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Installation, Operation, and Maintenance
PolyTherm™ Simultaneous
Chiller/Heater
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-SVX005A-EN
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Summary of Contents for Trane PolyTherm ARTC-SVX005A-EN
- Page 1 Installation, Operation, and Maintenance PolyTherm™ Simultaneous Chiller/Heater 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. When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment.
- 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 Power Interlock Switch ....23 ....6 Model Number and Coding Operating Principles . - Page 5 Table of Contents Maintenance Procedures Solenoid ‘E’ ......37 ....55 Solenoid ‘S’...
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Page 6: Model Number Descriptions
Model Number Descriptions Digit 1— Brand Digit 20, 21, 22—Configuration T = Trane 3HX = 3 Heat Exchanger (PolyTherm or Digit 2 — Model Series Ecotherm) HP = Heat Pump Process and Modular Series HR = Heat Recovery Medical and Critical Duty Series FC = Integral Free Cooling Digit 3, 4, 5—... -
Page 7: Model Number And Coding
This information is located on the blue plastic Chiller Reference Data. Refer to the Trane nameplate on chiller nameplate that is affixed to each module in the each module in the installed unit for the serial number and below figure. -
Page 8: General Information
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 PolyTherm Chiller/... -
Page 9: Customer Responsibilities
Failure to adhere to these long-term storage requirements may void the Trane warranty. Any component that is damaged or inoperable due to improper storage may have its warranty voided. Chiller Dimensions... - Page 10 General Information Figure 2. Chiller/Heater installation recommendations ARTC-SVX005A-EN...
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Page 11: Site Preparation And Clearances
Note: These clearances are general recommendations. install spring vibration isolators under individual Each installation has specific considerations. modules. Contact Trane for definitive guidance and approval on a job-by-job basis. Mounting Rails The chiller/heater must be positioned on a firm, level surface. -
Page 12: Rigging, Lifting, And Moving The Chiller/Heater
General Information Figure 4. Recommended chiller/heater clearances Figure 5. Recommended chiller/heater module rigging After setting each module, remove front or rear access panels or electrical boxes. Attach rigging bar on each panels to improve access to components when making end of module where 1 3/8 inch holes are provided. connections. -
Page 13: Chiller/Heater And Description
Chiller/Heater Scope WARNING This manual provides relevant data to properly operate, Hazardous Voltage! maintain, and troubleshoot the Trane PolyTherm Failure to disconnect power before servicing could Simultaneous chiller/heater. Operator and maintenance result in death or serious injury. personnel must be a qualified refrigeration technician and... -
Page 14: Components Parts
Chiller/Heater and Description Condenser The condenser is a key chiller/heater component that receives refrigerant in the form of gas from the compressor and changes it to liquid that absorbs the heat dissipated by a cooling tower or ground source well system. Evaporator The brazed plate heat exchanger that is the evaporator is constructed as a plate package of corrugated channel plates with filler material between each plate. - Page 15 Chiller/Heater and Description Fluid Piping source/sink heat exchanger to operate as an evaporator or condenser. The fluid piping is Schedule 10 steel covered in closed-cell Refrigerant Piping foam insulation to prevent condensation and retain heat and cold. Each heat recovery module is connected to the Piping is Type K seamless copper suction line covered in adjacent module using roll grooved steel couplings and closed-cell foam insulation, compressor rotalock service...
- Page 16 Chiller/Heater and Description Sight Glass When the sight glass shows a green indicator, no moisture is present. When the sight glass shows a yellow indicator, there is moisture in the refrigerant line. Bubbles can be observed whenever chiller/heater cycling causes the pressure to change up or down.
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Page 17: Pre-Installation
Failure to disconnect power before servicing could operating, with this form signed and returned to Trane, at result in death or serious injury. least 10 working days prior to scheduling an initial startup. - Page 18 Check the box if there are any customer-supplied devices connected to the chiller/heater wiring. List devices: ______________________________________________________________________________________ Check the box if there are any Trane remote devices connected to the chiller/heater wiring. Check the box if voltage drops are detected.
- Page 19 Pre-Installation Table 2. Initial startup readiness checklist (continued) Startup Readiness Dimension Check the box if source/sink chilled water lines have been leak tested according to prestartup instructions. Check the box if source/sink reservoir (if included) is at operating level with correct water/glycol mixture. ...
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Page 20: Installation Piping
Installation Piping Install Piping and External A 40-mesh screen strainer must be installed in each water/ liquid system piping inlet for proper filtration an Components protection of the heat exchangers. The following 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 the pipes. -
Page 21: Connecting Module Couplings
Installation Piping Only after the above steps have been completed should the water piping be connected to the chiller/heater. Dowfrost Important: Dowfrost inhibited propylene glycol-based solution is listed as chemically acceptable by the US Department of Agriculture (USDA). The two ingredients in Dowfrost water/glycol mixture are generally recognized by the FDA as safe food additives under parts 182 and 184 of the... -
Page 22: Installation Electrical
Installation Electrical Wiring and Piping Chiller/Heater Module Main Power Modular systems feature single-point power connection Modules must be installed in accordance with the from the utility service to the power distribution panel on manufacturer’s recommendations where shown on the the master module as standard. Main power phases A, B, drawings and other installation documents. -
Page 23: Power Interlock Switch
Installation Electrical Power Interlock Switch Some PolyTherm Chiller/Heater systems are optionally equipped with a panel-mounted disconnect switch installed on the outside of the power distribution panel. The disconnect switch must be turned to the off position before the panel can be opened for service. WARNING Hazardous Voltage! Failure to disconnect power before servicing could... -
Page 24: Operating Principles
Operating Principles The PolyTherm Simultaneous Chiller/Heater is a state-of- The PolyTherm Chiller/Heater is designed to operate with the-art six-pipe multipurpose system (See figure below) a water/glycol mixture to prevent rust, scaling, and organic featuring independent water circuits to satisfy end user's growth and uses R-410A or R-134a refrigerant. - Page 25 Operating Principles In cooling mode, the diverting valves direct the load chilled In heating mode, the diverting valves direct the load fluid to the evaporator and simultaneously direct the heating fluid to the condenser and the source/sink fluid to source/sink fluid to the source/sink brazed plate heat the source/sink brazed plate heat exchanger as refrigerant exchanger operating as a condenser.
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Page 26: Operating Procedures
Operating Procedures Operator Interface Panel-Mounted Disconnect Switch Some PolyTherm Chiller/Heater systems are optionally All PolyTherm Simultaneous Chiller/Heater units, whether equipped with a panel-mounted disconnect switch they are composed of a single module or up to ten installed on the outside of the power distribution panel (or modules, are automated systems that use a touchscreen on each module’s electrical and control panel if the chiller/ interface panel to monitor, report, and modify critical... -
Page 27: Electronic Control
Operating Procedures Module Electrical and Control Panel breakers and the microprocessor controller. See the figure below. Each module has its own electrical panel that distributes electricity to individual components. It also has fuses and Figure 12. Module electrical panel Each module has its own control panel that houses the Electronic Control microprocessor controller. -
Page 28: Client And Server Controllers
Operating Procedures Figure 14. Microprocessor controller A master controller is used to control and coordinate the pressures, and freeze protection are preserved. The functioning of all the modules that make up the chiller/ distributed microprocessor control programming only heater unit. For units consisting of more than a single lacks the ability to rotate the lead compressors which chiller/heater, each module has its own controller. -
Page 29: 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 30: Touchscreen Interface Tutorial
Operating Procedures 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 master module, and slave modules functions. See the features that are available in the interface. -
Page 31: Home Screen Features
Operating Procedures Access to these screens is restricted to administrator level number on the Mx button stands for the module only. number in the chiller/heater. Only modules that communicate directly with the touchscreen interface Home Screen Features are viewable via the module access buttons. •... -
Page 32: Project Name
Operating Procedures Alarm The active alarm access button provides fast access to a list of currently active system alarms. Date and Time The date/time displays the current settings of the system isochronon. Figure 18. The home screen, ‘System Control’ Project Name Figure 19. -
Page 33: Middle Section Functions
Operating Procedures Online This is the version of the interface software currently loaded in the system. This number consists of four sets of This is the number of chiller/heater modules currently two-digit numbers. communicating with the master microprocessor • The first two sets indicate major and minor software controller, including the master module. -
Page 34: Log In
Operating Procedures Log In Figure 20. User Log-in screen Pressing the Log-in button displays the Log-in window where the access-level password is entered for the ‘tech’ and ‘admin’ levels. There is no name or password required for the ‘user’ access level. Pressing the sign in button automatically logs the operator into the ‘user’... -
Page 35: Module Layout Screen Status Conditions
Operating Procedures Figure 21. Modules layout screen showing four compressors on two modules Module Layout Screen Status Conditions On the home screen, pressing the alarm button displays the active alarms screen. See Figure 21, p. Table 4. Module status conditions ... -
Page 36: Module Indicators
Operating Procedures On the home screen, pressing the M1 button displays the Modules Overview Screens Module #1 (master module) overview 1 screen. Each module controlled by the microprocessor controller Use the left and right scrolling buttons to scroll through the has its own module screen within which the operator can overview screens. -
Page 37: Lead Module
Operating Procedures • OFF by Heat Sensor - The chiller/heater heating • Its microprocessor controller has been assigned the temperature sensor has failed. IP address from the slave address range. • OFF by No Slaves - The master microprocessor • It is communicating with master module. controller cannot communicate with any of the slave •... -
Page 38: Compressor Overview Screens
Operating Procedures Table 6. D1/D2 and S1/S2 values (continued) Value Simultaneously Mode Cooling only Mode Heating only Mode Discharge 3 (D3) Open Open Closed Discharge 4 (D4) Closed Closed Open Compressor Overview Screens Use the left and right scrolling buttons to scroll through the overview screens. -
Page 39: Module I/O Screens
Operating Procedures • Demand Hot / Cold - This is the local cooling and When the module screen is displayed, pressing the i/o heating demand value in terms of the number of button displays the I/O menu. requested compressors. The I/O menu is comprised of four screens for Master •... -
Page 40: Analog Inputs
Operating Procedures Table 8. Module input/output screens (continued) Master I/O Expansion #2 Screen Slave I/O Expansion #2 Screen Master I/O Expansion #1 Screen When an I/O screen is displayed, switching to other I/O screens is accomplished by pressing their respective This input indicates the panel temperature (optional). -
Page 41: Digital Outputs
Operating Procedures Digital LEDs • Green LED This digital input is energized, the connected device is closed. There is an LED for each digital input that indicates its • Gray LED This digital input is de-energized, the current state. For all inputs, the color of the LED signifies connected device is open. -
Page 42: Expansion Io Screen
Operating Procedures Expansion IO Screen Another way to set cooling or heating set points is via BAS communication. This screen controls analog inputs and digital requests. All microprocessor Analog Inputs (AI) are actually There is an LED for each digital output that shows its state: Universal Inputs (UI), the same as the microprocessor controller UI. -
Page 43: Alarm History
Operating Procedures Reset PLC An alarm is considered “Active” (Triggered) if “State” = 1, meaning that it is still active in the PLC. This button, located in the upper right portion of the An alarm is considered “Not Active” (Not Triggered) if screen, resets the active alarms in the master “State”... -
Page 44: Trend Screen
Operating Procedures Figure 24. Alarm history Trend Screen The alarm history screen displays the history of alarms recorded by the master microprocessor (See Figure 24, 44). Sort History Items The alarm history list can be sorted by any column in When on the master module screen, pressing the Trend ascending or descending order by tapping the button displays the trend screen. - Page 45 Operating Procedures Figure 25. Cooling trend screen Cooling Trend Screen This is the drop-down text box used to select the trending time span. It is used to for focusing on a specific time Use the left and right scrolling buttons to switch between period.
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Page 46: Operator Tasks
Operating Procedures Heating Trend Screen Use the left and right scrolling buttons to switch between cooling trend and heating trend screens. The heating trends screen is similar to the cooling trends screen. Figure 27. Heat trend screen Operator Tasks Startup in the Installation section of this manual for instructions regarding that situation. -
Page 47: Emergency Power Shutdown
The results will enable the accurate adjustment of quality thereby increasing the operational life of the chiller/heater. Note: Trane will not validate the chiller warranty if the proper water/glycol mixture composition and quality is not maintained. -
Page 48: Prevent Freezing
The total hardness in terms of calcium carbonate should be less than 100 ppm. For best long-term results, de- NOTICE ionized or distilled water is recommended. Trane can Equipment Damage! provide concentrated solutions of Dowfrost, propylene glycol, or premixed solutions for use with the chiller. - Page 49 Operating Procedures behavior represents true freezing. The correction factors are the “best informed estimates” for second is known as super-cooling. Glycols chillers with copper evaporators. The percentages may do not have sharp freezing points. Under vary depending on the materials and alloys of the heat normal conditions, propylene glycol sets to exchangers, total surface area, the amount of present or a glass-like solid, rather than freezing.
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Page 50: Controls Interface
Controls Interface Chiller Controls The master module contains the master microprocessor controller. The master microprocessor communicates with the slave microprocessor in each module via a local Each system is provided with a touchscreen interface network communications protocol. The master module panel that is used to turn the chiller/heater on and off, also includes a phase monitor to protect against low adjust set points, clear alarms, and perform detailed set-... -
Page 51: Touchscreen Interface Panel
Controls Interface Panel Disconnect module). The disconnect switch must be turned to the off position before the panel can be opened for service. Some PolyTherm chiller/heater systems are optionally equipped with a panel-mounted disconnect switch Module Electrical Panel installed on the outside of the power distribution panel (or From the power distribution panel, power is fed to the on each module’s electrical and control panel if the chiller/ individual modules in the chiller/heater and connects to... -
Page 52: Microprocessor Control System
In applications where it is Figure 34. PolyTherm chiller/heater controller desired to operate with a lower flow rate or higher temperature change, consult Trane technical support for recommendations. Electronic Controls The PolyTherm Chiller/Heater is provided with a robust set of controls and indicators to monitor system performance and notify operators if problems arise. -
Page 53: Sequence Of Operations
Sequence of Operations This manual describes a typical water-cooled chiller/heater system with few, if any, optional components or devices attached: Description Simultaneous heating and cooling modules are built for single point power supply connection to a central distribution block inside the power distribution panel and incorporates circuit breaker overload protection for each module. -
Page 54: Chiller/Heater Performance Data
Chiller/Heater Performance Data This manual uses a typical 120-ton water-cooled chiller/ Table below) The model number and a chiller/heater’s heater consisting of four modules with brazed plate heat precise configuration can be found on the model exchangers and condensers for example purposes. (See nameplate. -
Page 55: 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 56: Inspection And Maintenance Schedule
Maintenance Procedures maintaining a operational log and conducting weekly, NOTICE quarterly, and annual inspections of the chiller/heater. See below table. Compressor Damage! Daily Failure to follow instructions could damage sensitive electronic components beyond repair. A daily visual inspection can reveal obvious problems. To prevent arcing or surges of electrical current, do not Keep notes of the chiller/heater performance: use wires or cables to jump components or bypass the... -
Page 57: Weekly
Maintenance Procedures Weekly Eventually, dry compressor starts could occur causing premature compressor failure. This may indicate that Weekly inspection is a continuation and elaboration of some oil has been lost from a previous refrigerant leak daily best practice: repair. The compressor data label indicates the correct oil type and quantity with which it should be filled. -
Page 58: Quarterly
Maintenance Procedures Note: Bubbles in the sight glass do not necessarily for voltage imbalance. The chiller/heater’s phase indicate loss or lack of refrigerant charge. Bubbles monitor will open if the voltage imbalance exceeds 4%. (commonly know as ‘flashing’) will occur until the 13. -
Page 59: Maintenance Tasks
13. Review logged alarms and look for repetitive trends. frequency needed for strainer cleaning. On multiple The chiller/heater can retain the previous 1,000 alarms module chiller/heaters, Trane provides service isolation with time and date of occurrence. valves on each evaporator to isolate each strainer for cleaning without disrupting the operation of any 14. -
Page 60: Heat Exchanger Cleaning Procedure
PolyTherm Chiller/Heater has been designed for ease of Remove Through the Roof Panel: Where there is a maintenance access. When properly positioned within a minimum of 48 inches of overhead clearance, remove the machine room or space, Trane compressors can be quickly ARTC-SVX005A-EN... - Page 61 Maintenance Procedures eight fasteners attaching the roof panel to the module. 3. Install the rotalock nuts on the compressor suction and Position a lifting device over the tandem compressors. discharge connections. The recommended torque is 80 lbf for 2-inch and larger and 60 lbf for rotalock nuts Remove Through the Side C Top Panel: Where there smaller than 2-inch.
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Page 62: Chiller/Heater Troubleshooting
15 minutes and 18 hours, followed by a compressor trip lasting longer than 7 minutes. When four Compressors used in Trane systems are highly automated consecutive or ten total CODE 5 events are recorded, the with digital capability to record and report a range of module will lockout the compressor and flash red five operating parameters and critical events. -
Page 63: Phase Monitor Protection
Chiller/Heater Troubleshooting Table 14. Compressor fault code summary Alert Alert Lockout Lockout Code Condition Level Indication Normal Run Normal operation, no alarm status. Solid Green CODE 1 Long run time. Compressor is running for more than 18 hours at full load. (CODE Yellow Flash 1 1 is disabled in heat pump mode.) CODE 2... - Page 64 Chiller/Heater Troubleshooting 1. Symptom: Compressor will not start Possible Causes Potential Solutions Circuit breakers are in the OFF position Moves circuit breakers to the ON position in the power distribution panel Temperature control not in demand Set point has been reached or still within band Differential pressure switch open due condenser flow switch open Condenser side loss of flow;...
- Page 65 Increase suction pressure; suction temperature pressure; check for Expansion valve malfunctioning proper superheat; check electronic expansion valve replace if necessary; cabling to stepping motor; contact Trane technical support Compressor service valves closed Open service valve (if so equipped) counterclockwise completely...
- Page 66 Chiller/Heater Troubleshooting 11. Symptom: High chilled water temperature (continued) Possible Causes Potential Solutions Load higher than capacity of chiller/heater Refer to chiller/heater design specifications Low refrigeration charge Conduct leak check on refrigeration system Temperature sensor not properly installed Check that sensor is properly installed in well Fouled evaporator Reverse flush evaporator;...
- Page 67 Chiller/Heater Troubleshooting 17. Symptom: Freeze protection safety activated Possible Causes Potential Solutions Temperature set point too low Reset above freezing temperature at evaporator or discharge Low water flow Remove restrictions; increase flow; clean strainer Low suction pressure See ‘low suction pressure’ ARTC-SVX005A-EN...
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Page 68: Logical Flow
Logical Flow High Voltage Logical Flow designed to operate with high voltage power supplied to the unit at all times. The PolyTherm Simultaneous Chiller/Heater is available in Control Logical Flow a range of voltage/amperage/phase configurations to meet the demands of a worldwide market. The high The chiller/heater uses low voltage for controller and voltage configuration for a chiller/heater module is listed sensor circuits. - Page 69 Logical Flow Figure 38. Expansion board wiring (master module) Figure 39. Expansion valve wiring ARTC-SVX005A-EN...
- Page 70 Logical Flow 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 the below figure. Figure 40. PolyTherm chiller/heater piping installation diagram...
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Page 71: 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. Delay Acronym List Differential Pressure Danfoss Turbocor Compressors Inc. - Page 72 Appendix A - Acronyms and Abbreviations Table 16. Acronyms and Abbreviations (continued) Table 16. Acronyms and Abbreviations (continued) Item Expansion Item Expansion Inch Pwrup Stg Up Power Up Stage Up INFO Information REFRIG Refrigeration Integration RemOff Remote Off Industry Pack Returned Merchandise Authorization Isolation RmpDn...
- Page 73 Appendix A - Acronyms and Abbreviations Table 16. Acronyms and Abbreviations (continued) Item Expansion YY.MM.DD Date: Year.Month.Day ARTC-SVX005A-EN...
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Page 74: Appendix B- Request For Initial Startup
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 75: 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 76: Appendix C - Active Alarm List
Appendix C - Active Alarm List Warning All active alarms are reported on the Active Alarms screen. Application This is an informative alarm; no action is required. Shows if alarm applies to master microprocessor Alarm Notes controller, slave microprocessor controller, or both. •... - Page 77 Appendix C - Active Alarm List Table 17. Touchscreen interface active alarm states (continued) Alarm Application Type Action cpCOe WRONG CONFIG Alarm Client Auto Reset Warning UI1 SENSOR FAILURE Client / Server Auto Reset Shuts down local cooling control *** UI2 SENSOR FAILURE Client / Server Auto Reset...
- Page 78 Appendix C - Active Alarm List Table 17. Touchscreen interface active alarm states (continued) Alarm Application Type Action cpCOe #2 WRONG CONFIG ALARM Client / Server Auto Reset Locks out module Valve D1 OPENING FAILURE Client / Server Operator Reset Locks out module Valve D1 CLOSING FAILURE Client / Server Operator Reset Locks out module...
- Page 80 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.
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