Operation Maintenance Water Cooled CenTraVac …

1 CVHE-SVU01E-ENX39640712050 OperationMaintenanceWater Cooled CenTraVac With CH530 2005 American Standard All rights reservedCVHE-SVU01E-ENWarnings andCautionsWarnings and CautionsNotice that warnings and cautionsappear at appropriate intervalsthroughout this manual. Warningsare provided to alert installingcontractors to potential hazards thatcould result in personal injury ordeath, while cautions are designed toalert personnel to conditions thatcould result in equipment personal safety and the properoperation of this machine dependupon the strict observance of :Warnings and Cautions appear at appropriate sections throughout this these carefully. WARNING Indicates a potentially hazardous situation which, if not avoided, could result indeath or serious injury. CAUTION Indicates a potentially hazardous situation which, if not avoided, may result inminor or moderate injury. It may also be used to alert against unsafe Indicates a situation that may result in equipment or property-damage-only and CautionsGeneral InformationUnit control Panel (UCP)Operator InterfaceChilled Water SetpointInter Processor Communication (IPC)

2 control System ComponentsControls Sequence of OperationMachine Protection and Adaptive ControlUnit StartupUnit ShutdownPeriodic MaintenanceOil MaintenanceMaintenanceForms2426284149506 3688587889193100 CVHE-SVU01E-EN4 Typical Product Description BlockMODL CVHEDSEQ 2 RNTON 320 VOLT 575 REF 123 HRTZ 60 TYPE SNGLCPKW 142 CPIM 222 TEST AIREVTM IECUEVTH 28 EVSZ 032 SEVBS 280 EVWC STDEVWP 2 EVWT NMAREVPR 150 EVCO VICTEVWA LELECDTM IECUCDTH 28 CDSZ 032 SCDBS 250 CDWC STDCDWP 2 CDWT NMARCDPR 150 CDCO VICTCDWA LELECDTY STDTSTY STDECTY WEORORSZ 230 PURG PUREWCNM SNMPSPKG DOMOPTI CPDWHHOP NOGENR NOGNSL NOSOPT SPSHACCY ISLSHGBP WOLUBE SNGLAGLT CULCNIF UCPSRTY USTRSRRL 207 PNCO TERMG eneralInformationUnit NameplateThe unit nameplate is located on theleft side of the unit control following information isprovided on the unit Serial NumberThe unit serial number provides thespecific chiller identity. Alwaysprovide this serial number whencalling for service or during Service Model NumberThe service model represents the unitas built for service purposes.

3 Itidentifies the selections of variableunit features required when orderingreplacements parts or : Unit-mounted starters areidentified by a separate numberfound on the Product Coding BlockThe CVHE, CVHF and CVHG modelsare defined and built using theproduct definition and selection(PDS) system. This system describesthe product offerings in terms of aproduct coding block which is madeup of feature categories and featurecodes. An example of a typicalproduct code block is given on thispage. The coding block preciselyidentifies all characteristics of a Identifies unit electricalrequirements5. Correct operating charges and typeof refrigerant6. Unit Test Pressures and MaximumOperating Pressures7. Identifies unit Installation andOperation and Maintenance manuals8. Drawing numbers for Unit WiringDiagramsLiterature changeApplicable to CVHE, CVHF, CVHGA bout this manualOperation and maintenanceinformation for models CVHE, CVHFand CVHG are covered in thismanual.

4 This includes both 50 and 60Hz. CVHE, CVHF and CVHG centrifugal chillers equipped with theTracer CH530 Chiller Controllersystem. Please note that informationpertains to all three chiller typesunless differences exist in whichcase the sections are broken downby Chiller type as applicable anddiscussed carefully reviewing thisinformation and following theinstructions given, the owner oroperator can successfully operateand maintain a CVHE, CVHF or mechanical problems do occur,however, contact a qualified serviceorganization to ensure properdiagnosis and repair of the : The CH530 controller was firstapplied to CVHE with DesignSequence 3K , and to CVHF withDesign Sequence 1W .5 CVHE-SVU01E-ENAn example of a typical modelnumber is:CVHF091 NAL00 ACU2758W7E8 TBC0000000K01G14C10W1A03B1 Model Number Digit IdentificationC = (1st digit) CenTraVac HermeticV = (2nd digit) CenTraVac HermeticH = (3rd digit) Direct DriveF = (4th digit) Development sequence091 = (5th, 6th, and 7th digit) Nominalcompressor tonnageN = (8th digit) Unit VoltageA = (9th digit) Unit TypeA = Cooling CondenserB = Heat Recovery CondenserC = Auxiliary CondenserD = Free Cooling OptionS = SpecialL0 = (10th and 11th digit) DesignSequence0 = (12th digit) Hot Gas By-PassW = With HGB0 = Without HGBS = SpecialA = (13th)

5 Starter typeA = Star-Delta Unit MountedC = Star Delta Remote MountedE = X-Line Full Volt RemoteMountedF = Autotransformer RemoteMountedG = Primary Reactor RemoteMountedH = X-Line Full Volt Unit MountedJ = Autotransformer UnitMountedK = Primary Reactor UnitMounted L = Solid State Unit MountedM = Solid State Floor MountedN = Solid State Wall MountedP = Adaptive Frequency Drive - UnitMountedR = Customer SuppliedC = (14th digit) control EnclosureS = SpecialC = Standard control EnclosureU = (15th digit) Compressor MotorPower (kw)275 = (16th, 17th, and 18th digit)Compressor Imp Cutback8 = (19th digit) Evaporator Shell SizeW = (20th digit) Evaporator TubeBundle7 = (21st digit) Evaporator TubesE = (22nd digit) Evaporator Waterbox8 = (23rd digit) Condenser Shell SizeT = (24th digit) Condenser TubeBundleB = (25th digit) Condenser TubesC = (26th digit) CondenserWaterboxes0 = (27th digit) Heat RecoveryCondenser Shell Size0 = (28th digit) Heat RecoveryCondenser Tube Bundle0 = (29th digit) Heat RecoveryCondenser Tubes0 = (30th digit) Heat RecoveryCondenser Waterboxes0 = (31st digit) Auxiliary CondenserSize and Waterboxes0 = (32nd digit) Auxiliary CondenserTubes0 = (33rd digit) Orifice SizeK = (34th digit) Orifice Size0 = (35th digit) Unit Option1 = (36th digit) control : EnhancedprotectionG = (37th digit) control : Generic BAS1 = (38th digit) control : Extendedoperation4 = (39th digit) Tracer communicationinterfaceC = (40th digit) control : Condenserrefrigerant pressure1 = (41st digit) control : Tracer IO0 = (42nd digit) Special OptionsW = (43nd digit) control : Water flowcontrol1 = (44th digit) control : Chilled waterresetA = (45th digit) control .

6 Heat Recoverytemperature sensors0 = (46th digit) Gas Powered Chiller3 = (47th digit) Compressor MotorFrame SizeB = (48th digit) Volute DischargeAngle1 = (49th digit) control : OperatingstatusW = (50th digit) Industrial ChillerPackage (INDP)0 = Without INDPW = With INDP1 = (51st digit) control PowerTransformer (CPTR)0 = Without CPTR1 = With CPTRS = SpecialB = (52nd digit) Motor and TerminalBoard ConfigurationA = Six Lead Low VoltageB = Three Lead MediumVoltageC = Six Lead MediumVoltageS = SpecialGeneralInformationCVHE-SVU01E-EN6 GeneralInformationCommonly Used AcronymsFor convenience, a number ofacronyms are used throughout thismanual. These acronyms are listedalphabetically below, along with the translation of each:AFD = Adaptive Frequency DriveASME = American Society ofMechanical EngineersASHRAE = American Society ofHeating, Refrigerating and AirConditioning EngineersBAS = Building Automation SystemCABS = Auxiliary Condenser Tube-Bundle SCDBS = Condenser Bundle SizeCDSZ = Condenser Shell SizeCH530 = Tracer CH530 ControllerDV = DynaView Clear LanguageDisplay, also know as the MainProcessor (MP)CWR = Chilled Water ResetCWR = Chilled Water Reset PrimeDTFL = Design Delta-T at Full Load( , the difference between enteringand leaving chilled watertemperatures)

7 ELWT = Evaporator Leaving WaterTemperatureENT = Entering Chilled WaterTemperatureFC = Free CoolingGPM = Gallons-per-minuteHGBP = Hot Gas BypassHVAC = Heating, Ventilating, and AirConditioningIE = Internally-Enhanced TubesIPC = Interprocessor CommunicationLBU = La Crosse Business UnitLCD = Liquid Crystal DisplayLED = Light Emitting DiodeMAR = Machine Shutdown AutoRestart (Non-Latching where chillerwill restart when condition correctsitself.)MMR = Machine Shutdown ManualRestart (Latching where chiller mustbe manually reset.)MP = Main ProcessorPFCC = Power Factor CorrectionCapacitorPSID = Pounds-per-Square-Inch(differential pressure)PSIG = Pounds-per-Square-Inch(gauge pressure)UCP = Unit control PanelLLID = Low Level Intelligent Device(Sensor, Pressure Transducer, orInput/output UCP module)RLA = Rated Load AmpsRTD = Resistive Temperature DeviceTracer CH530= Controls Platformutilized on this ChillerTOD = Temperature OutdoorControl Optional PackagesOPST Operating Status ControlGBAS Generic Building AutomationInterfaceEXOP Extended OperationCDRP Condenser PressureTransducerTRMM Tracer CommunicationsFRCL Free CoolingHGBP Hot Gas BypassWPSR Water pressure sensingEPRO Enhanced ProtectionACOS Auxillary Condenser sensorsCWR Chiller Water reset outdoor7 CVHE-SVU01E-ENGeneralInformationFigure 1.

8 General CVHE and CVHG unit componentsOverviewCVHE, CVHG, CVHFEach CVHE, CVHG, or CVHF unit iscomposed of 5 basic components. the evaporator, 3-stage compressor on CVHE,CVHG or 2 stage compressor onCVHF, 2-stage economizer on CVHE,CVHG, or single economizer onCVHF,See Figure 1 for Typical CVHE andCVHG, and Figure 2 for Typical CVHF major heat-recovery or auxiliarycondenser can be factory-added tothe basic unit assembly to provide aheat-recovery cycle. Water - Cooled condenser, related interconnecting 1. General CVHE and CVHG unit components - continued9 CVHE-SVU01E-ENGeneralInformationFigure 2. Illustrates the general component layout of a typical CVHF chillerCVHE-SVU01E-EN10 GeneralInformationCooling CycleCVHE, CVHG, CVHFWhen in the cooling mode, liquidrefrigerant is distributed along thelength of the evaporator and sprayedthrough small holes in a distributor( , running the entire length of theshell) to uniformly coat eachevaporator tube.

9 Here, the liquidrefrigerant absorbs enough heat fromthe system Water circulating throughthe evaporator tubes to gaseous refrigerant is thendrawn through the eliminators(which remove droplets of liquidrefrigerant from the gas) and first-stage variable inlet guide vanes, andinto the first stage : Inlet guide vanes are designedto modulate the flow of gaseousrefrigerant to meet system capacityrequirements; they also prerotate thegas, allowing it to enter the impellerat an optimal angle that maximizesefficiency at all load , CVHG CompressorCompressed gas from the first-stageimpeller flows through the fixed,second-stage inlet vanes and into thesecond-stage , the refrigerant gas is againcompressed, and then dischargedthrough the third-stage variable guidevanes and into the third the gas is compressed a thirdtime, it is discharged into thecondenser. Baffles within thecondenser shell distribute thecompressed refrigerant gas evenlyacross the condenser tube tower Water circulatedthrough the condenser tubes absorbsheat from the refrigerant, causing it tocondense.

10 The liquid refrigerant thenpasses through orifice plate A andinto the economizer reduces the energyrequirements of the refrigerant cycleby eliminating the need to pass allgaseous refrigerant through threestages of compression. See Figure that some of the liquidrefrigerant flashes to a gas becauseof the pressure drop created by theorifice plates, thus further cooling theliquid refrigerant. This flash gas isthen drawn directly from the first(Chamber A) and second (ChamberB) stages of the economizer into thethird-and second-stage impellers ofthe compressor, remaining liquid refrigerant flowsthrough another orifice plate C tothe CompressorCompressed gas from the first-stageimpeller is discharged through thesecond-stage variable guide vanesand into the second-stage , the refrigerant gas is againcompressed, and then dischargedinto the within the condenser shelldistribute the compressed refrigerantgas evenly across the condensertube bundle.