American Standard CH530 - Manuals

5 CDHF-SVU01C-EN GeneralInformation Model Number - An example of a typical duplex centrifugal chillermodel number is: CDHF2100AA0BC2552613C0B203B0B20KJAC1GW40C111340A010 Digit: Description 1 st -2 nd CD = CenTraVac ® Duplex - 2 compressors 3 rd H =Direct Drive 4 th F = Development Sequence (F - 2 St...

CDHF-SVU01C-EN 6 GeneralInformation V = 1890W = 2060X = 1475Z = 560 - 3 stage 935 - 2 stageY = 500 - 3 stage 835 - 2 stage1 = 630 - 3 stage 2245 - 2 stage2 = 800 - 3 stage 2345 - 2 stage3 = 900 - 3 stage 2450 - 2 stage4 = 1000 - 3 stage 2560 - 2 stage5 = 1120 - 3 stage 2675 - 2 stage6 = 12507 = 1600...

7 CDHF-SVU01C-EN GeneralInformation Commonly Used Acronyms For convenience, a number ofacronyms are used throughout thismanual. These acronyms are listedalphabetically below, along with the“translation” of each: AFD = Adaptive Frequency Drive ASME = American Society ofMechanical Engineers ASHRAE = A...

CDHF-SVU01C-EN 8 GeneralInformation Figure 1. General Duplex unit components - front view Overview CDHF - CDHG See Figure 1 for General Unitcomponents. Each Chiller unit iscomposed of the followingcomponents as viewed when facingthe control panel front side:• Common Evaporator and Common Condenser •...

9 CDHF-SVU01C-EN GeneralInformation Figure 2. General Duplex unit components (2 stage compressor)

CDHF-SVU01C-EN 10 GeneralInformation Cooling Cycle Duplex Chillers have two refrigerantcircuits that operate as their ownindependent circuits. These circuitsare discussed as individual chillerrefrigeration units in the followingdiscussion. The sequence ofoperation of the two refrigerationcircuits is...

13 CDHF-SVU01C-EN Overview Controls Operator Interface Information is tailored to operators,service technicians and owners. When operating a chiller, there isspecific information you need on aday-to-day basis — setpoints, limits,diagnostic information, and reports. When servicing a chiller, you need...

CDHF-SVU01C-EN 14 GeneralInformation CTV Duplex Sequence Of Operation This section will provide basicinformation on chiller operation forcommon events. Withmicroelectronic controls, ladderdiagrams cannot show today’scomplex logic, as the controlfunctions are much more involvedthan older pneumatic or...

15 CDHF-SVU01C-EN GeneralInformation Figure 8. CDHE/F/G sequence of operation: auto to running This diagram shows the sequence ofoperations for a start of the firstcompressor on a duplex chiller. The‘First’ compressor will be determinedby the type of duplex start selected. Staging Second Compressor ...

CDHF-SVU01C-EN 16 GeneralInformation Figure 11. CDHE, CDHF and CDHG sequence of operation: normal shutdown to stopped and run inhibit Figure 10. CDHE/F/G sequence of operation: staging second compressor off Staging Second Compressor Off: This diagram shows the sequence of operations where there is n...

17 CDHF-SVU01C-EN GeneralInformation Duplex Compressor Sequencing Four methods (Two fixed sequencemethods, a balanced start and hour’smethod, and a no staging method)are provided for order of acompressor sequencing on CTVDuplex chillers. The desired methodis selectable at startup via the servicetool...

19 CDHF-SVU01C-EN GeneralInformation Sequencing - Balanced Starts andHours When desired to balance the wearbetween the compressors. Thismethod will extend the time betweenmaintenance on the lead compressor.When balanced starts and hours isselected, the compressor with thefewest starts will start. If...

CDHF-SVU01C-EN 22 GeneralInformation Oil and Refrigerant Pump Compressor Lubrication System - A schematic diagram of thecompressor lubrication system isillustrated in Figure 16. (This can beapplied to circuit 1 or 2.) Oil is pumped from the oil tank (by apump and motor located within thetank) throug...

23 CDHF-SVU01C-EN GeneralInformation Figure 16. Oil refrigerant pump - circuit 1 or 2

CDHF-SVU01C-EN 24 GeneralInformation Base Loading ControlAlgorithm: This feature allows an externalcontroller to directly modulate thecapacity of the chiller. It is typicallyused in applications where virtuallyinfinite sources of evaporator loadand condenser capacity are availableand it is desirable...

CDHF-SVU01C-EN 26 GeneralInformation Ice Machine Control UCP provides a service level “Enableor Disable” menu entry for the IceBuilding feature when the IceBuilding option is installed. IceBuilding can be entered from “FrontPanel”, or if hardware is specified theUCP will accept either an isolatedcon...

27 CDHF-SVU01C-EN GeneralInformation Hot Water control Occasionally CTV chillers areselected to provide heating as aprimary mission. With hot watertemperature control, the chiller canbe used as a heating source orcooling source. This feature providesgreater application flexibility. In thiscase the o...

CDHF-SVU01C-EN 28 Unit ControlPanel (UCP) Control Panel Devices and UnitMounted Devices Unit Control Panel (UCP) Safety and operating controls arehoused in the unit control panel, thestarter panel and the purge controlpanel. The UCP ‘s operator interfaceand main processor is called theDynaView ™ (DV...

29 CDHF-SVU01C-EN Unit ControlPanel (UCP) Tracer CH530 Chiller Controller Revolutionary control of the chiller,chilled water system, and your entirebuilding with unprecedentedaccuracy, reliability, efficiency, andsupport for maintenance using thechiller’s PC-based service tool.Chiller reliability is...

CDHF-SVU01C-EN 30 OperatorInterface Figure 21. DynaView ™ main processor The DynaView ™ (DV) Operator Interface contains the “MainProcessor (MP)” and is mounted onthe unit control panel front doorwhere it communicates commandsto other modules, collecting data,status and diagnostic informationfrom th...

37 CDHF-SVU01C-EN OperatorInterface Diagnostic Screen The diagnostic screen is accessible by touching the Alarms enunciator. When an alarm is present, the alarmenunciator is present next to the Stopkey. A flashing “alarm” indicates amachine shutdown and a nonflashing “alarm” indicates aninformationa...

39 CDHF-SVU01C-EN OperatorInterface The left column text “Front Panel”,“BAS”, “External”, and “ActiveCurrent Limit Setpoint” will alwaysbe present regardless of installationor enabling those optional items. Inthe second column “- - - -” will beshown if that option is Not Installed,otherwise the curr...

CDHF-SVU01C-EN 40 OperatorInterface Reports To aid in comparing the status ofboth circuits, the heading on theReports list screen has buttons asindicated in the table above (i.e.,System, Ckt1, and Ckt2). The selectedbutton is darkened, presented inreverse video, or some how changedto indicate it is ...

43 CDHF-SVU01C-EN OperatorInterface Setting Tab screens provides a user the ability to adjust settings justifiedto support daily tasks. The layoutprovides a list of sub-menus,organized by typical subsystem. To change chilled water setpoint, firstselect the settings tab screen. Chilledwater setpoint ...

CDHF-SVU01C-EN 46 OperatorInterface Each Settings Sub screen consists of a setpoints list and the current value.The operator selects a setpoint to change by touching either the description orsetpoint value. Doing this causes the screen to switch to the Analog SettingsSubscreen shown below. Analog Se...

CDHF-SVU01C-EN 50 OperatorInterface The DynaView ™ Display Touch Screen Lock screen is shown below. This screen is used if the Display and Touch Screen Lock feature is Enabled. 30minutes after the last key stroke this screen will be displayed and the Displayand Touch Screen will be locked out until ...

51 CDHF-SVU01C-EN Control Panel Internallymounted devices For visual identification InternalControl Panel mounted devices areidentified by their respectiveschematic designation number.Control panel items are marked onthe inner back panel in the controlpanel. Figure 24 illustrated below,identifies th...

CDHF-SVU01C-EN 52 Control SystemComponents Figure 24. Control panel components layout

55 CDHF-SVU01C-EN Head Relief Request Output When the chiller is running inCondenser Limit Mode or in SurgeMode, the head relief request relayon the 1A9–J2-6 to J2-4 will beenergized (1 minute default) and canbe used to control or signal for areduction in the entering condenserwater temperature. Des...

CDHF-SVU01C-EN 56 Control SystemComponents EXOP Extended Operation OptionThe following modules (1A17, 1A18, and 1A19) are provide when this control package is specified. 1A5 Quad Relay EXOP Relay #4 Ice Building Relay J2-10 NO, J2-11 NC, Output module J2-12 common 1A17 Optional Dual Analog EXOP Sign...

57 CDHF-SVU01C-EN Control SystemComponents TRMM TRM4 (Tracer Comm 4 interface) 1A14 Optional TRM4 Tracer Communications J2-1 COMM+, J2-2 COMM -J2-3, Communication or COMM +J2-4, COMM -, Interface Module LCI-C CDRP (Condenser Refrigerant Pressure Output) 1A15 Optional Dual Analog CDRP Signal #2 Conde...

CDHF-SVU01C-EN 58 Control SystemComponents CDRP Refrigerant PressureOutput Option 1A15: Refrigerant Pressure Output can beconfigured at commissioning tocorrespond to either A) the absolutecondenser pressure, or B) thedifferential pressure of the evaporatorto condenser pressures. This vdc output is l...

59 CDHF-SVU01C-EN Control SystemComponents B) Refrigerant Differential PressureIndication Output: A 2 to 10 VDC analog output isprovided instead of the previouscondenser pressure output signal.This signal corresponds to apredetermined minimum andmaximum pressure settings setup atcommissioning of thi...

61 CDHF-SVU01C-EN Control SystemComponents External Chilled WaterSetpoint (ECWS) The External Chilled Water Setpointallows the chilled water setpoint tobe changed from a remote location.The External Chilled Water Setpointis found on 1A16 J2-5 to J2-6(Ground). 2-10 vdc and 4-20 macorresponds to a def...

CDHF-SVU01C-EN 62 Control SystemComponents 1A8, 1A9, 1A11, 1A12 Quad RelayOutput Status: Relay #1 J2-1 NO, J2-2 NC, J2-common Relay #2 J2-4 NO, J2-5 NC, J2-6common Relay #3 J2-7 NO, J2-8 NC, J2-9common Relay #4 J2-10 NO, J2-11 NC, J2-12common Relay Outputs: at 120 VAC: 7.2 Ampsresistive, 2.88 Amps p...

63 CDHF-SVU01C-EN Control SystemComponents 1A15, 1A16, 1A17, 1A21 Dual AnalogInput/output Module;Analog Output: The Analog Output is a voltage only signal. 2-10 Vdc at22mA J2: 14 - 26 AWG with a maximum oftwo 14 AWG J2-1 Output #1 to J2-3 (Ground), J2-4Output #2 to J2-6 (Ground). UCP provides a 2-10...

CDHF-SVU01C-EN 64 Control SystemComponents Unit mounted devices Vane Actuator Control The Stepper Module within thestepper vane actuator (4M2) (and 4M4extended capacity) pulses a DCvoltage to the windings of theStepper Motor Actuator(s) to controlinlet guide vane position. Whileoperation of this ste...

67 CDHF-SVU01C-EN Electrical Sequence This section will acquaint theoperator with the control logicgoverning CDHF/CDHG chillersequipped with Tracer CH530 UCPbased control systems. Whenreviewing the step-by-step electricalsequences of operation, refer to thetypical wiring schematics for Unitmounted W...

CDHF-SVU01C-EN 70 Interval Minimum Maximum Units Actual Design A. (Test for transition completeinput open) 160 to 240 milliseconds B. (Just delay time) 20 milliseconds C. (Close 1M (2K1) Contactor and testfor no current.) (Starter integrity test) 500 milliseconds D. (Hold 1M (2K1) Contactor and test...

CDHF-SVU01C-EN 72 Momentary Power Loss (MPL)Protection. Improved power measurement andprotection algorithms allow the unitto accommodate more poweranomalies than ever. If the chillermust shut down, faster restarts getthe machine up and running as soonas possible. Momentary power loss (MPL) detectsth...

73 CDHF-SVU01C-EN Current Overload Protection Motor currents are continuouslymonitored for over current protectionand locked rotor protection. Thisprotects the Chiller itself fromdamage due to current overloadduring starting and running modesbut is allowed to reach full loadamps. This overload prote...

CDHF-SVU01C-EN 74 Current Limit Protection Current Limit Protections exist toavoid motor current overload anddamage to the compressor motorduring starting and running.Compressor motor current iscontinuously monitored and currentis controlled via a limit function thatto prevent running into over curr...

75 CDHF-SVU01C-EN Differential to Start or Stop The Differential to Start setpoint isadjustable from 1 to 10°F (0.55 to5.55°C) and the Differential to Stopsetpoint adjustable from 1 to 10°F(0.55 to 5.55°C). Both setpoints arewith respect to the Active ChilledWater Setpoint. When the chiller isrunnin...

CDHF-SVU01C-EN 76 Evaporator Limit Evaporator refrigerant temperature iscontinuously monitored to provide alimit function that prevents lowrefrigerant temperature trips whichallows the chiller to continue to runat a reduced load instead of trippingoff at the Low Evaporator RefrigerantTemperature Cut...

77 CDHF-SVU01C-EN Low Refrigerant TemperatureCutout The purpose of the low evaporatorrefrigerant temperature protection isto prevent water in the evaporatorfrom freezing. When the LowEvaporator Refrigerant TemperatureCutout (LRTC) trip point is violated, alatching diagnostic indicating thecondition ...

CDHF-SVU01C-EN 78 Figure 31. Cutout strategy Machine Protectionand AdaptiveControl Limit Loading: The potential to limit loading increases as the saturatedevaporator temperature approaches the evaporator limit setpoint. Unload: The potential to unload increases as the saturated evaporatortemperature...

79 CDHF-SVU01C-EN Condenser Limit Condenser pressure is continuouslymonitored to provide a limit functionthat prevents High Pressure Cutout(HPC) trips. This protection is calledCondenser Refrigerant PressureLimit, or High Pressure Limit. A fullyloaded compressor, operating at highEvaporator Leaving ...

CDHF-SVU01C-EN 80 Restart Inhibit This function provides short cycleprotection for the motor, andindirectly also short cyclingprotection for the starter since thestarter is designed to operate themotor under all the conditions ofmotor performance. The operation of the restart inhibitfunction is depe...

CDHF-SVU01C-EN 84 Table 3. Values for start reset types The values for “RESET TYPE” are:Reset Outdoor Return Const Return Type: Disable Air Reset Reset Reset The values for “RESET RATIO” for each of the reset types are:Reset Reset Increment Increment Factory Type Ratio English SI Units Default Range...

85 CDHF-SVU01C-EN Reset Ratio: The Reset Ratio is displayed as apercentage. To use it in the aboveequation it must be converted to it’sdecimal form. Reset Ratio percent /100 = ResetRatio decimal Example of converting Reset Ratio: If the Reset Ratio displayed on theCLD is 50 percent then use (50/100)...

CDHF-SVU01C-EN 86 Figure 33. Reset function for return CWR Note: This graph assumes Maximum Reset is set to 20 degrees. Figure 34. Reset function for return CWR Machine Protectionand AdaptiveControl

87 CDHF-SVU01C-EN Example of Calculating Return Reset: If:Reset Ratio = 50%Start Reset = 25TWE = 65TWL = 45Maximum Reset = 8 How many Degrees of Reset willthere be? Degrees of Reset = Reset Ratio*(StartReset - (TWE-TWL))Degrees of Reset = .5*(25-(65-45))Degrees of Reset = 2.5 If:Reset Ratio = 70%Sta...

89 CDHF-SVU01C-EN Unit Start-Up Procedures Daily Unit Start-Up 1. Verify the chilled water pump and condenser water pump starter arein “ON” or “AUTO”. 2. Verify the cooling tower is in “ON” or “AUTO”. 3. Check both oil tank oil level(s); the level must be visible in or abovethe lower sight glass. Al...

CDHF-SVU01C-EN 90 When the cooling requirement issatisfied, the UCP originates a“Shutting down” signal. The inletguide vanes are driven closed for 50seconds, and the unit enters a 3-minute post-lube period. Thecompressor motor and condenserwater pump starter are de-energizedimmediately, but the oil ...

91 CDHF-SVU01C-EN Unit Shutdown Procedures Daily Unit Shutdown Note: Refer to Start-Run Shutdown sequence in General InformationOverview Sequence of Operation. 1. Press STOP. 2. After compressor and water pumps shutdown turn PumpContactors to OFF or open pumpdisconnects. Seasonal Unit Shutdown CAUTI...

CDHF-SVU01C-EN 92 Overview This section describes the basicchiller preventive maintenanceprocedures, and recommends theintervals at which these proceduresshould be performed. Use of aperiodic maintenance program isimportant to ensure the best possibleperformance and efficiency from aCenTraVac ® chil...

93 CDHF-SVU01C-EN      WARNING Hazardous Voltagew/Capacitors! Disconnect all electric power,including remote disconnects beforeservicing. Follow proper lockout/tagout procedures to ensure thepower cannot be inadvertentlyenergized. For variable frequencydrives or other energy storingcomponents p...

CDHF-SVU01C-EN 94 [ ] Complete all recommendedquarterly maintenance procedures. [ ] Lubricate the vane control linkagebearings, ball joints, and pivotpoints; as needed a few drops of lightmachine oil (SAE-20) is sufficient. [ ] Lubricate vane operator tango-rings as described in themaintenance secti...

95 CDHF-SVU01C-EN Oil Maintenance Compressor Oil Change It is recommended to change the oiland oil filter:• After the first 1000 hours of chiller operation. For a chiller operatedcontinuously this oil and oil filterchange may be performed as soonas 1.5 months after first start-up, fora chiller opera...

CDHF-SVU01C-EN 96 Oil Maintenance Replacing Oil Filter Replace oil filter: (1) annually, (2) ateach oil change, (3) or if erratic oilpressure is experienced duringchiller operation. Oil Filter Replacement Use the following procedure toservice the oil filter. Refer to Figure34. 1. Run the oil pump fo...

97 CDHF-SVU01C-EN Maintenance Other MaintenanceRequirements Compressors using new sealtechnology will not use O-rings. TheO-ring has been replaced by Loctite515 applied at a minimum filmthickness of .010 applied across thewidth of the flange. The current jackbolt holes remain for disassembly. CAUTIO...

CDHF-SVU01C-EN 98 Maintenance DO NOT LEAVE GREASE FITTINGSINSTALLED.If grease fittings have been used forthis procedure then they MUST BEREMOVED before returning the unitto service. Grease fittings are notvacuum-tight and will become a leakpath. 9. Using a clean wooden dowel or other similar tool, r...

99 CDHF-SVU01C-EN Maintenance Refrigerant Charge      WARNING Contains Refrigerant! System contains oil and refrigerantand may be under positive pressure.Recover refrigerant to relievepressure before opening the system.See unit nameplate for refrigeranttype. Do not use non-approvedrefrigerants,...

CDHF-SVU01C-EN 100 Maintenance Recovery and RecycleConnections To facilitate refrigerant removal andreplacement, newer-design CDHF,CDHG units are provided with a 3/4-inch vapor fitting with shutoff valveon the chiller suction and with a 3/4-inch liquid connection with shutoffvalve at the bottom of t...

101 CDHF-SVU01C-EN Maintenance Condenser tube fouling is indicatedwhen the approach temperature (thedifference between the condensingrefrigerant temperature and theleaving condenser watertemperature) is higher than predicted. If the annual condenser tubeinspection indicates that the tubesare fouled,...

CDHF-SVU01C-EN 102 Maintenance Purge System Because some sections of thechiller’s refrigeration system operateat less-than-atmospheric pressure,the possibility exists that air andmoisture may leak into the system. Ifallowed to accumulate, thesenoncondensables become trapped inthe condenser; this inc...