Page 2 - Warnings and Cautions; Read these carefully.; WARNING; death or serious injury.; CAUTION
© 2005 American Standard All rights reserved CVHE-SVU01E-EN Warnings andCautions Warnings and Cautions Notice that warnings and cautionsappear at appropriate intervalsthroughout this manual. Warningsare provided to alert installingcontractors to potential hazards thatcould result in personal injury ...
Page 3 - Contents
3 Contents CVHE-SVU01E-EN Warnings and Cautions General Information Unit Control Panel (UCP) Operator Interface Chilled Water Setpoint Inter Processor Communication (IPC) Control System Components Controls Sequence of Operation Machine Protection and Adaptive Control Unit Startup Unit Shutdown Perio...
Page 4 - Typical Product Description Block; Unit Nameplate; Service Model Number; Literature change
CVHE-SVU01E-EN 4 Typical Product Description Block MODL CVHE DSEQ 2R NTON 320 VOLT 575 REF 123 HRTZ 60 TYPE SNGL CPKW 142 CPIM 222 TEST AIR EVTM IECU EVTH 28 EVSZ 032S EVBS 280 EVWC STD EVWP 2 EVWT NMAR EVPR 150 EVCO VICT EVWA LELE CDTM IECU CDTH 28 CDSZ 032S CDBS 250 CDWC STD CDWP 2 CDWT NMAR CDPR ...
Page 6 - Commonly Used Acronyms; Control Optional Packages
CVHE-SVU01E-EN 6 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...
Page 7 - Figure 1. General CVHE and CVHG unit components; Overview
7 CVHE-SVU01E-EN GeneralInformation Figure 1. General CVHE and CVHG unit components Overview CVHE, CVHG, CVHF Each 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 singl...
Page 8 - Figure 1. General CVHE and CVHG unit components - continued
CVHE-SVU01E-EN 8 GeneralInformation Figure 1. General CVHE and CVHG unit components - continued
Page 10 - Cooling Cycle; Inlet guide vanes are designed; CVHE, CVHG Compressor
CVHE-SVU01E-EN 10 GeneralInformation Cooling Cycle CVHE, CVHG, CVHF When in the cooling mode, liquidrefrigerant is distributed along thelength of the evaporator and sprayedthrough small holes in a distributor(i.e., running the entire length of theshell) to uniformly coat eachevaporator tube. Here, t...
Page 11 - Figure 3. CVHE, CVHG pressure enthalpy curve
11 CVHE-SVU01E-EN Figure 3. CVHE, CVHG pressure enthalpy curve Figure 4. CVHE, CVHG 2-stage economizer GeneralInformation
Page 13 - chiller service tool, a
13 CVHE-SVU01E-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 needd...
Page 16 - Oil and Refrigeration Pump; Compressor Lubrication System -; Motor Cooling System
CVHE-SVU01E-EN 16 GeneralInformation Oil and Refrigeration Pump Compressor Lubrication System - A schematic diagram of thecompressor lubrication system isillustrated in Figure 12. Oil is pumped from the oil tank (by apump and motor located within thetank) through an oil pressure-regulating valve des...
Page 17 - Figure 12. Oil refrigerant pump
17 CVHE-SVU01E-EN GeneralInformation Figure 12. Oil refrigerant pump
Page 18 - Cogeneration plants; might use this
CVHE-SVU01E-EN 18 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...
Page 20 - Ice Machine Control; Satisfying an evaporator entering
CVHE-SVU01E-EN 20 GeneralInformation Ice Machine Control The control panel provides a servicelevel “Enable or Disable” menu entryfor the Ice Building feature when theIce Building option is installed. IceBuilding can be entered 1) from the“Front Panel”, 2) if hardware isspecified, will accept either ...
Page 21 - Free Cooling Cycle; Feature Settings” group
21 CVHE-SVU01E-EN GeneralInformation Free Cooling Cycle Based on the principle that refrigerantmigrates to the coldest area in thesystem, the free cooling optionadapts the basic chiller to function asa simple heat exchanger. However, itdoes not provide control of theleaving chilled water temperature...
Page 22 - Free Cooling FRCL; Enable the Free Cooling mode in
CVHE-SVU01E-EN 22 GeneralInformation it is then compressed anddischarged to the condenser. Most ofthe condensed refrigerant initiallyfollows the path of least resistance byflowing into the storage tank. Thistank is vented to the economizersump through a small bleed line;when the storage tank is full...
Page 23 - Hot Gas Bypass
23 CVHE-SVU01E-EN GeneralInformation Hot Gas Bypass The hot gas bypass (HGBP) controloption is designed to minimizemachine cycling by allowing thechiller to operate stably underminimum load conditions. In thesesituations, the inlet guide vanes are“locked” at a preset minimumposition, and unit capaci...
Page 24 - Hot Water control; Hot water temperature control
CVHE-SVU01E-EN 24 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...
Page 25 - Heat Recovery Cycle; Auxiliary Condensers
25 CVHE-SVU01E-EN GeneralInformation Heat Recovery Cycle ‘‘Heat recovery’’ is designed tosalvage the heat that is normallyrejected to the atmosphere throughthe cooling tower, and put it tobeneficial use. For example, a high-rise office building may requiresimultaneous heating and coolingduring the w...
Page 26 - Figure 16. Control panel and approximate dimensions
CVHE-SVU01E-EN 26 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...
Page 27 - Tracer CH530 Chiller Controller; User-defined language support
27 CVHE-SVU01E-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...
Page 28 - main processor; The DynaView; DynaView; The; Main screen; provides an overall
CVHE-SVU01E-EN 28 OperatorInterface Figure 17. 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...
Page 35 - Diagnostic Screen
35 CVHE-SVU01E-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...
Page 37 - active current limit setpoint; is
37 CVHE-SVU01E-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...
Page 41 - Setting Tab screens; provides a user; Chilled Water Setpoint:
41 CVHE-SVU01E-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. Settings screen for standard CTV : Chilled Water Setpoint: To change chilled water setpoint f...
Page 43 - Units
43 CVHE-SVU01E-EN OperatorInterface Display SettingsDescription Units notes 1. Date Format (“mmm dd, yyy”, “dd-mmm-yyyy”), “mmm dd, yyy” 2. Date 4 3. Time Format (12-hour, 24-hour), 12-hour 4. Time of Day 4 5. Keypad and Display Lockout (Enable, Disable), Disable 5 6. Display Units (SI, English), En...
Page 44 - Spin buttons used to change
CVHE-SVU01E-EN 44 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...
Page 48 - Touch Screen Lock; screen is shown below. This
CVHE-SVU01E-EN 48 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 ...
Page 49 - Functional Identification:
49 CVHE-SVU01E-EN InterprocessorCommunication Inter ProcessorCommunications IPC3 When using Tracer CH530, you willnot be required to know all thedetails about the structure of the IPC3bus. However this page givesdetailed information about thesystem for those of you that are reallyinterested in how i...
Page 52 - Terminals
CVHE-SVU01E-EN 52 Control SystemComponents Control Panel DevicesStandard Devices Controls Field Connection Description Package Purpose Point Terminals 1A1 Power Supply Standard #1 Converts 24 vac to 24 vdc not for field use 1A2 Power Supply (as required) #2 Converts 24 vac to 24 vdc not for field us...
Page 54 - Refrigerant Monitor Input 1A17
CVHE-SVU01E-EN 54 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 modules* J2-12 common 1A17 Optional Dual Analog EXOP Si...
Page 56 - Controls allow Delta Pressure; Temperature based
CVHE-SVU01E-EN 56 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...
Page 57 - • Target tower control at 4 psid
57 CVHE-SVU01E-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...
Page 59 - A7 High Power Relay
59 CVHE-SVU01E-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 macorrespond to a 34°F...
Page 60 - Ground
CVHE-SVU01E-EN 60 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...
Page 61 - The Analog Output is; Recommended Length to Run external Output signals; Gauge
61 CVHE-SVU01E-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...
Page 62 - Unit mounted devices; If the chiller is operating in a
CVHE-SVU01E-EN 62 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...
Page 63 - Electrical Sequence
63 CVHE-SVU01E-EN Electrical Sequence This section will acquaint theoperator with the control logicgoverning CVHE, CVHF and CVHGchillers equipped with Tracer CH530UCP based control systems. Whenreviewing the step-by-step electricalsequences of operation, refer to thetypical wiring schematics for Uni...
Page 66 - Figure 24. Test and start timing sequence
CVHE-SVU01E-EN 66 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...
Page 68 - and Starter module
CVHE-SVU01E-EN 68 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...
Page 69 - Current Overload Protection; Running Over Current Protection; Figure 26. Overload trip time versus percent RLA
69 CVHE-SVU01E-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...
Page 70 - Current Limit Protection; Current Limit Setpoint.; Phase Loss Protection; Reverse Rotation Protection; Phase Imbalance Protection; and an Overvoltage condition occurs:
CVHE-SVU01E-EN 70 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...
Page 71 - • Current Limit Control Softload Time
71 CVHE-SVU01E-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...
Page 72 - Evaporator Limit; Operating Mode
CVHE-SVU01E-EN 72 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...
Page 73 - Head Relief Relay
73 CVHE-SVU01E-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 ...
Page 74 - Figure 27. Cutout strategy
CVHE-SVU01E-EN 74 Figure 27. 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...
Page 75 - Condenser Limit; How It Works
75 CVHE-SVU01E-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 ...
Page 76 - When one of the three motor
CVHE-SVU01E-EN 76 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 dep...
Page 80 - Table 3. Values for start reset types; Constant Return
CVHE-SVU01E-EN 80 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...
Page 81 - Example of converting Reset Ratio:; TOD; = Outdoor Air Temperature; Start Reset; = Outdoor Air Start Reset; Figure 28. Outdoor air temperature versus degrees of reset
81 CVHE-SVU01E-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)...
Page 82 - Figure 29. Reset function for return CWR; Note: This graph assumes Maximum Reset is set to 20 degrees.; Figure 30. Reset function for return CWR
CVHE-SVU01E-EN 82 Figure 29. Reset function for return CWR Note: This graph assumes Maximum Reset is set to 20 degrees. Figure 30. Reset function for return CWR Machine Protectionand AdaptiveControl
Page 83 - Example of Calculating Return Reset:
83 CVHE-SVU01E-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...
Page 85 - Unit Start-Up Procedures; Unit Startup
85 CVHE-SVU01E-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 the oil tank oil level; the level must be visible in or abovethe lower sight glass. Also, ...
Page 86 - Seasonal Unit Start-Up; • Do not run evaporator water pump
CVHE-SVU01E-EN 86 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 ...
Page 87 - Unit Shutdown Procedures; Daily Unit Shutdown; Seasonal Unit Shutdown; Trouble Analysis; Unit Shutdown
87 CVHE-SVU01E-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...
Page 88 - IT IS HIGHLY
CVHE-SVU01E-EN 88 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...
Page 89 - Normal Chiller Operating Characteristics; Weekly Maintenance
89 CVHE-SVU01E-EN WARNING Hazardous Voltage w/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 provided b...
Page 90 - If the sensor is exposed to
CVHE-SVU01E-EN 90 [ ] 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...
Page 91 - Oil Maintenance; Oil Change Procedure
91 CVHE-SVU01E-EN Oil Maintenance Compressor Oil Change onCVHE, CVHF, CVHG Recommendations are to subscribeto an annual oil analysis programrather than automatically change theoil as part of scheduled maintenance.Change the oil only if indicated bythe oil analysis. Use of an oilanalysis program will...
Page 92 - Replacing Oil Filter; Oil Filter Replacement; Run the oil pump for two to three
CVHE-SVU01E-EN 92 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...
Page 93 - Maintenance; Lubrication
93 CVHE-SVU01E-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...
Page 94 - Figure 33. Rotary valve in drain position; Using a clean wooden dowel or
CVHE-SVU01E-EN 94 Maintenance Figure 33. Rotary valve in drain position Front View with Refrigerant Pump 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 wil...
Page 95 - Refrigerant Charge
95 CVHE-SVU01E-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, refrigera...
Page 96 - Leak Testing; Figure 34 - Typical Chemical Cleaning Setup
CVHE-SVU01E-EN 96 Maintenance Recovery and RecycleConnections To facilitate refrigerant removal andreplacement, newer-design CVHE,CVHF and CVHG units are providedwith a 3/4-inch vapor fitting withshutoff valve on the chiller suctionand with a 3/4-inch liquid connectionwith shutoff valve at the botto...
Page 97 - Remove the retaining nuts and; ALL OF THE; Cleaning the Evaporator
97 CVHE-SVU01E-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, ...
Page 98 - Purge System; Remove all liquid refrigerant if the; After the liquid refrigerant is
CVHE-SVU01E-EN 98 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 incr...