Trane Thermafit TACW Installation, Operation And Maintenance Manual
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Trane Thermafit TACW Installation, Operation And Maintenance Manual

Modular magnetic bearing water-cooled centrifugal chiller
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Installation, Operation, and Maintenance
Thermafit™ Modular Magnetic
Bearing Water-Cooled Centrifugal
Chiller
Model TACW
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.
July 2023
SAFETY WARNING
ARTC-SVX007A-EN

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  • Page 1 Installation, Operation, and Maintenance Thermafit™ Modular Magnetic Bearing Water-Cooled Centrifugal Chiller Model TACW 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 (HCFCs). Not all refrigerants containing these compounds bump cap, fall protection, electrical PPE and arc have the same potential impact to the environment. Trane flash clothing). ALWAYS refer to appropriate advocates the responsible handling of all refrigerants.
  • Page 3 Follow EHS Policies! This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in Failure to follow instructions below could result in part without written permission. Trane reserves the right to death or serious injury.

  • Page 4: Table Of Contents

    Table of Contents Model Number Descriptions ....6 Connecting Module Power and Control Wires ........15 Model Number and Coding.
  • Page 5 Table of Contents Stage-In State ......58 Federal Clean Air Act ....61 Restart State .

  • Page 6: Model Number Descriptions

    This information is located on the chiller Refer to the Trane nameplate on each module in the nameplate that is affixed to each module. installed unit for the serial number and model number Table 1.

  • Page 7: Model Number

    Reference to the actual chiller module serial number may also be beneficial. Each module has its own unique serial number. Model Coding Key Model numbers assigned to Trane systems provide a wealth of information about the features for a chiller’s “as built” configuration. ARTC-SVX007A-EN...

  • Page 8: Chiller Description

    Efficiency, and Quiet Operation This manual provides relevant data to properly operate, • 5 percent Line Reactor per Compressor maintain, and troubleshoot the Trane Thermafit™ TACW. Operator and maintenance personnel must be a qualified • Mounted Fused Isolation Switch per Compressor refrigeration technician and have a working knowledge of •...

  • Page 9: Component Specification

    Chiller Description Component Specification • Small hold up volume uses only fraction of heat transfer (refrigerant) medium Compact Turbocor Compressor • Copper enhanced tubing and steel tube sheet construction • Operates efficiently at even 1 K temperature difference • True counter-current flow allows close temperature approach •...

  • Page 10: General Data

    General Data Table 2. General data - Thermafit TACW modular chiller Capacity (Tons) TACW085 (65-90) TACW110 (80-115) TACW125 (90-135) General Unit Number of Independent SINGLE SINGLE SINGLE Refrigeration Circuits R-134a Refrigerant Charge (lbs/ module) R-513A Refrigerant Charge (lbs/ module) Chilled Fluid Volume(gal/module) 37.3...

  • Page 11: Installation Mechanical

    Verify the correct model number and that all skids and cartons have been delivered. Any damage must be Long Term Storage reported to the motor carrier and Trane within five days of receipt of the shipment. Requirements Inspect all exterior components for concealed damage as Appropriate preparation and storage of Trane chiller soon as possible.

  • Page 12: 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 13: Rigging, Lifting, And Moving The Chiller

    Installation Mechanical Figure 2. Recommended chiller clearances Rigging, Lifting, and Moving the • Do not push a chiller module while directly in contact with the floor using manual or mechanical means. Chiller Figure 3. Recommended chiller rigging assembled The Thermafit™ TACW modular chiller can be delivered to unit the customer’s site as individual modules.

  • Page 14: Installation Piping

    Installation Piping Install Piping and External debris, weld slag, and other contamination deposited during fabrication of the piping system. Components Typical flushing includes hot water with mild detergent Proper support of piping and pipe hangers must consider followed by a dilute phosphoric acid solution until all visible the weight of the piping as well as the water weight inside residue is removed.

  • Page 15: Installation Electrical

    Installation Electrical Connecting Module Power and Module Main Power Control Wires Each module in the bank must be fed by its own individual power. All power wiring, up to the power panel, is the Connections are typically made at the power distribution responsibility of the installing contractor.

  • Page 16: Pre-Startup

    Pre-Startup Preparation for Initial Startup Please ensure that the proper Request for Startup form has been completed and provided to your local representative. After the system is completely installed with all wires connected and all piping securely coupled, the chiller can be prepared for initial startup.

  • Page 17: Operating Principles

    Operating Principles This section contains an overview of the operating motor compartment of the motor. The refrigerant flows principles of the Thermafit™ TACW modules equipped with across the motor, providing the necessary cooling, then Danfoss MCX controllers. enters the compression chamber. Refrigerant is compressed in the compressor to discharge pressure conditions.

  • Page 18: Operating Procedures

    Controller and HMI The Control Panel includes, but is not limited to, primary The Thermafit TACW chiller models use “Danfoss MCX and companion controllers, HMI, BMS interface, Ethernet microprocessor controllers and Schneider 7” touchscreen components for internal network, low-power fusing, and a HMI to monitor and report critical operating parameters.

  • Page 19: Operating The Microprocessor

    Operating Procedures Operator Control Figure 7. Danfoss MCX primary controller A touchscreen interface panel is the primary means for the operator or maintainer to monitor and modify a host of functions involving temperatures, pressures, set points alarms, elapsed operating hours, etc. The touchscreen interface is connected to and communicates with all module controllers via the Ethernet and RS485 switch.
  • Page 20 Operating Procedures – Metric/Imperial Display Table 4. HMI main menu features (continued) – BMS Interconnectivity Feature Function – Compressor Staging Valve Control • Optional Functionalities – Free Cooling For debugging purposes, the system provides a display of raw inputs and outputs. •...
  • Page 21 The following is the Settings Menu: Displays controls that provide the chiller identity. Figure 11. Settings menu Important: Settings should only be changed by Trane- trained representatives. Accessed by Admin Level Security only. For debugging purposes, this page displays the complete data array that is sent to the BMS system.
  • Page 22 Operating Procedures Table 5. HMI settings menu features (continued) Table 6. HMI devices menu features Feature Function Feature Function Displays communication between chiller control Displays a control overview of the EXV(s) in components. Allows control to shutdown comms to the system. unused or faulty components.
  • Page 23 Operating Procedures Data Displays The following table shows the standard set of Main Menu HMI screens. Main Menu Table 7. HMI main menu screens Screen User Interface Function Access • Appears only after program has been loaded in HMI first Password time.
  • Page 24 Operating Procedures Table 7. HMI main menu screens (continued) Screen User Interface Function Access Displays current value of all hardwired analog inputs and outputs. Analog I/O Main Menu > I/O > Analog • Provides access to Digital I/O Displays current value of all hardwired Main Menu >...
  • Page 25 Operating Procedures Table 7. HMI main menu screens (continued) Screen User Interface Function Access Settings > HMI > Alarm Provides information on what may be limiting Diagnostics the chiller. • Admin access only. Displays water temperatures and system pressures in large font for easy long-distance Chiller Key reading.
  • Page 26 Operating Procedures Table 7. HMI main menu screens (continued) Screen User Interface Function Access • Displays trend of the last hour’s data: – Evaporator water temperatures in and out. Temperature Trend: – Water-cooled: Condenser water in Context- and out temperatures. Sensitive to Main Menu >...
  • Page 27 Operating Procedures Devices Menu The following table shows the standard set of Devices Menu screens. Table 8. HMI devices menu screens Screen User Interface Function Access • Display trend and settings of electronic expansion valves controls EXV Control Main Menu > Devices Menu > EXV (see “Special Functions,”...
  • Page 28 Operating Procedures Table 8. HMI devices menu screens (continued) Screen User Interface Function Access • Displays trend of free cooling controlled temperature against free cooling valve position and settings. Free Cooling Main Menu > Devices Menu > Fan > Free Valve •...
  • Page 29 Operating Procedures Table 8. HMI devices menu screens (continued) Screen User Interface Function Access Display and configure economizers Economizer settings and parameters (see “Optional Main Menu > Devices Menu > ECO Control Functionalities,” p. 48). Displays trend and settings of Hot Gas Hot Gas Valve controls (see “Optional...
  • Page 30 Operating Procedures Setting Menu The following tables shows the standard set of Setting Menu screens. Table 9. HMI settings menu screens Screen User Interface Function Access • Admin Level Chiller SP Control (see “Special Functions,” p. 32). • Display and adjust chiller PID settings (see section 3.8 Compressor Control of the Chiller Control manual).
  • Page 31 Operating Procedures Table 9. HMI settings menu screens (continued) Screen User Interface Function Access The control system is comprised of a dual controller configuration: T3C – larger controller. Handles compressors and staging. Companion – small controller. Handles refrigeration circuits – EXVs, Fans, etc.
  • Page 32 Operating Procedures Table 9. HMI settings menu screens (continued) Screen User Interface Function Access Provides an interface to the security User Manager system for the management of users Main Menu > Settings Menu > Users and passwords. Temperature Display and configure setpoint Main Menu >...
  • Page 33 Operating Procedures Figure 13. Main screen The Hand/Off/Auto function has 3 modes: • Off – no function. Compressors are off and remain so regardless of loop temperatures. All display functions work as normal. Chiller Enable is White and OFF. If pumps are controlled by the chiller and they are configured to Cooling Enable, the pumps will not be enabled.
  • Page 34 Operating Procedures Figure 16. Chiller setpoint control - Remote setpoint with digital offset The chiller control setpoint screen allows you to enter a value within setpoint range in °C or °F depending on the HMI configuration. Digital Input #4 enables the digital offset In this situation, the controller adds the offset value to the functionality.
  • Page 35 Operating Procedures Enhanced EXV Control 2. ArcticCool – ArcticCool T3C Companion Controller. ArcticCool Chiller has 2 options for controlling the EXV(s): 1. Disabled – Indicates that the EXV is controlled Preferred control option. See below. externally without any visibility at the HMI. The following table displays the varied EXV control screens with their options and limitations.
  • Page 36 2. Condenser Fan Control ArcticCool Control Note: Although available in the software, this is not an option available on the Thermafit TACW. However, this control can be used on a module-dedicated This option requires ArcticCool T3C Companion Controller. cooling tower.
  • Page 37 Operating Procedures Economizer Control Figure 18. Economizer control a. Displays trend and current values for Setpoint, Process Value and Control value. b. Setpoint is Tech level adjustable. If corresponding option selected on Setup screen. See below. c. Valve Control Mode: Auto/Manual/Off. d.
  • Page 38 Operating Procedures Figure 22. Flash tank level • HOA works on all isolation valves – setting control in had opens all valves. Control Algorithms: • Disabled – No barrel isolation control. • Compressor – System configures each compressor to a fluid circuit.
  • Page 39 Operating Procedures power from all compressors in the chiller. This value is fields: integrated over an hour period to provide Hourly Usage. The Hourly Usage value is totalized daily for the data logging report (resets at midnight) into Daily Usage variable.
  • Page 40 Operating Procedures BMS interconnectivity 2. Chiller Off/Hand/Auto control - Variable tag CHIL_SP_02. The chiller control system supports the following BMS communication protocols: These two points will be exposed to BMS as read-write variables when corresponding options are enabled on HMI •...
  • Page 41 Operating Procedures Table 12. BMS data listing - AV and AO (continued) Object Array Object Modbus Tag Name Description Type Offset Instance Address Suction Pressure (Integer Value with 1 implied decimal) - DTC2 Suction 40021 Compressor #2 Pressure Suction Pressure (Integer Value with 1 implied decimal) - DTC3 Suction 40022 Compressor #3...
  • Page 42 Operating Procedures Table 12. BMS data listing - AV and AO (continued) Object Array Object Modbus Tag Name Description Type Offset Instance Address DTC1 Suction Suction Temperature (Integer Value with 1 implied decimal) - 40061 Temperature Compressor #1 Suction Temperature (Integer Value with 1 implied decimal) - DTC2 Suction 40062 Temperature...
  • Page 43 Operating Procedures Table 13. BMS listing - BO Object Array Object Modbus Tag Name Array Type Offset Instance Address DTC1 Fault: Inverter Temperature DTC Faults 10001 DTC1 Fault: Discharge Temperature DTC Faults 10002 DTC1 Fault: Suction Pressure DTC Faults 10003 DTC1 Fault: Discharge Pressure DTC Faults 10004...
  • Page 44 Operating Procedures Table 13. BMS listing - BO (continued) Object Array Object Modbus Tag Name Array Type Offset Instance Address DTC3 Fault: Sensor Fault DTC Faults 10042 DTC3 Fault: SCR Temperature DTC Faults 10043 DTC3 Fault: Lockout Fault DTC Faults 10044 DTC3 Fault: Winding Temperature Fault DTC Faults...
  • Page 45 Operating Procedures Table 13. BMS listing - BO (continued) Object Array Object Modbus Tag Name Array Type Offset Instance Address DTC6 Fault: 3 Phase Over Current DTC Faults 10085 DTC6 Fault: Cavity Temperature DTC Faults 10086 DTC6 Fault: Leaving Air / Water DTC Faults 10087 DTC6 Fault: Total Compression Ratio Fault...
  • Page 46 Operating Procedures Table 13. BMS listing - BO (continued) Object Array Object Modbus Tag Name Array Type Offset Instance Address DTC3 Alarm: Total Compression Ratio DTC Alarms 10140 DTC3 Alarm: SCR Temperature DTC Alarms 10141 DTC3 Alarm: Super Heat Alarm DTC Alarms 10146 DTC4 Alarm: Inverter Temperature...
  • Page 47 Operating Procedures Table 13. BMS listing - BO (continued) Object Array Object Modbus Tag Name Array Type Offset Instance Address Chiller: Condenser Flow Fault with DPS Chiller Faults 10205 Chiller: Evaporator Flow Switch Chiller Faults 10206 Chiller: Condenser Flow Switch Chiller Faults 10207 Chiller: Evaporator Pump Enable...
  • Page 48 Operating Procedures Table 14. Fan state map (continued) As per control options, each Staging Valve can be in one of the modes: Fan State Definition 1. Off – staging valve is always off regardless of other Start conditions. Cooling 2. On – staging valve is forced on. Used mostly for troubleshooting or maintenance purposes.
  • Page 49 Operating Procedures Chiller and Condenser Pump Control • Rotation time – pumps alternate operations duty at discrete times. The control system allows for Duty-Standby functionality on both Chiller and Condenser Pumping. The image below • Flow warning time – when expires, pump is assumed shows Rotation and Mode: failed and the system switches operation.
  • Page 50 Operating Procedures Figure 37. Delta temperature control screen Figure 39. Dual speed control screen Pass-Through Flow Control Pass-through function takes an external Signal and passes If Flow meter present, pumps are control between max and it directly to the pump. min speed to maintain constant flow.
  • Page 51 Operating Procedures It also exposes the Chiller Array Screen via M/S button. below). Access: Main Menu>Devices Menu>M/S: d. T3C dP. Evaporator inlet / outlet pressure delta. e. Trend has y-axis zoom capability. Access: Main Menu > Devices Menu > HGV button.
  • Page 52 Operating Procedures 1. Main alarms list: a. Lists all the current / acknowledged / reset. b. When a fault occurs, a new message appears in RED on the alarm screen. c. All entries must be acknowledged with these buttons: This turns the entry YELLOW. a.

  • Page 53: Operator Tasks

    Use the services of a qualified water treatment to verify they are correct. specialist to determine what water treatment, if any, is required. Trane assumes no responsibility for 4. Restore power to all modules. equipment failures which result from untreated or 5.

  • Page 54: Monitor Water Quality

    When the chiller has a water set point that is below the Note: Trane will not validate the chiller warranty if the freezing point of the water/glycol in use, take precautions proper water/glycol mixture composition and quality against freezing.

  • Page 55: Prevent Freezing

    10 °F (-12 °C) 29% glycol mixture 20% glycol mixture glycol. Trane does not warranty any component that fails 0 °F (-17.8 °C) 36% glycol mixture 24% glycol mixture due to freezing.
  • Page 56 Operating Procedures Figure 43. Water/Glycol concentration freezing points (in degrees Fahrenheit) ARTC-SVX007A-EN...

  • Page 57: Unit Controls

    Unit Controls The control system is comprised of PLC, HMI and BAS NOTICE interface device. All unit controls and devices have been Proof of Flow Switch! factory installed and tested prior to shipment. The control Failure to provide flow switches or jumping-out of circuit incorporates all major safety devices and control switches could result in severe equipment damage.

  • Page 58: Sequence Of Operations

    (default 65%) is sent to the compressor and the compressor starts. 4. This software is capable of staging multiple compressors (up to 6) but Thermafit TACW is a single compressor chiller only. Therefore, this chiller should not go to state 'Stage-in' or 'Stage-out'.

  • Page 59: Restart State

    Restart State 1. The operator has taken the compressor offline for maintenance. Note: Not needed on Thermafit TACW. 2. The compressor encountered a fault state which cannot It is assumed in the stage-in state that the pressure ratio be recovered by the controller (the operator needs to will come down below the threshold where another recycle the power manually).

  • Page 60: Timeout State

    Sequence of Operations 1. The fault is reset, and the compressor is made 3. Some faults cannot be reset by the controller, for available for normal use again by switching into the idle example when the compressor is damaged. The state.

  • Page 61: Maintenance Procedures

    These include maintaining an maintenance program predicts and prevents unnecessary operational log and conducting weekly, quarterly, and and costly repairs and chiller down time. Trane chillers are annual inspections of the chiller. designed for ease of access with a premium placed on...

  • Page 62: Maintenance Schedule

    Maintenance Procedures Maintenance Schedule • Verify operation of Staging valves. • Verify system operation by recording chiller operation WARNING e.g. sub- cooling, superheat, water temps, etc. Hazardous Voltage! Winter - Major Inspection Failure to disconnect power before servicing could result in death or serious injury. •...
  • Page 63 Maintenance Procedures Table 19. Maintenance Schedule (continued) Task Daily Annually 6 Months 12 Months Other Ensure all communication cables are secure Ensure all electronic modules are secure. Check physical condition of all exposed printed circuit boards (PCBs). Check all exposed PCBs for dust build-up and clean if necessary. Check discharge and suction pressure/ temperature sensors for accuracy against calibrated pressure/temperature gauges Re-apply Gel Lanoline to connections suggested by Turbocor once...

  • Page 64: Winter Shutdown Preparation

    3. Remove condenser and chilled water bell ends. required. Trane assumes no responsibility for a. If chiller is single or three pass, one pipe end should equipment failures which result from untreated or be removed.

  • Page 65: Compressor Tasks

    Maintenance Procedures Compressor Installation Note: Chemical tube cleaning should always be followed by mechanical tube cleaning. WARNING Compressor Tasks Hazardous Voltage! Compressor Removal Failure to disconnect power before servicing could result in death or serious injury. WARNING Disconnect all electric power, including remote disconnects before servicing.

  • Page 66: Chiller Troubleshooting

    Chiller Troubleshooting Abnormal Operation Sequence Figure 46. Chiller alarm management routine chart Chiller in Alarm Avoidance The Chiller Management System continuously monitors for abnormal system conditions such as low suction pressure, high discharge pressure, low leaving temperature, high amp draw and others. The controller implements a three-stage alarm management strategy in order to stay online as long as possible.
  • Page 67 Chiller Troubleshooting Table 21. Chiller / Compressor alarms / Faults listing Alarm Warning Active Description Reset Period Start-up Steady Compressors Code in Off Relay Relay Main switch INTERLOCK Refrigerant NOT selected: Select, INTERLOCK Restart Evaporator flow switch alarm INTERLOCK Condenser flow switch alarm Communication fault INTERLOCK Entering chilled water sensor alarm...
  • Page 68 Chiller Troubleshooting Table 21. Chiller / Compressor alarms / Faults listing (continued) Alarm Warning Active Description Reset Period Start-up Steady Compressors Code in Off Relay Relay Compressor 3 interlock activated Compressor 4 interlock activated Cooling enable off Capacity limited Phase/Sequence alarm TC1 communication error TC1 AC - Inverter Temperature TC1 AC - Discharge Temp...
  • Page 69 Chiller Troubleshooting Table 21. Chiller / Compressor alarms / Faults listing (continued) Alarm Warning Active Description Reset Period Start-up Steady Compressors Code in Off Relay Relay TC2 AC - 3 Phase Current Trip TC2 AC - Shaft Cavity Temperature TC2 AC - Leaving Air /Water TC2 AC - Total Compression Ratio Fault TC2 AC - General Compressor...
  • Page 70 Chiller Troubleshooting Table 21. Chiller / Compressor alarms / Faults listing (continued) Alarm Warning Active Description Reset Period Start-up Steady Compressors Code in Off Relay Relay TC3 ANC - Super Heat TC3 ANC - Inverter Temperature TC3 ANC - Discharge Temp TC3 ANC - Suction Pressure TC3 ANC - Discharge Pressure TC3 ANC - 3 Phase Current Trip...
  • Page 71 Chiller Troubleshooting Table 21. Chiller / Compressor alarms / Faults listing (continued) Alarm Warning Active Description Reset Period Start-up Steady Compressors Code in Off Relay Relay TC4 ANC - SCR Temperature TC4 ANC - Super Heat Evaporator low flow rate alarm INTERLOCK Condenser low flow rate alarm Master connection lost...

  • Page 72: Thermafit™ Tacw Schematics

    Thermafit™ TACW Schematics Figure 47. TACW chiller schematic ARTC-SVX007A-EN...
  • Page 73 Thermafit™ TACW Schematics Figure 48. TACW power schematic ARTC-SVX007A-EN...
  • Page 74 Thermafit™ TACW Schematics Figure 49. TACW control wiring 2261 3081 2261 3091 ARTC-SVX007A-EN...
  • Page 75 Thermafit™ TACW Schematics Figure 50. TACW compressor I/O board ARTC-SVX007A-EN...
  • Page 76 Thermafit™ TACW Schematics Figure 51. TACW controller (T3C) schematic top layer ARTC-SVX007A-EN...
  • Page 77 Thermafit™ TACW Schematics Figure 52. TACW controller (T3C) schematic bottom layer ARTC-SVX007A-EN...
  • Page 78 Thermafit™ TACW Schematics Figure 53. TACW controller (companion) schematic top layer ARTC-SVX007A-EN...
  • Page 79 Thermafit™ TACW Schematics Figure 54. TACW controller (companion) schematic bottom layer ARTC-SVX007A-EN...
  • Page 80 Thermafit™ TACW Schematics Figure 55. TACW control connections schematic ARTC-SVX007A-EN...
  • Page 81 Thermafit™ TACW Schematics Figure 56. TACW communications schematic ARTC-SVX007A-EN...
  • Page 82 Thermafit™ TACW Schematics Figure 57. TACW hydronics schematic ARTC-SVX007A-EN...
  • Page 83 Notes ARTC-SVX007A-EN...
  • Page 84 For more information, please visit trane. com or tranetechnologies.com. Trane has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.

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