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Trane Technologies CVHE Installation, Operation And Maintenance Manual

Water-cooled centravac chillers with tracer adaptiview control
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Installation, Operation and Maintenance
CVHE, CVHF, CVHG Water-Cooled
CenTraVac Chillers
With Tracer AdaptiView™ Control
Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of
heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training.
Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury.
When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that
are attached to the equipment.
April. 2020
SAFETY WARNING
TCVHE-SVX04E-EN
Confidential and proprietary Trane information
X39641300002

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Summary of Contents for Trane Technologies CVHE

  • Page 1 Installation, Operation and Maintenance CVHE, CVHF, CVHG Water-Cooled CenTraVac Chillers With Tracer AdaptiView™ Control X39641300002 SAFETY WARNING Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training.

  • Page 2: Warnings, Cautions And Notices

    RELEASED 10/Mar/2020 06:59:20 GMT Warnings, Cautions and Notices Warnings, Cautions and Notices This Installation, Operation, and Maintenance manual Note that warnings, applies to CenTraVac chillers with two different refriger- cautions and notices appear at appropriate intervals ant and oil systems: throughout this manual.

  • Page 3: Trademarks

    RELEASED 10/Mar/2020 06:59:20 GMT D WARNING Contains Refrigerant! System contains oil and refrigerant under high pres- sure. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant additives. Failure to follow proper procedures or the use of non-approved refrigerants, refrigerant substitutes, or refrigerant additives could result in death or serious...

  • Page 4: Table Of Contents

    RELEASED 10/Mar/2020 06:59:20 GMT Table of Contents Warnings, Cautions and Notices ......2 Pressure Testing Waterside Piping ....24 Trademarks ............3 Purge Piping .............25 Unit Model Number Description ......6 EarthWise Purge Requirements - Purge Instal- lation ............... 25 Model Number Digit Description .....7 Vent Piping ............26 Pre-Installation...........8 Refrigerant Vent-Line ........
  • Page 5 General Requirements ........52 General Lubrication ........67 Cooling Cycle ..........52 Service for the 1st Stage Tang Operator..67 CVHE, CVHG 3-Stage Compressor ....52 Service for the 1st and 2nd Stage Tang Oper- CVHF 2-Stage Compressor ......52 ators ...............67 Oil and Refrigerant Pump ......53 Cleaning the Condenser .......68...

  • Page 6: Unit Model Number Description

    RELEASED 10/Mar/2020 06:59:20 GMT Unit Model Number Description The unit nameplate is located on the left side of the left Figure 1. Typical Unit Nameplate hand control panel. A typical unit nameplate is illustrated below and contains the following information. • Unit model and size descriptor • Unit electrical requirements • Correct operating charge and refrigerant type...

  • Page 7: Model Number Digit Description

    RELEASED 10/Mar/2020 06:59:20 GMT Model Number Digit Description Digit Description 1–3 Unit Type Development Sequence 5–7 Nominal Tonnage Unit Voltage Unit Type 10–11 Design Sequence Hot Gas Bypass Starter Type Control Enclosure Compressor Motor Power (CPKW) 16–18 Compressor Impeller Cutback Evaporator Shell Size Evaporator Tube Bundle (Nominal Tons) Evaporator Tubes...

  • Page 8: Pre-Installation

    RELEASED 10/Mar/2020 06:59:20 GMT Pre-Installation ASHRAE Standard 15 Compliance Trane recommends that indoor CenTraVac unit installa- tions fully meet or exceed the guidelines of the current version of ASHRAE Standard 15, in addition to any appli- cable local, state, or national requirements. This typically includes: • A refrigerant monitor or detector that is capable of monitoring and alarming within the acceptable ex-...

  • Page 9: Installation Requirements And Contractor Responsibilities

    RELEASED 10/Mar/2020 06:59:20 GMT Pre-Installation Installation requirements and D WARNING Combustible Material! Contractor responsibilities Failure to follow this instruction could result in death or serious injury or equipment damage. Shrink-wrap A list of the contractor responsibilities typically associat- is a combustible material. Avoid open flames and hot ed with the unit installation process is provided.

  • Page 10: Storage Requirements For Chillers Not Yet Installed

    RELEASED 10/Mar/2020 06:59:20 GMT Pre-Installation Storage Requirements for Chillers Not Yet Installed D Notice Insulation Damage! Direct exposure to sunlight may damage factory in- stalled insulation. Failure to follow these instructions could result in insulation damage. Less than 1 month 1 –...

  • Page 11: Unit Components

    RELEASED 10/Mar/2020 06:59:20 GMT Pre-Installation Unit Components Note: Components are identified from a viewpoint that faces the front side of the control panel. Figure 2. Typical CVHF CenTraVac Chiller 1. Suction Elbow 2. Compressor 3. Terminal Box 4. Control Panel 5.

  • Page 12: Unit Dimensions And Weights

    RELEASED 10/Mar/2020 06:59:20 GMT Unit Dimensions and Weights Recommended Unit Clearances • Minimum vertical clearance above the unit is 3 feet (91.44 cm). • Use a housekeeping pad to provide better service Adequate clearances around and above the chiller are clearances;...
  • Page 13 RELEASED 10/Mar/2020 06:59:20 GMT Unit Dimensions and Weights The weight information provided here should be used • INDP (Industrial Control Panel), add 50 lb (23kg) for general information purposes only. Trane does not • CPTR (Control Panel Transformer) option, add 130 lb recommend using this weight information for consid- (50 kg) erations relative to chiller handling.
  • Page 14 RELEASED 10/Mar/2020 06:59:20 GMT Unit Dimensions and Weights Table 1. Unit weights (continued) Without Starters With Starters Operating Weights Shipping Weights Operating Weights Shipping Weights MODEL NTON CPKW EVSZ CDSZ 480–565 050L 050L 23384 10607 20815 9442 24466 11098 21897 9932 480–565 060S...

  • Page 15: Installation Mechanical

    RELEASED 10/Mar/2020 06:59:20 GMT +5 °C to +40 °C Installation Mechanical Operating Environment D WARNING Heavy Objects! To assure that electrical components operate properly, Do not use cables (chains or slings) except as shown in do not locate the chiller in an area exposed to dust, dirt, Figure 4, p.

  • Page 16: Special Lift Requirements

    RELEASED 10/Mar/2020 06:59:20 GMT Installation Mechanical If the chiller cannot be moved using a standard chiller Figure 4. Rigging arrangements for Simplex units lift, consider the following: 16 feet (4.8768 meters) • When job site conditions require rigging of the chiller minimum effective length at an angle greater than 45°...

  • Page 17: Spring Isolators

    RELEASED 10/Mar/2020 06:59:20 GMT Installation Mechanical onto the isolation pads. In addition, all piping connected compress the springs until either the springs sup- to the chiller must be properly isolated and supported so port the load or the top plate rests on the bottom that it does not place any stress on the unit.
  • Page 18 RELEASED 10/Mar/2020 06:59:20 GMT Installation Mechanical Use of a laser level is an acceptable alternative method to level the unit. Immediately report any unit damage incurred during handling or installation at the job site to the Trane sales office. TCVHE-SVX04D-EN...

  • Page 19: Installation Water Piping

    RELEASED 10/Mar/2020 06:59:20 GMT Installation Water Piping Overview Valves - Drains and Vents Several water piping circuits must be installed and con- D NOTICE nected to the chiller. Waterbox Damage! Note: Piping must be arranged and supported to avoid Failure to follow instructions could result in damage stress on the equipment.

  • Page 20: Flow-Sensing Devices

    RELEASED 10/Mar/2020 06:59:20 GMT Installation Water Piping Flow-Sensing Devices 6. Adjust the flow switch to open when water flow is less than normal. Use either flow switches or differential pressure switches D NOTICE in conjunction with the pump interlocks to verify evapo- Proof of Flow Switch! rator and condenser water flows.

  • Page 21: Water Box Locations

    3 PSID (21 kPa) at all times. Failure to do so could result in operating prob- lems. Note: Whenever a CVHE, CVHF , and CVHG unit is equipped with an auxiliary condenser, use a bypass valve system to avoid circulating water through the auxiliary shell during unit shutdown.

  • Page 22: Water Piping Connections

    RELEASED 10/Mar/2020 06:59:20 GMT Installation Water Piping Water Piping Connections Figure 9. Typical evaporator water piping circuit Balancing Valve Gate (Isolation) Valve or Ball Valve Outlet Thermometer (if field supplied) Flanged Connection 1/2” (13 mm) NPT Couplings Drin, Vent, Anode Inlet Notes: Flow switch 5S1 (Item in Legend of Components) may be installed in either the entering or leaving leg of the chilled...

  • Page 23: Grooved Pipe Coupling

    1035 kPa victaulic Required propriate numerical sequence for the flange. Repeat this non-marine adapter sequence to apply the final torque to each bolt. only) Customer Customer CVHE, CVHF , Victaulic (All provided provided and CVHG others) Victaulic victaulic Coupling adapter...

  • Page 24: Pressure Testing Waterside Piping

    RELEASED 10/Mar/2020 06:59:20 GMT Installation Water Piping of the bolts in the proper order. Pressure Testing Waterside Piping Water side design pressure is either 150 or 300 psig refer to unit nameplate or to submittal documentation. D NOTICE Equipment Damage! 2 23 16 bolt flange 20 bolt flange...

  • Page 25: Purge Piping

    RELEASED 10/Mar/2020 06:59:20 GMT Purge Piping EarthWise Purge Requirements - 6. Using proper brazing techniques as per American Welding society (A.W.S.) braze the following four Purge Installation copper lines at the factory disassembly points: • Purge suction line (larger) For certain CenTraVacs, the purge system is not mount- • Purge liquid drain line ed on the chiller when it ships.

  • Page 26: Vent Piping

    RELEASED 10/Mar/2020 06:59:20 GMT Vent Piping Refrigerant Vent-Line (from Vibration Mounting and Control, Inc.), or equiva- lent, is recommended. Vent-Line Sizing General Recommendations Vent-line size must conform to local codes and require- State and local codes, and ASHRAE Standard 15 contain ments.

  • Page 27: Vent-Line Installation

    RELEASED 10/Mar/2020 06:59:20 GMT Vent Piping vent-line length in equivalent feet is the sum of line piping. the linear pipe length plus the equivalent length 4. Use a flexible connection between the vent-line and of the fittings (e.g., elbows). the rupture disc assembly to avoid placing stress on the rupture disc.
  • Page 28 RELEASED 10/Mar/2020 06:59:20 GMT Vent Piping D NOTICE Equipment Damage! All vent-lines must be equipped with a drip leg of sufficient volume to hold the expected accumulation of water and or refrigerant. The drip leg must be drained periodically to assure that it does not over- flow and allow fluid to flow into the horizontal por- tion of the vent-line.
  • Page 29 RELEASED 10/Mar/2020 06:59:20 GMT Vent Piping Table 6. “C” values used to determine rupture disc vent line sizes “C” Values for Unit Components Evaporator Condenser Size Total C val- Short H.R. Long H.R. Auxiliary With Free Size (CDSZ) (EVSZ) Condenser Condenser Condenser Cooling...
  • Page 30 RELEASED 10/Mar/2020 06:59:20 GMT Vent Piping Figure 15. Rupture disc vent pipe sizing Pipe size as a Function of “C” Value and Length of Run 1000 Pipe Size (I.D.) friction factor 6 NPS (6.065) f=0.0149 5 NPS (5.048) f=0.0155 4 NPS (4.026) f=0.0163 3 NPS...

  • Page 31: Insulation

    RELEASED 10/Mar/2020 06:59:20 GMT Insulation Unit Insulation Requirements Table 7. Evaporator insulation requirements EVSZ Standard Unit Free Cooling (Note 1) Factory-installed insulation is available as an option for 3/4” 3/8” 3/4” 3/8” (19 mm) (9.5 mm) (19 mm) (9.5 mm) all units.
  • Page 32 RELEASED 10/Mar/2020 06:59:20 GMT Insulation Figure 16. Recommended area for unit insulation Line to eductor Line from evap Filter drier and eductor lines Pipe (free cooling only) Control panel support Pipe Evaporator Pipe Suction Suction cover elbow Suction connection Eductor line See Notes See Notes See Note...

  • Page 33: Installation Controls

    RELEASED 10/Mar/2020 06:59:20 GMT Installation Controls Specifications This section covers information pertaining to the UC800 controller hardware. For information about the AdaptiV- iew display, which is used to interface with the internal Power Supply chiller data and functions provided by the UC800, refer to CTV-SVU01C-EN, Tracer AdaptiView™...

  • Page 34: Communication Interfaces

    RELEASED 10/Mar/2020 06:59:20 GMT Installation Controls Communication Interfaces Table 8. LED behavior There are four connections on the UC800 that support UC800 Status the communication interfaces listed. Refer to Figure 17, p. Powered. If the Marquee LED is green solid, the for the locations of each of these ports.
  • Page 35 RELEASED 10/Mar/2020 06:59:20 GMT Installation Controls Figure 19. Control panel - Tracer AdaptiView main unit assembly (showing low voltage and higher voltage areas for proper routing of field wiring) Right View Front View 30V TO 115V 30V TO 115V 1K2 1T2 1S1 1K1 30V TO 115V 30V TO 115V...

  • Page 36: Installing The Tracer Adaptiview Display

    RELEASED 10/Mar/2020 06:59:20 GMT Installation Controls Installing the Tracer AdaptiView D CAUTION Tension in Display Support Arm! Display To prevent unexpected movement of the spring- loaded support arm, ensure that the support arm is The Tracer AdaptiView display is boxed and shrink- in the full upright position when removing the Tracer wrapped behind the control panel during shipment.

  • Page 37: Adjusting The Tracer Adaptiview Display Arm

    RELEASED 10/Mar/2020 06:59:20 GMT Installation Controls Adjusting the Tracer AdaptiView Display Arm The Tracer AdaptiView display arm may be too loose or too tight and in need of adjustment. To adjust the tension on the display arm: 1. There are three joints on the display arm that allow the Tracer AdaptiView display to be positioned at a variety of heights and angles (refer to items labeled 1, 2, and 3 in...

  • Page 38: Electrical Requirements

    RELEASED 10/Mar/2020 06:59:20 GMT Electrical Requirements Installation Requirements The operation conditions .of the electrical parts .of the existing units ,are announced as follows: General Operating Condition D WARNING Environ- Medium and High Voltage Low Voltage Circuits ment Circuits Electrocution and Fire Hazards with Im- The temperature of indoor properly Installed and Grounded Field electric should be, at -5...
  • Page 39 RELEASED 10/Mar/2020 06:59:20 GMT Electrical Requirements • Always wear appropriate personal protective equip- D WARNING ment. Personal Protective Equipment (PPE) • Wait the required time to allow the capacitor(s) to Required! discharge; this could be up to 30minutes. Always wear appropriate personal protective equip- • Verify that all capacitors are discharged prior to ser- ment in accordance with applicable regulations and/ vice using a properly rated volt meter.

  • Page 40: Trane-Supplied Starter Wiring

    RELEASED 10/Mar/2020 06:59:20 GMT Electrical Requirements Trane-Supplied Starter Wiring Table 10. Standard field power wiring requirements Power Supply Wiring to Starter Panel Terminals Starter Panel 3-Phase Line Voltage: Terminal 2X3-U1, V1, V1, and PE Block (2TB3 or 2X3) 3-Phase Line Voltage: Circuit 2Q1-2X3-U1, V1, V1, and PE Breaker Starter to Motor Power...

  • Page 41: Customer-Supplied Remote Starter Wiring

    RELEASED 10/Mar/2020 06:59:20 GMT Customer-Supplied Remote Starter Wiring Table 11. Standard customer-supplied remote field wiring requirements Power Supply Wiring to Starter Starter Panel Termi- Panel nals See starter by others sche- Starter by others 3-phase power wiring matic Starter to Motor Power Wiring Starters Motor Remote starter to chiller motor junc-...

  • Page 42: Current Transformer And Potential Transform- Er Wire Sizing

    RELEASED 10/Mar/2020 06:59:20 GMT Customer-Supplied Remote Starter Wiring Current Transformer and Poten- Table 14. Max recommended total wire length (to and from) for PT leads in a dual PT system tial Transformer Wire Sizing Wire Max Wire Length Max Wire Length Gauge Primary Secondary...

  • Page 43: Power Supply Wiring

    RELEASED 10/Mar/2020 06:59:20 GMT Power Supply Wiring W 1 V 1 U 1 D WARNING W 1 V 1U 1 W 1 V 1 U 1 Ground Wire! All field-installed wiring must be completed by quali- fied personnel. All field-installed wiring must comply with NEC and applicable local codes.

  • Page 44: Rule 2 - Pfcc Wires Routed Through Current Transformers

    RELEASED 10/Mar/2020 06:59:20 GMT Power Supply Wiring If the current they provide isn’t registered by the over- D NOTICE load protectors, potentially damaging amperage can Motor Damage! reach the motor. The simplest way to ensure that the overloads “see” all current supplied to the motor is to PFCCs must be wired into the starter correctly.

  • Page 45: Starter To Motor Wiring (Remote-Mounted Starters Only)

    RELEASED 10/Mar/2020 06:59:20 GMT Power Supply Wiring Terminal Clamps Figure 22. Typical equipment room layout for units with remote-mounted starters Terminal clamps are supplied with the motor terminals to accommodate either bus bars or standard motor terminal wire lugs. Terminal clamps provide additional surface area to minimize the possibility of improper elec- trical connections.

  • Page 46: Starter To Control Panel Wiring

    RELEASED 10/Mar/2020 06:59:20 GMT Power Supply Wiring Bus Bars operation. 3. Separate low-voltage (less than 30V) wiring from the Bus bars and extra nuts are available as a Trane option. 115V wiring by running each in its own conduit. Install the bus bars between the motor terminals when 4.

  • Page 47: 10Kv-13.8Kv Medium Voltage Installation

    RELEASED 10/Mar/2020 06:59:20 GMT 10kV–13.8kV Medium Voltage Installation D WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious inju- All electrical circuits shall be treated as energized until all lockout-tagout procedures are in place and the cir- cuit has been tested to verify that it is de-energized.

  • Page 48: Motor Terminals

    RELEASED 10/Mar/2020 06:59:20 GMT 10kV–13.8kV Medium Voltage Installation Motor Terminals Field provided ring type lugs, with no sharp edges or corners, must be used by a qualified installer to con- nect the power wiring to the motor terminals. Follow all instructions provided with the field provided lugs to ensure proper connections.

  • Page 49: System Control Circuit Wiring

    RELEASED 10/Mar/2020 06:59:20 GMT System Control Circuit Wiring Table 15. Unit control panel wiring 120 Vac Standard Control Circuits: Unit Control Panel Control Wiring (120 Vac) Unit Control Terminations Input or Output Type Contacts Chilled Water Flow Proving Input 1X1-5 to 1A6-J3-2 Binary Input Normally Open, closure with flow Condenser Water Flow Proving...

  • Page 50: Water Pump Interlock Circuits And Flow Switch Input

    RELEASED 10/Mar/2020 06:59:20 GMT System Control Circuit Wiring Water Pump Interlock Circuits and Flow 1. Use 14 AWG, 600-volt copper wire to connect the auxiliary contacts of the condenser water pump Switch Input contactor (5K2) in series with the flow switch (5S2) installed in the condenser supply pipe D WARNING 2.

  • Page 51: Optional Control And Output Circuits

    RELEASED 10/Mar/2020 06:59:20 GMT System Control Circuit Wiring Optional Control and Output Circuits Starter Module Configuration Install various optional wiring as required by the owner’s The starter module configuration settings will be checked specifications. Refer to Table 15, p. (and configured for Remote Starters) during start-up commissioning.

  • Page 52: Operating Principles

    Operation and maintenance information for models third-and second-stage impellers of the compressor, re- CVHE, CVHF , CVHG are covered in this section. This spectively. All remaining liquid refrigerant flows through includes both 50 and 60 Hz centrifugal chillers equipped another orifice plate to the evaporator.

  • Page 53: Oil And Refrigerant Pump

    RELEASED 10/Mar/2020 06:59:20 GMT Operating Principles Oil and Refrigerant Pump Figure 26. Pressure enthalpy curve 2 stage Compressor Lubrication System condenser A schematic diagram of the compressor lubrication sys- compressor tem is illustrated below. Oil is pumped from the oil tank economizer (2nd stage) (by a pump and motor located within the tank) through...

  • Page 54: Motor Cooling System

    RELEASED 10/Mar/2020 06:59:20 GMT Operating Principles Tracer AdaptiView Display D WARNING Surface Temperatures! Information is tailored to operators, service technicians MAY EXCEED 150°F. Use caution while working on and owners. certain areas of the unit, failure to do so could result in death or serious injury.

  • Page 55: Start-Up And Shut Down

    RELEASED 10/Mar/2020 06:59:20 GMT Start-up and Shut Down Sequence of Operation Start-up Sequence of Operation— Wye-Delta This section will provide basic information on chiller operation for common events. With microelectronic con- Logic Circuits within the various modules will deter- trols, ladder diagrams cannot show today’s complex log- mine the starting, running, and stopping operation of ic, as the control functions are much more involved than the chiller.
  • Page 56 RELEASED 10/Mar/2020 06:59:20 GMT Start-up and Shut Down Figure 29. Sequence of operation: power up to starting Figure 30. Sequence of operation: running Figure 31. Sequence of operation: satisfied setpoint If the STOP key is pressed on the operator interface, the chiller will follow the same stop sequence as above except the chilled water pump relay will also open and stop the chilled water pump after the chilled water pump delay timer has timed out after compressor shut down.

  • Page 57: Power Up Diagram

    RELEASED 10/Mar/2020 06:59:20 GMT Start-up and Shut Down Power Up Diagram Ice Machine Control The Power up chart shows the respective Tracer Adap- The control panel provides a service level Enable or Dis- tiView screens during a power up of the main processor. able menu entry for the Ice Building feature when the Ice This process takes from 30 to 50 seconds depending Building option is installed.
  • Page 58 RELEASED 10/Mar/2020 06:59:20 GMT Start-up and Shut Down Figure 34. Sequence of operation: ice making: stopped to ice to ice building complete TCVHE-SVX04D-EN...

  • Page 59: Free Cooling Cycle

    RELEASED 10/Mar/2020 06:59:20 GMT Start-up and Shut Down Free Cooling Cycle must flow through the bleed line restriction. Because the pressure drop through the bleed line is greater than that of the orifice flow control device, the liquid refrigerant Based on the principle that refrigerant migrates to the flows normally from the condenser through the orifice coldest area in the system, the free cooling option adapts system and into the economizer.

  • Page 60: Hot Water Control

    RELEASED 10/Mar/2020 06:59:20 GMT Start-up and Shut Down close for unit shutdown. After a chiller starts and is run- setpoint. Tracer is also able to set the hot water setpoint. ning the inlet guide vanes will pass through the HGBP In the hot water mode the external chilled water setpoint Cut-In-Vane position as the chiller starts to load.

  • Page 61: Control Panel Devices And Unit Mounted Devices

    RELEASED 10/Mar/2020 06:59:20 GMT Start-up and Shut Down heat-recovery condenser, it is comparatively smaller in Unit Start-Up and Shut-down size, and its heating capacity is not controlled. Trane does Procedures not recommend operating the auxiliary condenser alone because of its small size. D WARNING Control Panel Devices and Unit Live Electrical Components!

  • Page 62: Daily Unit Shutdown

    RELEASED 10/Mar/2020 06:59:20 GMT Start-up and Shut Down 5. If necessary, readjust the current limit setpoint in the When the cooling requirement is satisfied, the control panel originates a Shutting down signal. The inlet guide Chiller Setpoints menu. vanes are driven closed for 50 seconds the compressor 6.
  • Page 63 RELEASED 10/Mar/2020 06:59:20 GMT Start-up and Shut Down Seasonal Unit Start-Up 1. Close all drain valves, and reinstall the drain plugs in the evaporator and condenser headers. 2. Service the auxiliary equipment according to the start-up and maintenance instructions provided by the respective equipment manufacturers.

  • Page 64: Maintenance

    RELEASED 10/Mar/2020 06:59:20 GMT Maintenance D NOTICE Daily Maintenance and Checks Moisture Contamination! Operating Characteristic Normal Reading If frequent purging is required, monitor purge pum- Approximate Evaporator Pres- 6 to 9 PSIA / -9 to -6 PSIG pout rate, identify and correct source of air or water sure leak as soon as possible.
  • Page 65 RELEASED 10/Mar/2020 06:59:20 GMT Maintenance Daily Every 3 Every 6 months Annual months evaporator and condenser pres- sures, oil tank pressure, differ- ential oil pressure and discharge oil pressure. Compare the read- ings with the values provided in the above. Check the oil level in the chiller oil sump using the two sight glasses provided in the oil sump...

  • Page 66: Compressor Oil Change

    RELEASED 10/Mar/2020 06:59:20 GMT Maintenance Compressor Oil Change When oil analysis indicates the need to change compres- sor oil, use the following procedure for removing oil. • Draw the oil from the chiller through the oil charging D Notice valve on the chiller oil sump into an approved, evac- Equipment Damage! uated tank;...

  • Page 67: General Lubrication

    RELEASED 10/Mar/2020 06:59:20 GMT Maintenance 8. Purge unit. effort required to operate the assembly. 9. Check oil pressure 18–22 psi. 4. Loosen but DO NOT REMOVE the 1/16” NPT lubrica- tion port plug that is highest on the assembly. 5. Loosen and remove the remaining lower 1/16” NPT plug.

  • Page 68: Cleaning The Condenser

    RELEASED 10/Mar/2020 06:59:20 GMT Maintenance Cleaning the Condenser D NOTICE Unit Corrosion Damage! D NOTICE Proper procedures must be followed when using Proper Water Treatment! corrosive chemicals to clean water side of unit. It is recommended that the services of a qualified chem- The use of untreated or improperly treated water in a ical cleaning firm be used.

  • Page 69: Long Term Unit Storage

    RELEASED 10/Mar/2020 06:59:20 GMT Maintenance • X= minutes/day of purge pump out operation 2. After the liquid refrigerant is removed, using a recov- ery or recycle unit or vacuum pump, pull a vacuum • Y= initial refrigerant charge to remove remaining refrigerant vapor from the unit. A graph has been developed to aid in determining when 3.

  • Page 70: Refrigerant Charge

    7. If refrigerant is supplied in new returnable cylinders, tial storage date. be sure and refer to General Service Bulletin CVHE- 13. When the unit is to be returned to service, the ser- SB-48B for information on returning cylinders. This vices of a qualified service organization should be service bulletin is available at the nearest Trane office.
  • Page 71 RELEASED 10/Mar/2020 06:59:20 GMT Maintenance Leak Testing D WARNING Hazard of Explosion! Never use an open flame to detect gas leaks. Explo- sive conditions may occur. Use a leak test solution or other approved methods for leak testing. Failure to follow recommended safe leak test procedures could result in death or serious injury or equipment or property-only-damage.

  • Page 72: Waterbox Removal And Installation

    RELEASED 10/Mar/2020 06:59:20 GMT Waterbox Removal and Installation Important: ONLY QUALIFIED TECHNICIANS SHOULD turing location. PERFORM THE INSTALLATION AND SER- 2. Select the proper lift connection device from the Con- VICING OF THIS EQUIPMENT. nection Devices table. The rated lifting capacity of the selected lift connection device must meet or exceed Discussion the published weight of the waterbox.
  • Page 73 9. Torque waterbox bolts. Refer to Table CenTraVac Refer to Table 16 for torque and refer to CVHE-SVN02D- EN, Installation - Piping Information: Water- Cooled CenTraVac with CH530, or the most recent version for CVHE torquing procedure. Table 16. CenTraVac torque...

  • Page 74: Sound Pressure Level

    Drive Load Load Load Load 142L 030A, 030A CVHS 300 CVHF 1070 030B, 030B 210L, 250L 032S, 032L CVHE 230–250 142L 050S, 050L CVHF 1300 210, 250L 032S, 032L CVHE 280 210L 050S, 050L CVHF 1470 250L 032S, 032L CVHE 320...
  • Page 75 % Load 63 Hz 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000 Hz CVHS 300 CVHE 230–250 CVHE 280 CVHE 320 CVHE 360–400 CVHE 450 CVHE 500 CVHF 350 CVHF 410 CVHF 485 CVHF 570 CVHF 620–650...
  • Page 76 60 Hz sound pressure (dB) by octave band with AHRI relief and Adaptive Frequency™ drive (AFD) (continued) Model % Load 63 Hz 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000 Hz CVHF 1070 CVHF1300 CVHF 1470 CVHF 1720 CDHF 1500 CDHF 2000...
  • Page 77 50 Hz sound pressure (dB) by octave band with AHRI relief and starter Model Number % Load 63 Hz 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000 Hz CVHE 190–270 CVHE 300–330 CVHE 370–420 CVHG 480 CVHG 565 CVHG 670 CVHG 780 CVHG 920 CVHG 1100 TCVHE-SVX04D-EN...

  • Page 78: Forms

    RELEASED 10/Mar/2020 06:59:20 GMT Forms CenTraVac Commissioning Checklist Job Name Location Model # Serial # Sales Order # Start-up Date Note: The Unit Installation, Operation and Maintenance Manuals including Warning and Cautions, Applicable Service Alerts and Bulletins, Submittals, and Design Specifications must be used in conjunction with this checklist. I.
  • Page 79 RELEASED 10/Mar/2020 06:59:20 GMT Forms II. COMMISSIONING PROCEDURES A. Pre-start Operations 1. Holding Charge  psig. Must be positive pressure or leak test must be done. 2. Before relieving the holding charge, calibrate the H.P .C. high-pressure control This is a check of pressure to the H.P .C. as well as calibration of the control. Disconnect and cap the flare.
  • Page 80 RELEASED 10/Mar/2020 06:59:20 GMT Forms tor starter. Verify correct operation of flow proving circuit.  E vaporator water flow balanced. PSID design GPM design PSID actual GPM actual 7. Electrical and Controls a. Motor Starter Panel  A ll terminals tightened.  W iring free from abrasion, kinks, and sharp corners.
  • Page 81 RELEASED 10/Mar/2020 06:59:20 GMT Forms 5. Return Oil Pump control to ‘Auto’ from within the AdaptiView.  C heck vane operator and vanes (Service Tool). 1. Use the Service Tool manual override menu to manually override the vane control. 2.
  • Page 82 RELEASED 10/Mar/2020 06:59:20 GMT Forms  A fter the unit has the system down to design leaving chilled water temp and is under control, and the purge is no longer relieving non-condensables, begin taking the start-up test log. Log the unit a minimum of 3 times at 15-minute intervals.
  • Page 83 RELEASED 10/Mar/2020 06:59:20 GMT Forms CenTraVac® Pre-commissioning Checksheet and Request for Serviceman Trane Service Company ® CenTraVac Pre-commissioning Checksheet and Request for Serviceman S.O. No.: Serial #s: Trane Service Company Job/Project Name: S.O. No.: Serial #s: Address: Job/Project Name: The following items are being installed and will be completed by: Address: Check boxes if the task is complete or if the answer is “yes”...
  • Page 84 RELEASED 10/Mar/2020 06:59:20 GMT Forms 10. Equipment Room (continued) 11. Owner Awareness Does the equipment room have proper Has the owner been fully instructed on the mechanical ventilation? proper use of refrigerant HCFC-123? If it is required by local code, is a Does the owner have a copy of the MSDS for self-contained breathing apparatus available? refrigerant HCFC-123?
  • Page 85 RELEASED 10/Mar/2020 06:59:20 GMT Forms Annual Inspection Checklist (typical) Follow the Annual Maintenance Instructions provided in the text of this manual, including but not limited to: Compressor Motor Evaporator … Motor continuity … Once every 3 years on a closed …...
  • Page 86 RELEASED 10/Mar/2020 06:59:20 GMT Forms Leak Test Chiller Purge … Check purge times and unit … Review the purge operation and performance logs. Pressure leak maintenance manual and perform test if warranted or every 3 years. all maintenance items identified. …...
  • Page 87 RELEASED 10/Mar/2020 06:59:20 GMT Forms STARTUP Test Log Water Cooled CenTraVac With UC800 Controller AdaptiView Reports - log sheet Log 1 Log 2 Log 3 Evaporator Entering Leaving Saturated Refrig. Press Approach Flow Sw Status Condenser Entering Leaving Saturated Refrig. Press Approach Flow Sw Status Compressor...
  • Page 88 RELEASED 10/Mar/2020 06:59:20 GMT Forms STARTUP Chiller Report – Water Cooled CenTraVac With UC800 Controller Service Tool Records Configuration Unit Information Unit Name Unit Model Number Unit Sales Order Number Unit Serial Number Application Firmware Boot Firmware Build Part Number Date/Time Chiller Configuration Main...
  • Page 89 RELEASED 10/Mar/2020 06:59:20 GMT Forms Operating Status Programmable Relays LonTalk (Comm5) BAS Interface Purge Control % RLA and Condenser Rfgt Pressure Output Max Capacity Relay Filter Time Head Relief Relay Filter Time Base Loading Options Setup ECWS Minimum Temperature ECWS Maximum Temperature Rfgt Pressure Output Type Min Delta Rfgt Pressure Output Max Delta Rfgt Pressure Output...
  • Page 90 RELEASED 10/Mar/2020 06:59:20 GMT Forms Stator Resistance Flux Current Reference Acceleration Time Deceleration Time Starter Current Limit Current Limit Gain Power Loss Mode Power Loss Time Flying Start Flying Start Gain Use Trane Defaults RTD Type TCVHE-SVX04D-EN...
  • Page 91 RELEASED 10/Mar/2020 06:59:20 GMT Forms STARTUP Chiller Report – Water Cooled CenTraVac With UC800 Controller Service Tool Records Setpoints Chiller Service Setpoints Chiller Setpoints Front Panel Chilled Water Setpt Front Panel Current Limit Setpoint Front Panel Ice Building Command Differential to Start Differential to Stop Setpoint Source Evaporator Water Flow Point 1...
  • Page 92 RELEASED 10/Mar/2020 06:59:20 GMT Forms Evaporator Leaving Water Temp Cutout Inlet Guide Vane Max Steps First Stage Low Refrigerant Temp Cutout Condenser Limit Setpt Restart Inhibit Free Starts Local Atmospheric Pressure High Evaporator Water Temperature Cutout High Evaporator Refrigerant Temperature Warning Ice Building Feature Current Limit Softload Start Point Phase Unbalance Limit Protection...
  • Page 93 RELEASED 10/Mar/2020 06:59:20 GMT Forms LLID List Create a list of all installed LLIDs. Manual Entries Refrigerant Level ____________________________________________________ __________________________________________________________ Addition of Refrigerant ______________________________________________ __________________________________________________________ Oil Level ____________________________________________________________ __________________________________________________________ Vibration Levels _____________________________________________________ __________________________________________________________ Addition of Oil ______________________________________________________ __________________________________________________________ Signed _____________________________ Date _______________________________ TCVHE-SVX04D-EN...
  • Page 94 RELEASED 10/Mar/2020 06:59:20 GMT Forms AdaptiView Display Customer Training Checklist Equipment Description, including Equipment Settings how to use the touch screen Viewing the Settings Screen Screen Overview Viewing and Changing Chiller Status Area Equipment Settings Main Display Area/Home Screen Chiller Settings Component Screens Setpoint Sources Main Menu Area...
  • Page 95 RELEASED 10/Mar/2020 06:59:20 GMT Trane - by Trane Technologies (NYSE: TT), a global climate innovator - creates comfortable, energy efficient indoor environments for commercial and residential applications. For more information, please visit trane.com or tranetechnologies.com. Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice.

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