Trane CVHE Troubleshooting Manual
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Trane CVHE Troubleshooting Manual

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Literature History: CVHE-SB-32 (8/95)—Original Issue of Bulletin.
Troubleshooting and Checkout Procedures
Subject:
For CVHE/F/G Units with UCP2 Controls
Introduction
:
The purpose of this service bulletin is to provide troubleshooting information on CVHE/F/G Centrifugal
Chillers with UCP2 Control Panel. Additional UCP2 information is found in the following manuals:
CVHE-OM-8, Operation/Maintenance Manual
CVHE-IN-9,10,11, Installation Manual
CVHE-W-8A, Wiring Manual
CVHE-CLD-1A, Clear Language Display Manual
General
Service
Bulletin
Library
Product Section
Product
Model
Literature Type
Sequence
Date
File No.
Supersedes
Since the Trane Company has a policy of continuous product improvement, it reserves the right to change
specifications and designs without notice. The installation and servicing equipment referred to into this book-
let should be done by qualified experienced technicians.
Centrifugal Liquid Chiller, Water-Cooled
General Service Bulletin
CVHE-SB-32A
Service Literature
Refrigeration
CVHE, F, G
32A
August 1999
SV-RF-CVHE-SB-32A
CVHE-SB-32

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Summary of Contents for Trane CVHE

  • Page 1 CVHE-W-8A, Wiring Manual CVHE-CLD-1A, Clear Language Display Manual Since the Trane Company has a policy of continuous product improvement, it reserves the right to change specifications and designs without notice. The installation and servicing equipment referred to into this book-...

  • Page 2: Table Of Contents

    Problem 10: Check Clock (lFW) Informational you cannot remove............ 14 Warning Diagnostics. On a loss of power, the clock does not keep time if there is an extended Troubleshooting and Checkout Procedures for CVHE/F/G Units with UCP2 Controls...
  • Page 3 29 Problem 46: Loading Problems ........19 Problem 47: Memory Error ........20 Problem 48: Momentary Power Loss (MPL) .....20 CVHE/F/G Trim Balance Procedure ..30 Problem 49: Motor winding temperatures changing rap- idly and randomly ............. 21 Run Procedure: ........... 30 Start sequence: ...........
  • Page 4 II. Quick Test of Stepper Board........50 II. Check Stepper Motor and Wiring for Shorts and Opens Current Overload Protection: ..... 94 IV. Motor Voltages for CTV Stepper Motor ....54 Troubleshooting and Checkout Procedures for CVHE/F/G Units with UCP2 Controls...
  • Page 5 Evaporator Refrigerant Temperature Limit ............... 95 Condenser Refrigerant Pressure Limit..96 Head Relief Request ........... 97 Free Cooling Relay Checkout ...... 98 Hot Gas Bypass ........... 100 Install and Enable ............. 101 1) HGBP mode, IGV Target:% ........ 102 2) Guide Vane Closed Travel Stop:% ...... 102 3) Maximum HGBP Time: ........

  • Page 6: General Troubleshooting Index

    Cond. Refrig. Temp. Sensor diagnostic, when the displayed Cond. Refrig. Temp. is reading fine. Condenser and Evaporator entering and leaving water temps. changing rapidly and reading incorrectly, i.e. -25° F to 900°F. Condenser Water Flow lost diagnostic. Unit will not restart until manually reset. Capacity limited by current limit CVHE-SB-32A...
  • Page 7 Oil Pump Discharge Pressure Sensor Diagnostic and Oil Pressure Calibration. Corrective Action. Over/Under Voltage Diagnostic on Startup. Phase Loss Severe Phase Unbalance Phase Reversal Printer will not work. Purge Compressor will not run in the manual “ON” mode. Sensor errors Transition resistors stay in too long. CVHE-SB-32A...
  • Page 8 Rapid Time of Day Scrolling or Date jumps back one day. Unit did not Transition diagnostics. Tracer Diagnostics e.g., tracer loss of comm with options, starter, etc. as well as other Tracer related diagnostics. Unit Tons Read-out on CLD does not work. Unknown diagnostics 1217 informational warning. CVHE-SB-32A...

  • Page 9: Ucp2 Control Panel And Module Description

    Major components within each of these control groups are described below. Unit-mounted temperature sensors, pressure transducers and functional switches provide analog and binary inputs to the various modules. The “microprocessor-based” modules described are shown below. All connections to the modules are made with pluggable phoenix connectors. CVHE-SB-32A...
  • Page 10 Figure 1 UCP2 Control Panel I/O Module 1U10 IPC Buffer Module 1U9 or U7 TCI-Printer Tracer Com 1U8 TCI (COMM3 or COMM4) Stepper Mod 1U3 Options Mod 1U5 Chiller Mod 1U1 Circuit Mod 1U2 CVHE-SB-32A...

  • Page 11: Ucp2 Control Panel And Module Description

    The Starter module provides interface to and control of Y-Delta, X-Line, P-Reactor, A-Transformers, Solid State Starters and Trane® Adaptive Frequency Drive. The Starter module also provides protection to both the motor and the compressor in the form of running overload, phase reversal, phase loss, phase unbalance, momentary power loss, and compressor surge, in addition to others.

  • Page 12: Purge Module

    65°F. Tracer Communications Interface TCI COMM 3 is an optional module that provides a 1200 baud isolated communications link to TRACER. TCI COMM 4 (Tracer Summit) is an optional module that provides a 9600 baud non-isolated link to Summit. CVHE-SB-32A...

  • Page 13: Printer Interface Module

    Display panel. Each unit can be reset or stopped separately through each CLD. The dip switch setting on the board is ON-OFF-ON. IPC communication with the downstream chiller “A” panel connects to J1, 1 & 2. IPC communication with the upstream chiller “B” panel connects to J3, 1 & CVHE-SB-32A...

  • Page 14: General Troubleshooting Information

    Problem 4: Auto X-former starter: Runs (3) seconds and trips. Unit will not transition. Corrective Action: 1 Verify Starter module. If X-13650453-07 or later, it requires transition circuit. 2 No voltage on transition complete J4 circuit. Trace circuit path. Reference Trane CVHE-SB- Problem 5: IGV BPI not found or low Corrective Action: 1 BPI switch location may have changed.

  • Page 15: Problem 6: Bearing Temperatures 1 And 2 Locations

    Corrective Action: This diagnostic is shown in active diagnostic menu. Note: If you clear this IFW diagnostic while the machine is running, you will shut down the unit. Wait to clear the diagnostic when the unit is off. CVHE-SB-32A...

  • Page 16: Problem 11: Chiller Loss Of Communication With Starter And The Igv Calibrates

    Guide Vane action. Mode is “Resetting” and can move through the menus. Corrective Action: 1 IPC to Starter module disconnected or reversed 2 Starter module not powered up. 3 Verify that a good ground exists between all modules including the CLD that needs a dedicated green wire ground CVHE-SB-32A...

  • Page 17: Problem 16: Loss Of Communication Or Intermittent

    Corrective Action: 1 Verify the Chiller and CLD versions are compatible with Tracer. 2 Reference Trane CTV-CSB-90 and 92 for module compatibility numbers. 3 ICS address at CLD should match with Tracer. 4 Are the DIP switches set correctly? They should be all off for COM 3; OFF-ON-OFF for Comm 4.

  • Page 18: Problem 17: No Communication, On A Power Up, Get

    The compressor discharge temperature exceeded 200°F. Corrective Action: 1 Check unit operating conditions for something that would generate high gas discharge temperatures, such as condenser water flow. 2 Extended operation in hot gas bypass. Set the hot gas bypass timer lower. CVHE-SB-32A...

  • Page 19: Problem 22: Cond. Pressure 2-10 Vdc Output Will Not Work

    4 Defective CT. Problem 28: Custom menu - Unwanted items that you did not install and you cannot re- move. Corrective Action: 1 The initial problem was if you had installed an option, put it in the Custom menu, then de- CVHE-SB-32A...

  • Page 20: Problem 29: Display Is Locked Up. No Communication, Data Not Valid Diagnostic

    9 Input type must be selected in the field start-up menu. 10 May need to install an isolation device (DC to DC converter), 11 Set to 2-10 VAC and hook an 8-volt battery to the input to verify the module works. CVHE-SB-32A...

  • Page 21: Problem 32: External Current Limit Setpoint Does Not Work

    4 Once the condenser water pump is running and confirmed. The FC valve relays #1 & #2 and the FC aux relay are all energized. If the FC valve-closed limit switches do not close within 3 minutes, a MMR diagnostic will be generated. CVHE-SB-32A...

  • Page 22: Problem 36: Evaporator Water Temperatures Are Reversed (2 Pass Units Only)

    Problem 39: GPM/Tonnage option problems Corrective action: 1 Correct Flow Coefficients and Exponents settings. 2 Reference Trane service bulletin CHVE-CSB-45C. For upgrade modifications, CLD X- 13650782-01 or newer is required to see all new screens. Updated chiller module X- 13650450-15 or newer is required.

  • Page 23: Problem 41: Hot Gas Bypass (Hgbp) Does Not Work

    ~ Set Front panel ice termination setpoint. ROM default is 27 ~ Set the ice making to normal cooling transition timer. ROM Default is 5 min. 4 Ice building shall be able to be terminated by one of three methods: CVHE-SB-32A...

  • Page 24: Problem 43: Igv Will Not Move In The Service Test Manual Mode

    Typical changes should be small. 1-2% proportional gain change or 0.01% integral gain changes. Always adjust proportional gain first. This is the coarse adjustment, while integral is the fine and derivative is the micro adjustment. CVHE-SB-32A...

  • Page 25: Problem 47: Memory Error

    13 If the unit trips on Momentary Power Loss, vanes stay where they were and then restart without going through a Vane Closure or BPI search, two modules need to be changed: ~ Chiller module needs to be a X-13650450 -04 or newer. CVHE-SB-32A...

  • Page 26: Problem 49: Motor Winding Temperatures Changing Rapidly And Randomly

    9 Differential oil pressure when the unit is off. The unit sees current due to Feedback via the PFCCs or CTs. We get a starter interrupt failure. The UCP2 thinks the motor is running and brings on the oil pump and logs differential oil pressure diagnostics. CVHE-SB-32A...

  • Page 27: Problem 52: Oil Temperature High

    3 The oil tank heater is off when the unit is running (Trane Service Alert 206). A UCP2 software change was made 6/98 so that the chiller is allowed to operate at a condition of saturated °...

  • Page 28: Problem 57: Over/Under Voltage Diagnostic On Startup

    5 Problem in the Start Relay circuit on J8 of Starter module. Check all connections and circuit. 6 Verify currents are over 10% RLA. 7 Check the current overload settings. 8 Defective Starter module. 9 Turns through the CTs may be incorrect. CVHE-SB-32A...
  • Page 29 X1 to X2 576-864 A X-13580047-02 X1 to X3 720-1080 A X-13580048-05 X1 to X3 720-1080 A X-13580047-02 X1 to X4 864-1296 A X-13580047-01 X1 to X2 1008-1512 A X-13580047-01 X1 to X3 1200-1800 A X-13580047-01 X1 to X4 CVHE-SB-32A...

  • Page 30: Problem 59: Severe Phase Unbalance

    4 Verify the printer interface is working properly. ~ Verify there is IP communication ~ RxA (Green LED near J1) is IPC receive and should be blinking ~ TxA (Red LED near J1) is IPC transmit and should not be blinking CVHE-SB-32A...

  • Page 31: Problem 62: Purge Compressor Will Not Run In The Manual "On" Mode

    1 If the J8 terminal on the Starter module is loose, the control does not latch in and extends the timing keeping the resistors in longer. Reference Trane Service Bulletin CVHE-CSB-35. Problem 65: Setpoints are not being stored, service tests will not work and we are calling many diagnostics on the CLD.

  • Page 32: Problem 66: Starter Contactor Interrupt Failure Diagnostic When Powering Up The Ucp

    5 Check CT connections to the Starter module. Problem 70: Stepper motor is humming. Corrective Action: While in the hold mode, the stepper motor is driven with 1.0 amps. This is the case even if the actuator is fully closed. The humming is normal. CVHE-SB-32A...

  • Page 33: Problem 71: Extended Surge

    5 Check for 120 VAC on the Starter module J4-1 and 2. J4 is an OPTO input circuit that recognizes transition complete. If there is no signal on J4, the unit will not transition. 6 Replace bad Starter module. CVHE-SB-32A...

  • Page 34: Problem 75: Tracer Diagnostics E.g.,Tracer Loss Of Comm With Options, Starter, Etc. As Well As Other Tracer Related Diagnostics

    ~ Check y-strainer. ~ Check wiring. ~ Check coefficients in the service settings menu. ~ For an open system, follow special procedures in Trane CVHE-CSB-45B Problem 77: Unknown diagnostics 1217 informational warning. Corrective action: 1 You have a newer Chiller and Starter module and an OLD clear language display (CLD).

  • Page 35: Cvhe/F/G Trim Balance Procedure

    CVHE/F/G Trim Balance Procedure This procedure outlines the modifications necessary to the Starter module to allow operation of the motor in the Wye configuration during test runs. 1 Unplug the connector from J10 to prevent the run contactor from coming in.

  • Page 36: Sensor And Transducer Operating Ranges

    Sensor And Transducer Operating Ranges Temperature range on sensors: 140°F to 212°F ± 2.5°F Transducer range: 0 to 35 psig. CVHE-SB-32A...

  • Page 37: Temporary Forced Unload Setup

    4 Provide a binary switch to enable/disable the input to J7. 5 With the binary switch closed the unit will operate with a 100% current limit. 6 With the binary switch open the unit will operate with a 40% current limit. CVHE-SB-32A...

  • Page 38: Communications Test

    The counters are reset to 0 every 15 seconds. Hitting any key while on this screen will cause an exit. Packet #: 2 3 4 5 6 7 8 9 10 11 12 14 15 Received: x x x x x x x x x x x x x x x CVHE-SB-32A...

  • Page 39: Troubleshooting Ipc Communication Diagnostics

    1 Make sure the wiring to the stepper motor is correct. If the wiring is not correct it will destroy the power supply on the module, and a loss of comm with Stepper will result. The Correct stepper wiring follows: CVHE-SB-32A...

  • Page 40: Heat Sink Temperature

    1.8°F (1°C) below the Start Inhibit Temperature, at which time the unit will complete the pre-start procedures and start, or there is no longer a call for cooling. The heat sink temperature sensor connects to Starter module terminals J7-1 and J7-2. CVHE-SB-32A...

  • Page 41: Module Compatibility

    13650460-02 or greater is required. 5 To read evaporator approach temperature, you need a CLD of X-13650448-04 and later along with a Chiller module of X-13650450-04 and later. 6 See Trane service bulletins CVHE-SB-90 and 91 for additional module compatibility information. CVHE-SB-32A...

  • Page 42: Description Of Ucp2 Options

    5. Printer Interface Module This option must be ordered if the UCP2 is to have a direct connect serial printer. The printer and cable must be ordered separately. This option includes ASHRAE Guideline 3 Report. CVHE-SB-32A...

  • Page 43: Chilled Water Reset Outdoor Air Temperatures

    12. Starter By Others When the starter is being furnished by others, Trane furnishes the Starter module in the UCP2, and other wiring/components as needed. The starter must be built per Trane starter specifications.

  • Page 44: Ucp2 Modules

    Outdoor Ambient Temp Ext. Base Load Comp. Run Relay Mach. Man. Alarm Relay Ext. Base Load Setpt Limit Warning Relay Mach. Auto Alarm Reset Evap. EWP and LWP (Optional) Chilled Water Flow Switch Cond. EWP and LWP Cond. Water Flow Switch CVHE-SB-32A...

  • Page 45: Circuit Module

    Motor Wind Temp 2 Motor Wind Temp 3 Oil Temp Refgt Monitor Condenser Pressure Vent Line Solenoid Oil Tank Heater Cond. Refgt. Press. Oil Pump Motor Refgt Pump Relay Oil Sump Pressure Cond. High Press. Switch Oil Sump Disch. Pressure CVHE-SB-32A...

  • Page 46: Lnput/Output Module

    Module Provided only when chiller is equipped with Hot Gas Bypass (HGBP) option. The I/O module (1U10) operates the Hot Gas Bypass valve on CVHE and CVHF units in response to signals from stepper module 1U3. The module also receives input on HGBP valve position from the HGBP valve end switch.

  • Page 47: Options Module

    Ice Making Relay Ice Machine Control FC Actuators Closed Evap. Diff. Water Press Head Relief Request Relay Max. Capacity Relay FC Actuator Relay #1 %RLA-Comp. Tracer Controlled Relay Tracer Temp. Sensor FC Aux. Relay FC Actuator Relay Cond. Diff. Water Press CVHE-SB-32A...

  • Page 48: Purge Module

    Purge Module The purge module (3U1) is provided with the Trane Purifier Purge on CVHE and CVHF chillers. It is located in the purge control panel at the purge. It provides all inputs and outputs for the UCP2 to control purge operation.

  • Page 49: Starter Module Values

    The starter module (2U1) is present in all Trane-provided starter panels, whether unit-mounted or remote. For CTVs, if no Trane starter is provided and the customer is providing the starter, 2U1 is mounted in an extension of the unit control panel. It is still designated as 2U1.

  • Page 50: Stepper Module

    Stepper Module IP Communications 24 VAC Inputs Sat. Evap. Refgt. Temp. (Optional) Discharge Temp. (Optional) Bearing Temp. 1 (Optional) Bearing Temp. 2 Outputs Inlet Guide Vane Actuator Binary Position Actuator (BPI) Stepper Motor Vane Actuator Sat. Cond. Refgt. Temp. CVHE-SB-32A...

  • Page 51: Duplex Module

    Duplex Module The Duplex Chiller control is accomplished by the Duplex Control Module (DCM). The DCM is a Trane Communications Interface (TCI) based module. Its two main tasks are setpoint control and compressor staging/control The DCM will actually control two separate UCP2 panels (“Panel A” and “Panel B”). These panels are for the most part identical and know nothing of each other.

  • Page 52: Module Dip Switch Settings

    ON (SW2-2 and SW2-3 are not used) Options Module Switch 0-10V 4-20mA External Current Limit SW2-1 ON (SW2-2 and SW2-3 are not used) External Chilled Water SW3-1 ON (SW3-2 and SW3-3 are not used) Tracer COM 3 Switch Tracer COM 4 Switch IPC Buffer Switch CVHE-SB-32A...

  • Page 53: Duplex Control Module (Dcm)

    Switch 1 odd parity even parity Parity Switch 2 No parity With parity Data Bits Switch 3 8 bits 7 bits Handshaking Switch 4 Ready/Busy X-on/X-off Test Select Switch 5 Circuit Monitor Mode Select Switch 6 Print mode Test mode CVHE-SB-32A...
  • Page 54 DSR Input Signal Switch 4 Active Inactive Buffer Switch 5 32 bytes 256 bytes Busy Signal Timing Switch 6 200 ms 1 second DTR Signal Switch 7 After power on Printer selected Not Used Switch 8 CVHE-SB-32A...

  • Page 55: Diagnosing A Non-Working Stepper Module

    Section III to check motor and wiring resistances. 2 If the UCP2 Control Panel is powered, measure and compare the Power Input (J2) and the 4 Table 5 Test Points at the right side of the Stepper board with CVHE-SB-32A...
  • Page 56 Seal wire or run new TP1-TP4 on Stepper together inside wire through conduit. module conduit between See Table 4 for wiring Stepper module and diagram. Motor winding actuator motor. resistance check pin to pin fails. Motor does not move. CVHE-SB-32A...

  • Page 57: Ii. Check Stepper Motor And Wiring For Shorts And Opens

    Stepper module and the motor or the in motor winding. Note that nominal values are not including wire resistances. Table 7 6 If the resistance is higher than the limits in the wiring between the Stepper module and the motor or a winding is open. Note that nominal values are not including wire resistances. CVHE-SB-32A...
  • Page 58 B. If you need to disconnect the wires going to the motor for any reason, is a wiring table you can use to reconnect them. Table 8 Stepper Motor Connections JB or J8 Connector Pin# on Motor Winding Output Signal Stepper Motor Terminal Stepper Name Connection CVHE-SB-32A...

  • Page 59: Iv. Motor Voltages For Ctv Stepper Motor

    J6 - (4 to (11.4 - 17.3) (9.1 -10.1) conduit) J6 - (4 to (11.4 - 17.3) (9.1 -10.1) conduit) J6 - (4 to (11.4 - 17.3) (9.1 -10.1) conduit) J6 - (4 to (11.4 - 17.3) (9.1 -10.1) conduit) CVHE-SB-32A...

  • Page 60: Procedures For Module Set-Up

    % RLA Output Options module J7-3,-4 -2-10 VDC As an option, the UCM shall provide a 0-10 VDC analog output to indicate % RLA. The transfer function shall be 2 to 10 VDC corresponding to 0 to 120% RLA. CVHE-SB-32A...

  • Page 61: External Chilled Water Setpoint

    °F=4.0625(mA)-16.25 The following graph shows External Chilled Water Setpoint with a 4-20 mA input: External Chilled Water Setpoint with (ma) Input 70.00 60.00 50.00 Degrees F 40.00 30.00 Degrees F 20.00 Degrees C 10.00 Degrees C 0.00 -10.00 -20.00 CVHE-SB-32A...

  • Page 62: External Auto-Stop

    The Auto-Stop input allows the operator to use a remote signal, such as a time clock or a generic BAS, to signal the start of the chiller. Disabling the chiller through this input will not result in a diagnostic since it is an expected routine shutdown. CVHE-SB-32A...
  • Page 63 STOP. The input is closed for external AUTO operation and open to put the unit in external STOP. The external stop is a friendly shutdown, i.e. the chiller will unload before the stop command is given. The External Auto-Stop input is located on Chiller module terminals J5-1 and J5-2. CVHE-SB-32A...

  • Page 64: Analog Input Table Abbreviations

    Minimum and Maximum DC Voltage measure at the appropriate module terminal. Table 11 Pressure vs Voltage for Oil Pressures Differential Voltage Oil Pressure (PSIG) -0.0017 0.0000 0.0017 0.0033 0.0050 0.0067 0.0083 0.0100 0.0117 0.0093 0.0110 0.0127 0.0103 0.0120 0.0137 0.0113 0.0130 0.0147 0.0122 0.0140 0.0158 CVHE-SB-32A...
  • Page 65 0.0303 0.0330 0.0357 0.0313 0.340 0.0367 0.0322 0.0350 0.0378 0.0369 0.0400 0.0431 0.0417 0.0450 0.0483 0.0464 0.0500 0.0536 Table 12 Voltages and Resistances of Oil Pressure Input Terminals +5V to GND 4.75 5.25 V- to GND V+ to GND CVHE-SB-32A...

  • Page 66: Pressure Vs Voltage For Water Pressures

    0.0277 0.0027 0.0280 0.0030 0.0283 0.0033 0.0287 0.0037 0.0290 0.0040 0.0293 0.0043 0.0297 0.0047 0.0300 0.0050 0.0303 0.0053 0.0307 0.0057 0.0310 0.0060 0.0313 0.0063 0.0317 0.0067 0.0320 0.0070 0.0323 0.0073 0.0327 0.0077 0.0330 0.0080 0.0333 0.0083 0.0337 0.0087 0.0340 CVHE-SB-32A...
  • Page 67 0.0390 0.0140 0.0393 0.0143 0.0397 0.0147 0.0400 0.0150 0.0403 0.0153 0.0407 0.0157 0.0410 0.0160 0.0413 0.0163 0.0417 0.0167 0.0420 0.0170 0.0423 0.0173 0.0427 0.0177 0.0430 0.0180 0.0433 0.0183 0.0437 0.0187 0.0440 0.0190 0.0443 0.0193 0.0447 0.0197 0.0450 0.0200 0.0453 CVHE-SB-32A...
  • Page 68 0.0223 0.0477 0.0227 0.0480 0.0230 0.0483 0.0233 0.0487 0.0237 0.0490 0.0240 0.0493 0.0243 0.0497 0.0247 0.0500 0.0250 Voltages and Resistances of Pressure Input Terminals +5V to GND 4.75 5.25 V- to GND V+ to GND Water Pressure Rout 1.2K CVHE-SB-32A...

  • Page 69: Purge Compressor Suction Temp

    Thermistor Accuracy Type U Thermistor Temperature Versus Resistance and Terminal Voltage Table for a pullup resistor of 24900 Ohms. Used to sense temperatures at the following point: 1. Purge Compressor Suction Temp. CVHE/F/G Temp ° ° F Min Res Max Res...
  • Page 70 Type U Thermistor Temperature Versus Resistance and Terminal Voltage Table for a pullup resistor of 24900 Ohms. Used to sense temperatures at the following point: 1. Evap. Entering and Leaving Water Temp. Pair CVHE/F/G Table 15 Temp ° ° F...
  • Page 71 20203 20794 2.227 2.270 50.0 19668 20242 2.194 2.237 55.0 17225 17718 2.033 2.075 60.0 15120 15546 1.879 1.919 65.0 13303 13670 1.731 1.770 70.0 11729 12048 1.592 1.629 75.0 10364 10641 1.462 1.496 80.0 9177 9418 1.339 1.372 CVHE-SB-32A...
  • Page 72 Thermistor Accuracy = 0.54° ° F from 15 to 140° ° F Type U Thermistor Temperature Versus Resistance and Terminal Voltage Table for a pullup resistor of 6980 Ohms. Saturated Cond. Refrigerant Temp CVHE/F/G Table 16 Temp ° ° F...
  • Page 73 4921 5039 2.051 2.089 109.0 4709 4821 1.999 2.036 111.0 4507 4614 1.946 1.983 113.0 4315 4417 1.895 1.931 115.0 4133 4230 1.845 1.880 117.0 3959 4051 1.795 1.830 119.0 3794 3882 1.747 1.781 121.0 3636 3720 1.699 1.733 CVHE-SB-32A...
  • Page 74 Table 16 (Continued) Temp ° ° F Min Res Max Res Min Vterm Max Vterm 123.0 3487 3566 1.653 1.686 CVHE-SB-32A...
  • Page 75 Type U Thermistor Temperature Versus Resistance and Terminal Voltage Table for a pullup resistor of 6980 Ohms. Used to sense temperatures at the following points: 1. Bearing #1 Temp CVHE/F/G (Journal Bearing) 2. Bearing #2 Temp CVHE/F/G (Thrust Bearing) 3. Oil Temp CVHE/F/G 4.
  • Page 76 2772 2853 1.411 1.447 135.0 2716 2796 1.391 1.426 136.0 2662 2740 1.371 1.406 137.0 2610 2685 1.351 1.385 138.0 2558 2632 1.331 1.365 139.0 2508 2580 1.312 1.346 140.0 2458 2529 1.293 1.326 141.0 2410 2479 1.274 1.307 CVHE-SB-32A...

  • Page 77: Bearing Temp., Oil Temp. And Compressor Discharge Temp

    0.699 0.718 183.0 1102 1130 0.678 0.697 185.0 1064 1091 0.658 0.676 187.0 1027 1053 0.638 0.656 189.0 1017 0.619 0.636 191.0 0.601 0.617 193.0 9.583 0.599 195.0 0.565 0.581 197.0 0.549 0.564 199.0 0.532 0.547 201.0 0.517 0.531 CVHE-SB-32A...
  • Page 78 Type U Thermistor Temperature Versus Resistance and Terminal Voltage Table for a pullup resistor of 6980 Ohms. Used to sense temperatures at the following point: 1. Auxiliary HR Entering and Leaving Water Temp. Pair CVHE/F 2. Condenser Ent. and Leaving Water Temp. Pair CVHE/F Table 19...
  • Page 79 4315 4417 1.895 1.931 114.0 4223 4322 1.870 1.906 115.0 4133 4230 1.845 1.880 116.0 4045 4139 1.820 1.855 117.0 3959 4051 1.795 1.830 118.0 3876 3965 1.771 1.806 119.0 3794 3882 1.747 1.781 120.0 3714 3800 1.723 1.757 CVHE-SB-32A...
  • Page 80 2839 2901 1.434 1.464 134.0 2782 2843 1.414 1.444 135.0 2726 2786 1.393 1.423 136.0 2672 2730 1.373 1.403 137.0 2619 2676 1.354 1.383 138.0 2567 2623 1.334 1.334 139.0 2517 2571 1.315 1.315 140.0 2467 2520 1.296 1.296 CVHE-SB-32A...
  • Page 81 Thermistor Accuracy = 1.80° ° F from 70 to 150° ° F Type U Thermistor Temperature Versus Resistance and Terminal Voltage Table for a pullup resistor of 6980 Ohms. Used to sense temperatures at the following point: 1. Outdoor Air Temp. CVHE/F/G Table 20 Temp ° ° F Min Res...
  • Page 82 4022 4340 1.816 1.909 120.0 3616 3897 1.696 1.784 125.0 3259 3506 1.581 1.665 130.0 2941 3161 1.473 1.552 135.0 2658 2854 1.371 1.446 140.0 2406 2581 1.274 1.345 145.0 2181 2337 1.184 1.250 150.0 1980 2120 1.099 1.161 CVHE-SB-32A...
  • Page 83 A4 Analog Input Type U Thermistor Temperature Versus Resistance and Terminal Voltage Table for a pullup resistor of 38300 Ohms. Used to sense temperatures at the following point: 1. Saturated Evap. Refrigerant Temp. CVHE/F/G Table 21 Temp ° ° F Min Res...
  • Page 84 7903 8592 0.853 0.915 90.0 7029 7632 0.773 0.830 95.0 6264 6792 0.701 0.753 100.0 5592 6056 0.635 0.682 105.0 5002 5410 0.576 0.619 110.0 4482 4841 0.523 0.561 115.0 4022 4340 0.474 0.509 120.0 3616 3897 0.430 0.462 CVHE-SB-32A...
  • Page 85 Motor Winding RTD Temperature Versus Resistance and Terminal Voltage Table for a pullup resistor of 1000 Ohms. Used to sense temperatures at the following point: 1. Compressor Motor Winding Temp. #1- CVHE/F/G 2. Compressor Motor Winding Temp. #2 CVHE/F/G Table 22 Temp °...
  • Page 86 210.0 102.3333 0.4672 215.0 103.4280 0.4717 220.0 104.5281 0.4762 225.0 105.6336 0.4807 230.0 106.7444 0.4852 235.0 107.8604 0.4898 240.0 108.9817 0.4944 245.0 110.1082 0.4989 250.0 111.2398 0.5035 255.0 112.3765 0.5081 260.0 113.5182 0.5127 265.0 114.6648 0.5173 270.0 115.8164 0.5220 CVHE-SB-32A...

  • Page 87: Information On The Oil Pressure Sensor Calibration Diagnostic

    The change was implemented to avoid nuisance pressure fluctuations caused by the start of evaporator water flow and the guide vanes bpi search. Suspend calling out the oil pressure sensor calibration diagnostic until evaporator water has been flowing for a minimum of 5 minutes. CVHE-SB-32A...

  • Page 88: Transducer Checkout Procedure

    Allow transducer to stabilize under power (approximately 15 - 30 seconds). Readings: 1 Transducer used for Condenser Pressure, Oil Discharge Pressure and Oil Sump. Trane Part Number TDR0272. A good Transducer reading is: 15 mV ± 1mV 2 Evaporator and Condenser Water Flow Transducer and Part Number TDR0274 A good Transducer reading is: 0 mV ±...
  • Page 89 MMR diagnostic is generated. Closed Start Open Closed Open Stop Closed Open Closed Short Open Closed Transition Open Closed Transition Complete Open Input Maximum Phase Current < or = to 85 % RLA CVHE-SB-32A...

  • Page 90: Starter Contactor Sequence

    M. (Wait to look for Transition complete) N. (Filtering time msec 2.32 to 2.38sec on Transition complete input) N. (Filtering time on Transition complete input) msec 160 to 240 sec Note: The transition complete contact closure is expected to be an auxiliary contact to the “Run Contactor’ (2K2). CVHE-SB-32A...

  • Page 91: Current Input Transfer Function

    4.62 1.67 4.75 1.81 4.88 1.95 5.02 2.09 5.15 2.23 5.41 2.36 5.67 2.50 5.94 2.63 6.20 2.77 6.46 2.90 6.72 3.03 6.99 3.17 7.25 3.30 7.51 3.43 7.77 3.57 8.03 3.70 8.29 3.83 8.56 3.96 8.82 4.10 9.08 CVHE-SB-32A...

  • Page 92: Starter Module Ct Voltage And Currents

    936 amps. The first-stage CT part numbers are in the X-13580047 and X- 13580048 families. The second stage is a custom current transformer (X-13580266-01) which has a transformation ratio of 3.6A:0.1A. The secondary of this transformer is then applied to the Starter module. Trane Part Number Resistance in Ohms X-13580266-01 Primary: 0.020 Secondary: 5.5...

  • Page 93: From Ucp2 Initial Release (July 93) To 10/21/96 Software Release

    2.0 VDC. For an out of range high on the sensor, the output will be limited to 10.0 VDC. When a Condenser Pressure Sensor is Used (Optional): If the Condenser Pressure sensor goes out of range, like due to an open or short, a pressure sensor diagnostic will be called CVHE-SB-32A...

  • Page 94: Troubleshooting The Percent Condenser Output

    If the saturated condenser temperature is used to determine condenser pressure, it takes about 11.5 seconds for UCP2’s % condenser pressure output to respond to a step change in saturated condenser temperature. The Percent Condenser Pressure output can source a maximum of 30mA of current. CVHE-SB-32A...
  • Page 95 The following equations are what UCP2 uses: Voltage Signal Current Signal As generated from external source VDC=.10*(%)-2.0 mA=.20(%)-4.0 As processed by UCP2 %=10.0*(VDC)+20.0 %=5.0(mA)+20.0 The following graph shows External Current Limit Setpoint with a 2-10 VDC input: % RLA Volts DC CVHE-SB-32A...

  • Page 96: External Current Limit Setpoint

    2-1 should be in the off position. To use a 4-20 mA signal, switch 2-1 should be in the on position. The user must also specify the type of External Setpoint Input (4-20 mA or 2-10 VDC) in the machine configuration menu. CVHE-SB-32A...

  • Page 97: Percent Rla Output

    The following graph illustrates the output: The % RLA output is found on the Options module terminals J7-3 and J7-4. The % RLA output is polarity sensitive. J7-3 is + J7-4 is - The % RLA output’s maximum source capability is 30mA. CVHE-SB-32A...

  • Page 98: Current Overload Protection

    Overcurrent protection is based on the phase with the highest current. It will trigger a manually resettable diagnostic shutting down the compressor when the current exceeds the time-trip curve. The compressor overload is based on unit RLA. The time-trip curve follows: Figure 10 Overload Trip Time vs % RLA %RLA CVHE-SB-32A...
  • Page 99 The Low Refrigerant Temperature Cutout setpoint is found in the Field Startup menu. Design: Lowest standard chilled water setpoint (CWS) = 37°F Lowest standard low refrig. temp. cutout (LRTC) = 28.5°F Lowest standard refrig. temp. limit setpoint (LRTLS) (28.5 + 2) = 30.5°F Minimum differential between LRTC and CWS = 6.0°F CVHE-SB-32A...

  • Page 100: Evaporator Refrigerant Temperature Limit

    Where ERR2 = CPLS(% HPC) - actual pressure (% HPC) Figure 11 Condenser Pressure Limit Control Regions for an Arbitrary Setpoint Forced Limit Unload Limit Hold Loading 1250 (#steps) 100.0*(Err2 - 4.0) ERR2 = Pressure Error % 375.0*Err2 CPLS CVHE-SB-32A...

  • Page 101: Condenser Refrigerant Pressure Limit

    It is recommended that an adjustable off-delay relay be used to provide some control adjustment. It is not recommended that a tower fan be turned on and off solely based on the condenser limit mode; excessive cycling may result. CVHE-SB-32A...
  • Page 102 FC valve limit switches close, the FC mode shall be terminated. 4 FC cannot be entered if the chiller is in STOP; FC can only be entered from AUTO. Either setting the FP CLD to FC On or closing the Ext FC Switch binary input, or receiving a CVHE-SB-32A...

  • Page 103: Free Cooling Relay Checkout

    MMR diagnostic will be generated. The IGVs must be held closed for 3 minutes on each startup following a free cooling mode. 7 On FC units the failure of communications between the Options module and the Chiller module will cause a MMR diagnostic at the Chiller module. CVHE-SB-32A...
  • Page 104 By adding HGBP a portion of this gas comes directly from the condenser, thus reducing the amount of cooling done by the chiller. For CVHE/F/G/B Chillers: See also High Compressor Discharge Temperature Protection. In the Machine Configuration menu, UCP2 has an entry to indicate that hot gas bypass is installed.

  • Page 105: Hot Gas Bypass

    To enable the HGBP control algorithm enter the Field Start-up Group. 2 Enable Hot Gas Bypass Control. In addition, this group also has three user adjustable setpoints associated with the HGBP control option. The three setpoints are: CVHE-SB-32A...

  • Page 106: Guide Vane Closed Travel Stop

    CWS. If the ELWT exceeds the CWS by 0.5°F, the staging integral begins to integrate. Once the staging integral reaches a preset number, capacity control transitions back to the inlet guide vanes. CVHE-SB-32A...

  • Page 107: Hgbp Mode, Igv Target

    ICE-BUILDING; that is, the IGVs or Slide Valve will be fully loaded/ stroked/extended during ICE BUILDING. ICE-BUILDING and ICE-BUILDING COMPLETE are modes displayed by the UCM at the front panel and communicated to the Tracer. CVHE-SB-32A...

  • Page 108: Ice Machine Control

    Ice Building will only be permitted when both the unit is in Auto and the last mode of operation has been normal (non-ice building) AUTO (either running or not running). See the following table: Unit Status Ext Ice Input Entr Evap Chiller Mode 0 = Stop Temp 1 = Auto Compared to Ice-ter Setpt CVHE-SB-32A...
  • Page 109 Said another way, the ice building relay is on whenever there is a Ice Building command (External or Remote Communicated (Tracer)) but we are not in the Ice Building Complete mode. CVHE-SB-32A...
  • Page 110 Recommended Wire Lengths for PTs The maximum recommended wire length for PTs in a single PT system: Wire Gauge Max lead length(ft) Max lead length (m) 5339 1627 4234 1291 3357 1023 2663 2112 1674 1328 1053 CVHE-SB-32A...

  • Page 111: Recommended Wire Lengths For Pts

    Secondary (m) 3061 2428 1924 1526 1211 Note: These wire lengths are for copper conductors only Note: The above lengths are maximum round trip wire lengths. The maximum distance the PT can be located is 1/2 of the listed value. CVHE-SB-32A...

  • Page 112: Checking For An Open, Burnt, Or Shorted Centravac Motor Winding

    * The rated motor voltage multiplied by 1,000 is the minimum resistance that you should measure here. The actual resistance that you measure will probably be higher. For High Voltage Machines (4160 V and higher): Consult Trane Technical Service for this information.

  • Page 113: Leds

    Confirm that all of UCP2 modules are equal to or greater than the revision levels listed below. Module Module Hardware Software CTV Chiller X-13650450-02 Circuit X-13650451-04 CTV Stepper X-13650455-03 LCLD X-13650448-02 TCI Com 4 X-13650457-03 Baud 9600 TCI Com 3 X-13650460-02 Baud 1200 Options X-13650452-02 CVHE-SB-32A...

  • Page 114: Ucp2 Clock

    February 5th, 2116. No date problems will occur in this range, including the year 2000. There will be no operating effect for UCP2 going to the year 2000. 90 percent of all Trane centrifugal chillers installed in 1938 were still running in 1994. However, it is unlikely that a chiller installed in 1996 will run twice that amount of time and make it until 2116.
  • Page 115 The maximum reset's are with respect to the chilled water setpoint. The equations for each type of reset are: Return CWS' = CWS + RATIO (START RESET - (TWE - TWL)) and CWS' > or = CWS and CWS' - CWS < or = Maximum Reset CVHE-SB-32A...

  • Page 116: Chilled Water Reset

    The values for “START RESET” for each of the reset types are: Start Reset Increment Increment (SI Factory Default Reset Type Range (English Units) Units) Value 4 to 30°F 1°F 0.1°C 10°F (5.6°C) Return (2.2 to 16.7°C) 50 to 130°F 1°F 0.1°C 90°F (32.2°C) Outdoor (10 to 54.4°C) CVHE-SB-32A...
  • Page 117 CWS is reset immediately (within one minute) for Return Reset and at a rate of 1°F every 5 minutes for Outdoor Reset. The chiller will start at the Differential to Start value above a fully reset CWS or CWS' for both Return and Outdoor Reset. CVHE-SB-32A...
  • Page 118 The Reset Ratio on the CLD is displayed as a percentage. To use it in the above equation it must be converted to it’s decimal form. Reset Ratio percent /100 = Reset Ratio decimal Example of converting Reset Ratio: If the Reset Ratio displayed on the CLD is 50% then use (50/100)=.5 in the equation CVHE-SB-32A...

  • Page 119: Using The Equation For Calculating Cwr For Outdoor Air Temp

    Start Reset = 90 TOD = 100 Maximum Reset = 17 How many Degrees of Reset will there be? Degrees of Reset = Reset Ratio* (Start Reset - TOD) Degrees of Reset = -.7*(90-100) Degrees of Reset = 7 CVHE-SB-32A...
  • Page 120 The following graph shows the reset function for Return CWR: Reset Ratio 30 deg Start Reset Return CWR 20 deg Start Reset +100 _______________________ 10 deg Start Reset 12.6 11.2 TWE-TWL Note: This graph assumes Maximum Reset is set to 20 degrees. CVHE-SB-32A...
  • Page 121 Reset Ratio = 70% Start Reset = 20 TWE = 60 TWL = 53 Maximum Reset = 14 How many Degrees of Reset will there be? Degrees of Reset = Reset Ratio* (Start Reset - (TWE-TWL)) Degrees of Reset =.7*(20-(60-53)) CVHE-SB-32A...
  • Page 122 50 % RR SR = 25 SR = 20 (TWE-TWL) The following graph illustrates the Reset Actions of the above examples: Note: This graph assumes a Design Delta Temp of 10 degrees. Constant CWR 10 Degree Design Delta Temp TWE-TWL CVHE-SB-32A...

  • Page 123: Information On The Printer Option

    X-ON X-OFF handshaking is enabled. The Red LED labeled TXB will blink constantly while the printer is printing. The DIP switch settings for the Printer module follow: 1-off 2-off 3-on Dip switch settings for the Okidata Microline 184 turbo printer follow: CVHE-SB-32A...
  • Page 124 Switch 4 Ready/Busy X-on/X-off Test Select Switch 5 Circuit Monitor Mode Select Switch 6 Print mode Test mode Busy Line Selection Switches 7,8 SSD-Pin 11 off, on SSD+ Pin 11 off,off DTR- Pin20 on, on RTS- Pin 4 on, off CVHE-SB-32A...
  • Page 125 DSR Input Signal Switch 4 Active Inactive Buffer Switch 5 32 bytes 256 bytes Busy Signal Timing Switch 6 200 ms 1 second DTR Signal Switch 7 After power on Printer selected Not Used Switch 8 CVHE-SB-32A...
  • Page 126 Condenser refrigerant pressure limit Guide vane stepper motor Condenser water flow Constant return reset Handshaking Control circuit Head relief Control Panel Heat recovery module description 4 35, 44 Heat sink 34, 44 Control panel Heat sink temperature layout 4 CVHE-SB-32A...
  • Page 127 Power loss Memory error Pressure transducers 14, 16, 23, 27, 39, 84, 98, 103 25, 37, 48, 118 Printer 8, 37 Module compatibility Printer interface module 108, 118 Module setpoints Printer module 8, 25, 118 Module set-up Printer option CVHE-SB-32A...
  • Page 128 Trane service bulletin CVHE-CSB-35 Service settings group Trane service bulletin CVHE-CSB-45B 26, 29, 48 Service settings menu Trane service bulletin CVHE-SB- 91 Service test manual mode Trane service bulletin CVHE-SB-90 12, 18, 30 Service test menu Trane service manual CVHE-CSB-31...

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