Trane Duplex Water-Cooled Hermetic CenTraVac User manual

Installation
Duplex Water-Cooled
Hermetic CenTraVac™ With
CH530 Controller
CDHF-SVN01B-EN
X39640669020
Cooling Only
Direct Drive with CH530 Control Panel

© 2005 American Standard Inc. All rights reserved. CDHF-SVN01B-EN
Warnings and
Cautions
Warnings and Cautions
Notice that warnings and cautions
appear at appropriate intervals
throughout this manual. Warnings
are provided to alert installing
contractors to potential hazards that
could result in personal injury or
death, while cautions are designed
to alert personnel to conditions that
could result in equipment damage.
Your personal safety and the proper
operation of this machine depend
upon the strict observance of these
precautions.
NOTICE:
Warnings and Cautions appear at appropriate sections throughout this manual.
Read these carefully.


WARNING – Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.


CAUTION – Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe practices.
CAUTION – Indicates a situation that may result in equipment or property-damage-only accidents.

3
Contents
CDHF-SVN01B-EN
Warnings and Cautions
General Information
Water Piping
Vent Line Piping
Insulation
Electrical Information
Trane Supplied Starter
Customer Supplied Starter
Line Power Supply
PFCC
PFCC and Unit Mounted Starters
Remote Starter
Starter to UCP Control Wiring
Control Circuit Wiring
System Control Wiring
Wiring Diagrams
2
4
25
35
41
43
44
45
47
48
50
51
53
54
56
59

CDHF-SVN01B-EN
4
About this Manual
Original date of manual:
This manual contains information
regarding installation of Models
CDHF 60 Hz and CDHG 50 Hz chillers
equipped with Tracer CH530
controller. Reference is made to the
CDHF. All installation procedures
described for the CDHF apply also to
the CDHG. By carefully reviewing the
information in this manual and
following the instructions given
along with the submittal package
provided for the unit will assure that
the chiller is installed correctly.
General Information
Product Description Block
Trane 60 Hz. Model CDHF hermetic
CenTraVac™units are defined by the
product definition and selection
system (PDS). Each unit is defined by
the product description block which
appears on the unit nameplate. An
explanation of the PDS product code
is provided in the unit operation and
maintenance literature.

5
CDHF-SVN01B-EN
General Information
Warnings and Cautions
Notice that WARNINGS and
CAUTIONS appear at appropriate
intervals throughout this manual.
WARNINGS are provided to alert
installing contractors to potential
hazards that could result in personal
injury or death, while CAUTIONS are
designed to alert personnel to
conditions that could result in
equipment damage.
Your personal safety and the proper
installation of this machine depend
upon the strict observance of these
precautions.
Unit Nameplate
The CDHF unit nameplate is located
on the left side of the left hand unit
control panel (UCP). A typical unit
nameplate is illustrated in Figure 1.
The following information is
provided on the CDHF unit
nameplate.
- Unit model and size descriptor
- Unit serial number
- Unit electrical requirements
- Correct operating charge and type
of refrigerant.
- Unit test pressures and maximum
operating pressures
- Unit Installation and Operation and
Maintenance manuals
- Product description block (identifies
all unit components and unit
“design sequence” used to order
literature and make other inquiries
about the unit).
Metric Conversion
The following conversions apply for
tables and charts in this manual,
In. x 2.54 = cm
Ft. x 30.48 = cm.
Lb. x .453 = kg.
Commonly Used Acronyms
ASME = American Society of
Mechanical Engineers
ASHRAE = American Society of
Heating, Refrigerant and Air
Conditioning Engineers
BAS = Building Automation System
LBU = La Crosse Business Unit
CABS = Auxiliary Condenser Tube-
Bundle Size
CDBS = Condenser Bundle Size
CDSZ = Condenser Shell Size
CWR = Chilled Water Reset
DTFL = Delta-T at Full Load (i.e., the
difference between entering and
leaving chilled water temperatures at
design load)
EVBS = Evaporator Bundle Size
EVSZ = Evaporator Shell Size
GPM = Gallons-per-Minute
HVAC = Heating, Ventilating, and Air
Conditioning
IE = Internally Enhanced Tubes
IPC = Interprocessor Communication
PFCC = Power Factor Correction
Capacitor
PSID = Pounds-per-Square-Inch
(differential pressure)
PSIG = Pounds-per-Square-Inch
(gauge pressure)
UCP = Chiller Control Panel
CH530 = Tracer CH530 Chiller
Controller

CDHF-SVN01B-EN
6
Figure 1 – Information from a Typical CDHF Unit Nameplate
General Information
MODEL: CDHF2000 DATE OF MFG (DD/MM/YY): @TODAY05
MODEL NO:
CDHF2000KR0TA2802745B0A106B0A1CFFRR10W4C0010330001S
SERIAL NO: S.O. NO: SAMPLE
RATED VOLTAGE: 4160 VOLTS 60 HZ 3 PH
VOLTAGE UTILIZATION RANGE: 3744-4576 VAC
LH CIRCUIT RH CIRCUIT
MINIMUM CIRCUIT AMPACITY: 96 AMPS 103 AMPS
MAXIMUM OVERCURRENT
PROTECTIVE DEVICE: 150 AMPS 175 AMPS
COMPRESSOR MOTOR MAX
VOLTS-AC HZ PH RLA KW LRAY
LH CIRCUIT 4160 60 3 75 480 400
RH CIRCUIT 4160 60 3 82 523 473
VOLT HZ PH
OIL TANK HEATER (LH&RH): 115 60 1 750 WATTS
CONTROL CIRCUIT (LH&RH): 115 60 1 4000 VA MAX
CARBON TANK HEATER (LH&RH):115 60 1 1.7 RLA
PUMPOUT COMPRESSOR(LH&RH): 115 60/50 1 1.55 RLA
PURGE COMP MTR(LH&RH): 115/110 60/50 1 8RLA 34.6LRA
WHEN MOTOR CONTROLLER PROVIDED BY OTHERS
TRANE ENGINEERING SPEC. S6516-0513 APPLIES
REFRIGERANT SYSTEM LH RH
FIELD CHARGED WITH: 1850 1850 LBS. OF R-123
ACTUALLY CHARGED WITH: LBS. OF R-123
MAXIMUM WORKING PRESSURE: 15 15 PSIG HIGH SIDE
MAXIMUM WORKING PRESSURE: 15 15 PSIG LOW SIDE
FACTORY TEST PRESSURE:
HIGH SIDE 45 PSIG LOW SIDE 45 PSIG
FIELD LEAK TEST PRESSURE 8 PSIG MAX.
TESTED AT PSIG
MANUFACTURED UNDER ONE OR MORE OF THE FOLLOWING
U.S. PATENTS: 4232533 4686834 4689967 4715190
4751653 4800732 5031410 5056032 5058031 5355691
5434738 5537830 5553997 5563489 5600960 5675978
5836382 5848538 6065297 6098422 6250101
SERVICE LITERATURE
INSTALLATION MANUAL: CDHF-SVN01A-EN
OPERATION/MAINTENANCE MANUAL: CDHF-SVU01A-EN
PRODUCT DESCRIPTION:
TVSQ 1 PTON 1975 VTR1 165 VTR2 165
CTM1 75 CTM2 100 MAC1 6 MAC2 6
MODL CDHF DSEQ R0 NTON 2000 VOLT 4160
HRTZ 60 CPM1 512 CPD1 280 CPM2 588
CPD2 274 EVSZ 210D EVBS 1850 EVTM TECU
EVTH 35 EFLD WATE EVWT MAR EVWP 1
EVWC STD EVPR 150 EVCO VICT EVWA RRLR
CDSZ 210D CDBS 1900 CDTM TECU CDTH 35
CFLD WATE CDWT MAR CDWP 1 CDWC STD
CDPR 150 CDCO VICT CDWA LFRF ORC1 1265
ORC2 1265 AGLT UL TEST CWSP TTOL SPCL
WCNM BNMP CNIF CH53 OPST YES WPSR WFC
TRMM TRM4 EPRO YES CDRP YES SPKG DOM
ASCL OUTS APTY STD SRT1 CXL SRT2 CXL
SOPT 3RTD GENR NO

7
CDHF-SVN01B-EN
General Information
Responsibilities of Installing
Contractors
For your convenience, a summary of
the contractor responsibilities
typically associated with the chiller
installation process is provided
below. Table 1 further categorizes
these responsibilities by
differentiating between Trane-
supplied and field-supplied and field
installed components.
Refer to the Installation section of
this manual for more detailed
instructions.
• Locate and maintain the loose
parts, i.e. isolators, bulb wells,
temperature sensors, flow sensors
or other factory-ordered field
installed options, for installation as
required. Loose parts are located in
the starter panel on units with
factory-installed unit-mounted
starters or in the motor terminal
box for units with remote-mounted
starters.
• Install unit on a foundation with flat
support surfaces level within 1/16”,
and of sufficient strength to
support concentrated loading.
Place manufacturer-supplied
isolation pad assemblies under
unit. (Use spring isolators for upper
floor installations).
• Install unit per applicable Trane
installation manual.
• Complete all water piping and
electrical connections.
Note: Field-piping must be arranged
and supported to avoid stress on the
equipment. It is strongly
recommended that the piping
contractor refrain from piping closer
than 3’-0” minimum to the
equipment. This will allow for proper
fit-up upon arrival of the unit at the
jobsite. Any adjustment that is
necessary can be made to the piping
at that time.
• Where specified, supply and install
valves in water piping upstream
and downstream of evaporator and
condenser water boxes to isolate
shells for maintenance, and to
balance/trim system.
• Supply and install flow switches (or
equivalent devices) in both chilled
water and condenser water piping.
Interlock each switch with proper
pump starter to ensure unit can
only operate when water flow is
established.
• Supply and install taps for
thermometers and pressure
gauges in water piping adjacent to
inlet and outlet connections of both
evaporator and condenser.
• Supply and install drain valves on
each water box.
• Supply and install vent cocks on
each water box.
• Where specified, supply and install
strainers ahead of all pumps and
automatic modulating valves.
• Supply and install pressure relief
piping from pressure-relief rupture
disc to atmosphere.
• If necessary, supply sufficient
Refrigerant-HCFC-22 (maximum of
1 lb. per machine) and dry nitrogen
(8 psig per machine) for pressure
testing under manufacturer’s
supervision.
• Start unit under supervision of a
qualified service technician.
• Where specified, supply and
insulate evaporator and any other
portions of machine as required to
prevent sweating under normal
operating conditions.
• Unit-Mounted Starters Only,
remove top of starter panel and cut
access area for line-side wiring;
front left quadrant of top provides
recommended access to starter
lugs.
• Supply and install wire terminal
lugs to starter.
• Unit-Mounted Starters Only,
Supply and install field wiring to
line-side lugs of starter.
• Supply and install a Refrigerant
Monitor per ASHRAE 15
specifications. Reference the
compliance to ASHRAE Standard
15 as shown on the “Model
CenTraVac™Checksheet and
Request for Serviceman”.
To obtain a copy of “Model
CenTraVac™Checksheet and Request
for Serviceman” (Form 1-27.08-6)
order from your local Trane office.

CDHF-SVN01B-EN
8
General Information
Table 1 – Installation Requirements
Type of Trane-Supplied Trane-Supplied Field-Supplied
Requirement Trane-Installed Field-Installed Field-Installed
Rigging A. Safety chains
B. Clevis connectors
C. Lifting beam
Isolation A. Isolation pads or A. Isolation pads or spring isolators
spring isolators
Electrical A. Circuit breakers or A. Jumper bars A. Circuit breakers or fusible
fusible disconnects B. Temperature sensor disconnects (optional)
(optional) (optional outdoor air) B. Remote-mounted starter
B. Unit-mounted C. Flow switches (may C. PFCCs (Remote-mounted
starter (optional) be field supplied) starter option only)
C. PFCCs (optional) D. Terminal lugs
E. Ground connection(s)
F. Jumper bars
G. BAS wiring (optional)
H. IPC wiring (remote-
mounted starters only
I. Control voltage wiring
(remote-mounted starters only)
J. Oil pump interlock wiring
(remote-mounted
starters only)
K. High condenser pressure
interlock wiring
(remote-mounted starters only).
L. Chilled water pump contactor
and wiring
M.Condenser water pump
contactor and wiring
N. Option relays and wiring
(See Table 14 & 16)
Water Piping A. Flow switches (May A. Thermometers
be field supplied) B. Water flow pressure gauges
C. Isolation and balancing valves
water piping
D. Vents and drain valves
(1 each per class)
E. Pressure-relief valves
(for water boxes as required)
Rupture Disc A. Rupture disc assy A. Vent line and flexible connector
Insulation A. Insulation (Optional) A. Insulation

9
CDHF-SVN01B-EN
General Information
Unit Shipment
Each chiller ships from the factory as
a hermetically assembled package; it
is factory piped, wired and tested. All
openings are covered or plugged to
prevent contamination during
shipment and handling.
See Figure 2 for an illustration of a
typical unit and its components. As
soon as the unit arrives at the job
site, inspect it thoroughly for
damage and material shortages. In
addition:
1. Verify the chiller’s hermetic
integrity by checking the
evaporator pressure for an
indication of holding charge
pressure.
Note: Since there are two refrigerant
circuits both must be checked.
To prevent damaging moisture from
entering the unit and causing
corrosion, each chiller is pressurized
with dry nitrogen before shipment.
Note: The holding charge should
register approximately 5 psig (at sea
level) on the gauge. If the charge has
escaped, contact your local Trane
sales office for instructions.
2. Check the oil sump sight glasses
to verify that the sump was
factory-charged with 9 gallons of
oil. If no oil level is visible, contact
your local Trane sales office.
3. Compare the unit nameplate data
(including electrical characteristics)
with the corresponding ordering
and shipping information to verify
that the correct unit was shipped
to the job site.
If a thorough inspection of the
chiller reveals damage or material
shortages, be sure to file these
claims with the carrier
immediately. Specify the extent
and type of damage found, and
notify the appropriate Trane sales
representative. Do not install a
damaged unit without the sales
representative’s approval!
Storage
If the chiller will be stored at the job
site for an extended period of time
before it is installed, exercise these
precautionary measures to protect
the unit from damage:
1. Do not remove the protective
coverings factory-installed on the
control panel and compressor
inlet vane actuator for shipment.
2. Store the chiller in a dry vibration
free and secure area. If factory
insulated, protect chiller from
prolonged exposure to sunlight.
CAUTION
Insulation Damage!
To prevent damage to the factory-
installed insulation, do not allow
excessive exposure to sunlight.
3. Periodically check the condenser
and evaporator pressure to verify
that the 5 psig dry nitrogen at 72°F
ambient holding charge is still in
the chiller. If this charge escapes,
contact a qualified service
organization and the Trane sales
engineer that handled the order.
Note: The storage range for the
microcomputer-based devices in the
unit control panel is -40°F to 158°F
(-40°C to 70°C).

CDHF-SVN01B-EN
10
Figure 2 – Typical CDHF Chiller
General Information