive Control
external base load setpoint,
limit point.
providing that the base load
setpoint is not equal to 0 (or out
of range). If it is out of range, the
front panel current limit setpoint
is used. During base loading, all
limits are enforced with the
exception of current limit.
DynaView™ displays the
message “Unit is Running Base
Loaded.”
CVGF-SVU02B-E4 45
Base Loading
Control Algorithm
Figure 16. Base loading with external mA input and with external voltage input
100
90
80
70
%RLA
60 —— %RLA
50
40
30
20
4 6 8 10 12 14 16 18 20
mA
100
90
80
70
%RLA
60 —— %RLA
50
40
30
20
4 6 8 10 12 14 16 18 20
Volts
46 CVGF-SVU02B-E4
Control System
Components
OPTIONAL
OPTIONAL
OPTIONAL
OPTIONAL
OPTIONAL
OPTIONAL
OPTIONAL
OPTIONAL
OPTIONAL
CVGF-SVU02B-E4 47
Control System
Components
Chilled and Condenser Water Head Relief Request Output Maximum Capacity Relay
Flow Interlock Circuits When the chiller is running in When the chiller has been
Condenser Limit Mode or in operating at maximum capacity
Proof of chilled water flow for Surge Mode, the head relief for over a 10 minute (TechView™
the evaporator is made by the request relay on the 1A9-J2-6 to adjustable) time period this relay
closure of flow switch 5S1 and J2-4 will be energized and can will activate. Also upon being
the closure of auxiliary contacts be used to control or signal for a less than maximum capacity for
5K1 on terminals 1X1-5 and 1A6- reduction in the entering 10 minutes, this relay will
J3-1 and J3-2. Proof of condenser water temperature. deactivate. This is located at
condenser water flow for the This is designed to prevent high LLID 1A9-J2-1 and J2-3.
condenser is made by the refrigerant pressure trip-outs
closure of flow switch 5S2 and Compressor Running Relay
during critical periods of chiller Relay activates while the
the closure of auxiliary contacts operation.
5K2 on terminals 1X1-6 and 1A6- compressor is running.
J2-1 and J2-2.
48 CVGF-SVU02B-E4
Control System
Components
CVGF-SVU02B-E4 49
Control System
Components
50 CVGF-SVU02B-E4
Control System
Components
CAP
10 vdc
2 vdc
CVGF-SVU02B-E4 51
Control System
Components
10 vdc
2 vdc
52 CVGF-SVU02B-E4
Control System
Components
1A16 Optional Dual GBAS Signal #1 Chilled Water Reset input, or J2-2 Input #1, J2-3 Ground
Analog Input/output External Chiller Water Setpoint
Module
1A16 Optional Dual GBAS Signal #2 External Current limit Setpoint J2-5 Input #2, J2-6 Ground
Analog Input/output
Module
Voltage
CVGF-SVU02B-E4 53
Control System
Components
54 CVGF-SVU02B-E4
Control System
Components
1A5, 1A8, 1A9 Quad Relay Output 1A13, 1A18, 1A19, 1A24 Dual
Status: Binary input module:
Relay #1 J2-1 NO, J2-2 NC, J2-3 J2-1 Binary Input Signal #1, J2-2
common Ground, J2-3 Binary Input Signal
Relay #2 J2-4 NO, J2-5 NC, J2-6 #2, J2-4 Ground
common Binary Input: Looks for a dry
Relay #3 J2-7 NO, J2-8 NC, J2-9 contact closure. Low Voltage 24V
common 12 mA.
Relay #4 J2-10 NO, J2-11 NC, 14 - 26 AWG with a maximum of
J2-12 common two 14 AWG
Relay Outputs: at 120 Vac: 7.2 Power, 24 +/- 10 percent Vdc, 40
Amps resistive, 2.88 Amps pilot mA maximum Trane IPC3
duty, 1/3 HP, 7.2 FLA, at 240 Vac: protocol.
5 Amps general purpose 14-26 1A14 Communication interface
AWG, two 14 AWG Maximum Module
Power, 24 Power, 24 ± 10 percent Vdc, 50
±10 percent Vdc, 100 mA mA maximum. Trane IPC3
maximum. Trane IPC3 protocol. protocol.
CVGF-SVU02B-E4 55
Control System
Components
56 CVGF-SVU02B-E4
Control System
Components
CVGF-SVU02B-E4 57
Control System
Components
Electrical Sequence With the supply power 2. Circuit Breaker 1Q3 which
This section will acquaint the disconnect switch or circuit provides power to
operator with the control logic breaker (2Q1 or 2K3) on, 115-volt Transformer (1T1) which steps
governing chillers equipped with control power transformer 2T5 down the 115 Vac to 24 Vac.
Tracer CH530 control systems. and a 15-amp starter panel fuse This 24 Vac then powers the
Note: The typical wiring (2F4 ) to terminal (2X1-1) starter 24 Vdc power supply 1A1, and
diagrams are representative of panel to terminal 1X1-1 in the 1A2 if present. The 24 Vdc is
standard units and are provided control panel. From this point, then connected to all modules
only for general reference. They control voltage flows to: using the IPC Bus providing
may not reflect the actual wiring 1. Circuit Breaker 1Q1 which module power. 1Q3 also
of your unit. For specific provides power to the starter provides power to the
electrical schematic and module (2A1) relay outputs external chiller water proof of
connection information, always and the High Pressure Cutout flow device connected
refer to the wiring diagrams that switch (4S1). between terminal block
shipped with the chiller. 1X1-5 to 1A6-J3-2, and
condenser water proof of flow
device connected at 1X1-6 to
1A6-J2-2.
3. The DynaView™ display
module 1A22, receives 24 Vdc
power from the IPC bus.
58 CVGF-SVU02B-E4
Control System
Components
CH530 and Wye-Delta Based on the restart inhibit 3. Close start contactor (2K1)
Starter Control Circuits function and the differential to and check for no current - 500
start setpoint, oil pump (4M3) msec. If currents are detected,
(Sequence of Operation) will be energized by 1A9 module the MMR diagnostic ‘‘Starter
Logic Circuits within the various (1A9-J2-7). The oil pressure Fault Type I’’ is generated and
modules will determine the switch must be closed for 30 closes for one second.
starting, running, and stopping continuous seconds and 4. Delay time - 200 msec.
operation of the chiller. When condenser water flow verified (Opens 2K1).
operation of the chiller is within 4 minutes 15 seconds for
required the chiller mode is set the compressor start sequence 5. Close shorting contactor,
at ‘‘Auto.” Using customer- to be initiated. (2K3) and check for no current
supplied power, the chilled water (1A23 or 2A1 J4-1) for one
When less than 5 seconds second. If currents are
pump relay (5K1) is energized by
remain before compressor start, detected the MMR diagnostic
the 1A5 Module output at 1A5-
a starter test is conducted to ‘‘Starter Fault Type II’’ is
J2-4, and chilled water flow must
verify contactor state prior to generated. (Starter Integrity
be verified within 4 minutes 15
starting the compressor. The test)
seconds by the 1A6 module. The
following test or start sequence
main processors logic decides to 6. If no diagnostics are
is conducted for “Wye-Delta”
start the chiller based on the generated in the above tests,
starters:
differential to start setpoint. With the stop relay (2A1- J10) is
the differential to start criteria 1. Test for transition complete closed for two seconds and
met module 1A5 then energizes contact open (1A23X or the start relay (2A1-J8) is
the condenser water pump relay 2A1-J12-2) –160 to 240 msec. closed to energize the start
(5K2) using customer-supplied An MMR diagnostic will be contactor (2K1).
power at 1A5 J2-1. generated if the contact is
closed.
2. Delay time - 20 msec.
CVGF-SVU02B-E4 59
Control System
Components
The shorting contactor (2K3) 10. The run contactor (2K2) is An MMR diagnostic will be
has already been energized closed through relay 2A1-J6, generated if the transition
from (F) above. The shorting out the transition complete contacts (2K2-AUX) do
compressor motor (4M1) starts resistors 260 milliseconds not close.
in the “Wye” configuration, an after the opening of the Now that the compressor motor
auxiliary contact (2K1-AUX) shorting relay 2A1-J4. This (4M1) is running in the “Delta”
locks in the start contactor places the compressor motor configuration, the inlet guide
(2K1) coil. in the “Delta” configuration vanes will modulate, opening
7.After the compressor motor and the starter module waits and closing to the chiller load
has accelerated and the to look for this transition for variation by operation of the
maximum phase current has 2.35 seconds through the stepper vane motor actuator
dropped below 85 percent of closure of the transition (4M2) to satisfy chilled water
the chiller nameplate RLA for complete contacts 2K2- AUX setpoint. The chiller continues to
1.5 seconds, the starter at module 2A1-J12 input. run in its appropriate mode of
transition to the “Delta” 11. The starter module must now operation: Normal, Softload,
configuration is initiated. confirm closure of the Limit Mode, and so forth
8.The transition contactor (2K4) transition complete contact
is closed through relay 2A1-J2, (2K2- AUX) within 2.32 to
placing the transition resistors 2.38 seconds after the run
(2R1, 2R2, and 2R3) in parallel relay (2A1-J6) is closed.
with the compressor motor Finally, the transition relay
windings. (2A1-J2) is opened de-
energizing the transition
9.The shorting contactor (2K3) is contactor (2K4) and the
opened through the opening compressor motor starting
of relay 2A1-J4 100 msec after sequence is complete.
the closure of the transition
relay 2A1-J2.
60 CVGF-SVU02B-E4
Control System
Components
CVGF-SVU02B-E4 61
Machine Protection
and Adaptive
Machine Protection and The oil pump will be run for the
Adaptive Control post-lube time period when
power returns. The compressor
Momentary Power Loss (MPL) and compressor motor are
Protection protected from damage from
Momentary power loss detects large torques and inrush
the existence of a power loss to currents resulting from
the compressor motor and reconnecting the compressor
responds by initiating the motor to the power source
disconnection of the compressor following a momentary loss of
motor from the power source. power.
Power interruptions of less than MPLs greater than 2 or 3 cycles
30 line-cycles are defined as are detected resulting in unit
momentary power losses. Tests shut down. Disconnection from
have shown that these short- the line is initiated within 6 line-
term power interruptions can be cycles of the power loss. MPL
damaging to the motor and protection is active anytime the
compressor if the chiller is compressor is in the running
reconnected to the line while the mode. (The transition complete
motor and line phases do not input has been satisfied.)
match. The chiller will be shut
down when a MPL is detected Note: MPL is defaulted to
and will display a non-latching enabled however can be
diagnostic indicating the failure. disabled, if required using
TechView™.
62 CVGF-SVU02B-E4
Machine Protection and
Adaptive
Figure 21. CVGF sequence of operation: momentary power loss, (DynaView™ and starter module remain
powered)
Compressor
Starting
Running Shutting Down Waiting to Start
De-Energize
Compressor
De-Energize Condenser
Water Pump Relay
CVGF-SVU02B-E4 63
Machine Protection and
Adaptive
Nominal Triptime
(Sec)
Minimum Triptime
(Sec)
Maximum Triptime
(Sec)
64 CVGF-SVU02B-E4
Machine Protection and
Adaptive
CVGF-SVU02B-E4 65
Machine Protection and
Adaptive
Differential to Start or Stop There are three independent Minimum and Maximum
The Differential to Start setpoint Softload setpoints: Capacity Limit
is adjustable from 1 to 10°F (0.55 • Capacity Control Softload Time A Minimum Capacity can be set
to 5.5°C) and the Differential to default is to 10 minutes and to limit the unloading ability of
Stop setpoint adjustable from 1 settable from 0-120 minutes. the compressor forcing
to 10°F (0.55 to 5.5°C). Both This setting controls the time differential stop to be reached
setpoints are with respect to the constant of the Filtered Chilled cycling the chillers. Minimum
Active Chilled Water Setpoint. Water Setpoint. capacity limit will be displayed
When the chiller is running and when in this limit mode. This
the Leaving Water Temperature • Current Limit Control Softload
Time default is 10 minutes and indicates when the chiller is
(LWT) reaches the Differential to running fully unloaded. Similarly
Stop setpoint the chiller will go settable from 0-120 minutes.
This setting controls the time a maximum capacity can be set
through its shutdown sequence to limit normal chilled water
to Auto. Reference Figure 10. constant of the Filtered Current
Limit Setpoint. temperature control. The
maximum capacity relay is
SoftLoading • Current Limit Softload Starting energized which is a signal used
Softloading stabilizes the startup Percent default is 40 percent by generic BAS systems to start
control during the initial chiller RLA and settable from 20-100 another chiller.
pulldown. Soft loading is used to percent. This setting controls
bring the building loop the Starting point of the The minimum (default at 0
temperature from its start value Filtered Current Limit Setpoint. percent) and maximum (default
to the Chilled Water or Hot Water at 100 percent) capacity are
Note: TechView™ provides adjustable using TechView™.
Setpoint in a controlled manner.
access to these three setpoints.
Without soft loading, the chiller
controls will load the chiller
rapidly and use the full chiller
capacity to bring the loop
temperature to setpoint.
Although the start temperature
of loop may have been high, the
actual system load may be low.
Thus, when the setpoint is met
the chiller must unload quickly
to the system load value. If it is
not able to unload quickly
enough, the supply water
temperature will drop below
setpoint and may even cause the
chiller to cycle off. Soft loading
prevents the chiller from going
to full capacity during the
pulldown 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.
66 CVGF-SVU02B-E4
Machine Protection and
Adaptive
Evaporator Limit Evaporator Limit uses the The Leaving Water Temperature
Evaporator refrigerant Evaporator Refrigerant Cut-out Setpoint is
temperature is continuously Temperature sensor in a PID independently adjustable from
monitored to provide a limit algorithm (similar to the Leaving the chilled water setpoint.
function that prevents low Water Temperature control) that Shutdown of the compressor
refrigerant temperature trips. allows the chiller to run at the due to violation of the Leaving
This allows the chiller to LRTC + 2 degree F (1.1°C). Water Temperature Cut-out
continue to run at a reduced When actively limiting machine results in an automatically
load instead of tripping off at the control “Evaporator resettable diagnostic (MAR). The
Low Refrigerant Temperature Temperature Limit” will be DynaView™ Operating Mode
Cutout Setpoint (LRTC). displayed as a suboperating indicates when the Leaving
mode. Water Temperature Cut-out
Evaporator limit could occur
Setpoint conflicts with the
with an initial pulldown of a loop
Leaving Water Temperature chilled water temperature
temperature where the
setpoint by a message on the
condenser is colder than the Cut-out display. The Leaving Water
evaporator (inverted start), and Leaving water temperature Temperature Cutout Setpoint
the evaporator refrigerant cutout is a safety control that and chilled water setpoint, both
temperature may drop below the protects the chiller from damage active and front panel, are
LRTC. This limit prevents the caused by water freezing in the separated by a minimum of
unit from shutting down on a evaporator. The cutout setpoint 1.7°F (0.94°C). (See Cut-out
diagnostic during this type of is factory set at 36°F (2.2°C) Strategy Figure 23.) When either
pulldown. Another example is a however is adjustable with difference is violated, the CH530
chiller that is low on refrigerant TechView™. The cut-out strategy does not permit the above
charge. It will run with low is illustrated in Figure 23. differences to be violated and
evaporator refrigerant
the display exhibits a message
temperatures. This limit allows
to that effect and remains at the
the chiller to continue to run at a
last valid setpoint. After violation
reduced load.
of the Leaving Water
Temperature Cut-out Setpoint
for 30°F (16.7°C) seconds the
chiller will shutdown and
indicate a diagnostic.
Low Refrigerant
Temperature Cut-out
The purpose of the low
evaporator refrigerant
temperature protection is to
prevent water in the evaporator
from freezing. When the LRTC
trip point is violated, a latching
diagnostic indicating the
condition is displayed. The LRTC
Diagnostic is active in both the
Running and Stopped modes.
CVGF-SVU02B-E4 67
Machine Protection and
Adaptive
Differential to stop
adjustment range
Integrate to trip
Evaporator
Limit loading limit
Evaporator limit set point Hold
Unload
Evaporator refrigerant
temperature cutout
68 CVGF-SVU02B-E4
Machine Protection and
Adaptive
Restart Inhibit Note: When the start is inhibited If enhanced oil temperature
This function provides short by the restart inhibit function, protection is disabled or below a
cycle protection for the motor, the time remaining will be given Low Oil Temperature
and indirectly also short cycling displayed along with the restart Inhibit setting (default 95°F/35°C)
protection for the starter since inhibit mode. There is no ‘free’ the compressor cannot be
the starter is designed to operate start on a power up of the MP started. This is an inhibit mode
the motor under all the since a real time clock is used to and will be reported to the
conditions of motor determine when the next start operator interface.
performance. will be allowed based on the
start time of the previous start. The oil heater is energized in an
Restart Inhibit Function Using attempt to raise the oil
Time Base Low Oil Temperature Start Inhibit temperature over this inhibit
This method uses straight start- When oil temperature is at or temperature setpoint. The
to-start timer to determine when below the low oil temperature compressor is inhibited from
to allow the next start. A Restart start inhibit setpoint (80- starting until the oil temperature
Inhibit Start-to-Start Time 140°F/26.7-60°C), the heater is is raised 5°F (2.7°C) or more
setpoint is used to set the energized to raise the oil degrees above this setpoint.
desired start-to-start time. temperature.
The Low Oil Temperature Start
Default is 20 minutes and can be Low oil temperature is indicative Inhibit is tested on every start
altered using the TechView™. A of refrigerant dilution in the oil. unless a quick restart is being
time based restart inhibit Oil temperature is used to performed during post-lube.
function is used if the Restart estimate this dilution since the
oil temperature directly If the Enhanced Oil Temperature
Inhibit Type is set to ‘Time’ using Protection setting is enabled, the
TechView™ or if the motor corresponds to amount of
refrigerant dilution in the oil. It is Low Oil Temperature Start
winding temperatures are Inhibit value is 136°F (57.8°C).
determined to be invalid. required that oil contains
minimal refrigerant in it. This is If the Enhanced Oil Temperature
accomplished by boiling the Protection setting is not enabled,
refrigerant out of the oil by the Low Oil Temperature Start
maintaining a high enough oil Inhibit value is settable with the
temperature. Low Oil Temperature Start
Inhibit Setpoint using the
TechView™.
CVGF-SVU02B-E4 69
Machine Protection and
Adaptive
Oil Temperature Control High Oil Temperature Cutout Controls Chilled Water Reset
The oil heater is used to This is a latching diagnostic
maintain the oil temperature
(CWR)
resulting in an immediate
within +/- 2.5°F (1.4°C) of the oil shutdown. Default Setpoint Chilled water reset is designed
temperature control setpoint. The value: 165°F (73.9°C) for those applications where the
oil heater is commanded off when Implemented to avoid design chilled water temperature
the oil pump is commanded on. overheating of the oil and the is not required at partial load. In
bearings. these cases, the leaving chilled
If the oil temperature is at or
water temperature setpoint can
below the Low Oil Temperature If the oil temperature is at or be reset upward using the CWR
Cutout setpoint, this diagnostic above the High Oil Temperature features.
will be issued and stops the Cut-out setpoint this diagnostic
compressor. This diagnostic is will be issued, which will stop When the CWR function is based
ignored for the first 10 minutes the compressor. If Oil on return water temperature, the
of compressor run. After that, if Temperature violates this CWR feature is standard. When
the oil temperature falls below temperature cut-out for more the CWR function is based on
this cutout temperature for more than 120 seconds, this diagnostic outdoor air temperature, the
than 60 consecutive seconds this is issued. CWR feature is an option
diagnostic is issued. requiring an outdoor
Manual Oil Pump Control temperature sensor.
Low Oil Temperature Cutout The oil pump control accepts
If the oil temperature is at or commands to turn on the oil The type of CWR is selected in
below the Low Oil Temperature pump. The manual oil pump the Operator Interface settings
Cutout, for more than 60 choices will be “Auto” or “On.” Menu along with the Reset Ratio,
consecutive seconds this When the oil pump is Start Reset Setpoint, and the
diagnostic will be issued commanded “On,” it will revert Maximum Reset Setpoint.
stopping the compressor. to “Auto” in 10 minutes, and is
This diagnostic does not take adjustable at DynaView™ or
affect during the first 10 minutes TechView™.
of compressor run.
70 CVGF-SVU02B-E4
Machine Protection and
Adaptive
High Lift Unloading (500 Ton The HLUV valve does not Note: There is noticeable noise,
Family Only) modulate the flow rate, but due to gas flow, when the high
rather is either open or closed. lift unloading valve is open.
High Lift Unloading Valve directs Further, the valve was sized to
discharge gases from the Functional Description
handle a mass flow sufficient to The following equation
condenser through a solenoid permit operation below 35% IGV
valve directly into the determines action of the high lift
position but not necessarily to unloading function:
economizer. From the 0%. The valve was sized to
economizer, this gas then flows permit substantial but Trigger IGV% = 0.98 * Lift + -
to the second stage compressor incomplete unloading and yet 0.065 * CPIM + C
where the economizer normally was kept as small as practicable Where Lift is defined as
is connected. The purpose of to minimize power requirements Condenser Saturated Refrigerant
HLUV is to increase the gas flow with HLUV operation. Temperature minus Evaporator
rate through the second stage Saturated Refrigerant
compressor. Bypass gas is Not all CVGF chillers require the
bypassing of condenser gas. In Temperature in °F. The CPIM is
allowed to occur using an inline the average impeller diameter in
normally closed solenoid valve. some tonnages, the High Lift
Unloading Valve and copper inches times 100.
The high lift unloading function
is dependent on the lift (where lines do not exist. The LLID (1A9)
lift is defined as the difference with the High Lift Unloading
between Condenser Saturated relay always exists.
Refrigerant Temperature and the
Evaporator Saturated Refrigerant
Temperature) and on chiller load.
When the high lift unloading
mode is entered, the High Lift
Unloading valve is opened and
the inlet guide vane close travel
is limited.
CVGF-SVU02B-E4 71
Machine Protection and
Adaptive
72 CVGF-SVU02B-E4
Unit
Startup
Pre-Commissioning Bump The following checks require 7. After three seconds, activate
Start Procedure TWO personnel to complete. the emergency stop by
During the bump start of the pressing the Immediate Stop
Note: The following procedure is compressor, one person will look button at the CH530 twice in
a requirement prior to the first at the rotor from the rear of the quick succession. During this
start of the chiller. Failure to motor through the sight glasses three second period, the rotor
complete may result in damage to determine correct direction. should be seen to rotate in a
to the compressor and void the Looking at the sight glass, the counter-clockwise direction.
warranty. direction will be counter- 8. If the direction is incorrect, the
Procedure clockwise. Do not check the 3 phases must be isolated
1. Complete all control settings. rotation of the motor after the from the power source and
start sequence has completed as two legs swapped to obtain
2. Ensure water flows in the the indication may be incorrect.
condenser and evaporator are the correct direction.
correct according to the pre- 5. With the voltage applied to the
commissioning procedures. mains on the starter, place the
chiller in Auto mode.
3. Ensure the unit has been
charged with the correct 6. After the pre-lube is complete,
amount of refrigerant and oil let the starter energize the
and that the oil is the proper motor, permitting a start.
operating temperature.
4. Complete a phase rotation test
if the voltage is less than 600
volts.
CVGF-SVU02B-E4 73
Unit
Startup
Unit Startup 4. Check the chilled water Oil pressure must be verified
setpoint and readjust it, if within 3 minutes or a MMR
Unit Start-Up Procedures
necessary, in the Chiller diagnostic is generated.
Daily Unit Start-Up Settings menu. When less than 5 seconds
1. Verify the chilled water pump 5. Check the current limit remain on the restart inhibit, the
and condenser water pump setpoint and readjust it, if pre-start test is conducted on Y-
starter are in “ON” or necessary, in the chiller Delta starters. If faults are
“AUTO.” settings menu. detected, the unit’s compressor
2. Verify the cooling tower is in 6. Press <AUTO>. will not start, and a MMR
“ON” or “AUTO.” Diagnostic will be generated.
Next, the CH530 checks the
3. Check the oil tank oil level; the leaving evaporator water Note: Whenever the CH530
level must be visible in or temperature and compares it to detects a MMR diagnostic
above the lower sight glass. the chilled water setpoint. If the condition during start-up, unit
Also be sure to check the oil tank difference between these values operation is locked out, and
temperature; normal oil tank is less than the start differential manual reset is required before
temperature before start-up is setpoint, cooling is not needed. the start-up sequence can begin
140°F to 145°F (60° to 63°C). again. If the fault condition has
If the CH530 determines that the not cleared, CH530 will not
Note: The oil heater is energized difference between the permit restart.
during the compressor off cycle. evaporator leaving water
During unit operation, the oil temperature and chilled water When the cooling requirement is
tank heater is de-energized. setpoint exceeds the start satisfied, the CH530 originates a
differential setpoint, the unit “Shutting down” signal. The
enters the initiate in the start inlet guide vanes are driven
mode, the oil pump and the closed for 50 seconds, and the
condenser water pump are unit enters a 1 minute post-lube
started. If condenser water flow period. The compressor motor
is not proven (flow switch 5S2 and condenser water pump
does not close) within 4 minutes starter are de-energized
15 seconds, the unit is locked out immediately, but the oil pump
on a MMR Diagnostic. continues to run during this 3
minute interval; the evaporator
pump will continue to run. Once
the post-lube cycle is done, the
unit returns to auto mode.
74 CVGF-SVU02B-E4
Unit
Startup
CVGF-SVU02B-E4 75
Unit
Shutdown
76 CVGF-SVU02B-E4
Periodic
Maintenance
CVGF-SVU02B-E4 77
Periodic
Maintenance
78 CVGF-SVU02B-E4
Periodic
Maintenance
CVGF-SVU02B-E4 79
Periodic
Maintenance
Weigh the cylinder as the oil is Figure 24. CVGF compressor oil system component locations
being transferred and shut off
the cylinder valve when the
desired weight of oil has been
transferred. Backseat the angle
valve to shut off oil flow and
remove the hose from the
Schrader valve. Be sure to
replace the Schrader and angle
valve cap and secure them when
sampling is complete. Recover Oil filter isolation valves
the oil and refrigerant from the 1/4” Schrader valve
oil sample hose or line with an
approved R134a recovery unit. Oil filter cover Oil level sightglasses
When oil analysis indicates the Oil heater - 500 w
need to change the oil (high
Oil sump drain valve
acidity, moisture, and so forth),
use the following procedure for Oil Heater - 500 w
removing the oil.
80 CVGF-SVU02B-E4
Periodic
Maintenance
CVGF-SVU02B-E4 81
Periodic
Maintenance
3. Attach the oil transfer hose of 10. Close the oil sump drain 4. Make sure the oil heaters are
the recovery unit oil pump to valve and remove the oil energized and the oil is up to
the oil sump charging and charging line. temperature (greater than
drain valve and evacuate. 11. Reinstall the oil drain valve 122°F (50°C)).
4. Open the oil charging valve on cap and tighten securely. 5. Continue pulling a vacuum on
the bottom of the oil tank of Unit in a Vacuum. the unit to remove any
the CVGF and operate the oil residual moisture or non-
recovery and recharge unit oil 1. Connect one end of an oil condensables, which may
pump to charge the oil into charging line to an oil supply have been introduced during
the tank. (15 gallons (56.8 l) total the oil charging. A vacuum of
required) and the other end to at least 500 microns (0.5 mm
5. When the oil is at the center of the oil sump drain valve
the upper sight glass, stop the Hg) should be attained before
located at the bottom of the blanking off the vacuum
transfer of oil. oil sump (See Figure 23). If pump. A vacuum rise test
6. Energize the oil heaters. possible, evacuate the oil should be performed to insure
7. At the control panel, go to the charging line to remove any all non-condensables and
Service Tests menu and scroll non-condensables and moisture have been removed
down to the “oil pump” moisture. This will require a from the system before
screen. Turn the oil pump on shutoff valve on the oil supply charging the unit with
in manual mode and let it run side of the line and an access refrigerant 134a. The vacuum
for several minutes. This will valve located on the line itself. level should not rise by more
charge the oil lines and oil 2. Open the oil sump drain valve than 100 microns (0.1 mm Hg)
cooler with oil. and allow the vacuum to draw in a 2 hour period.
8. After shutting the oil pump the oil into the sump until the 6. After charging the unit with
off, check the oil level in the upper sight glass ball is refrigerant, operate the oil
sump sight glasses. The level located in the center of the pump in the manual mode as
should be between the center upper sight glass. outlined in step 7 in the
of the upper glass and center 3. Close the oil sump drain valve preceding procedure and
of the lower sight glass. Float and remove the oil charging follow that procedure if
balls are installed in each sight line. Reinstall the oil drain additional oil is required to
glass to allow easy level valve cap and tighten bring the level between the
determination. securely. center of the two sight
9. If the oil level is below the glasses.
center of the lower sight glass,
charge oil into the sump as
outlined in step 4.
82 CVGF-SVU02B-E4
Periodic
Maintenance
Replacing the Oil Filter Note: When removed, do not 10. Evacuate the oil filter cavity
allow any contaminants to get by attaching a deep vacuum
The oil filter should not be
on the oil filter cover. Re- pump to the 1/4 inch
changed unless absolutely
installing a contaminated oil Schrader valve and pulling at
required due to plugging, which
filter cover could decrease the least a 500 micron (0.5 mm
will shut the chiller off on low oil
life of the compressor. Hg) vacuum. Do a standing
pressure or if the oil is required
7. Remove the oil filter and o- vacuum rise test to
to be changed. To replace the oil
ring. determine if any leaks are
filter, use the following
present. If leak free, remove
procedure: 8. Install a new oil filter, o-ring, the vacuum pump from the
1. Be sure the chiller is in the and Roto-Lock nylon seal. valve.
Stop mode. 9. Replace the oil filter cover and 11. Replace the Schrader valve
2. Locate the two oil filter torque the bolts and Roto- cap and tighten.
isolation valves (See Figure Lock connector. The cover is
torqued to 19 lb-ft (2.62 N-m) 12. Open both isolation valves.
24).
and the Roto-Lock to 90 lb-ft 13. On the DynaView™ display,
3. Connect an approved
(12.44 N-m). select Settings, Mode
refrigerant recovery unit for
overrides and select Oil
R134a to the 1/4 inch Schrader
Pump. Start and run the oil
valve on the oil filter inlet
pump in manual mode to
isolation valve to allow
charge the oil filter with oil.
removal of oil and refrigerant
Allow the pump to run for
from the oil filter cavity.
several minutes and shut the
4. Close both isolation valves. oil pump off by going back
5. Recover the refrigerant and oil to the Auto mode at the
out of the oil filter cavity. control panel.
6. Remove the oil filter cover by 14. Check the oil level in the
removing the bolts and sump and if it is below the
loosening the Roto-Lock center of the lower sight
connector on the outlet oil glass, add oil by following
filter isolation valve. the oil charging procedure
outlined previously.
CVGF-SVU02B-E4 83
Periodic
Maintenance
84 CVGF-SVU02B-E4
Periodic
Maintenance
3. To reverse the oil pump motor 5. When the oil filter change is CVGF Oil Pump
rotation, two leads must be completed, check the The oil pump for the CVGF is a
swapped on the oil pump differential oil pressure and if positive displacement, direct
motor contactor. Be sure to it is below 18 psid (124 kPa), drive pump, three phase motor.
remove all power from the adjust the oil pressure The motor must be phased
unit before doing any regulator to obtain a reading correctly to provide positive
electrical wiring changes. of between 18 to 22 psid (124- differential oil pressure. This
Note: Be sure to perform the 151 kPa). pump and motor is located
Bump Start test to determine If the pressure drop across the within the oil sump and can not
proper compressor rotation filter is not excessive, but the be serviced without recovering
before operating the chiller. oil differential pressure is the refrigerant and removing the
below 18 psid, adjust the oil oil from the machine.
If the differential oil pressure
measured is below 12 psid (82 pressure regulating valve to
kPa), the oil filter may be obtain 18 to 22 psid (124-151
plugging or the regulator may kPa) oil pressure. To increase
need adjustment. pressure, remove the oil
pressure regulator cap and
4. Then check the pressure drop screw the regulator stem in a
across the oil filter, connect a clockwise direction. Be sure to
gauge to the service valve replace the cap and tighten
before the oil filter and when adjustment is complete.
another gauge to the service
valve after the oil filter. 6. Remove the pressure gauges
Subtract the pressure reading when all diagnostic work is
taken from after the oil filter complete. Be sure and replace
from the gauge before the oil and secure any valve caps
filter to obtain the pressure which were removed.
drop. If the pressure drop is
excessive (more than 8 psid
(54 kPa)), shut the oil pump off
and replace the oil filter per
the procedure outlined
previously.
CVGF-SVU02B-E4 85
Periodic
Maintenance
86 CVGF-SVU02B-E4
Literature Order Number CVGF-SVU02B-E4
File Number SL-RF-CTV-CVGF-SVU02B-E4-0205
Supersedes CVGF-SVU02A-E4-1202
Stocking Location China
Trane has a policy of continuous product and product data improvement and reserves the right to
Trane change design and specifications without notice. Only qualified technicians should perform the
A business of American Standard Companies installation and servicing of equipment referred to in this publication.
www.trane.com Société Trane – Société Anonyme au capital de 41500 000 F – Siege Social: 1 rue des Amériques –
For more information contact your local Trane office 88190 Golbey – France – Siret 306 050 188-00011 – RSC Epinal B 306 050 188
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