CVGE - CVGE HR

Water cooled liquid chiller with

centrifugal compressor

Sizes : 23 to 80
Installation
Operation
Maintenance

CVGE - CVGE HR Sizes : 23 to 80

With UCP2 control module

B60 IM 012 E
 Foreword
These installation, operation and maintenance instruc- ful operation of this equipment. The services of a quali-
tions are given as a guide to good practice in the installa- fied technician should be employed through the medium
tion, putting into service, operation and maintenance, by of a maintenance contract with a reputable service com-
the user, of Trane CVGE chillers. They do not contain full pany.
service procedures necessary for the continued success-

Warranty
Warranty is based on the general terms and conditions of Failure to have the maintenance procedures carried out
Société Trane or Trane U.K. Ltd. The warranty is void if may entail cancellation of warranty and liabilities by
the equipment is repaired or modified without the written Trane.
approval of Trane, if the operating limits are exceeded or Local code requirements for external wiring and piping
if the control system or the electrical wiring is modified. have to be followed by the installer.
Damage due to misuse, lack of maintenance or failure to Warranty coverage is given only in the case of the unit
comply with the manufacturer's instructions or recom- being started-up by a Trane service engineer.
mendations is not covered by the warranty obligation.

Safety recommendations
To avoid accidents and damage the following recom- 3. Close the starter and control panel doors before pro-
mendations should be observed during maintenance viding electrical power to the unit.
and service visits. 4. Service work on the refrigeration system and the elec-
1. Provide sufficient ventilation in the equipment room trical system should be carried out only by qualified
during refrigerant charging. and experienced personel.
2. The maximum pressure allowable for system leak tes- 5. Before removing a panel for access to the unit for any
ting with dry nitrogen is 7 bar. Always provide a pres- reason, always open the unit master disconnect
sure regulator with the testing equipment. switch, lock it in the open position and remove the
fuses.

General information
About the unit About this manual
Trane CVGE chillers are assembled, pressure tested, Warnings and Cautions appear at appropriate places in
dehydrated, charged and run tested before shipment. For this manual. Your personal safety and the proper opera-
the CVGE-HR, the heat recovery condenser is delivered tion of this machine require that you follow them care-
dismounted to facilitate transport. The information fully. Trane Europe assumes no liability for installations
contained in this manual applies to units designated or servicing performed by unqualified personnel.
CVGE and CVGE-HR.
Unit wiring diagrams, submittals, installation instructions
operation and maintenance literature are attached to the
back of the starter panel door. Read the literature to beco-
me familiar with the unit before start-up. Optional acces-
sories such as the flow switch and spring isolators are
shipped in a separate crate with the compressor lubrica-
ting oil.

2
 Index

Installation
General information ................................................................................................................................2
Reception .................................................................................................................................................4
Lifting and moving instructions.............................................................................................................4
Location and clearances .........................................................................................................................4
Water connections ...............................................................................................................................5-6
Temperature sensor installation and connection ................................................................................7
Electrical connections .............................................................................................................................8
Starter panel layout ..............................................................................................................................12
Control panel layout .............................................................................................................................12

Operation
Refrigerant cycle....................................................................................................................................13
Lubrication system................................................................................................................................15

Initial start-up
Preparation by the installer..................................................................................................................16
Preparation by Trane technician ..........................................................................................................16
Oil charging............................................................................................................................................16
Start-up...................................................................................................................................................16

Chiller control system

Operator interface .................................................................................................................................19
Custom report........................................................................................................................................19
Chiller report ..........................................................................................................................................19
Refrigerant report..................................................................................................................................23
Compressor report ................................................................................................................................24
Operator settings ..................................................................................................................................25
Service settings .....................................................................................................................................28
Daily unit start-up..................................................................................................................................32
Seasonal unit start-up...........................................................................................................................33
Daily unit shutdown..............................................................................................................................33
Seasonal unit shutdown.......................................................................................................................33

Maintenance
Weekly and annual maintenance.........................................................................................................35
Condenser and evaporator cleaning ...................................................................................................35
Control settings .....................................................................................................................................35
Trouble analysis .....................................................................................................................................35
Diagnostic codes ...................................................................................................................................35
Centrifugal chiller operating reports ...................................................................................................37
Remote human interface ......................................................................................................................49
Installation checksheet .........................................................................................................................51
Weekly operating log ............................................................................................................................52
Safety recommendations .....................................................................................................................56
Maintenance contract ...........................................................................................................................56
Training ...................................................................................................................................................56

3
 Installation

CVGE unit nameplate Caution : Do not forget to open shut-off valves (they
The CVGE unit nameplate is found on the control panel are factory closed).
door.
The refrigerant operating charge is not included in the
N° DE COMMANDE
ORDER N° 1 standard Trane warranty cover.
N° DE MODELE
2
MODEL N° Until start-up by Trane service personel, valves, controls
N° DE SERIE
SERIAL N° 3 and electrical panels must remain wrapped in the original
MOIS ET ANNEE DE FABRICATION
MANUFACTURING DATE (MONTH/YEAR) covering as shipped. Oil containers and the loose parts
REFRIGERANT
12 4 box should be stored in a dry and secure place to prevent
CARACTERISTIQUES ELECTRIQUES
ELECTRICAL CHARACTERISTICS
damage or pilferage.
QTE TENSION ±%
QTY VOLTAGE HZ PH IN MAX ID MAX KW MAX.
MOTEUR COMPRESSEUR
1 5 V 6 5 3 9 A 9 A 10
COMPRESSOR MOTOR

MOTEUR VENTILATEUR
Warning : Do not open any valves or connections
12 5 V 6 5 3 9 A 11
CDS FAN MOTOR
which could cause the loss of the refrigerant charge.
MOTEUR POMPE A HUILE
1 5 V 6 5 3 9 A 13
OIL PUMP MOTOR
Initial start-up can only be executed by a Trane Service
RESISTANCES CH. HUILE
2 7 V 10 5 1 1250 W
OIL TANK HEATER
Engineer.
AUXILIAIRES
AUXILIARY 1 7 V 10 5 1 8 A
CIRCUIT CONTROLE
CONTROLE CIRCUIT 1 220 V 10 5 1 1000 VA.MAX
Lifting and moving instructions
TM

88190 GOLBEY FRANCE 1. Rigging slings and spreader bar are to be provided by
the rigger.
2. Recommended sling lengths and sling loadings for a
Reception particular unit size are available from your Trane
All model CVGE chillers arrive on job site completely fac- Sales Office upon request.
tory assembled and wired, ready for start up. On arrival, 3. The machines have four lifting lugs on the unit shell
inspect the unit and accessory box and check the assembly.
contents against the packing note before signing the deli-
very note. Specify any damage or shortage on the delive- Caution : Rigging of the unit should be done with
ry note and send a registered letter of protest to the last extreme care and shocks be avoided by all means.
carrier of the goods within 72 hours of delivery. Notify the Improper handling of the machine may cause internal
local Trane sales office at the same time. damage and shorten the life of certain components.
The unit should be totally inspected within 7 days of deli-
very. If any concealed damage is discovered, send a For all information about dimensions and weight of the
registered letter of protest to the last carrier within 7 days unit, see the lifting drawing provided with the unit.
of delivery and notify the local Trane sales office.
Depending on the purchase order requirements, the units Unit location and clearances
are either shipped with a complete operating charge of The selected location should be flat, levelled to within
R134a or with a refrigerant holding charge (R134a) under 3 mm and of sufficient strength to support the concentra-
a pressure of 1 bar. ted weight of the unit and connecting water piping. For
The oil charge is shipped separately with the unit. upper storey installations, spring type isolators are
Before the initial start-up, units shipped with complete recommended and the total maximum vertical deflection
operating charges must be carefully leak tested (using an of horizontal structural members must not exceed 4 mm.
accurate R134a electronic leak detector). Due to the high weight of the unit parts, the provision of
For units shipped with holding charges, check the hol- lifting gear should be taken into account.
ding pressure ; if the pressure is correct (1 bar), the R134a For unit dimensions and general unit data including
refrigerant quantity mentionned on the unit nameplate piping connection sizes, see the submittal provided with
can be charged by means of a specific pump out unit the unit.
approved for R134a.
Unit isolation
Ifthe pressure is not correct : Isolation pads are provided with each unit (packed in
- Pressurize the unit with 7 bars of dry nitrogen loose parts box) and should be placed between the bot-
- Locate the leaks by using soap and water tom mounting rail of the unit and the foundation. (See the
- Release to the atmosphere submittal joined to the unit).
- Repair the leaks
- Perform another leak test with unit under pressure Starter and control panel
(7 bars of dry nitrogen) Due to its size, the starter panel for 785 to 880kW motors
- Release to the atmosphere cannot be mounted on the units with a supply voltage of
- Vacuum the unit 400V.
- Charge the R134a refrigerant quantity mentionned on For units equipped with evaporator size P or below, the
the unit nameplate by means of a specific pump out main disconnect switch is located at a height of 2m above
unit approved for R134a. the floor. For evaporator QL, RL, and TL, refer to the sub-
mittal joined to the unit to know the exact main discon-
Units which are stored for more than 2 weeks before nect switch location.
being moved to the final location should be leak tested The contractor may install a platform, according to local
within 3 days of their arrival on site. standard to facilitate access.
For unit pad weights, operating weights and recommended

4
Figure 1 : Typical piping lay out (cooling only CVGE)

Cooling tower
fan motor

chilled
water pump Cooling tower

Cooling load

Cooling tower
thermostat
Shutt off valves Condenser
water pump

Cooling water temperature

Strainer outlet 5R53

Thermometers
Flow switch
Shutt off valves Thermometers 6557
Chilled water
temperature outlet
sensor 5R51
Pressure tegulating
valve

Strainer Chilled water Flow

temperature inlet switch
sensor 5R52 6556
Pressure gauges
with shut off
valves Cooling water
temperature inlet 5R54

clearances for tube pulling and normal unit servicing, Water piping and piping connections must meet the fol-
check on submittal provided with the unit. lowing requirements :
1. Connections at the unit must permit removal of the
Assembly water box covers for maintenance and possible tube
CVGE units require no assembly except heat recovery cleaning or removal. Spools or elbows may be used.
units with width dimension above 2.5m which are delive- 2. Piping must be supported and fixed to the building
red with the heat recovery condenser dismounted to faci- near the unit. Isolation type hangers and supports are
litate the transport. recommended.
Assembly of the heat recovery condenser is simple ; the 3. The use of flexible connections which eliminate stress
components have previously been assembled in the fac- and vibration transmission is strongly recommended.
tory for the run test so an easy fitting is guaranteed. All 4. 2 vent holes and drain plugs (1/2" NPT) are installed
necessary gaskets, bolts ,... are shipped with the unit in on the bottom of evaporator and condenser water
the accessory box. boxes.
5. Thermometer wells and pressure gauge connections
Water connections are to be installed in the supply and return horizontal
The evaporator water connections are on opposite ends, lines close to the unit, so that they can easily be used.
for single pass and three pass evaporator and on the These have to be provided by the installer.
same end for two pass evaporator. The connections are 6. Flow switches are to be installed in the upright posi-
on the horizontal axis. tion on a horizontal pipe run with a minimum of five
Condenser water connections are on opposite ends for pipe diameters of straight pipe upstream and downs-
single pass and on the same end for two pass condenser tream of the flow switch. Connection required for the
and are on the vertical axis. optional Trane supplied flow switch = 1" female gas
Single pass heat exchangers may have water flow in thread.
either direction through the unit.
Two pass condensers must be piped so that the water Note :
enters the shell at the bottom connection and leaves the 1. The cooling tower circuit may require a 3 way
shell at the top connection. control valve to provide adequate head pressure
Two and three pass evaporators may be piped so that control.
either connection can be the inlet or the outlet. 2. Locate water pumps so that make up water connec-
Water boxes are provided as standard for 10.5 bar tion is as close as possible to the pump suction
(150 PSI) operating pressure and grooved for Victaulic inlet, and that pumps discharge into the chiller heat
couplings. exchangers.

5
Water treatment Heat recovery control (CVGE-HR only)
The use of untreated or improperly treated water in this The control of the heat recovery circuit is not supplied
unit may result in scaling, algae, erosion, corrosion, or with the CVGE HR unit. It must be furnished and installed
slime. It is recommended that the services of a qualified by the contractor. It is mandatory to control the conden-
water treatment specialist be engaged to determine what sing temperature when the heating load is reduced in the
treatment, if any, is advisable. Trane assumes no respon- heat recovery loop. This can be achieved through the use
sability for equipment failures which are the result of of a thermostat, placed in the return line of the heat reco-
untreated or improperly treated water. very condenser, which controls a three-way valve to
bypass the water coming from the cooling tower. The
Safety valve amount of heat rejected through the condenser piped to
One or several safety valves are factory mounted on the the cooling tower is then controlled to compensate for
compressor suction elbow depending on the local code reduced heating load.
requirements.
Gauge and control tubing Figure 2 : Unit gauge and control tubing
All gauges and control tubing are factory fitted (see connections
Figure 2). Check piping and piping connections before
start-up to be sure they are leak tight and have not been
damaged during shipment or handling. Open the shut-off
LOP
valves only at start-up or at leak testing of the unit. Compressor
B30 HPC
Oil pressure
Thermal insulation HP HOP
The thermal insulation is illustrated figure 3.

Evaporating Evaporator
pressure

B51
Condensing Condenser
pressure

Figure 3 : Thermal insulation

Size 47 to 80 : detail of the motor

and compressor cooling line insulation

A : Standard insulation

B : A + EPV head insulation

cold parts insulation

C : B + motor + motor cooling

line insulation

D : A + motor insulation
+ motor cooling line
insulation

6
Temperature sensor installation and Evaporator entering and leaving water temperature
connections sensors (5R51, 5R52)
Install these standard matched pair chilled water tempe-
Regardless of which control sensors are required for a
rature sensors in the entering and leaving water piping of
particular unit application, always position the sensor
the evaporator. Refer to the same guideline as above
bulbwell far enough from the evaporator or condenser to
(Temperature sensor installation and connection) to
ensure that the sensor reads a good, mixed water tempe-
ensure proper installation. Connect the entering tempe-
rature. Install the bulbwell at 4 o'clock in the water pipe in
rature sensor between terminals J3-5 and J3-6 (module
order to avoid condensation (figure 4).
A11) and the leaving temperature sensor between termi-
nals J3-3 and J3-4 (module A11).
When installing the standard and optional temperature
sensors described below, be sure to follow these general
Condenser entering and leaving water temperature sen-
guidelines :
sors (5R53, 5R54)
1. Add thermastic paste to each bulbwell before inser-
Install this matched thermistor pair in the condenser
ting the sensor.
water piping ; refer to the general guidelines at the begin-
2. Ensure that the sensor "bottoms out" at the base of
ning of this section to ensure proper sensor installation.
the bulbwell.
Connect the leaving condenser water temperature sensor
(5R53) between terminals J3-7 and J3-8 (module A11),
Caution : To prevent possible sensor malfunction due
and the entering condenser water sensor (5R54) between
to electrical noise, run sensor leads in conduit.
terminals J3-5 and J3-6 (module A11).
However, do not route sensor leads in conduit with
other conductors carrying voltages of 30 VAC or more !
Note : Both matched pair sensors (entering+leaving
water temperature for condenser + evaporator) are
All field-installed temperature sensors are identified with
shipped as standard ; the installer/operator can intall
a part number and serial number that appear on the sen-
them or not, as required.
sor body. Notice, too, that both sensors of a matched pair
are marked with the same serial number.
Chilled water reset (CWR) sensors
Chilled water reset is designed for those applications
Extending sensor leads
where the system operates at part load, and does not
The leads on current temperature sensors may not reach
require design chilled water temperature at part load. In
all the way back to the UCP2. If this is the case with your
these cases, the leaving chilled water temperature set-
installation, route the sensor leads to a junction box
point can be raised using the chilled water reset.
mounted in a convenient location. Splice the sensor leads
Centrifugal units are shipped as standard with the four
inside the junction box, then route the added length of
water temperature sensors (entering/leaving for conden-
wire back to the control panel in conduit. (Remember that
ser/evaporator) ; these sensors can be used for return
jacketed cable can be cut to length).
evaporator water CWR or based-load CWR if the function
in the UCP2 "operator setting" menus is enabled at first
Note : To extend the leads of the sensors, use 0,75 to
start-up.
1,5 mm2, 600 V wire. The wire added between the junc-
If ambient-based CWR is desired, install the sensor 5R3 in
tion box and the control panel must be either shielded
the building's fresh air intake duct or on the north wall of
or run in conduit. If shielded cable is used, be sure to
the building. Be sure that it is protected from direct sun-
tape off the conduit, do not run them in the same
light and sheltered from the elements. The sensor is
conduit with other circuits carrying 30 VAC or more.
connected between terminals J5-5 and J5-6 (module A11)
in the UCP2 panel ; this function must be enabled in the
UCP2 "operator setting" menus at first start-up.

Figure 4 : Temperature sensor bulbwell

47 38 1/2” NPT

61
+0,5
Ø INT. = 6,5 – 0
18
143

201

7
Table 1 : UCM field electrical connections (1)

Description of Electrical Terminal Installation guidelines Potential

electrical connection(s) designator(s) block
Leaving evaporator 5R51 J3-3, -4 Install sensors in evaporator Low voltage (i.e. ; 30V
water temperature sensor (2) entering and leaving water pipings ; A.C. or less)
Entering evaporator 5R52 J3-1, -2 see note 3.
water temperature sensor (2)
(matched pair)
Leaving condenser water 5R53 J3-7, -8 Install sensors in condenser Low voltage (i.e. 30V
temperature sensor (2) entering and leaving water A.C. or less)
Entering condenser water 5R54 J3-5, -6 pipings ; see note 3.
temperature sensor (2)
(matched pair).
Standard ambient temperature 5R3 J5-5, -6 Install 1 sensor in fresh air
sensor ; (2) intake duct or on north wall of
building. See note 3.

Notes :
(1) Refer to filed connection diagram that shipped with unit, or to typical field connection diagram.
(2) Requires low-voltage conductors (30V or less ; 0.75 to 1.25 sq.mm, 600V wire) run in separate conduit.
(3) See "Temperature sensor connections" for sensor installation guidelines.

Electrical connections 2. Voltage between 660 and 6600 V

All wiring should comply with local and national codes.
Type and location of disconnect switches should comply Remote mounted starter
with local and national codes. For installation wiring use - three phase power supply to the starter (mains connec-
copper conductors only. Unit terminals are not designed tions)
to accept other type of wiring. The use of aluminium wire - single phase power supply to the auxiliary panel
may cause galvanic corrosion and/or overheating at the (220-240 V)
connection points with resultant equipment failure. - wiring between the starter and the auxiliary panel to
Determination of the size of the conductors is the instal- connect the current transformers (115 V) plus one shel-
ler responsability. Motor characteristics and wiring dia- ded cable
grams are given at time of the order. A copy of the wiring
diagrams is provided with the unit. Copies are also avai- 3. Wiring of the chilled water and condenser water pump
lable from your Trane Sales Office (figure 5). motor starters, flow switches to the control panel.

Warning : Open the unit power fused disconnect swit- 4. Wiring between control panel and temperature sensors
ch before performing any work. Failure to do so will (see paragraph "Temperature sensor installation and
cause hazardous conditions and possible injury to ope- connections").
rating personnel due to electric shocks.
Note : Connections are directly on components output.
1. Voltage between 220 and 660 V max : An oil sump heater is used to prevent excessive refri-
gerant absorption by the oil. Acceptable voltage varia-
1.1 Unit mounted starter : tions are limited to 10%.
- three phase power supply to the starter (mains connec-
tion) Caution : All single phase power must always remain
- single phase power supply to the starter (220-240 V) energized.

1.2 Remote mounted starter (Trane supply)

- three phase power supply to the starter (mains connec- Table 2 : Maximal capacity of the connections
tion)
- single phase power supply to the starter (220-240 V) Oil pump 4 mm2
- wiring between starter and compressor motor
Oil sump heater 10 mm2
- three phase power wiring between starter and oil pump
(700 W) Control 2.5 mm2
- single phase power supply between starter and oil hea-
ters (220-240 V/2500 W)
- single phase power supply to the control panel
(220-240V)
- IPC connection between starter panel and control panel
(2 wire twisted link)

8
 Caution : After connecting the motor leads meg the motor from the
1. Care must be exercised in cutting power cable starter panel to check the integrity of motor leads and the
access openings and pulling power cables. Do not motor itself. The minimum acceptable resistance is 10
allow steel shavings, copper wire particles or cable megohms.
insulation to drop inside the starter housing or
upon any components. Properly shield and protect Caution : Do not meg the motor while the unit is under
from damage all contactors, relays, bars, terminal vaccum. Doing so would lead to motor destruction.
strips and control wiring while pulling in power
cables. Screw torques
2. Install power cables as per the connection diagram The tightening torque for cross head and slothead screws
supplied. Trim insulation properly and do not let is given in Table 2, by screw diameter in millimetres.
insulation chips fall into the device or its compo-
nents. Final connections to be supervised by the
Trane start-up technician.

Connections on motor terminals

Caution : Do not exert any force or torque on motor

terminals. They must not support the cable stress.

Remote mounted starter

Connect the external motor leads to the studs. When tigh-
tening the motor lead, be sure to use a back-up wrench
on the bottom nut to avoid cracking the porcelain.
Nuts should be tightened to the following torque values.

Table 3
Stud nut size Torque
1/2" 19,5Nm
5/8" 34,5Nm

Figure 6 : Power connections on the starter

Range 800 A Range 1000 A Range 1250 A Range 1600 A

13
16x11
9 12,5
40
25
33

15
17,5

20
17
10

e 8,5 33 8,5 14 35 14 19 25 19 20 40 20
50 63 63 80

Type1 Type2 Type3 Type4

9
Figure 5 : Typical customer unit mounted
starter
Trane wiring
Customer wiring

L1
L2
L3

K
A 16
B 15
1T10 C 14 1K4
D 21

6
L2
L3

1Q11 1Q10

1F25

L2
/1.3 L3

1Q8
69

70

1T2

220 V

1XL
220…240V L
1XN
50 Hz Ñ

A11 Chiller module

A15 Option module
X.X2... Control terminal block
1F25 Compressor fuse
1K4 Protection relay
1Q1...8 Circuit breaker
1Q10 Disconnect switch
1Q11...31 Circuit breaker
1T2...5 Transformer
1T10...20 Current transformer
1X Control terminal block
5R3 Ambient air sensor
5R51 Leaving EVP water temp..sensor
5R52 Entering EVP water temp. sensor
5R53 Leaving CDS water temp. sensor
5R54 Entering CDS water temp. sensor
6F51...53 Water pump overload relay
6K51 Chilled water pump contactor
6K52 Condensing water pump contactor
6K53 HR condensor water pump contactor
6S1 ON/OFF switch unit
6S2 Unit emergency stop
6S5 Reset fault
6S56 EVP water flow switch
6S57 CDS water flow switch
6S58 HR CDS water flow switch
K Ground fault relay
6 Auxiliary circuit transformer
2 Do not use with option 6
3 Remove this jumper when using this entry
4 See detail if option K mounted
5 This option includes the module A15.
S1 Condensing pressure information
S2 Compressor running
S3 Alarme
S4 RLA compressor information
S5 Head relief request
S6 Maximum capacity
E1 External current limit setpoint
E2 External chilled water setpoint

10
Table 4 : Crosshead and slot head screw torques

Screw dia. mm 2.5 3.0 3.5 4 5 6 8 10

Torque, Nm. 0.6-0.8 0.7-0.9 1.0-1.3 1.5-2.0 2.4-3.2 3.0-4.0 4.2-5.6 4.8-6.4
Torque, FT-LB 0.4-0.6 0.5-0.6 0.7-0.9 1.0-1.4 1.7-2.2 2.0-2.8 3.0-4.0 3.4-4.5

Table 5 : Large contactor tightening torques

Screw dia. mm 5 6 8 10 12 16
Torque, Nm. 2.4-3.2 3.6-4.8 7.2-9.6 12-16 18.6-24.8 36-48
Torque, FT-LB 1.7-2.2 2.5-3.4 5.1-6.8 8.4-11.3 13.0-18.0 25-34

Table 6 : Steel bolt tightening torques

Screw dia. mm 6 8 10 12 14 16
Torque, Nm. 9-11 16-20 32-38 52-64 63-77 100-120
Torque, FT-LB 6-8 12-14 23-27 36-44 45-55 70-84

Connecting strips Table 8 : Screw tightening torques (10%)

For units where connections are made with strip copper, flexible copper connecting strip
the following screw tightening torques should be used (in
the case of two different size sections being joined toge-
Section Screw dia. Torque Torque
ther, use the smaller value) :
(mm) (mm) (Nm) FT-LB
Table 7 : Screw tightening torques (10%) 9 6 6 4
rigid copper connecting strip 13 6 6 4
15.5 8 12 8.5
Section Screw dia. Torque Torque
20 8 18 13
(mm) (mm) (Nm) FT-LB
24 8 18 13
2 x 15 1x8 12 8.5
32 10 24 17
3 x 20 1x8 19.5 14
40 10 24 17
3 x 25 1x8 20.5 14.5
50 2 x 10 18 13
3 x 30 1 x 10 26.5 19
63 2 x 12 25 18
3 x 40 1 x 10 26.5 19
80 4 x 10 12 8.5
5 x 30 1 x 12 69 49
100 4 x 10 18 13
5 x 40 1 x 12 69 49
5 x 50 2 x 10 19.5 14
5 x 60 2 x 12 29.4 21 Figure 7
5 x 80 4 x 10 12 8.5
5 x 100 5 x 12 18.5 13 Contact
washer
10 x 90 4 x 12 24.5 17
10 x 100 5 x 12 18.6 13
10 x 120 5 x 12 27.5 20
10 x 160 9 x 12 26.5 19
10 x 200 9 x 16 41 29

Flat
Rigid copper strip washer
Screw torque values are given in Table 5. Values are plus
or minus 10 percent.
Figure 8
Flexible copper strip
Screw torque values are given in Table 6. Values are plus Lockwasher
or minus 10 percent. or
contact washer
Screws
Steel screws must be zinc-coated, chrome-plated or gal-
vanised. Non-steel screws must be nickel or chrome elec-
tro-tinned. All screws must be to DIN ISO 898 class 8.8
minimum.
Flat
Mounting washer
The connections should be made as shown in Figures 7
and 8.
In the case of connection being made to flexible copper
strip, the use of a counter plate assures good contact.

11
Figure 9 : Exterior view of starter and control panel

Figure 10 : Interior view of starter panel Figure 11 : Interior view of control paneL

12
 Operation
Refrigerant cycle Two stage compression
The refrigerant cycle, schematically illustrated in Figure Using Figure 12 as a guide, refrigerant gas enters the first
13 is as follow. stage inlet, passes through the prerotation vanes into the
The evaporator on the compressor suction side main- first stage impeller. The vanes assure proper gas flow
tains a lower pressure and a lower temperature than the direction to the impeller. The impeller accelerates the gas
condenser. Liquid refrigerant entering the evaporator flow. The gas passes internally into the second stage inlet
expands through a series of orifices causing some of the through the second stage inlet guide vanes. The second
liquid to flash, thus chilling it to evaporator temperature. stage impeller accelerates the gas again and discharges it
This chilled flash gas and refrigerant mixture is then into the diffuser. The diffuser converts the high velocity
spread throughout the evaporator by a distributor passa- of the gas into pressure. The high pressure gas is then
ge running the full shell length. Distributor openings discharged into the condenser.
discharge liquid and flash gas against deflectors. This
produces a spray effect, uniformly wetting tube surfaces. Motor cooling system (Fig. 13)
Heat transfers from the tubes to the refrigerant causing The motor windings are cooled by liquid refrigerant from
the refrigerant to vaporize. This evaporative process chil- the condenser. Flow of refrigerant to the motor is control-
ls water within the tubes to a predetermined temperatu- led by a calibrated orifice. Liquid refrigerant and refrige-
re. rant gas from the motor are discharged into the evapora-
Refrigerant vapor and flash gas generated in this process tor.
pass upward through the eliminator, where entrained
refrigerant droplets are removed. After the eliminator the Lubrication system (Fig. 13)
gas passes through the enlarged chamber at the evapo- The compressor journal bearings and the motor bearings
rator top and into the compressor. are pressure lubricated by an oil pump driven by an elec-
This low pressure vapor now passes through two stages tric motor. Oil under pressure is also sprayed over the
of compression and by centrifugal action is compressed compressor gears. During operation, oil is supplied to the
to the higher condenser pressure. This high pressure gas bearings and gears through an oil cooler and oil filter.
discharges into the condenser. Design oil temperature is maintained by the oil cooler
A baffle in the condenser prevents direct gas impinge- located inside the evaporator. A relief valve bypasses oil
ment against the tubes. Although some gas aspirates back into the oil sump if oil pressure exceeds design ope-
through the baffle, the remainder travels along the open rating pressure.
shell portion and is condensed by relatively cold water An oil pressure safety control in the unit control panel
passing through the tubes. provides oil pressure and temperature failure protec-
The condensed refrigerant collects in the sump at the tions.
condenser shell base. From the sump, it expands through
an orifice into the economizer.
The economizer is an intermediate pressure chamber
vented to the second stage suction chamber of the com-
pressor. Since second stage suction pressure is lower
than condensing pressure, a portion of entering liquid
flashes. This chills liquid remained in the economizer to
the temperature corresponding to the second stage suc-
tion pressure. Resulting flash gas passes through an eli-
minator to remove any entrained liquid refrigerant. It
then passes through a vent pipe to the compressor
second stage.
The liquid then flows from the economizer to the evapo-
rator, completing the refrigerant cycle.

13
Figure 12A : Compressor cross section (sizes 23 to 45)

Figure 12B : Compressor cross-section (sizes 47 to 80)

14
Figure 13A : Lubrication system - refrigerant flow diagram - cooling only unit

Figure 13B : Lubrication system - refrigerant flow diagram - heat recovery unit

15
 Initial start-up
Preparation by the installer 3. Sight glasses
The installer must make sure that the following points are 4. Welded joints
checked before the Trane Service Agency is asked to per- 5. Gauges and gauge connections
form the initial start-up. 6. Relief valve
1. Chilled water circuit operational, filled with water, pres- Follow the recommended procedure.
sure tested, purged, strainer cleaned after two hours
operation of the chilled water pump. Oil charging
2. Condenser water circuit operational, filled with water, The oil charge as well as an oil filter cartridge are furni-
pressure tested, purged, strainer cleaned after two shed with the machine. The oil should be charged into
hours operation of the condenser water pump. Cooling the oil tank by means of a pump and the filter installed.
tower operational, water supply and overflow checked, After charging, the oil heaters are to be switched on (swit-
fan operational. ch 1Q31).
3. Heat recovery condenser water circuit operational, It is mandatory to have the heaters in operation for at
filled with water, pressure tested, purged, strainer clea- least 24 hours prior to the initial unit start-up.
ned after two hours operation of the heat recovery loop
water pump. Caution : Once the machine is charged with oil and
4. Heat recovery control installed and operational. refrigerant, the oil heaters must never again be swit-
5. Thermometers and manometers installed in chilled ched off for more than 4 hours. The oil temperature
water and condenser water inlet and outlet. should never drop below 40°C.
6. Chilled water pump, condenser water pump, cooling
tower fan electrically interlocked with unit control Approved oil
panel. The approved oil for all centrigal units is Trane oil :
7. Flow switches installed and wired to unit control panel. OIL 020E or OIL 021E.
8. Check customer wiring and tightening of all terminals. The lubrificating oils recognised by Trane have been sub-
jected to extensive testing in our laboratories and have
Table 9 : Oil charging been found to give the required satisfactory results for
use with Trane compressors.
Size Oil (liters) The use of any oil not conforming to Trane required stan-
23 to 45 42 dards is at the sole responsability of the user and could
result in warranty cancellation.
47 to 80 55

9. Temperature sensors installed in entering and leaving Table 10 : Normal gauge readings
CDS and EPV water line and wired to unit control panel.
10. All electrical connections made. Evaporator pressure 2.1 to 2.4 bar
11. Sufficient cooling load available at day of start-up Condenser pressure (1) 7.3 to 13 bar
(minimum of 50% of design load).
Differential oil pressure (2) 1.0 to 2.0 bar

Preparation by Trane technician (1) Condenser pressure is dependent on condenser water temperature. The pressure
should be equal to the saturation pressure of the refrigerant at a temperature of
1.2°C to 4°C above the leaving condenser water temperature.
Leak test (2) Difference between oil high pressure gauge and low pressure gauge readings.
All machines whether supplied with a holding charge
only or with the full R134a operating charge should be Normal operating conditions
carefully checked for refrigerant leaks before start-up. After system water temperatures stabilize, the gauge rea-
Particular attention should be paid to : dings provided in Table 10 should be observed.
1. Gasket joints
2. Bolt heads

Table 11 : General data

CVGE 23D 26E 30F 34G 39H 45J 50K 56L 63M 71N 80P 80T
Shipping weight (1) (3) (kg) 3910 4140 4430 5690 5930 6120 9820 10090 10330 10620 10940 15450
Operating weight (2) (3) (kg) 4300 4550 4900 6250 6500 6770 10660 10980 11400 11750 12200 19350
Refrigerant charge R134a (kg) 300 300 300 370 370 370 470 520 580 650 730 1250
Motor size (kw) 211 235 265 287 325 373 436 436 483 535 589 785
Full load current (4) (6) (A) 327 364 417 449 511 598 693 693 751 836 942 1240
Starting (5) (6) (A) 654 655 667 988 971 970 1040 1040 1389 1379 1413 2108

Notes :
(1) With refrigerant charge and starter, nominal heat exchanger size (without starter for size 80T).
(2 )Including water in exchangers.
(3 )Weights given for information only, refer to the unit submittals provided with the unit.
(4) At nominal motor kW.
(5 )Star-delta start.
(6) At 400/3/50.

16
 Chiller control system
Unit control panel power loss. Inputs and Outputs are chilled water system
Safety and operating controls are housed in the UCP2 level I/O including evaporator and condenser water tem-
unit control panel and the starter panel (Control Panel peratures, outdoor air temperature, evaporator and
layout is illustrated in figure 14). condenser water pump control, status and alarm relays,
external Auto-Stop, emergency stop and external
The UCP2 control consists of a modular design partitio- condenser heating (heat pump)
ned by major function or group of functions. All modules
communicate with each other thru the IPC circuit. Circuit Module (A12)
The Circuit Module serves as an input/output expander
Major components within each of these control groups and has inputs and outputs associated with motor, refri-
are described below. gerant, and lubrication, functions.

Unit-mounted temperature sensors, and functional These include, motor winding temperatures, oil tempera-
switches provide analog and binary inputs to the various ture, oil pressure differential, oil pump discharge pressu-
modules. re ; valve control vent line valve operation (CVGE 47 to
The "microcomputer-based" modules are described 80), oil tank heater operation.
below. All wiring of the modules are to pluggable termi-
nal blocks. Stepper Module (A13)
The Stepper Module drives the stepper motor Inlet Guide
Chiller module (A11) Vane Centrifugal Actuator on Chillers. The Stepper
The Chiller Module, located in the UCP2 control panel, is Module receives from the Chiller Module the direction
the Master of the chiller communicating commands to and distance to drive the inlet guide vanes and then gene-
other modules and collecting data/status/diagnostic rates the appropriate signals to operate the stepper
information from other modules over the IPC (Inter motor. The Stepper Module has inputs and outputs used
Processor Communications Link). The Chiller Module to support functions on the stepper module. These inclu-
performs the Leaving Chilled Water Temperature and de saturated evaporator refrigerant temperature, com-
Limit Control Algorithms arbitrating capacity against any pressor discharge temperature (on HGBP option), inlet
operating limit the chiller may find itself working against. guide vane binary position indicator (B.P.I.), and satura-
The Chiller Module contains non-volatile memory both ted condenser refrigerant temperature.
checking for valid set points and retaining them on any

Figure 14 : UCP2 Control Panel

17
Option Module (A15)
The Options Module provides control or interface requi- Clear Language Display Module (A53)
rements for a number of options. Features supported by The Clear Language Display Module, located on the UCP2
the Options Module include, Heat Recovery, External control panel door, provides display of chiller data and
Chilled Water Setpoint, External Current Limit Setpoint, access to operator/serviceman controls, set points and
Percent RLA of Compressor, Tracer Temperature Sensor, chiller setup information. All information is stored in non-
Head Relief Request, Maximum Capacity relay, and volatile memory in the Chiller Module ; the Clear
Tracer Controlled Relay. Language Display and the Chiller Modules work together
to display and store information requiring non-volatility.
Starter Module (1A14) The clear Language Display Module (A53) is shown in
The Starter Module located in the Compressor Motor figure 15.
Starter Panel provides control of the Starter when star- The front face of the Clear Language Display Module
ting, running and stopping the motor. The Starter Module consists of a LCD Display, a LED, and a keypad. The LCD
provides interface to and control of Y-Delta, Direct-Line, Display presents the operating status of the unit, opera-
and of Auto-Transformer. The Starter Module also pro- ting set points, operating conditions, unit configurations,
vides protection to both the motor and the compressor in service test, unit configuration, and diagnostics in a clear
the form of starting and running overload, phase rever- language display. The LED is red and will only be "ON"
sal, phase loss, phase unbalance, momentary power loss, when a manual reset is required to restore the unit to full
and compressor surge. See "as built" wiring diagrams operation. The keypad has 16 keys arranged in a 4 x 4
that ship with the unit for specific details. matrix.

Figure 15 : Clear Language Display Module

18
Operator Interface

All operator is through the key/display on the front of the unit control panel as shown in figure 15. The keypad consists
of four selectable Report Group keys, four Settings Group keys, six keys to change setpoints, unit configuration and
variables, the AUTO key, and the STOP key.

Report Group Keys

The four Report Group keys for CVGE units are :

- Custom Report Group

- Chiller Report Group
- Refrigerant Report Group
- Compressor Report Group

Selecting and pressing a Report Group key will display, the header display for that Report Group showing the title of the
Report Group and a summary of the reports in a Report Group.

The NEXT and PREVIOUS keys cause the display to step through the displays in a Report Group. The Report Group dis-
play will wrap around top to bottom as the display is scrolled through the sequence using the NEXT or PREVIOUS keys.

Custom Report

The Custom Report Group can be programmed by the operator and can contain a maximum of 20 reports. To add a
report to the Custom report Group, press the "+" key when the desired report is being displayed from its normal report
location. To remove a report from the Custom report Group, press the "-" key when the desired reports is being displayed
in the Custom Report.

Report heading :

User Define Custom Report

Press (Next) (Previous) to Continue

Followed by selected reports. If no reports are selected to be in the Custom Report Group, the second entry is :

See Operators Manual to select entries.

Chiller Report
The Chiller Report Group Sequence is as follows :

Report heading :

Chiller Status, Wtr Temps & Setpts

Press (Next) (Previous) to Continue

Chiller Operating Mode

Friendly mode line 1

Friendly mode line 2

Friendly mode line 1 is indicative of a unit mode. Friendly mode line 2 is usually a verbal continuation of line 1 and can
be viewed as a continuous message along with line 1. In some cases Friendly mode line 2 is the display of an associa-
ted timer or system parameter.

19
[Friendly mode] will be one of the following :

FRIENDLY
MODES

FRIENDLY MODE (First line/Second line)

Display is Blank
Resetting
Local Stop : Cannot be overridden by any External or Remote Device
Remote Display Stop : Chiller may be set to Auto by any Ext or Rmt Device
Remote Run Inhibit From Remote Computer
Remote Run Inhibit From External Source
Remote Run Inhibit From Tracer
Heat Sink Temperature Start Inhibit
Diagnostic Shutdown Stop
Diagnostic Shutdown Auto
Auto
Waiting For Evaporator Water Flow
Auto
Waiting For a Need To Cool
Auto
Waiting For a Need To Heat
Wainting For Tracer Communications To Etasblish Operating Status
Starting Is Inhibited By Stagered Star :
Time Remaining : MIN : SEC

Starting Is Inhibited By Restart

Inhibit Timer : Time Remaining [Min : SEC]
Establishing Cond Water Flow
Establishing Oil Pressure
Establishing Cond Water Flow
PreLubrication - [XX] Sec Remaining
Cond Water is Flowing
PreLubrication - [XX] Sec Remaining
Cond Water Is Flowing
Establishing Oil Pressure
Cond Water is Flowing
Performing IGV, BPI search and calibration

Unit Is Running
Unit Is Running
Capacity Limited By High Current
Unit Is Running
Capacity Limited By Phase Unbalance
Unit Is Running
Capacity Limited By High Cond Press
Unit Is Running
Capacity Limited By Low Evap Temp

20
 Unit Is Running
Capacity Limited By Vane Open Travel Stop
Unit Is Running
Limited by Capacity Limited By Vane Closed Travel Stop
Unit Is Running
Unit Is Running In Surge Condition
Unit Is Running
Capacity Limited By Pulldown Rate Based Soft Loading
Unit Is Running
Capacity Limited By Current Based Soft Loading

Unit Is Running ; Hot Water Control

Unit Is Running ; Hot Water Control
Capacity Limited By High Current
Unit Is Running ; Hot Water Control
Capacity Limited By Phase Unbalance
Unit Is Running ; Hot Water Control
Capacity Limited By High Cond Press
Unit Is Running ; Hot Water Control
Capacity Limited By Low Evap Temp
Unit Is Running ; Hot Water Control
At Vane Open Travel Stop
Unit Is Running ; Hot Water Control
At Vane Closed Travel Stop
Unit Is Running ; Hot Water Control
In Surge Condition
Unit Is Running ; Hot Water Control
Pulldown Rate Based Soft Loading
Unit Is Running ; Hot Water Control
Current Based Soft Loading
Unit Is Running in min. Cap ; Hot Water Control
Time Remaining HR : MIN : SEC

Unit Is Running ; Base Loaded

Unit Is Running ; Base Loaded
Capacity Limited By High Current
Unit Is Running ; Base Loaded
Capacity Limited By Phase Unbalance
Unit Is Running ; Base Loaded
Capacity Limited By High Cond Press
Unit Is Running ; Base Loaded
Capacity Limited By Low Evap Temp
Unit Is Running ; Base Loaded
At Vane Open Travel Stop
Unit Is Running ; Base Loaded
At Vane Closed Travel Stop
Unit Is Running ; Base Loaded
In Surge Condition
Unit Is Running ; Base Loaded
Pulldown Rate Based Soft Loading
Unit Is Running ; Base Loaded
Current Based Soft Loading

Unit Is Running in Hot Gas ByPass

Unit Is Running in Hot Gas ByPass
Time Remaining HR : MIN : SEC

21
 Unit Is Running in Minimum Capacity
Unit Is Running in Hot Gas ByPass
Time Remaining HR : MIN : SEC

Panic Shutdown
Post Lubrication
Time Remaining :
[XX]
** Combine with Reset Inhibit **
Starter Guide Vane Actuator Test/Opening Inlet Guide
Inlet Guide Vane Actuator Test/Closing Inlet Guide

Chiller Report

The chiller Report Group sequence is as follows.

Active Chilled Water Setpoint/Evap Leaving Water Temp

Active Chilled Water Setpoint : XXX.X F/C

Evap Leaving Water Temp : XXX.X F/C

If the chiller is in the hot water control state, the following display is displayed :

Active Hot Water Setpoint : XXX.X F/C

Cond Entering Water Temp : XXX.X F/C

Active Chilled Setpoint/Chilled Water Setpoint Source Setpoint

Active Chilled Water Setpoint : XXX.X F/C

[Settings source] CWS : XXX.X F/C

Settings source will be one of the following : Front Panel, Tracer, External source,

Active Hot Water Setpoint : XXX.X F/C

[Settings source] CWS : XXX.X F/C

Active hot water setpoint/Hot water setpoint source

The following will be displayed only if the chiller is in the hot water control state.

Active Hot Water Setpoint : XXX.X F/C

[Settings source] CWS : XXX.X F/C

Settings source will be one of the following : Front Panel, Tracer, External source,

Evaporator Entering Leaving Water Temperatures

Evap Entering Water Temp : XXX.X F/C

Evap Leaving Water Temp : XXX.X F/C

Condenser Entering and Leaving Water Temperatures

Dashes will be displayed for condenser entering or leaving water temperature if the corresponding input is open.

Cond Entering Water Temp : XXX.X F/C

Cond Leaving Water Temp : XXX.X F/C

Active Current Limit Setpoint

Active Current Limit Setpoint : XXX %

22
Active Current Limit Setpoint/Current Limit Setpoint Source Setpoint

Active Current Limit Setpoint : XXX %

[settings source] CLS : XXX %

Settings source will be one the following : Front Panel, Tracer, External Source.

Outdoor Temperature
If the outdoor air temperature input is open or not installed and Outdoor Air Reset is not enabled, display "-----" in place
of "XXX.XF". Otherwise display the temperature received from the CHILLER MODULE.

Outdoor Air Temperature : XXX.X F/C

Heat Recovery Temperatures

The following will be displayed only if the Heat Recovery Option is installed :

Aux/Heat Rcvy Entrg Wtr Temp : XXX.X F/C

Aux/Heat Rcvy Lvg Wtr Temp : XXX.X F/C

Chilled Water Setpoint Source

Chld Wtr Setpt Source : [settings source]

Reset Condition : [reset condition]

Settings Source will be one of the following : Front Panel, Tracer, External Source.
Reset Condition will be one of the following : None, Outdoor Temp, Return Wtr Temp.

Current Limit setpoint Source

Cur Lim Setpt Source : [settings source]

Press <Next> <Previous> to Continue

Settings source will be one of the following : Front Panel, Tracer, External Source.

Hot Water Setpoint Source

The following will be displayed only if Heat Pump Control is Enabled :

Hot Wtr Setpt Source : [settings source]

Press <Next> <Previous> to Continue

Settings source will one of the following : Front Panel, Tracer, External Source.

Refrigerant Report

The refrigerant Report Group sequence is as follows :

Report Heading

Refrigerant Temp & Pressure Report

Press <Next> <Previous> to Continue

Evaporator and Condenser Refrigerant Pressure

Evap Rfgt Pressure : XXX.X psig/kPa

Cond Rfgt Pressure : XXX.X psig/kPa

Saturated Evaporator Temperature/Evaporator Refrigerant Pressure

This screen was added for CTV UCP2 Phase C Release.

Saturated Evap Temp : XXX.X F/C

Evap Rfgt Pressure : XXX.X psig/kPa

Satured Condenser Temperature/Condenser Refrigerant Pressure

Saturated Cond Temp : XXX.X F/C

Cond Rfgt Pressure : XXX.X psig/kPa

23
Saturated Evap Temp and Discharge Temp.

Sat Evap Rfgt Temp : XXX.X F/C

Compressor discharge temp : XXX.X F/C

Compressor Report

The compressor Report Group sequence is as follows :

Report Heading :

Compressor Hours, Starts & Amps

Press <Next> <Previous> To Continue

Differential Oil Pressure, Oil Temperature

Differential Oil Pressure : [status]

Oil tank temp : XXX.X F/C

The possible value for [status] is "Open" or "Closed".

Inlet Guide Vane position

Inlet Guide Vane Position : XXX.X % Open

Inlet Guide Vane Position : XXX.X Degrees

Compressor Phase Current % RLA

Compressor Phase Currents - % RLA

A XXXX.X % B XXXX.X % C XXXX.X %

Compressor Phase Currents Amps

Compressor Phase Currents - Amps

A XXXX.X Amps B XXXX.X Amps C XXXX.X Amps

Compressor Phase Voltages

The following will be displayed only if the Line Voltage Sensing Device is Installed.

Compressor Phase Voltages

AB XXXX V BC XXXX V CA XXXX V

Compressor Power Factor and Watts

The following will be displayed only if the Line Voltage Sensing Device installed.

Compressor Power Factor : XX %

Compressor KiloWatts : XXXXX KW

Compressor Winding Temperatures

Compressor Winding Temperatures

W1 XXX F/C W2 XXX F/C W3 XXX F/C

Compressor Starts and Running Time

The starts and hours counters are displayed as follows :

Compressor Starts : XXXXX

Compressor Running Time : HRS : MIN : SEC

HGBP Time
The following will be displayed only if HGBP is installed in the unit.

HGBP Time : HTS : MIN : SEC

Press <Next> <Previous> to Continue

24
Settings Group Keys

The 4 Settings Group keys for UCP2 are :

- Operator Settings
- Service Settings
- Service Tests
- Diagnostics

Operator Settings Group

The Operator Setting Group sequence is as follows :

Report Heading

Chiller Water & Current Limit Setpts

Press <Next> <Previous> to Continue

Following proper password entry or suppression the remaining sequence will follow :

If the Menu Settings Password is Enabled in the Service Setup Group, following each setting group heading the follo-
wing will be displayed :

Settings In This Menu Are [status]

[password message]

Likewise, if the Menu Settings Password is Disabled in the Service Setup Group, the above screen will be suppressed.

The possible values for status are "Locked" or "Unlocked". If the password status is locked, the password message will
be "Enter Password to Unlock". The user will then depress "-, +, -, +, -, +" followed by the <Enter> key. The password
keystrokes will be echoed to the screen as a visual aide. The last six keystrokes represent the current password and up
to twenty keystrokes can be entered. An incorrect password or the twenty-first keytroke will result in the password mes-
sage "Invalid Password".

If the password status is unlocked, the password message will be "Press <Enter> to Lock". Pressing <Enter> locks the
settings in ALL menus. If the password is entered to unlock the settings in ALL menus.

Whenever a password in use the "Press <+><-> to change setting" message will be suppressed on setpoint screens. Any
attempt to change the setting will result in the message "Setting is Locked". The password once entered will remain valid
until canceled.

Time Of Day Setting

Current Time/Date HH : MM Xm Mon, XX XXXX

<Enter> to Change : <Next> to Continue

The top level "Current Time/Date" will be displayed when this screen is first selected. Pressing the <Next> or <Previous>
key will go to the next or previous screen as usual.

If the <Enter> key is selected, five separate screens can be displayed with which the time may be set. The "Current
Time/Date" will be displayed on line one of each of these screens. Each of these screens will change one element of the
current time/date. The second line of each screen will indicate which element of the current time/data is being changed
as well as its current value. The instructional messages which are normally displayed on line two will not be present
although the instructions which would normally be displayed are still valid ...i.e. if the setpoint has been changed,
<Enter> or <Cancel> must be pressed to continue. If the first time changing screen is being displayed and the <Previous>
key is pressed, the top level "Current Time/Date" screen will be displayed and the <Enter> key will have to be selected
to re-enter the time changing screens. If the fifth time changing screens is being displayed and the <Next> key is pres-
sed, the next screen will be displayed. If <Previous> is selected at this point, the top level "Current time/Date" screen will
be displayed and the <Enter> key will have to be selected to re-entrer the time changing screens.

In order to change an element of the current time/date, select <Enter> from the top level "Current Time/Date" screen to
enter the time changing screens. Hit <Next> or <Previous> to get to the proper screen. Press the <+> <-> keys to chan-
ge the element to its proper value and press the <Enter> key to store the new time/date. A message "Updating Chiller
Clock. Please Wait" is displayed for two seconds after the <Enter> key is pressed.

25
The five time changing screens are as follows :

Current Time/Date HH : MM xm Mon, XX,XXXX

Change Hour : <+> <-> and <Enter> HH

Current Time/Date HH : MM xm Mon, XX,XXXX

Change Minute : <+> <-> and <Enter> MM

Current Time/Date HH : MM xm Mon, XX,XXXX

Change Month : <+> <-> and <Enter> MON

Current Time/Date HH : MM xm Mon, XX,XXXX

Change Day : <+> <-> and <Enter> HH

Current Time/Date HH : MM xm Mon, XX,XXXX

Change Year : <+> <-> and <Enter> HH

Front Panel Chilled Water Setpoint

Front Panel Chilled Wtr Setpt : XXX.X F/C

Press <+> <-> to Change Setting

Range of Values is 0 to 65 F (-17.8 to 18.3C) in increments of 1 or 0.1 F or C depending of the Service Setup Screen XXX
or XXX.X. Factory default is 44.0 F (6.7 C).

As shown above, the second line of a setting display normally says :

"Press <+> <-> to Change Setting"

The following is displayed as the second line of the display if an attempt is made to increment the setpoint above the
end of the setpoint range :
"Top of Range, Press <-> to Change"

The following is displayed as the second line of the display if an attempt is made to decrement the display below the
end of the setpoint range :
"Bottom of Range, Press <+> to Change"

The following is displayed as the second line of the display if an attempt is made to decrement the display below the
end of the setpoint range :
"Bottom of Range, Press <+> to Change"

The following is displayed as the second line of the display if a key other then <+>, <->, <Enter>, or <Cancel> is pressed
after <+> or <-> is pressed :
"Pressed after <+> <-> <Enter> <Cancel> to Advance"

The exception to the above message is when the <Stop> key is depressed. Stop is always active. Other messages are
displayed on the second line of the display for special cases as noted below in association with the affected setpoint dis-
play.

When the Front Panel Chilled Water Setpoints is within 1.7 F (0,8°C) of the Leaving Water Temperature Cutout Setpoint
or within 6 F (3C) of the Low Refrigerant Temperature Cutout Setpoint, the second line of this display will read :
"Limited by Cutout Setpt, <+> to Change "

Front Panel current Limit Setpoint

Front Panel Current Limit Stpt : XXX %

Press <+> <-> to Change Setting

Range of Values is 40 to 100% in increments of 1% Factory Default is 100%

Front Panel Hot Water Setpoint

The Front Panel Hot Water Setpoint is only displayed when the Hot water option is enabled.

Front Panel Hot Wtr Setpt : XX.X.X F/C

Press <+> <-> to Change Setting

Range of values is to 80 to 125 F (26.7 to 51.7C) in increments of 1 or 0.1 F or C depending on the Service Setup Screen
XXX or XXX.X. Factory Default is 90 F (32.2C).

26
Control Type
The following will be displayed only if the hot water control option is installed.

Control type is : [Control]

Press <+> <-> to Change Setting

Possible values for [Control] are : Chilled Water, ROM default, Hot water, Ext. hot/chilled Wtr input.

Chilled Water Reset Type

Chilled Water Reset Type [type]

Press <+> <-> to Change Setting

Possible values for [type] are : Return, Constant Return, Outdoor Air, Factory Default is Disable.

If either Disable or Constant Return are selected, the remaining chilled water reset displays are skipped by the human
interface. If either Return or Outdoor Air are selected, the first word of the remaining chilled water reset displays will be
the type of reset.

Reset Ratio

[type] Reset Ratio : XXX %

Press <+> <-> to Change Setting

The values for "RESET RATIO" for each of the reset types are :

Factory
Reset Ratio Increment Increment SI Default
Reset Type Range English Units Units Value
Return : 10 to 120% 1% 1% 50%

Outdoor : 80 to -80% 1% 1% 10%

Start Reset Setpoint

[type] Start Reset Setpoint : XXX %

Press <+> <-> to Change Setting

The values for "START RESET" for each of the types are :

Start Factory
Reset Reset Increment Increment Default
Type Range English Units SI Status Value

Return : 4 to 30 F 1F 0.1 C 10 F (5.6C)

(2.2 to 16.7 C)

Outdoor : 50 to 130 F 1F 0.1 C 90 F (32.2 C)

(10 to 54.4 C)

Max Reset Point

[type] Max Reset Setpoint : XXX.X F

Press <+> <-> to Change Setting

The values for MAXIMUM RESET for each of the reset types are :

Maximum Factory
Reset Reset Increment Increment Default
Type Range English Units SI Units Value

Return : 0 to 20 F 1F 0.1 C 5 F (2.8C)

(2.2 to 16.7 C)

Outdoor : 0 to 20 F 1F 0.1 C 5 F (2.8 C)

(10 to 54.4 C)

27
Chilled Water Setpoint Source
If the Tracer option is installed the word "Default" will appear in front of the setpoint source.

[Default] Chilled Water Setpoint Source :

[source]

Possible values of [source] are : Front Panel ; Factory Default.

Future 1
Future 2
External Source
Future 3

Current Limit Setpoint Source

If the Tracer option is installed the word "Default" will appear in front of the setpoint source.

[Default] Current Limit Setpoint Source :

[source]

Possible values of [source] are : Front Panel ; Factory Default.

Future 1
Future 2
External Source

Hot Water Setpoint Source

If the Tracer is installed the word "Default" will appear in front of the setpoint source. The following be displayed only if
Heat Pump Controls enabled.

Hot Water Setpoint Source :

[source]

Possible values of [source] are : Front Panel ; Factory Default.

Future 1
Future 2
External Source
Future 3

Outdoor air temperature source

Outdoor air temperature source :

[source]

Possible values of [source] are : Local, Tracer

Setpoint Source Override

Setpoint Source Override :

[source]

Possible values of [source] are : None - ROM Default

Use Front Panel Setpoints
Override Tracer. Use Default Setpoints. (Available only if Tracer
Option is installed).

Service Settings Group

The Service settings menu has three distinct groupings of items within it. The first group is the basic setups non-pass-
word protected group that consists of all of the settings, feature enables, setpoints etc, that are benign ; while they are
unlikely to be changed often by a user or operator. Changes in them do not seriously effect the standard protection or
reliability of the chiller.

The other two groupings are protected, each with a separate password. These two groups are for changing parameters
and settings regarding field commissioning and fundamental protection and control of the chiller subsystems (Field
Startup) or for programming of the UCM as to how the specific chiller was built in the factory (Machine Configuration).
Once properly set, the items in these protected menus should never be changed without specific knowledge of the
effects of the changes.

Caution : Settings in the Service Settings Group are only be set or changed by qualified Trane service technicians.
Improper settings in the group may adversely affect the operation of the unit.

28
Figure 16

Service Setting key

Password screen

Password screen

Field Startup
Group

Machine
Configuration
Group

Service Settings - Basic Setups

Service Settings : Basic setups

Press <Next> <Previous> to Continue

Menu Settings Password

If the Menu Settings Password is Enabled in the Service Setup Group, following each setting group heading the follo-
wing will be displayed :

Settings In This Menu Are [status]

[password message]

If the Menu Settings Password is disabled in the Service Setup Group, the above screen will be suppressed.

The possible values for [status] are "Locked" or "Unlocked". If the password status is locked, the password message will
be "Enter Password to Unlock". The user will the depress "-, +, -, +, -, +" followed by the <Enter> key. The password keys-
trokes will be echoed to the screen as a visual aide. The last six keystrokes represent the current password and up to
twenty keystrokes can be entered. An incorrect password or the twenty-first keystroke will result in the password mes-
sage "Invalid Password".

If the password status is unlocked, the password message will be "Press Enter to Lock". Pressing <Enter> will lock all of
the setpoint menus. Likewise, if the password status is locked and the correct password is entered, all to the setpoint
menus will be unlocked.

Whenever a password is in use the "Press <+> <-> to change setting" message will be suppressed on all setpoint screens.
Any attempt to change a setpoint will result in the message "Setting is Locked" being displayed for 1 second. The pass-
word once entered will remain valid until canceled.

29
Keypad/Display Lockout
The display only appears if the keypad lockout feature is enabled.

Press <Enter> to Lock Display & Keypad

Password Will be Required to Unlock
If the <Enter> key is pressed to lock the keypad, the following message is displayed, and all further input from the key-
pad is ignored, including the <Stop> key, until the password is entered. The password consists of pressing the
<Previous> and <Enter> keys at the same time.

******DISPLAY AND KEYPAD ARE LOCKED*****

********ENTER PASWORD TO UNLOCK********
If the keypad is locked and the password is entered, the display will go to the Chiller Operating Report.
Language Setting
This screen is displayed when the languages are available.

Language : XXXXXXXX
Press <+> <-> to Change Setting
Possible language selections are : English ; Factory Default, Francais, Deutch, Espanol, Nippon (also known as Katakan,
Use Japanese characters), Italiano and Nederlands.
Display Units

Display Units : [type]

"Press <+> <-> to Change Setting"
Possible values of [type] are : SI, Factory Default is English.
Decimal Places Displayed Setpoint :

Decimal Places Displayed : [status]

"Press <+> <-> to Change Setting"
Possible choices for [status] are : XXX, Factory Default is XXX.X.
Display Menu Headings Enable

Display Menu Headings : [d/e]

Press <+> <-> to Change Setting

The factory default value is Enabled. If the setting is changed to disabled the Menu Headings in each Menu or Group will
be suppressed.
Differential to Start Setpoint

Differential to Start Setpoint : XXX.X F/C

Press <+> <-> to Change Setting
Range of values is 1 to 10 F (0.5 to 5.5 C) in increments of 1 or 0.1 F or C depending on the Service Setup Screen XXX
or XXX.X. Factory default is 5 F (2.8 C).
Differential to Stop Setpoint

Differential to Stop Setpoint : XXX.X F/C

Press <+> <-> to Change Setting
Range of values is 1 to 10 F (0.5 to 5.5 C) in increments of 1 or 0.1 F or C depending on the Service Setup Screen XXX
or XXX.X. Factory default is 5 F (2.8 C).
Evap Pump Off Delay Time

Evap Pump Off Delay : XXX Min

Press <+> <-> to Change Setting
Range of values is to 1 to 30 minutes in encrements of 1 minute. Factory default is 1 minute.
Clear Restart Inhibit Timer

Press <Enter> to
Clear the Restart Inhibit Timer

When <Enter> is pushed a 2 second message appears as shown below and then returns to above screen.

Restart Inhibit Timer

Has been Cleared

30
Restart Inhibit 5. Unit Restarted after 10 minutes Restart Inhibit in (4),
BT incremented another 30 minutes. Unit ran 10
A Restart Inhibit (RI) Timer is used to prevent high fre- minutes, so BT decreases by 10 minutes :
quent chiller ON-OFF cycling and subsequent motor ove- BT = 60 + 30 - 10 = 80 minutes.
rheating. RI = 80-50 = 30 minutes.

The Restart Inhibit (RI) timer is set based on a Background 6. Unit Restart Inhibit is 30 minutes from (5).
Timer (BT) that is incremental by (XX) minutes at every
start is tiled out from the new total only while the chiller 7. Unit restarted after 30 minutes Restart Inhibit in (6),
is running and is based on the equation : BT incremented another 30 minutes. Unit ran for 110
minutes, and BT goes to zero :
RI = BT - 50 BT = 80 + 30 - 110 = 0 minute.
RI = 0 - 50 = - 50 minutes ==>RI = 0.
The value of XX is set in Factory. See hereafter Figure for
an example of how the Restart Inhibit (RI) Timer func- Leaving Water Temperature Cutout
tions. Leaving water temperature cutout is a safety control that
protects the chiller from damage caused by water free-
Any other pre-start system timers, e.g. prelub = 30 zing in the evaporator.
seconds, overlap the RI Timer to anticipate its time out For freeze protection from low leaving water temperatu-
and permit start of the compressor at or shortly after the re the UCP2 provides a low leaving water temperature
RI. If the RI Timer value ever reaches 45 minutes an IFW cutout based on leaving water temperature. The "Leaving
diagnostic is generated. If calculated RI is negative then Water Temperature Cutout Setpoint" is independently
RI = 0. adjustable from the chilled water setpoint and factory set.
Shutdown of the compressor due to violation of the
Figure 17 : Example of restart inhibit Leaving Water Temperature Cutout results in an automa-
tically resettable diagnostic (MAR).
The UCP2 indicates when the "Leaving Water
120
Temperature Cutout Setpoint" conflicts with the chilled
water temperature setpoint by a message on the display.
The "Leaving Water Temperature Cutout Setpoint" and
90
chilled water setpoint, both active and front panel, are
separated by a minimum of 1.7°F (0,9°C) (Figure 18).
BT Minutes

When either difference is violated the UCP2 does not per-

60
mit the above differences to be violated and the display
displays a message to that effect and remains at the last
valid setpoint.
30

1 2 3 5
7
When the chilled water setpoint, both active and front
panel, is adjusted downward, it does not violate the
0
30 4 60 90 120 150 180 above minimum differences and the "Leaving Water
Enlapsed time, Minutes
6
Temperature Cutout Setpoint" remains at its current set-
ting. When the "Leaving Water Temperature Cutout
RI Minutes

30
Setpoint" is adjusted upward, the above minimum diffe-
rence is not violated and the "Leaving Water Temperature
60
Cutout Setpoint" is adjusted upward the chilled water set-
point, both active and front panel, is raised to maintain
the minimum difference.
Example for Motor Heating
After violation of the "Leaving Water Temp. Cutout
Constant XX = 30
Setpoint" for 30°F (16°C) seconds the chiller will shut-
down and indicate a diagnostic.
1. Unit started and ran 10 minutes, BT incremented 30
minutes and decreased by 10 minutes :
Low Refrigerant Temperature Cutout
BT = 30 - 10 = 20 minutes
This is a safety function that prevents water in the eva-
RI = 20-50 = -30 minutes ==>RI = 0.
porator from freezing due to low evaporator refrigerant
temperatures. When the trip point is violated, the chiller
2. Unit restarted, BT incremented another 30 minutes.
will shut down and display a latching diagnostic (MMR)
Unit ran 10 minutes, so BT decreases by 10 minutes :
indicating the violation.
BT = 20 + 30 - 10 = 40 minutes
RI = 40 - 50 = - 10 minutes ==>RI = 0.
The UCP2 indicates when the "Low refrigerant Temp.
Cutout Setpoint" conflicts with the chilled water tempera-
3. Unit restarted, BT incremented another 30 minutes.
ture setpoint by a message on the display. The "Low
Unit ran 10 minutes, so BT decreases by 10 minutes :
Refrigerant Temp Cutout Setpoint" and chilled water set-
BT = 40 + 30 - 10 = 60 minutes
point, both active and front panel, are separated by a
RI = 60 - 50 = 10 minutes.
minimum of 6° F (3,3°C) (figure 18).When either diffe-
rences is violated, the UCP2 does not permit the abive dif-
4. Unit Restart Inhibit is 10 minutes from (3).
ferences to be violated and the display displays a messa-
ge to that effect and remains at the last valid setpoint.

31
Figure 18 : Cutout Strategy

Chilled Water Setpoint

Differential to Stop
Adjustment Range

X degrees Minimum Differential Y degrees Minimum Differential

2 degrees F (1.1 C)

Evap Leaving Water Temp Cutout 0,5 degrees F (0.28 C) 2.5 degrees F (1.36 C)

Integrate to Trip

Limit Loading Evap.

Evap. Limit Stpt Hold
Limit
Unload

Evap Rfgt Temp. Cutout Integrate to trip

When the chilled water setpoints, both active and front rate stably under minimum load conditions. In these
panel, is adjusted downward, it does not violate the situations, the inlet guide vanes are "locked" at a preset
above minimum differences, and the "Low Refrigerant minimum position, and unit capacity is governed by the
Temp Cutout Setpoint" remains at its current setting. HGBP valve actuator.
When the "Low Refrigerant Temp Cutout Setpoint" is
adjusted upward, the above minimum difference is not Control circuitry is designed to allow both the inlet guide
violated, and as the "Low Refrigerant Temp Cutout vanes and the HGBP valve to close for unit shutdown.
Setpoint" is adjusted upward, the chilled water setpoints,
both active and front panel, are raised to maintain the After a chiller starts and is running the inlet guide vanes
minimum difference. will pass through the HGBP Cut-In Vane position as the
chiller starts to load. As the chiller catches the load and
After violation of the "Low Refrigerant Temp Cutout starts to unload, the inlet guide vanes will close to the
Setpoint" for 30° F (16°C) - seconds, the chiller will shut- HGBP Cut-In Vane position. At this point the movement
down and indicate a diagnostic. of the inlet guide vanes is frozen and further unloading of
the chiller is controlled by the opening of the HGBP Valve
Enhanced Condenser Limit Control (option) 2Y51 by the A16 module. The A16 module modulates the
When the chiller is running in Condenser Limit Mode or HGBP valve at low loads.
in Surge Mode, the head relief request relay on the
Options Module will be energized and can be used to When the control algorithm determines the chiller to be
control or signal for a reduction in the entering conden- shut down, the inlet guide vanes will be driven fully clo-
ser water temperature. sed, and the HGBP valve will be driven closed. After the
Designed to prevent high refrigerant pressure trip-outs inlet guide vanes are fully closed the chiller will shut
during critical periods of chiller operation, this UCP2 down in the Friendly mode.
option consists of :
1. The Options Module (A15) with the head relief request Chillers with HGBP have a discharge temperature sensor
relay. (5R55) monitoring the discharge gas temperature from
2. Interconnecting Wiring. the Compressor. If this temperature exceeds 212°F
(100°C), the chiller will shut off on a MAR diagnostic. The
The unit will use the condenser refrigerant temperature chiller will reset automatically when this temperature
sensor (input converted to saturated refrigerant pressure) drops 50°F (27,8°C) below the trip-point.
to perform the Standard Condenser Limit function, by
limiting inlet guide vane stroke and chiller capacity. Unit Start-Up Procedures
Keep in mind that the UCP2 Condenser Limit Control sup- Daily Unit Start-Up
plements the protection provided by the condenser pres- 1. Verify the chilled water pump and condenser water
sure high pressure cutout switch B51. pump starters are in "ON" or "AUTO".
2. Verify the cooling tower is in "ON" or "AUTO".
Hot Gas Bypass (option)
The hot gas bypass (HGBP) control options is designed to Note : Refer to Figure 5 for UCP Start-Run-Shutdown
minimize machine cycling by allowing the chiller to ope- sequence and UCP timing functions.

32
3. Check the oil tank oil level ; the level must be visible val ; the evaporator pump will continue to run.
in the middle sight glass. Also, be sure to check the oil
tank temperature ; normal oil tank temperature before Once the post-lube cycle is complete, the unit returns to
start-up is 131°F to 136°F (55 to 57,8°C). the auto mode.

Note : The oil heater is energized whenever power is Seasonal Unit Start-Up
supplied to the unit and the oil temperature is less than
131°F (55°C). Note : Refer to Figure 5 for UCP Start-Run-Shutdown
sequence and UCP timing functions.
4. Check the chilled water setpoint and readjust if, if
necessary, in the Operator Settings menu. 1. Close all drain valves, and re-install the drain plugs in
5. If necessary, readjust the current limit setpoint in the the evaporator and condenser headers.
Operators Setting menu.
6. Press "AUTO". 2. Service the auxiliary equipment according to the start-
up/maintenance instructions provided by the respecti-
The UCP also checks compressor motor winding tempe- ve equipment manufacturers.
rature, and a minimum 30 second delay is initiated if the
winding temperature is less than 165°F (74°C). If it is grea- 3. Vent and fill the cooling tower, if used, as well as the
ter than 165°F (74°C), however, a 15-minute delay period condenser and piping. At this point, all air must be
begins. The chilled water pump relay is energized and removed from the system (including each pass). Then
evaporator water flow is proven. close the vent valves in the condenser water boxes.

Next, the UCP checks the leaving evaporator water tem- 4. Open all of the valves in the evaporator chilled water
perature and compares it to the chilled water setpoint. If circuit.
the difference between theses values is less than the start
differential setpoint, cooling is not needed. 5. If the evaporator was previously drained, vent and fill
the evaporator and chilled water circuit. When all air
If the UCP determines that the difference between the is removed from the system (including each pass),
evaporator leaving water temperature and chilled water close the vent valves in the evaporator water boxes.
setpoint exceeds the start differential setpoint, the unit
enters the Initiale Start Mode and the oil pump and the 6. Lubricate the external vane control linkage.
condenser water pump are started.
7. Check the adjustment and operation of each safety
If condenser water flow is not proven (i.e, flow switch and operating control.
6S56 does not close) within 3 minutes, the unit is locked
out on a MMR Diagnostic. 8. Close all disconnect switches.

Oil pressure must be verified within 3 minutes or a MMR Warning : To prevent injury or death due to electrical
diagnostic is generated. shock or contact with moving parts, use care when
measurements, adjustments, or other service related
When less than 5 seconds remain on the restart inhibit, operations are performed with power on.
the pre-start starter test is conducted on Y-Delta starters.
If faults are detected, the unit's compressor will not start, 9. Perform instructions listed in "Daily Unit Start-Up"
and a MMR Diagnostic will be generated. section.

After the pre-start Starter test, the UCP sends a start Unit Shutdown Procedures
signal to the compressor motor. Within 2-seconds,
3 phases of current in the correct phase sequence must
Daily Unit Shutdown
be detected. If there is no current, 1 or 2 phases missing,
or reverse electrical sequence, diagnostics will occur.
Note : Refer to figure 5 for UCP Start-Run-Shutdown
Acceleration and proof of transition must occur within
sequence and UCP timing functions.
2.5-seconds of transition initiation, or unit start-up is
aborted. If this occurs, the unit goes into the post-lube
1. Press STOP.
mode, and a MMR diagnostic is generated.
2. After compressor shutdown turn Pump Contactors to
off or open pump disconnects.
If the compressor motor starts and accelerates success-
fully, "Unit is Running" appears on the display.
Seasonal Unit Shutdown
Note : Whenever the UCP detects a MMR diagnostic
condition during start-up, unit operation is locked out, Note : Refer to Figure 5 for UCP Start-Run-Shutdown
and manual reset is required before the start-up sequence and UCP timing functions.
sequence can begin again. If the fault condition has
not cleared, the UCP will not permit restart. 1. Press STOP
2. After compressor shutdown turn off the chilled water
When the cooling requirement is satisfied, the UCP origi- pump at the pump's push-button station. (Or, stop
nates a "Shutdown" signal. The inlet guide vanes are dri- chilled water flow by the means devised for this parti-
ven closed for 50 seconds, and the unit enters a 1-minu- cular application).
te post-lube period. The compressor motor and conden-
ser water pump starter are de-energized immediately, but 3. Open all disconnect switches except the control
the oil pump continues to run during this 1-minute inter- power disconnect switch.

33
Figure 19 : CVGE - UCP Sequence/timing

Centravac Sequence of Operation With WYE-DELTA Starter

DISPLAY blank Reset Stop Auto Pre Lube

STARTED TEST
(Hard) Close IGV - 50 Sec IGV test - 75 Sec < 30 sec remaining < 5 seconds
remaining
Re-start Inhibit Timer Timing out < 30 sec remaining

Time 1 Second < 30 sec remaining

Events Power Off Power On Last Mode was Stop Chiller mode set to Auto Call for Cooling or Heating
on power loss.
CHWP relay energized Start Oil Pump
CHWP relay De-energized Comfirm CHW Flow - time Confirm Oil Press
out 33 min if no flow
CWP relay De-energized CWP relay Energized
comfirm CW Flow - time
out 3 min if no flow

Display Starting compressor Unit is Running Unit is preparing to Shutdown

Maximum Accel. Timer - 27 Sec.

Energize Vent Line Solenoid - 100 Sec.

Time 50 seconds

Events Start Compressor Modulaire IGV to Satisfy Setpoint Cooling or Heating Rq mt

in WYE Configuration Satistied or Chiller Mode
is set to Stop

Close IGV for 50 Seconds

Display Post Lube Auto Stop Stop

CHWP off delay timer -
1 min - CVGE adjustablel - 30 Minutes
Time

Events Compressor De-energized Oil Pump De-energized Chiller mode set to Stop CHWP relay De-energized

CWP relay De-energized

procedures described under "Annual Maintenance" in

Warning : To prevent injury or death due to electrical
the Periodic Maintenance section of this manual
shock or contact with moving parts, use care when ser-
should be performed by qualified Trane service tech-
vicing system with power on.
nicians.
Caution : Control Power disconnect must remain clo-
Caution : Do not allow the chiller to increase in tempe-
sed during entire shutdown period to allow oil sump
rature pressure while the unit is off to a temperature
heater operation. This prevents refrigerant from
above 40°C since this will cause the opening of the
condensing in oil sump.
safety valve and discharge the refrigerant from the
machine. Continuous running of pumps while the
4. Drain the condenser piping and cooling tower, if used.
machine is off may cause this condition to occur.
5. Remove the drain and vent plugs from the condenser
headers to drain the condenser.
6. Once the unit is secured for winter, the maintenance

34
 Maintenance
Weekly unit prior to shipment. Any adjustments should be made
Check the following after the machine has been in opera- exclusively by authorized Trane Service Personel.
tion for at least 30 minutes : It is strongly recommended to have proper functioning
1. Chilled water and condenser water entering and lea- and set points of all controls checked once per year.
ving temperatures.
2. Current drawn by the compressor (Amps). Note : Trane assumes no responsibility if deterioration
3. Oil level in the oil sump. The oil level must be visible of the unit is due to inadequate water treatment.
in the sight glass.
4. Condenser pressure, evaporator pressure and oil Table 12 : Control setting
pressure gauge reading.
5. Unusual noise, vibration, etc. Discharge temperature 72,2 ±1°C cut in
(hot gas by-pass option) 100 ±1°C cut out
It is strongly recommended that unit readings and obser-
Motor temperature 113°C cut in
vations are recorded on a weekly log sheet.
(Not adjustable) 130°C cut out
The acceptance of a warranty claim may be dependent on
this. Oil pressure control (B30) 0.9 bar cut in
0.7 bar cut out
Annually
The yearly maintenance should be performed by an High pressure control B51 (1st step) 10.5±0.2 bar cut in
13.0±0.2 bar cut out
authorized Trane service technician.
1. Check the oil acidity, if it is above 0,5 mg KOH/g, the (2nd step) 10.9±0.2 bar cut in
oil and oil filter must be changed. 13.4±0.2 bar cut out
2. Check setting and operation of all controls and safety
devices. Control settings
3. Leak-test the entire machine for refrigerant leaks.
The normal settings and adjustments for the various
4. Check starter contactors for wear and replace
security systems are listed in Table 12. This table is for
if required.
reference only. If an unsatisfactory control condition
5. Check motor winding insulation.
develops, consult the "Diagnostic code" section.
6. Check motor drawn amps.
Trouble Analysis
Condenser cleaning
If the red light on the control panel is flashing, an MMR
Water available for condensing frequently contains mine-
diagnostic has occurred. See Diagnostic Section for
rals that collect on the condenser tube walls as carbona-
trouble shooting information. The diagnostic must be
te scale. Scale accumulation rate will be increased by
analyzed, corrections made by qualified personnel and
high condensing temperatures and water with a high
the MMR diagnostic reset before the chiller can be retur-
mineral content.
ned to operation.
Cooling towers, when used, may collect dust and form
material that will deposit in the condenser tubes forming
sludge.
Diagnostic Codes
Scale and sludge formation is indicated by high conden- As shown below, a "LATCHING" diagnostic is a condition
sing temperatures and large differences between which shall cause the machine or a portion of the machi-
condensing and leaving water temperatures. ne as noted to shut down and shall require a manual
To maintain maximum efficiency, the condenser must reset to restore operation. A diagnostic that is non-lat-
remain free of scale and sludge. Even a very thin coating ching shall reset automatically when the condition cau-
on the tube surface may greatly decrease condenser heat sing the diagnostic goes away. A non-latching diagnostic
transfer capacity. The two methods for cleaning conden- shall shut down the machine or a part of the machine if
ser tubes are mechanical and chemical. so indicated. If a diagnostic is informative only, no
The mechanical method removes sludge and loose mate- machine or a part of the machine if so indicated. If a dia-
rial from the condenser tubes. Working a round nylon or gnostic is informative only, no machine or circuit is taken
bristle brush attached to a rod, in and out of the tubes except to load a diagnostic code into the last diagnostic
loosens the sludge. After cleaning, flush the tubes with register.
clear water.
The chemical method removes scales deposits. The stan- Unless otherwise stated, all active diagnostics will be lost
dard condenser water circuit consists of copper, steel and on loss of power.
cast iron. Any reliable water treatment company will be
able to recommend a cleaning solution for the job.

Evaporator cleaning
The evaporator is part of a closed water circuit and
should not accumulate an appreciable amount of scale or
sludge. However, if cleaning should be required, use the
same methods outlined for cleaning the condenser.

Controls checkout and adjustments

Controls are checked and calibrated during run-in of the

35
Diagnostic types and action : Remotely resettable diagnostics :

MMR = MACHINE SHUTDOWN - MANUAL RESET Except for the following, all diagnostics can be reset
MAR = MACHINE SHUTDOWN - AUTO RESET remotely from either the Remote Clear Language Display,
CMR = CIRCUIT SHUTDOWN - MANUAL RESET Applies the Tracer, or the External Diagnostic Reset input at the
to Multiple Rfgt Circuit Units Options Module. The following diagnostics shall only be
Only - Defaults to an MMR on single Circuit Units. resettable ONLY at the Local Clear Language Display, e.g.
CAR = CIRCUIT SHUTDOWN - AUTO RESET Applies to with the operator standing at the unit.
Multiple rfgt Circuit Only -
Defaults to an MAR on single Circuit Units.
IFW = INFORMATION - WARNING May or may no affect
machine ; lowest level of diagnostic.

Table 13
Diagnostic description Code Diag Can Be
Type Remotely
Reset
Starter Contactor Interrupt Failure CA MMR No
Phase Loss E4 MMR No
Phase Reversal E5 MMR No
Current Overload EC MMR No
Starter did not Transition F0 MMR No
High Pressure Cutout Tripped F5 MMR No
Low Evap Rfgt Temp. Fb MMR No
Emergency Stop Input Fd MMR No
Starter Dry Run Test 188 MMR No
High Motor Temp Position #1 18b MMR No
High Motor Temp Position #2 18C MMR No
High Motor Temp Position #3 18d MMR No
Severe Phase Unbalance 1b2 MMR No
Starter Fault Type I 1E9 MMR No
Starter Fault Type II 1Ed MMR No
Starter Fault Type III 1F1 MMR No
Cprsr did not Accelerate Fully 1F5 MMR No

The following are samples of applicable diagnostics.

36
 CENTRIFUGAL CHILLER OPERATING REPORTS

Job name: .......................................................................... Order number: ..................................................

Job location: ...................................................................... Serial number: ..................................................
Start up date: .................................................................... Model: ................................................................

FIFTEEN MINUTE INTERVALS AT DESIGN CONDITIONS Start up: Maintenance visit:

Others: ........................................................
Comp L1-L2 ....................................................
Motor L2-L3 .................................................... MOTOR DATA:
Voltage L3-L1 .................................................... - Manufacturer : ..................................
- Type and Frame : ..................................
- Serial Number: ..................................
Comp L1 .................................................... - KW on Shaft: ..................................
Motor L2 .................................................... - Voltage : ..................................
Amperage L3 ....................................................
STARTER DATA
Fan n°1 L1 .................................................... - Manufacturer: ..................................
Motor L2 .................................................... - Start Delta - Direct on line - Auto/transfo
Amperage L3 .................................................... - Others : ................................
- Starter Drawing : ..................................
Fan n°2 L1 .................................................... - Voltage : ................................
Motor L2 .................................................... - Amperage : ................................
Amperage L3 .................................................... - Contactor Sizes : ................................
- Line : ................................
Fan N°3 L1 .................................................... - Delta : ................................
Motor L2 .................................................... - Star : ................................
Amperage L3 .................................................... - Transition : ................................
- Current transformer size :........................
Oil Pump L1 ....................................................
Motor L2 ....................................................
Amperage L3 .................................................... DESIGN CONDITIONS:
- KW cooling: ................................
Outside T° C°/F° .................................................... - KW input: ................................
Chiller water in C°/F° .................................................... - Refrigerant: ................................
Chiller water out C°/F° ....................................................
Cds water in C°/F° .................................................... Evaporator Condenser
Cds water out C°/F° .................................................... - Type: .................... ....................
Evp pressure bar/Psig .................................................... - Nb pass: .................... ....................
Cds pressure bar/Psig .................................................... - W. Flow: .................... ....................
Evp T° saturat C°/F° .................................................... - EWT: .................... ....................
Cds T° saturat C°/F° .................................................... - LWT: .................... ....................
Evp approach T° C°/F° .................................................... - Glycol : .................... ....................
Cds approach T° C°/F° .................................................... - type : .................... ....................
Igv % opening % .................................................... - %: .................... ....................
Winding T° W1 C°/F° ....................................................
Winding T° W2 C°/F° .................................................... MOTOR INSULATION MEGOHMS:
Winding T° W3 C°/F° ....................................................
Oil pressure bar/Psig ....................................................
Oil level % .................................................... Ter 1 to Gnd > ..............Ter 1-2 > ..............
Oil sump C°/F° .................................................... Ter 2 to Gnd > ..............Ter 1-3 > ..............
Evp delta P bar/Psig .................................................... Ter 3 to Gnd > ..............Ter 2-3 > ..............
Cds delta P bar/Psig ....................................................

COMMENTS: ..........................................................................................................................................................................
........................................................................................................................................................................................................
........................................................................................................................................................................................................
........................................................................................................................................................................................................
........................................................................................................................................................................................................
........................................................................................................................................................................................................
........................................................................................................................................................................................................
Date : ................................................................................
Service Engineer: .............................................................. Owner: ......................................................................
Signature : ........................................................................ Signature : ............................................................................

37
 Diag. Active
Diag Modes
Diagnostic description Cause Help Message
Type (Non-Active
Modes)
Aux/Ht Rcvry Ent Water IFW All Open or shorted and Heat Recovery Check Sensor, Wiring
Temp Sensor. is installed (at the CLD) and Connections.

Aux/Ht Rcvry Lvg Water IFW All Open or shorted and Heat Check Sensor, Wiring
Temp Sensor . recovery is installed (at the CLD). and Connections.

Check Clock IFW All On loss of power the clock does not Check Main Power
keep time, if there is an extended Supply, Reset Clock.
power loss (greaterthan 15 seconds)
this diag. is also generated to alert
the operator tocheck the clock.
Chilled Water Flow Lost MAR All modes except a. The chilled water flow switch Check Pump, Valves,
STOP (00) and input was open for more than 6-10 Flow Switch
EXTERNAL STOP contiguous seconds..
(100). b. 6-10 seconds of contiguous flow
shall clear this diagnostic.
Chiller Mod Ref Voltage IFW All An improper reference voltage was Check Chiller Module
Calibration detected at the Chiller Module.A Voltages.
2.54 vdc reference is used to cali-
brate the non-ratiometric analog I/O
such as 2-10 vdc and 4-20ma inputs
as well as PWM Analogoutputs. The
micro checks to see that the A/D
value falls within an acceptable
range.
Chiller : Loss of Comm IFW All The Tracer was setup as "installed" Check IPC
with TCI at the CLD and the chiller module Wiring/Connections.
lost communications with the TCI
(comm 3 or comm 4) module for 15
contiguous seconds.
Chiller : Loss of Comm MMR All The chiller module lost communica- Check IPC
with Circuit. tions with the Circuit module for 15 Wiring/Connections.
contiguous seconds.
Chiller : Loss of Comm IFW-AR All The chiller module lost communica- Check IPC.
with Local CLD.Note : As tions with the CLD module for 15 Wiring/Connections.
implemented this is a lat- contiguous seconds.
ching IFW diagnostic. That
is, once generated it can-
not be regenerated until a
manual reset is done.
Chiller : Loss of Comm IFW All The chiller lost communications Check IPC
with Options with the Options module for 15 Wiring/Connections.
contiguous seconds. This IFW dia-
gnostic is generated if Free Cooling
is Not Installed, otherwise this an
MMR diag. under code 2F6.
Chiller : Loss of Comm MMR All The chiller module lost communica- Check IPC
with Options. tions with the Options module for Wiring/Connections.
15 contiguous seconds. This MMR
diagnostic is generated if Free
Cooling is installed, otherwise this
is an IFW diag. under code 2AE.
Chiller : Loss of Comm MMR All The chiller module lost communica- Check IPC
with Starter tions with the Starter module for 15 Wiring/Connections.
contiguous seconds.
Chiller : Loss of Comm MMR All The chiller module lost communica- Check IPC
with Stepper #1 tions with the Stepper #1 module Wiring/Connections.
for 15 contiguous seconds.

38
 Diag. Active
Diag Modes
Diagnostic description Cause Help Message
Type (Non-Active
Modes)

Circuit Mod Ref Voltage IFW All An improper reference was detec-
Calibration ted at the Circuit Module. A 2.5 vdc
reference is used to calibrate the
non-ratiometric analog I/O such as
2-10 vdc and 4-20ma inputs as well
as PWM Analog outputs. The micro
checks to see that the A/D value
falls within in acceptable range.
Circuit Module 24 Vdc Ref IFW All 24vdc reference missing and the Check Rfgt Monitor
Missing Rfgt monitor is installed. Wiring/24 Vdc Supp.

Circuit : Loss of Comm MMR All The circuit module lost communica- Check IPC
with Chiller. tions with the Chiller module for 15 Wiring/Connections.
contiguous seconds. On loss of
communications, the circuit module
shall run the oil pump for the post
lube time and then turn the oil
pump off. On loss of communica-
tions, the circuit module shall conti-
nue to control the oil heater.
Circuit : Loss of Comm MMR All The circuit module lost communica- Check IPC
with Starter. tions with the Starter module for 15 Wiring/Connections.
contiguous seconds.
Cond Entering Wtr Temp IFW All Open or Short. Check Sensor, Wiring
Sensor. And Connections.
Cond Leaving Wtr Temp IFW All Open or Short. Check Sensor, Wiring
Sensor. a. IFW on Chilled Water Control. And Connections.
b. MMR on Heat Pump (Hot Water)
Control.
Condenser Rfgt Temp MMR All Open or Short. Check Sensor, Wiring
Sensor. And Connections.
Cprsr did not Accelerate MMR Starting a. Using a Solid State Starter the Check End of Lim/At
Fully. UCP2 did not receive an Up to Speed Input.
Speed or At Speed Signal within
the Maximum Acceleration Timer
Setting.
b. The Up to Speed/At Speed input
was found to be shorted before the
compressor was started.
c. Applies only to Solid State
Starters.

Cprsr did not Accelerate : MMR Start Mode a. The compressor did not come up Check Main Power
Shutdown to speed in the allotted time defined Supply & Wiring.
by the Maximum Acceleration
Timer.
b. The Human Interface setups defi-
ned "Shutdown" as the action when
the Maximum Acceleration Timer
was exceeded.
Cprsr Did Not Accelerate : IFW Start Mode a. The compressor did not come up
Transition (The Motor is to speed in the allotted time defined
put across the line). by the Maximum Acceleration
Timer.
b. The Human Interface setups defi-
ned "Transition" as the action when
the Maximum Acceleration Timer
was exceeded.

39
 Diag. Active
Diag Modes
Diagnostic description Cause Help Message
Type (Non-Active
Modes)

Current Overload MMR All Running Modes Motor current exceeded overload Check Main Power
time vs trip characteristic. Supply & Wiring

Current Overload Setpts IFW All a. The redundant overload settings Review Overload Set Up.
Error. did not agree for 30 contiguous
seconds. (Continue to use the pre-
vious value for the 30 second
timeout). When this diagnostic
occurs the affected Starter Module
shall use the minimum (00000 bina-
ry, 00 decimal) overload setting as a
default until either the UCP2 is reset
or, if the redundant settings agree
again, the starter module can go
back to using the actual setting.
CWS/Leaving Wtr Temp. None All No diagnostic, limit value to last N/A
Cutout Setpt Overlap. legal value and tell the operator
about it on the second line of the
display.
Note : The above is not a diagnostic
because you don't want the display
vectoring you to a different display
state when you are trying to set
either the chilled water setpoint or
the leaving water temp. cutout set-
point as it will in the case of a dia-
gnostic.

Differential Oil Pressure MMR Pre-Lube A differential oil pressure was not
Overdue established within 3 minutes of
starting the Oil Pump in the Pre-
Lube Mode.
Design : Some hysteresis was intro-
duced into this diagnostic.

Discharge Temp Sensor MMR All Open or Short, only if HGBP and Check Sensor Wiring
the Discharge Temp. Sensor is cal- And Connections.
led out as "Installed" at the Human
Interface.

Emergency Stop Input MMR All a. EMERGENCY STOP input is open. Check Emergency Stop
An external interlock has tripped. Input Device.
Time to trip from input opening to
unit stop shall be 0.1 to 1.0
seconds.
Evap Entering Wtr Temp IFW All Open or Short Check Sensor, Wiring
Sensor a. Normal operation, no affects on And Connections.
control.
b. Chilled Water Reset, Will just run
at either normal CWS or will run at
maximum reset permitted.

Evap Leaving Water Temp MMR All Open or Short Check Sensor, Wiring
Sensor and Connection

Evap Rfgt Temp Sensor MMR All Open or Short. Check Sensor, Wiring
And Connections.

40
 Diag. Active
Diag Modes
Diagnostic description Cause Help Message
Type (Non-Active
Modes)

Ext Energy Valve Position MMR All a. Not "Enabled" : no diagnostics. Check Signal at input.
Setpt b. "Enabled" : Out-Of-Range Low or
Hi, set diagnostic.
Extended Compressor MMR All Running Modes An extended Surge condition was Check Condenser Water
Surge detected and the Surge protection Temp.
feature was Enabled at the Clear
Lang. Display.
Extended Power Loss IFW All The unit lost power for an extended Check Main Power
period of time. On CTV units if Supply & Wiring.
Note : This diagnostic and power is lost for an extended period
the functions tied to it are of time the oil pump is not run on
handled by the Check Power Up. If a power loss is deter-
Clock diagnostic. mined to be a Momentary Power
Loss the Oil Pump is run on the
Power Up to Post Lube the bea-
rings. The deciding factor determi-
ning if a power loss is Extended or
Momentary is TBD.
External Chilled Water IFW-AR All a. Not "Enabled" : no diagnostics. Check Signal At Input.
Setpoint. b. "Enabled" : Out-Of-Range Low or
Hi, set diagnostic, default CWS to
next level of priority (e.g. Front
Panel SetPoint). This IFW diagnostic
will automatically reset if the input
returns to the normal range.
External Current Limit IFW-AR All a. Not "Enabled" : no diagnostics. Check Signal At Input.
Setpoint. b. "Enabled" : Out-Of-Range Low or
Hi, set diagnostic, default CLS to
next level of priority (e.g. Front
Panel Setpoint. This IFW diagnostic
will automatically reset if the input
returns to the normal range.
External Hot Water IFW-AR All a. Not "Enabled" : no diagnostics. Check Signal At Input.
Setpoint b. "Enabled" : Out-Of-Range Low or
Hi, set diagnostic, default HWS to
next level of priority (e.g. Front
Panel SetPoint). This IFW diagnsotic
will automatically reset if the input
returns to the normal range.
External Vane Position MMR All a. Not "Enabled" : no diagnostics. Check Signal At Input.
Setpoint. b. "Enabled" : Out-Of-Range Low or
Hi, set diagnostic.
High Cprsr Discharge MAR All a. The discharge temp. exceeded
Temp. the trip value ; 212°F + or - 5F
(100°C+/-2,7) for CVGE. The
Discharge Temp Cutout is adjus-
table at the Human Interface.
b. Time to trip from trip value
exceeded shall be 0.5 ro 2.0
seconds. (Note : BT, WT and DT
may be" instantaneous trip" but
consistent with the analog input fil-
tering function).
d. The diag. shall reset automatical-
ly 50F (27,8°C) below the trippoint.

41
 Diag. Active
Diag Modes
Diagnostic description Cause Help Message
Type (Non-Active
Modes)

High Motor temp MMR Any Start and Run The Motor Winding Temp. at sensor
Position #1 Mode. #1 exceeded 265F + or - 15F
(130°C+/-8°C) for 0.5-2 seconds.
(Note : BR, WT, and DT may be "ins-
tantaneous trip" but consistent with
the analog input filtering function).
High Motor Temp MMR Any Start and Run The Motor Winding Temp. at sensor
Position #2 Mode #2 exceeded 265F + or - 15F
(130°C+/-8°C) for 0.5-2 seconds.
(Note : BR, WT, and DT may be "ins-
tantaneous trip" but consistent with
the analog input filtering function).
High Motor Temp MMR Any Start and Run The Motor Winding Temp. at sensor
Position #3 Mode #3 exceeded 265F + or - 15F
(130°C+/-8°C) for 0.5-2 seconds.
(Note : BR, WT, and DT may be "ins-
tantaneous trip" but consistent with
the analog input filtering function).

High Oil Temp MMR All starting and run- UCP2 shall provide a fixed High Oil Check Oil System.
ning Modes. Temperature Cutout of 180F (82.2C).
If the oil temperature violates the
cutout by 120°F seconds (66.6°C
seconds) an MMR diagnostic shall
be generated.
High Pressure Cutout MMR All A high pressure cutout was detec- Check Condenser Water
Tripped. ted. See the trip points for the Temp.
various products under the HPC
switch description of this specifica-
tion.
High Restart Inhibit Timer IFW All The Restart Inhibit timer has rea- Check for Excessive
Warning. ched a maximum threshold for the Chiller Cycling.
host chiller. For CTV chillers this is
45 minutes. This indicates excessive
chiller cycling steps should be taken
to correct this.
IGV BPI Found Low IFW All The Inlet Guide Vane Actuator Check Stepper Module,
During Search. Binary Position Indicator was found Wiring, & Motor.
too low in the stroke of the IGV
during the BPI search.
IGV BPI Not Found During IFW All The Inlet Guide Vane Actuator
Search. Binary Position Indicator was not
found over the entire stroke of the
IGV during the BPI search.

IGV BPI Shorted. IFW Pre-Start At what is believed to be a closed Check Sensor, Wiring
position, The IGV BPI was found to and Connections.
be shorted.

IGV Electrical Drive Circuit MMR On Demand and Run the IGV Acturator electrical
Open (Available CTV Pre-Start drive circuit test both on demand
Phase ?? release). from the human interface and just
before the chiller starts.

42
 Diag. Active
Diag Modes
Diagnostic description Cause Help Message
Type (Non-Active
Modes)
Incorrect Chiller Software MMR All The incorrect Eprom was loaded (No message is requi-
Installed. into this module. The diagnostic is red).
detected when a factory test com-
puter sets the unit type to some-
thing other than what the Eprom
software was intended for.
Incorrect Stepper MMR All The incorrect Eprom was loaded (No message is requi-
Software Installed. into this module. This diagnostic is red).
detected when a facttory test com-
puter sets the unit type to some-
thing other than what the Eprom
software was intended for.
Low Chilled Water Temp : IFW-AR Unit in Auto and a. The chilled water temp. fell below Check Flow, Sensor &
Unit Off (Unit in Auto but No Ckt's Energzd the cutout setpoint while the com- Wiring.
not Starting or Running). (Any Ckt(s) pressor (or Solution Pump) was not
Energized) running for 30°F (16,6°C) seconds.
Automatic Reset of the IFW diag
shall occur 2°F (1.1°C) above the
cutout setpoint.
Low Chilled Water Temp : MAR Any Ckt(s) Energzd a. The chilled water temp. fell below Check Flow, Sensor &
Unit On (No Ckt's the cutout setpoint while the com- Wiring.
(Unit Starting or Running) Energized) pressor (or Solution Pump) was not
running for 30°F (16,6°C) seconds.
Automatic Reset of the IFW diag
shall occur 2°F (1.1°C) above the
cutout setpoint.
Low Evap Rfgt Temp. MMR Starter Contactor a. The Saturated Evap Rfgt Temp Check Operation, Call
Energized dropped below the Low Rfgt Temp. Service
Cutout Setpoint when the circuit
was running for 30°F (16,6°C)
seconds.

Low oil Temp MAR All Non-running The oil temperature dropped below
Modes. its adjustable Low Oil Temp. Cutout
("Instantaneous trip" but consistant
with the analog input fittering func-
tion). Automatic Reset of the MAR
diag shall occur 5°F (2.8°C) above
the cutout setpoint.

Max Acceleration Setpts IFW All a. The redundant Maximum Review Max
Error Acceleration settings did not agree Acceleration Set Up.
for 30 contiguous seconds.
(Continue to use the previous value
for the 30 second timeout). When
this diagnostic occurs the affected
Starter Module shall use 6 seconds
as a default until either the UCM is
reset or, if the redundant settings
agree again, the starter module can
go back to using the actual setting.

43
 Diag. Active
Diag Modes
Diagnostic description Cause Help Message
Type (Non-Active
Modes)

Memory Error Type I : MMR On UCM Power Up a. On UCM either power up or follo- Call Service to Check all
NOVRAM or following a Type wing a Type II memory Error a Settings.
II Memory error NOVRAM memory error was detec-
diag. ted. The UCM is operating all
Engineering ROM defaults for all
setup parameters. Check all setup
parameters and continue to run
chiller. Replace the Chiller Module
as soon as a replacement is avai-
lable. Note : It is expected that this
diagnostic will be detected on the
very first power up of the Chiller
Module at the Manufacturer since
the NOVRAM will not contain valid
data on first power up.
Memory Error Type II : IFW All a. A Shadow RAM memory error No Settings Were Lost.
Shadow RAM was detected. The UCM is operating
on all last valid values (pulled from
NOVRAM) for all setup parameters.
No setup parameter changes were
pending to be loaded into
NOVRAM, a complete recovery of
all setup parameters was made and
there in no need to check unit setup
paramaters. Compressor starts and
hours were lost for not more than
the last 24 hours. This is expected
to be an isolated event and repair
or replacement is not required. If
this diagnostic does occur repeated-
ly, then replace the Chiller module.
Memory Error Type III IFW All a. A Shadow Ram memory error Settings Changed in The
was detected. The UCM is operating Last 24 Hours Lost
on all last valid values (pulled from
NOVRAM) for all setup parameters.
Setup parameter changes less than
24 hours old pending to be loaded
into NOVRAM were lost. Check all
setup parameters made in the last
24 hours. Compressor starts and
hours were lost for not more than
the last 24 hours. This is expected
to be an isolated event and repair
or replacement is not required. If
this diagnostic does occur repeated-
ly, then replace the Chiller module.

Momentary power Loss MAR All Running Modes Determine Cause of

(Start Mode, e.g. Power Interruption.
Before Transition)
Motor Temp Sensor #1 MMR All Open or Short Check Sensor, Wiring
and Connections.

Motor Temp Sensor #2 MMR All Open or Short Check Sensor, Wiring
and Connections.
Motor Temp Sensor #3 MMR All Open or Short Check Sensor, Wiring
and Connections.

44
 Diag. Active
Diag Modes
Diagnostic description Cause Help Message
Type (Non-Active
Modes)

MPL Detect Circuit MMR All A failure was detected in the

Inoperative Momentary Power Loss detect cir-
cuit. If there are no zero cross inter-
rupts on Vab for approx. 3 half line
cycles, the timer interrupt will trip
and generate a diagnostic that indi-
cates that our ability to detect MPL
is gone. If Vab was truely gone the
module would be powered down so
if we can detect that Vab is gone
then there must be a hardware fai-
lure on the board.

Oil Temp Sensor MMR All Open or Short Check Sensor, Wiring
and Connections.

Option Mod Ref Voltage IFW All An improper reference voltage was
Calibration. detected at the Options Module. A
2.45 vdc reference is used to cali-
brate the non-ratiometric analog I/O
such as 2-10vdc and 4-20 mA inputs
as well as PWM Analog outputs.
The micro checks to see that the
A/D value falls within an acceptable
range.
Options Module 24 Vdc IFW All 24 Vdc reference missing and the Check Press Xducer
Ref Missing differential water pressure transdu- Wiring/24 Vdc Supply.
cers are installed.

Options Module 24 Vdc MMR All 24 Vdc reference missing and the Check Press Xducer
Ref Missing differential water pressure transdu- Wiring/24 Vdc Supply.
cers are installed and VSD installed.

Options : Loss of Comm IFW All The options module lost communi- Check IPC
with Chiller. cations with the Chiller module for Wiring/Connections.
15 contiguous seconds.
Options : Loss of Comm IFW All The options module lost communi- Check IPC
with Starter cations with the Starter module for Wiring/Connections.
15 contiguous seconds.

Outdoor Air Temp Sensor None All Open or Short N/A

(Both Outdoor Air Rst and a. Display end of range value.
Low Ambient Lockout not
selected).

Outdoor Air Temp Sensor IFW All Open or Short. Check Sensor, Wiring
(Either Outdoor Air Rst or a. Use end of range value (whatever and Connections.
Low Ambient Lockout value the open or short gives).
selected). b. Clear diag. when the resistance
returns to normal range.

Over Voltage. MAR Pre-Start and Any a. Line voltage above + 10% of Check Main Power
Ckt(s) Energized nominal. (Must hold = +10% of Supply & Wiring.
nominal. Must trip = +15% of nomi-
nal. Reset differential = min. of 2%
and max. of 4%. Time to trip = mini-
mum of 1 min. 10 sec. and maxi-
mum of 5 min
20 seconds). Design : Nom. trip : 60
seconds at greater than 112.5%,
Auto Reset at 109.5% or less.

45
 Diag. Active
Diag Modes
Diagnostic description Cause Help Message
Type (Non-Active
Modes)

Phase Loss MMR Contactor a. No current was sensed on one or Check Main Power
Energized (All Non- more of the current xformer inputs. Supply & Wiring.
Rng Modes) (Must hold = 20% RLA. Must trip =
5% RLA). Time to trip shall be 1
second minimum, 3 seconds maxi-
mum. Actual design trippoint is
10%.
Phase Reversal MMR Contactor energized a. A phase reversal was detected on Check Main Power
to transition com- the incoming current. On a com- Supply & Wiring.
mand (All Other pressor startup the phase reversal
Times) logic must defect and trip in a maxi-
mum of 0.7 second from compres-
sor start for CTV.
Phase Reversal Protection MMR Starter Contactor a. The phase reversal protection on Check Starter Module.
Lost energized to transi- the compressor has become inope-
tion command rative. The phase rotation protec-
tion system failed to detect 2 in a
row of one of the four phase circuit
states ; Phase reversal, Phase rota-
tion OK, Phase A lost, Phase B lost.
Severe Phase Unbalance MMR All Running Modes a. A 25% Phase Unbalance diagnos- Check Main Power
tic has been detected. Items to Supply & Wiring.
check are the Current Transformer
Part Numbers (they should all
match). The Current Transformer
resistances, line voltage phase
balance, all power wiring connec-
tions, the contactor pole faces, and
the motor. If all these are OK, repla-
ce the Starter module.
Starter Contactor Interrupt MMR Starter Contact not a. Welded Starter contactor. Complete Starter
Failure Energized (Starter b. Detected a welded compressor Checkout Required.
Contact Energized) contactor when the compressor was
commanded off but the current did
not go to zero. Detection time shall
be 5 second minimum and 10
seconds maximum for all
Electromechanical and Solid State
Starters. Detection time for Variable
Speed Drives shall be 12 seconds
minimum and 17 seconds maxi-
mum. On detection, generate the
diagnostic, energize the appropriate
alarm relay, continue to command
the affected compressor off.
Starter did not Transition MMR On the first check a. The UCM did not receive a transi- Complete Starter
after transition tion complete signal in the designa- Checkout Required.
ted time from the UCM command
to transition. The must hold time
from the UCM transition command
is 1 second. The Must trip time
from the transition command is 6
seconds. Actual design is 2.5
seconds.
b. The Transition Complete input
was found to be shorted before the
compressor was started.
c. Item a. above is active only for Y-
Delta, Auto-Transformer and
Primary Reactor Starters.
d. Item b. above is active for all
electromechanical starters.

46
 Diag. Active
Diag Modes
Diagnostic description Cause Help Message
Type (Non-Active
Modes)

Starter Dry Run Test MMR Starter Dry Run While in the Starter Dry Run Mode Current or Voltage
Mode either 50% Line Voltage was sensed Detected.
at the Potential Transformer or 10%
RLA Current was sensed at the
Current Transformers.
Starter Fault Type I MMR Starting a. This is a specific starter test
where 1M is closed first and a check
is made to ensure that there are no
currents detected by the CT's. If cur-
rents are detected when only 1M is
closed first at start, then one of the
other contactors is shorted.
b. This test applies only to Y-Delta
Closed Transition Starters.
Starter Fault Type I MMR Starting a. This is a specific starter test
where the Shorting Contactor(s) is
individually energized and a check
is made to ensure that there are no
currents detected by the CT's. If cur-
rent is detected when only S is
energized at Start, then 1M is shor-
ted.
b. This test in a. above applies to all
forms of starters (Note ; It is
understood that many starters do
not connect to the Shorting
Contactor).
Starter Fault Type III MMR Starting a. As part of the normal start
sequence to apply power to the
compressor the Shorting
Contactor(s) and then the Main
Contactor (1M) were energized. 1.6
seconds later there were no cur-
rents detected by the CT's for the
last 1.2 Seconds on all three
phases.
b. This test in a. above applies to all
forms of starters except Variable
Speed Drives (Note : It is unders-
tood that many starters do not
connect to the Shorting Contactor).
c. For VSD's, TBD.
Starter Mod Ref Voltage IFW All An improper reference voltage was
Calibration detected at the Starter Module. A
2.5 vdc reference is used to calibra-
te the non-ratiometric analog I/O
such as 1-10vdc and 4-20mA inputs
as well as PWM Analog outputs.
The micro checks to see that the
A/D value falls within an acceptable
range.
Starter : Loss of Comm MMR All The starter module lost communica- Check IPC
with Chiller. tion with the Chiller module for 15 Wiring/Connections.
contiguous seconds.
Starter : Loss of Comm MMR All The starter module lost communica- Check IPC
with Circuit. tion with the Chiller module for 15 Wiring/Connections.
contiguous seconds.

47
 Diag. Active
Diag Modes
Diagnostic description Cause Help Message
Type (Non-Active
Modes)

Stepper #1 : Loss Of MMR All The Stepper #1 module lost com- Check IPC
Comm with Chiller. munications with the Chiller module Wiring/Connections.
for 15 contiguous seconds.
Stepper #1 : Loss Of MMR All The Stepper #1 module lost com- Check IPC
Comm with Starter. munications with the Chiller module Wiring/Connections.
for 15 contiguous seconds.
TCI : Loss of Comm with IFW All The TCI module lost communica- Check IPC
Chiller. tions with the Chiller module for 15 Wiring/Connections.
contiguous seconds.
TCI : Loss of Comm with IFW All The TCI module lost communica- Check IPC
Circuit. tions with the Circuit module for 15 Wiring/Connections.
contiguous seconds.
TCI : Loss of Comm with IFW All The TCI module lost communica- Check IPC
Options. tions with the Options module for Wiring/Connections.
15 contiguous seconds.
TCI : Loss of Comm with IFW All The TCI module lost communica- Check IPC
Purge. tions with the Purge module for 15 Wiring/Connections.
contiguous seconds.
TCI : Loss of Comm with IFW All The TCI module lost communica- Check IPC
Starter. tions with the Starter module for 15 Wiring/Connections.
contiguous seconds.
TCI : Loss of Comm with IFW All The TCI module lost communica- Check IPC
Stepper #1. tions with the Stepper #1 module Wiring/Connections.
for 15 contiguous seconds.

Tracer Communications IFW All The Tracer was setup as "installed" Check Tracer to UCP
Lost at the CLD and the TCI lost commu- Wiring/Connections.
nications with the Tracer for 15
contiguous minutes after it had
been established. Continue to run
the chiller with the last valid Tracer
Setpoints/Mode.
Tracer failed to Establish IFW At power-up The Tracer was setup as "installed" Check Tracer
Comm at the CLD and the Tracer did not Wiring/Connections/
communicate with the TCI within 2 Power.
minutes after power-up. `
Tracer Outdoor Air Temp IFW All Check Sensor, Wiring
Sensor Fail and Connections.
Tracer Temperature IFW All Input Shorted. Check Sensor, Wiring
Sensor and Connections.

Under Voltage. MAR Pre-Start and Any a. Line voltage below - 10% of Check Main Power
Ckt(s) Energized nominal or the Under/Overvoltage Supply & Wiring.
transformer is not connected. (Must
hold = -10% of nominal. Must trip =
-15% of nominal. Reset differential =
min. of 2% and max. of 4%. Time to
trip = min. of 1 min. and max. of 5
min.)
Design : Nom. trip : 60 seconds at
less than 87.5%, + or -2.8% at 200V
or + or -1.8% at 575V, Auto Reset at
90.5% or greater.

48
Remote Human InterFace

General Characteristics
Each unit control can support two human interfaces, one machine mounted ("local") and one remote. A remote human inter-
face is not weatherproof, and is intended for indoor use. The remote human interface is mounted in a plastic enclosure. It
uses a molded rubber keypad, not a membrane keypad. The keys will have the same labels on both the local and remote
keypad.

IPC Buffer
The use of a remote human interface requires that an additional module be added to the unit control. The IPC Buffer Module
is added, to buffer and protect the inter processor communication bus. This is required because the bus is brought outside
the unit. The buffered IPC link will be electrically identical to the COM4 non-isolated protected digital communications link.
With the correct twisted pair type, the remote display can be 1600 m (5000 feet) from the unit.

Multiple Unit Communication

The machine mounted human interface communicates only with its associated unit. The standard remote human interface
communicates. A separate wire pair is run from each unit control to the remote human interface.

Operation
The operation of the remote human interface will be indentical to the operation of the machine mounted human interface,
with the following exceptions :

Unit Identification
For remote human interfaces with the multiple unit option board installed, the following display will be inserted as the
second display in each setting group, immediately following the report heading :

Modify Settings for Unit : X

"Press (+) (-) to Change Setting"

where x is equal to 1, 2, 3 or 4.

When the unit number is changed, the human interface will clear the buffers of any data from the previous unit, and update
the buffers with new data before any of the new unit data is received or for 5 seconds, whichever comes first :

Updating Unit Data,

Please Wait

If the new unit data is not received after 5 seconds, the following display is used. For remote human interfaces with the mul-
tiple unit option board installed, this display will always be used in place of the "No Communication to Unit, Data Not Valid"
display.

When Enter is pressed, the display returns to the "Modify Settings for Unit X" display.

For remote human interfaces with the multiple unit option board installed, the following displays will be inserted as the
second display in the various reports, immediately following the report heading :

Custom Report for Unit X

"Press (Next) (Previous) to continue"

The custom report can be different for each unit, since the report sequence for each unit is stored at the unit.

Chiller Report for Unit X

"Press (Next) (Previous) to continue"

Refrigerant Report for Unit X

"Press (Next) (Previous) to continue"

Compressor Report for Unit X

"Press (Next) (Previous) to continue"

49
Stop Auto
The CHILLER MODULE will maintain the Stop/Auto status based on Stop and Auto commands received from the local and
remote human interfaces. The CHILLER MODULE will store the source (local human interface or remote human interface) of
the current Stop or Auto status. Whether a Stop or Auto command will be accepted and stored is based on the following
hierarchy :

1. Local Stop will always replace Local Auto, Remote Auto, and Remote Stop.
2. Local Auto will always replace Local Stop, Remote Auto, and Remote Stop.
3. Remote Stop will always replace Local Auto and Remote Auto. It will not replace Local Stop.
4. Remote Auto will always replace Local Auto and Remote Stop. It will not replace Local Stop. If a Auto command is
requested at the remote human interface when the unit stopped based on a command from the local human interface,
the following message is displayed for one second. The display then returns to the previous display. The human interfa-
ce will respond normally to any key presses during that one second.

Stop Commanded at Unit cannot be

overridden at Remote Human Interface

Remote Reset
There are diagnostics which cannot be cleared from a remote Human Interface. To distinguish between a local system reset
and a remote system diagnostic clear. The reset screen in the diagnostic menu is modified for a remote Human Interfaces as
shown below.

If any active diagnostics are present, the following screen will be displayed :

Press (Enter) To Clear

Remote Reset Diagnostics

If the enter key is depressed, the following message is displayed for 4 seconds :

Remote Reset Diagnostics Have Been Cleared

Diagnostic report is Being Reset

The display will be reset to the top of the Diagnostic menu after this message clears.

50
 Installation check sheet
Trane CVGE centrifugal chiller Condenser water system
All piping inspected for leakage
This form should be filled out by the installing contractor to Thermometers installed
ensure complete and proper installation before starting the Water pressure manometers installed
unit. System balancing valves installed
System flushed, cleaned and refilled
Warning : Disconnect electrical power before inspecting Cooling water temperature control installed
the unit. If power must be on, exercice extreme caution Pump run and condenser pressure drop checked
near electrical wiring. Failure to do so may result in inju- Flow switch installed
ry or death from electrical shock.
Electrical
Fan motors rotate in correct direction
Receiving Circulating pump motors rotate in correct direction
Unit inspected for shipping damage Supply power wiring run to unit control panel
Unit checked for missing material Supply power to unit matches nameplates specifications
Proper rigging and hoisting procedures applied before lif- Pump starter and flow switch circuit complete and opera-
ting unit, including lifting brackets and spreader bars tional
Thermostatically controlled heat cable installed on all expo-
Unit location sed piping
Shipping runners and channels removed and discarded All connections correctly tightened and torqued
Unit secured in correct location
Unit level General
Service clearances good Cooling load available = minimum 50%
Isolators installed Other trades coordinated for commissioning

Chilled water system

All piping inpected for leakage
Thermometers installed
Water pressure manometers installed
System balancing valves installed
Flow switch installed
System flushed, cleaned and refilled
Pump run and evaporator pressure drop verified

Comments Customer order N° :

Signed Job name :
Name : Trane s/o reference :

Send this to the Trane office commissioning the unit.

51
Weekly operating log centrifugal equipment

Hour/Date of readings : . . . . . . .Machine model :................

Readings taken by : . . . . . . . . . . .Serial number :.................

Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . .Value .......

Hour counter . . . . . . . . . . . . . . . . . . . . . . . hours .......
Start counter . . . . . . . . . . . . . . . . . . . . . . . . . . N° .......
High pressure . . . . . . . . . . . . . . . . . . . . . . . . bar .......
Low pressure . . . . . . . . . . . . . . . . . . . . . . . . . bar .......

Compressor
Oil pressure HP . . . . . . . . . . . . . . . . . . . . . . . bar .......
Oil pressure LP . . . . . . . . . . . . . . . . . . . . . . . bar .......
Oil temperature - Tank . . . . . . . . . . . . . . . . . . °C .......
Oil temperature - Cooler . . . . . . . . . . . . . . . . . °C .......
Oil level in tank . . . . . . . . . . . . . . . . . . . . . . . . (1) .......
Entering chilled water pressure . . . . . . . . . . bar .......

Evaporator
Leaving chilled water pressure . . . . . . . . . . . bar .......
Entering chilled water temperature . . . . . . . . °C .......
Leaving chilled water temperature . . . . . . . . . °C .......
Entering condenser water pressure . . . . . . . bar .......

Heat rejection
Leaving condenser water pressure . . . . . . . . bar . . . . . . .
Entering condenser water temperature . . . . . °C . . . . . . .
Leaving condenser water temperature . . . . . °C . . . . . . .

Condenser
Entering condenser water pressure . . . . . . . bar . . . . . . .

Heat recovery
Leaving condenser water pressure . . . . . . . . bar . . . . . . .
Entering condenser water temperature . . . . . °C . . . . . . .
Leaving condenser water temperature . . . . . °C . . . . . . .

(1) Indicate : 0 -1/4 - 1/3 - 1/2 - 2/3 - 3/4 - 1

52
Notes

53
Notes

54
Notes

55
 Safety recommendations
To avoid accidents and damage, the following recommen- 2. Disconnect the main supply before any servicing on the
dations should be observed during maintenance and servi- unit.
ce visits : 3. Service work on the refrigeration system and the electri-
1. The maximum allowable pressures for system leak tes- cal system should be carried out only by qualified and
ting on low and high pressure side are given in the chap- experienced personnel.
ter "Installation". Always provide a pressure regulator.

Maintenance contract
It is strongly recommended that you sign a maintenance occur. Finally, regular maintenance ensures the maximum
contract with your local Service Agency. This contract pro- operating life of your equipment. We would remind you
vides regular maintenance of your intallation by a specia- that failure to respect these installation and maintenance
list in our equipment. Regular maintenance ensures that instructions may result in immediate cancellation of the
any malfunction is detected and corrected in good time warranty.
and minimizes the possibility that serious damage will

Training
The equipment described in this manual is the result of charge. Emphasis is particularly given to the importance of
many years of research and continuous development. To periodic checks on the unit operating parameters as well as
assist you in obtaining the best use of it, and maintaining it on preventive maintenance, which reduces the cost of
in perfect operating condition over a long period of time, owning the unit by avoiding serious and costly breakdown.
the constructor has at your disposal a refrigeration and air
conditioning service school. The principal aim of this is to
give operators and maintenance technicians a better know-
ledge of the equipment they are using, or that is under their

This equipment with its mounted accessories is in conformity with the

provisions of the low Voltage directive 73/23/EEC and Electromagnetic
compatibility directive 89/336/EEC as amended, and in conformity
with national implementing legislation.

The constructor's policy is one of continuous product improvement, and he reserves the
right to alter any details of the products at any time without notice For additional information, contact :

This publication is a general guide to install, use and properly maintain our products. The
information given may be different from the specification for a particular country or for a
specific order. In this event, please refer to your nearest office.

Distributor / Installer stamp

All rights reserved. No part of this publication may be reproduced or

transmitted in any form or by any means without the written authori- B60 IM 012 E - 0698 •
zation of the constructor. Supersedes B60 IM 012 E- 0495
Imprimeur
Printed in France

Société Trane - Société Anonyme au capital de 41 500 000 F - Siège Social : 1, rue des Amériques - 88190 Golbey - France -
Siret 306 050 188-00011 - RCS Epinal B 306 050 188