Table of Contents
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Installation, Operation, and Maintenance
Manhattan™ Gen II Water-Cooled
Modular Chiller
Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of
heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training.
Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury.
When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are
attached to the equipment.
February 2021
SAFETY WARNING
ARTC-SVX002A-EN
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Table of Contents
Related Manuals for Trane Manhattan Gen II
Summary of Contents for Trane Manhattan Gen II
- Page 1 Installation, Operation, and Maintenance Manhattan™ Gen II Water-Cooled Modular Chiller SAFETY WARNING Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury.
- Page 2 (Global Harmonized System of Classification and compounds have the same potential impact to the Labeling of Chemicals) guidelines for information on environment. Trane advocates the responsible handling of allowable personal exposure levels, proper all refrigerants-including industry replacements for CFCs respiratory protection and handling instructions.
- Page 3 Copyright This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part without written permission. Trane reserves the right to revise this publication at any time, and to make changes to its content without obligation to notify any person of such revision or change.
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Page 4: Table Of Contents
Table of Contents Model Number Descriptions Electronic Control ....23 ....6 Model Number and Coding Client and Server Controllers . - Page 5 Table of Contents Chiller Control Water/Glycol Mixture Logical Flow ......42 ..76 Power Distribution .
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Page 6: Model Number Descriptions
Model Number Descriptions Digit 1 — Brand Trane Digit 2 — Model Series Process and Modular Series Digit 3, 4, 5 — Condenser Type ACH = Air-Cooled, Horizontal Air Flow ACV = Air-Cooled, Vertical Air Flow ACR = Air-Cooled Remote Condenser WCC = Water-Cooled Condenser Digit 6 —... -
Page 7: Model Number And Coding
Chiller Reference Data. Refer to the Trane nameplate on model number and serial number of the chiller modules in each module in the installed unit for the serial number and question. -
Page 8: Chiller Description
99.9% copper brazing materials. Standard interconnecting headers are composed of carbon steel. This manual provides relevant data to properly operate, maintain, and troubleshoot the Trane Manhattan™ Gen II Water quality must be monitored and maintained by a Water-Cooled Modular Chiller. It assumes that operator... - Page 9 Chiller Description Optional Shell and Tube Condenser The optional shell and tube condensers are independent, cleanable shell and tube types with copper inner tubing and a steel shell. Brazed Plate Evaporator The brazed plate evaporator is constructed as corrugated channel plates with filler material between each plate.
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Page 10: Pre-Installation
8. Check that pressure switches and thermostats have correct “cut-in” and “cut-out” settings. 9. Confirm the oil level is correct in each compressor. Note: If Trane pumps are provided, check that each pump’s overload setting matches the nameplate amperage of the pumps as described previously. - Page 11 Check the box if there are any customer-supplied devices connected to the chiller wiring. List devices: ______________________________________________________________________________________ Check the box if there are any Trane remote devices connected to the chiller wiring. Check the box if voltage drops are detected.
- Page 12 Pre-Installation Table 2. Initial startup readiness checklist (continued) Startup Readiness Dimension Check the box if control wiring is complete, including any additional remote interface panel or special-purpose wiring. Check the box if all responsible installing contractors and sub-contractors have been notified to have ...
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Page 13: Installation Mechanical
Verify the correct model number and that all skids and cartons have been delivered. Any damage must be Long Term Storage Requirements reported to the motor carrier and Trane within five days of receipt of the shipment. Appropriate preparation and storage of Trane chiller... -
Page 14: Customer Responsibilities
Failure to adhere to these long-term storage requirements Chiller modules must be installed on a level surface that may void the Trane warranty. Any component that is has been checked by a qualified structural engineer to damaged or inoperable due to improper storage may have support the weight of the fluid-filled modules and the its warranty voided. - Page 15 Installation Mechanical Figure 2. Recommended chiller clearances ARTC-SVX002A-EN...
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Page 16: Rigging, Lifting, And Moving The Chiller
Installation Mechanical Rigging, Lifting, and Moving the • Rig, lift, and move by strapping and lifting using a properly configured floor jack or fork lift or by Chiller overhead means. • Position lifting beams to prevent lifting straps from The Manhattan™ Gen II Water-Cooled Modular Chiller can rubbing or contacting module side panels or be delivered to the customer’s site as individual modules electrical boxes. - Page 17 Installation Mechanical Figure 4. Chiller installation on mounting rails For vibration isolation, spring isolators or rubber-in-shear isolator pads must be installed under the structural steel mounting rails. After setting each module, remove front or rear access panels to improve access to components when making connections.
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Page 18: Installation Piping
Installation Piping Install Piping and External the pipes. A 40-mesh screen strainer must be installed in each water/liquid system piping inlet for proper filtration Components an protection of the heat exchangers. Below figure provides a recommended installation of components. Proper support of piping and pipe hangers must consider the weight of the piping as well as the water weight inside Figure 5. - Page 19 Installation Piping 3. Position each subsequent module approximately 16 inch from the previous module when positioning the headers. 4. Lubricate the main header coupling gasket with an approved lubricant and re-install onto the roll grooved header pipe. Push the gasket flush with the pipe end to avoid damage when installing the next module.
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Page 20: Installation Electrical
Installation Electrical Connecting Module Power flashes green/red. To correct this, swap any two line voltage connections at the mounting socket. No further and Control Wires adjustment should be required. Power Interlock Switch Connections are made at the client module, which typically contains the power distribution panel. -
Page 21: Operating Principles
Operating Principles The Manhattan™ Gen II Water-Cooled Modular Chiller is designed to operate with a water/glycol mixture to prevent rust, scaling, and organic growth. The Manhattan™ Gen II Chiller provides 44 °F (7 °C) water/ glycol under a heat load with a return temperature of 54 °F (12 °C). -
Page 22: Operating Procedures
Operating Procedures Operator Interface Panel-Mounted Disconnect Switch Some Manhattan™ Gen II Chiller systems are optionally All Manhattan™ Gen II Water-Cooled Modular Chiller equipped with a panel-mounted disconnect switch units, whether they are composed of a single module or up installed on the outside of the power distribution panel (or to 10 modules, are automated systems that use a client on each module’s electrical and control panel if the chiller electrical panel to monitor, report, and modify critical... -
Page 23: Electronic Control
Operating Procedures Module Electrical and Control Panel fuses and breakers, compressor switches, and the microprocessor controller. See below figure. Each module has its own electrical and control panel that distributes electricity to individual components. It also has Figure 7. Module electrical and control panel Electronic Control Client and Server Controllers Manhattan™... -
Page 24: Operating The Microprocessor
The basic level, ‘user,’ does not require a password. The higher access levels are the technician (‘tech’) and administrator (‘admin’) levels that can only be accessed by Trane technical personnel. Contact Trane technical support regarding the possibility of any potential issues involving the higher-level functions. -
Page 25: Touchscreen Interface Tutorial
Operating Procedures Figure 10. Touchscreen interface Touchscreen Interface Tutorial Interface Menu Structure This section consists of a tutorial that first-time personnel Key interface screens are organized according to system, can use to navigate through the various functions and client module, and server modules functions. See features that are available in the interface. -
Page 26: Home Screen Features
Operating Procedures Home Screen Features Figure 12. HMI home screen ARTC-SVX002A-EN... -
Page 27: Hmi Functions
Operating Procedures HMI Functions Figure 13. User logging screen 1 - HMI Software Version Calls up the pop-up window Project Name: HMI software project name; Software Version.: HMI software version. Consists of 4 two-digit numbers. First 2 numbers: major and minor software revision. - Page 28 Operating Procedures Figure 14. Cooling / heating setpoint • Comp Run / Avail. Number of compressors 6 - Controlled Temperature Reading currently running and number of compressors available for Client/Server temperature control. Bar 7 - System Temperature Sensors Reading graph showing this ratio available as well. Based on chilled water entering / leaving temperatures for •...
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Page 29: Modules Layout Screen
Operating Procedures Modules Layout Screen Each module diagram is a set of symbols and colors that show the real-time status of the compressors, the refrigeration circuit, the isolation valves and the module The chiller can be composed of up to a maximum of ten overall. -
Page 30: Active Alarms Screen
Operating Procedures Table 3. Module status conditions (continued) Isolation Valves: - Valve LED is green = valve is open - Valve LED is gray = valve is closed Compressor 1 is OFF; Compressor 2 is ON Compressor 1 is ON; Compressor 2 is in alarm Active Alarms Screen from the list, so only 'Active' alarms will remain on the list. -
Page 31: Alarm History
Operating Procedures When all non-active alarms have been acknowledged, only active alarms will remain on the list. Description Save This column describes the nature of each alarm. Pressing this button saves the changes made to the active Time alarms list. Any changes that are made without saving will be lost. -
Page 32: Modules Overview Screens
Operating Procedures requires that earlier records appear on the list first. For all • TRIGGERED / NOT ACKNOWLEDGED other columns, alphabetical sorting applies. • TRIGGERED / ACKNOWLEDGED Duration Tag Value Allows the selection of the time period for which the alarm This is the same as Source Value for active alarms. -
Page 33: Overview Module
Operating Procedures Overview Module 4. OFF by no Servers. Client PLC communicates with no Servers. Module En/Dis a. Client Status states 3 or 4 will cause all the modules Pressing this button enables or disables a module. It is to run in Stand-alone mode. These failing used for testing and maintenance purposes. -
Page 34: Module I/O Screens
Operating Procedures Liq Line Solenoid 10. ON by Pumpdown. Compressor has been called off but keeps running due to Pump-down sequence. Status of the solenoid valve installed on the liquid line pipe. Comp (X) Speed EX Valve Can be displayed in different units. 1. -
Page 35: Analog Inputs
Operating Procedures When an I/O screen is displayed, switching to other I/O screens is accomplished by pressing their respective These outputs indicate the variable speed compressor’s buttons: hard-wired control signal. The ANALOG button displays the analog screen. Digital Inputs The DIGITAL button displays the digital screen. Analog Inputs Digital input (DI) data includes these parameters: Digital LEDs... -
Page 36: Digital Outputs
Operating Procedures opened - pressure is exceeding normal range threshold (faulty state). These show the Suction Pressure of Circuit 2. Digital Outputs There is an LED for each digital output which shows its These show the Discharge Pressure of Circuit 2. current state. -
Page 37: Operator Tasks
Operating Procedures Figure 18. Module trend screen 1. Trending variables instantaneous values according to 7. Buttons used to scroll back and forth in time. High cursor position. Current cursor timestamps are resolution time axis scrolling. displayed as well. 8. Button is used to pause / resume real-time trending. 2. -
Page 38: Emergency Power Shutdown
This cuts power to the compressors in a single module. It does not cut power to electrical Note: Trane will not validate the chiller warranty if the and control panel or other chiller modules. proper water/glycol mixture composition and quality is not maintained. -
Page 39: Maintain Glycol Level
Operating Procedures Protect the chiller from freezing, particularly if the chiller has a set point that is lower than the freezing point of the water/glycol mixture in the chiller. The chiller is designed to operate with a maximum propylene glycol concentration of 50%. -
Page 40: Prevent Freezing
50% regardless of the be less than 100 ppm. For best long-term results, de- ambient temperature conditions. ionized or distilled water is recommended. Trane can provide concentrated solutions of Dowfrost, propylene NOTICE glycol, or premixed solutions for use with the chiller. - Page 41 Operating Procedures water solutions become slushy during freezing. As the Figure 19. Water/Glycol concentration freezing points temperature falls, the slush becomes more and more (in degrees fahrenheit) viscous and finally fails to flow. Table 8. Freeze protection chart Water/Glycol Temperature Freeze Protection Burst Protection 20 °F (-7 °C) 18% glycol mixture...
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Page 42: Controls Interface
Controls Interface Microprocessor Control System Figure 21. Touchscreen interface panel with heat recovery data Manhattan™ Gen II Chiller models employ a Carel c.pCO all-digital data control system to control and report key system settings and indicators. Client Microprocessor Controller Both the Client and Server modules use a Carel c.pCO medium microprocessor controller. -
Page 43: Electrical Controls
Controls Interface Main Power Distribution Figure 23. Module electrical panel The power distribution panel distributes electricity from the external building power supply. It also houses breakers, phase monitor, and a built-in interface panel (and, potentially, an optional door-mounted client power disconnect switch). -
Page 44: Refrigeration Controls
Controls Interface Expansion Valve NOTICE An expansion valve is a metering device controlling the Proof of Flow Switch! flow of refrigerant to the evaporator based on evaporator superheat. Failure to provide flow switches or jumping-out of switches could result in severe equipment damage. Superheat is factory-set for around 12 °F (-11 °C). - Page 45 Controls Interface Thermal Capacity The thermal capacity of the chiller modules is dependent on the leaving temperature of the chilled water/glycol mixture, maintaining a minimum flow of water through the evaporator and keeping debris out of the air-cooled condenser. In applications where it is desired to operate with a lower flow rate or higher temperature change, consult the technical support for recommendations.
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Page 46: Sequence Of Operations
4. When the system is enabled, the chiller pump (if there is a requirement for cooling, the lead compressor provided by Trane) will energize. If the differential of the lead module will energize provided all safeties pressure switch within the tank and pump module on that circuit are satisfied. - Page 47 Sequence of Operations bypass control regardless of the system pressure redundant client microprocessor on a server chiller differential between the supply and return headers.) module, all functions of the client microprocessor are transferred to the redundant client microprocessor 7. Once this minimum flow is established and the system should the client microprocessor fail.
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Page 48: Chiller Performance Data
Chiller Performance Data This manual uses a typical 120-ton water-cooled chiller precise configuration can be found on the chiller model consisting of four modules with brazed plate evaporators nameplate. See “Model Number and Coding,” p. for example purposes. The model number and a chiller’s Table 9. -
Page 49: Maintenance Procedures
Maintenance for HVAC equipment and facilities can unnecessary and costly repairs and chiller down time. include a “preventive maintenance checklist” which Trane chillers are designed for ease of access with a includes small checks which can significantly extend premium placed on locating key components to facilitate service life. -
Page 50: Inspection And Maintenance Schedule
Maintenance Procedures governments may have additional requirements that must NOTICE be followed to responsibly handle HVAC refrigerants. Component Damage! Inspection and Maintenance Failure to follow instructions could damage sensitive Schedule electronic components beyond repair. To prevent arcing or surges of electrical current, do not use wires or cables to jump components or bypass the Proactive measures should be taken to prevent potential manufacturer's safety systems. -
Page 51: Weekly
Maintenance Procedures Weekly lacks proper refrigerant velocity to return oil to the compressor sump. Eventually, dry compressor starts Weekly inspection is a continuation and elaboration of could occur causing premature compressor failure. daily best practice: This may indicate that some oil has been lost from a previous refrigerant leak repair. -
Page 52: Quarterly
Maintenance Procedures Quarterly Annually The quarterly maintenance inspection is a comprehensive The annual chiller maintenance inspection is critical to the event that examines all aspects of the chiller to identify long-term performance of the chiller. Whether a chiller has early problems before they can damage a chiller and a service life of 15 years or 30 years is almost entirely require major repair or refurbishment: dependent upon how consistently and how diligently the... -
Page 53: Maintenance Tasks
9. Inspect all copper lines and control capillary tubing to frequency for evaporator cleaning. ensure that the lines are separated and not vibrating On multiple module chillers, Trane provides service against one another or the frame or housing. isolation valves on each evaporator to isolate each strainer 10. -
Page 54: Compressor Tasks
Maintenance Procedures 6. Clean the strainer inside and out using a soft natural 1. Close the suction and discharge rotalock valves. Firmly bristle brush and tap water. front-seat both rotalock valves clockwise. 7. Clean the interior of the end cap (or service cap), and Note: Do not over-tighten as the valve can become the gasket using a soft natural bristle brush and tap difficult to loosen if over-tightened. -
Page 55: Pump Tasks
Maintenance Procedures 7. Reconnect compressor electrical connections exactly Capture any escaping fluids encountered during the as they were removed, crankcase heater, and high pump change out process. pressure switch. Notes: 8. Replace the electrical and control panel cover securely. • Always use a second, counter, wrench, when performing plumbing tasks to firmly hold the fittings or WARNING... - Page 56 Maintenance Procedures 6. Tighten the suction and discharge unions using large 4. Close valves. There are isolation valves on the suction adjustable wrenches or pipe wrenches. To minimize and discharge sides of the pump as well as union the torque on the piping, apply an equal and opposite connections.
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Page 57: Controller Tasks
Maintenance Procedures 19. Attach the conduit to the box with the ring nut. Use a 6. Energize power to the module by turning power ON at standard screwdriver to secure the nut. the breaker and/or disconnect. 20. Secure the leads with crimp-type bell caps. 21. -
Page 58: Chiller Troubleshooting
Fault detection is recognizing that a problem has occurred, even if the root cause is not yet known. Fault isolation is the Trane manufactures chillers with embedded fault process of reducing potential causes to determine the detection and diagnostics in each module’s controller that most likely source of chiller failure. -
Page 59: Compressor Diagnostic Codes
(This code is inactive for heat pumps.) Copeland compressors used in Trane chillers are highly automated with digital capability to record and report a CODE 2 – Compressor (Pressure) Trips: The module will range of operating parameters and critical events. - Page 60 Chiller Troubleshooting winding of the compressor, but no current is detected in CODE 9 – Low Voltage: The module will flash nine times if the s winding of the compressor for 2 seconds. the module supply voltage drops below 17 Vac for 2 seconds.
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Page 61: Variable Frequency Drive Diagnostic Codes (Optional)
Chiller Troubleshooting Variable Frequency Drive Diagnostic Indicators Diagnostic Codes (Optional) Drive LEDs: Drive LEDs (green POWER and a red FAULT) are found on The ABB ACH580 Variable Frequency Drive (VFD) provides the front of the drive. LEDs are visible through the panel proven reliability and flexibility in an intelligent variable cover but not visible if a control panel is attached to the frequency drive dedicated to saving energy, producing... -
Page 62: Phase Monitor Protection
Chiller Troubleshooting Figure 25. ABB ACH580 variable frequency drive Table 15. LED phase monitor diagnostic codes LED Display Indication Glowing green: All voltages are acceptable and phase sequence is correct. Flashing red: Trip delay prior to de- energizing. Glowing red: Output has been de- energized upon fault detection. - Page 63 Chiller Troubleshooting 2. Symptom: Compressor will not run Possible Causes Potential Solutions Compressor will not run Assure all breakers and switches are on Main switch open or circuit breakers open Check circuits and motor winding for shorts or grounds Fuse is blown Replace fuse or reset breakers after fault is corrected Overloads are auto-reset.
- Page 64 Chiller Troubleshooting 7. Symptom: Low refrigeration suction pressure (continued) Possible Causes Potential Solutions Low water temperature Raise set point; check design specification Compressor will not unload Replace solenoid or controller Low discharge pressure Refrigerant charge; replace compressor Expansion valve malfunctioning Reset for proper superheat (10-12 º...
- Page 65 Chiller Troubleshooting 11. Symptom: Low chilled water temperature Possible Causes Potential Solutions Temperature controllers set too low Reset temperature controllers to correct design specifications Water velocity through evaporator too low Clean strainer; check pump, VFD, and differential pressure settings Temperature controllers malfunctioning Replace temperature sensor 12.
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Page 66: Variable Frequency Drive Fault Codes (Optional)
Chiller Troubleshooting 18. Symptom: Freeze protection safety activated Possible Causes Potential Solutions Thermostat set too low Reset above freezing temperature at evaporate or discharge Low water flow Remove restrictions. Increase HP Low suction pressure See “low suction pressure” Variable Frequency Drive Fault Faults latch inside the drive and cause the drive to trip, and the motor stops. - Page 67 Chiller Troubleshooting Code (hex) Fault / Aux. code Cause What to do Check there are no power factor correction capacitors or surge absorbers in motor cable. Check for an earth fault in motor or motor cables by measuring the Drive has detected load unbalance insulation resistances of motor and Earth leakage Programmable fault: 2330...
- Page 68 Chiller Troubleshooting Code (hex) Fault / Aux. code Cause What to do Check ambient temperature. If it exceeds 40 °C/104 °F (frames R5…R9) or if it exceeds 50 °C /122 °F (frames R0…R9), ensure that load current does not exceed derated load capacity of drive.
- Page 69 Chiller Troubleshooting Code (hex) Fault / Aux. code Cause What to do 5690 PU communication internal Internal communication error. Contact your local ABB representative. 5691 Measurement circuit ADC Measurement circuit fault. Contact your local ABB representative. 5692 PU board powerfail Power unit power supply failure.
- Page 70 Chiller Troubleshooting Code (hex) Fault / Aux. code Cause What to do Fault reserved for the EFB protocol Check the documentation of the 6686 EFB fault 3 application. protocol. Reset the fault. Contact your local ABB 6882 Text 32-bit table overflow Internal fault.
- Page 71 Chiller Troubleshooting Code (hex) Fault / Aux. code Cause What to do Check status of fieldbus communication. See user documentation of fieldbus interface. Check settings of parameter groups 50 Cyclical communication between drive Fieldbus adapter (FBA), 51 FBA A FBA A communication Programmable and fieldbus adapter module A or 7510 settings, 52 FBA A data in and 53 FBA A...
- Page 72 Chiller Troubleshooting Code (hex) Fault / Aux. code Cause What to do Check the nominal motor values in parameter group 99 Motor data. Check that no external control system is connected to the drive. Cycle the power to the drive (and its Motor ID run was not completed FF61 ID run...
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Page 73: Logical Flow Diagrams
Logical Flow Diagrams Control Logical Flow The following section presents the simplified logical flow block diagrams for the principal systems in the Manhattan™ Gen II Water-Cooled Modular Chiller. The chiller uses low voltage for controller and sensor circuits. See below figure. Figure 26. -
Page 74: High Voltage Logical Flow
Logical Flow Diagrams Figure 27. Expansion board wiring configurations to meet the demands of a worldwide chiller market. The high voltage configuration for a chiller High Voltage Logical Flow module is listed on each module’s name plate. The chiller is designed to operate with high voltage power supplied to Manhattan™... -
Page 75: Refrigeration Logical Flow
Logical Flow Diagrams Refrigeration Logical Flow The thermal capacity of the chiller modules is dependent on the leaving temperature of the chilled water maintaining a minimum flow of water through the The Manhattan™ Gen II Chiller uses independent evaporator. refrigeration circuits per module using scroll compressors. -
Page 76: Water/Glycol Mixture Logical Flow
Logical Flow Diagrams Water/Glycol Mixture Logical Flow Trane recommends using a water/glycol mixture instead of an all-water fluid. The water/glycol mixture is used within a closed system as shown in below figure. Figure 30. Water/glycol mixture logical flow ARTC-SVX002A-EN... -
Page 77: Appendix A - Acronyms And Abbreviations
Appendix A - Acronyms and Abbreviations All acronyms and abbreviations used in this manual, on Table 16. Acronyms and abbreviations (continued) the chiller controllers, and on module indicators and Item Expansion gauges are listed in the following tables. Friday Acronym List gallons per minute Graphical User Interface All acronyms and abbreviations in this publication are... - Page 78 Appendix A - Acronyms and Abbreviations Table 16. Acronyms and abbreviations (continued) Item Expansion Pres pressure pounds per square inch PumpDown Pump Down PumpMod Pump Module Pulse Width Modulation Pwrup Stg Up Power Up Stage Up REFRIG Refrigeration RemOff Remote Off Returned Merchandise Authorization Rotation revolutions per minute...
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Page 79: Appendix B- Request For Initial Startup
Trane customer service department. Submitting this form indicates that all critical work described on the form has been completed. To prevent additional charges for aborted startups, the following items must be completely functional and operating and this form signed and returned to Trane at least 10 working days prior to the scheduled initial startup date. -
Page 80: Initial Start-Up Agreement
Appendix B- Request for Initial Startup Initial Start-up Agreement By signing this form, you agree the chiller is ready for initial startup. It is understood that, if the chiller is not ready for initial startup due to site problems, the initial startup will be aborted at the discretion of the designated start-up technician. Payment for an aborted startup will be forfeited. - Page 82 For more information, please visit trane.com or tranetechnologies.com. Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.