Trane CenTraVac 2100 Troubleshooting guide

'I'IIAIIE
Operation
Maintenance
Ubrary
Product Section
Product
Model
literature Type
Sequence
Date
File No.
Supersedes
Duplex Water-Cooled
Hermetic Stage CenTraVac®
CDHF 60 Hz Models 2100 -2500 - 2 Stage
CDHG 50 HZ Models 2150 -3 Stage
Coollng-Only
Dlrect-Drlve with UCP2 Control Panels
Design Sequence AO
r--
-h
cDHF-OM-1
Service Literature
Refrigeration
Centrifugal LiquidChillers
CDHF
Operation/Maintenance
CDHF-OM-1
March
6,1997
SV-RF-CTV-CDHF-OM-1-397
New
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Page 1 of 58
PETITIONER EXHIBIT 1019

Table of Contents
Subject Page
Product Coding Definition 3
Introduction 3
Typical Product Description Block 3
CDHF Product Coding Explanation 3
Control Options 5
Unit Options 6
Starter Options 6
General Information 8
About this Manual 8
Product Description Block 8
Commonly Used Acronyms 8
WaminQs and Cautions 8
Unit Nameplate 8
Metric Conversion 8
Mechanical Operation -CDHF 9
Overview 9
CoolinQ-Only Cycle 9
Lubrication System 9
Oil Recovery System
13
MotorCooling System 13
Chiller Control System 15
Unit Control Panel
15
Electrical Seguence of Operation 16
Overview
16
Chilled and CondenserWater Flow Interlock Circuits 16
UCP2 and 'Wye-Delta" Starter Control Circuits 16
Duplex Chiller Loading Sequence 17
Duplex Unit UCP2 Displays and DiaQnostic Description 18
Chiller Report Settings 18
Operator SettinQs 18
Service Settings 18
Diagnostic Description
18
Vane Actuator Control
20
Circuit Breaker 1CB3 Oil Pump
20
Unit Start-Up Procedures
20
Dailv Unit Start-Up 20
Seasonal Unit Start-Up
21
Unit Shutdown Proc.edures
22
Daily Unit Shutdown 22
Seasonal Unit Shutdown
22
Trouble Analysis
22
Periodic Maintenance 23
Overview
23
Daily Maintenance and Checks
23
Weekly Maintenance 24
Every 3 Months 24
Every 6 Months 24
Off-Season Maintenance 24
Annual Maintenance
24
Compressor Oil Change 24
Oil ChanQe Procedure 24
Replacing Oil Filter 25
Oil Filter Re~lacement Procedure 25
Refrigerant Charge 25
Recovery/Recycle Connections 28
Leak Testing 28
CAmerican Standard 1997 2 CDHF-OM-1
Page 2 of 58
PETITIONER EXHIBIT 1019

Table of Contents
Subject Page
Cleaning the Condenser 28
Cleaning the Evaporator 28
Control Settings and Adiustments
28
Purge System 28
UCP2 "Settings Group" Menu Record 32
Operator Settings Group
32
Service Settings GrouD 34
Refrigerant Monitor Settings 39
Machine Configuration GrouD
41
Refriaerant Monitor Calibration Group 44
Service Tests 45
Periodic Maintenance: Annual Inspection Check List
and Report: CenTraVacs® w/UCP2 Control Panels
47
CenTraVac® with UCP2 Commissioning Checklist
&Start-Up Test Log 48
Start-Up TestLog: Water Cool CenTraVac®
With UCP2 Control Panel 54
CenTraVac® Checksheetand Request for Serviceman
56
Fi1lure and Table Index
Figure 1 "Illustrates the General Component Layout ofa Typical CDHF Chiller"
10
Figure 2 "CDHF Pressure/Enthalpy Curve"
11
Figure 3
"CDHF Compressor Lubrication System"
12
Fiaure 4 "Motor Cooling
and Oil Reclaim" 14
Figure 5 "Control Panel Layouf' 15
FiQure 6 "Rotary Valve
in Drain Position"
26
Figure 7 "Drum
Bung Fitting with Quick Connect Coupling"
27
-
Figure 8 "Chemical Cleaning Setup"
29
Table 1 "Diagnostics that
relate to the DUDlex Unit'
19
Table 2 "Normal Chiller Operating Characteristics"
23
Table 3 "Unit Time Delays
and Safety Control Cutout Settings for UCP2"
30
28
CDHF-OM-1
Page 3 of 58
PETITIONER EXHIBIT 1019

''-"' Introduction
The CDHF/CDHG is defined using
the productdefinition and selection
(POS) system. This system
describes the product offerings in
terms of a productcoding block
which is made up of feature
categories and feature codes.
Typical Product
Description Block
MODlCDHF
EVWA
EVWCSTD CDBS2500
EVCOFlNG NTON25oo
OSEQAO CDWC 150
CDHF/CDHG Product
Coding Explanation
ProductCoding
Definition
The operating components and 258
options for any Model CDHF/CDHG 259
CenTraVaC® unit can be identified 260
by referring to the alpha-numeric 261
product identification coding block 262
located on the nameplate forthe 263
unit. The coding block precisely 264
identifies all characteristics of a unit. 265
CDCOFlNG
PURGHERM
SRT1 RPIR
VOLT 460
EVBS2500
EVWC 150
HGBPW/O
266
267
268
269
270
271
272
Unit Type 273
SNGl =Single Condenser 274
(Cooling Only) 275
MODL 276
Unit Model TYPO 277
CDHF =CenTraVac Direct Drive Unit Type 278
Duplex Hermetic - 2 Stage STD = Standard Shells 279
COHF Development Sequence "pi 280
Unit Hertz =60 Hertz Note: Be sure to refer to H!e service 281
CDHG = CenTraVac Direct Drive model number when ordenng
Duplex Hermetic - 3 Stage replacement parts orrequesting 282
CDHG Development Sequence "G" service. An example of a typical 283
Unit Hertz = 50 Hertz product code is gIVen on this page. 284
DSEQ
Design Sequence - "AO"
Factory Assigned
NTON
Compressor Nominal Capacity
2100 =2100 Nominal Tons
2500 = 2500 Nominal Tons
2150 =2150 Nominal Tons
VOLT
Nota: Unit-mounted starters are
identified by a separate number
found on the starter.
CPM1
Compressor Motor Power
LH Circuit
285
286
287
288
289
290
291
292
293
CPM2
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
UnitVoltage
380 = 380 Volt 60 3 Phase
440 = 440 Volt 60 3 Phase
460 =460 Volt 60 3 Phase
480 =480 Volt60 3 Phase
575 =575 Volt60 3 Phase
600 =600 Volt60 3 Phase
2300 = 2300 Volt 60 3 Phase
2400 = 2400 Volt 60 3 Phase
3300 = 3300 Volt 60 3 Phase
4160 = 4160 Volt 60 3 Phase
6600 =6600 Volt 60 3 Phase
380A =380 Volt 50 3 Phase
400 = 400 Volt 50 3 Phase
415 =415 Volt50 3 Phase
330A =3300 Volt 50 3 Phase
6000A =6000 Volt 50 3 Phase
660A =6600 Volt 50 3 Phase
588 KW60 Hz
653 KW60 Hz
745 KW60 Hz
856 KW60 Hz
957 KW60 Hz
1062 KW60 Hz
1228 KW60 Hz
433 KW50 Hz
489 KW50 Hz
548 KW50 Hz
621 KW50 Hz
716 KW50 Hz
799 KW50 Hz
892 KW50 Hz
CompressorMotorPower
RH Circuit
CPD1
Compressor Impeller
Diameter L.H. Circuit
255 294
256 295
257 296
3
588 KW60 Hz
653KW60Hz
745KW60Hz
856KW60Hz
957 KW60 Hz
1062 KW60 Hz
1228 KW60 Hz
433 KW50 Hz
489 KW50 Hz
548 KW50 Hz
621 KW50 Hz
716 KW50 HZ
799 KW50 Hz
892 KW50 Hz
CDHF-OM-1
Page 4 of 58
PETITIONER EXHIBIT 1019

Product Coding
Definition
CPD2 EVWC coco
Compressor Impeller Evaporator Waterbox Condenser Waterbox
DiameterRH Circuit 150 PSIG 1 Pass Marine Connection
255 294 300 PSIG 1 Pass Marine VICT=
Victaulic
256 295 FLNG =
Flanged
258 296 EVCO
259 298
Evaporator Waterbox CDWA
Connection
Condenser Waterbox
260 299 VICT=Victaulic
Arrangement
261
300 FLNG =Flanged LFRF =Inlet -LH Front
263
301
LFRF =Outlet - RH Front
264 303 EVWA
265 304
Evaporator Waterbox
RFLF =Inlet -RH Front
266 305
Arrangement
RFLF =Outlet - LH Front
268 306 LFRF =Inlet-
LH Front
269 308 LFRF =Outlet -RH Front LRRR =Inlet -LH Rear
270 309 LRRR =Outlet -
RH Rear
RFLF =Inlet -
RH Front
271
310 RFLF =Outlet -LH Front RRLR =Inlet -RH Rear
273
311
RRLR =Outlet- LH Rear
274 313 LRRR =Inlet -
LH Rear
275 314 LRRR =Outlet -RH Rear LTRT =Inlet -L.H. Top
276 315 L
TRT =Outlet- RH Top
278 316 RRLR =Inlet-RH Rear
279 318 RRLR =Outlet -
LH Rear RTLT =Inlet -RH Top
280 319 RTLT =Outlet -LH Top
281
320 LFRR =Inlet-
LH Front
LFRR =Outlet-RH Rear LBRB =Inlet -LH Bottom
283
321
LBRB =Outlet - RH Bottom
284 323 RFLR =Inlet-
RH Front
285 324 RFLR =Outlet -LH Rear RBLB =Inlet -RH Bottom
286 325 RBLB =Outlet -
LH Bottom
288 326 LRRF =Inlet-
LH Rear
289 328 LRRF =Outlet -
RH Front LFRR =Inlet -LH Front
290 329 LFRR =Outlet -
RH Rear
291 330 RRLF =Inlet-
LH Rear
RRLF =Outlet -
LH Front LFRT =Inlet -LH Front
293 LFRT =Outlet -
RH Top
EVBS CDBS
Condenser Tube Bundle Size LFRB =Inlet -LH Front
EvaporatorTube
Bundle Size 2100 Nominal Ton
Condo
LFRB =Outlet -RH Bottom
2100 Nominal Ton Evap. 2300 Nominal Ton
Condo
2300 Nominal Ton Evap. 2500 Nominal Ton
Condo
RFLR =Inlet -RH Front
2500 Nominal Ton Evap. RFLR =Outlet -LH Rear
EVTB CDTB
Condenser Tubes
RFLT =Inlet -RH Front
Evaporator Tubes
TE28 .028 Wall liE CopperTube RFLT =Outlet -LH Top
TE28 .028 Wall liE CopperTube TE35 .035 Wall liE CopperTube
TE35 .035 Wall liE CopperTube SB28 .028 Wall SIB CopperTube RFLB =Inlet -RH Front
SB28 .028 Wall SIB CopperTube SB35 .035 Wall SIB CopprTube RFLB =Outlet-
LH Bottom
SB35 .035 Wall SIB CopprTube
EFLD CFLD LRRF = Inlet -LH Rear
Evaporator Fluid Type
Condenser Fluid Type LRRF = Outlet- RH Front
WATE=Water
WATE = Water CLCA = Calcium Chloride LRRT = Inlet -LH Rear
CLCA = Calcium Chloride
EG = Ethylene G~COI
LRRT = Outlet - RH Top
EG = Ethylene Glycol
PG =Propylene Iyeol
PG =Propylene Glycol LRRB = Inlet -LH Rear
CDWC LRRB =Outlet - RH Bottom
Condenser Waterboxs
150 PSIG 1 Pass Marine RRLF = Inlet -
L. H. Rear
300 PSIG 1 Pass Marine RRLF = Outlet-LH Front
4 CDHF-OM-1
Page 5 of 58
PETITIONER EXHIBIT 1019