'r u h e

A/R CONDITIONING

°1S07

SERVICE GUIDE
HERMETIC CENTRAVAC®
VOLUME 2, CVHE

COMMERCIAL AIR CONDITIONING DIVISION

 01607

TABLE OF CONTENTS CONFIDENTIAL1

HERMETIC CENTRAVAC SERVICE GUIDE uCe s tric t^
VOLUME 2 - CVHE
FOREWORD Page 1

GENERAL INFORMATION
Section 1.0 (General Information) Pages 1.0-1 through 1.0-3
Section 1.1 (Precautionary Safety Information) Pages 1.1-1 and 1.1-2

OPERATION
Section 2.0 (Operation) Pages 2.0-1 through 2.0-15

INSTALLATION
Section 3.0 (Installation including CVHE-IN-1, CVHE-IN-2)

START-UP
Section 4.0 (Start-Up) Pages 4.0-1 through 4.0-8

MAINTENANCE
Section 5.0 (Periodic Maintenance) Pages 5.0-1 through 5.0-4
Section 5.1 (Maintenance Procedures) Pages 5.1-1 through 5.1-5
Section 5.2 (Purge Drum Clean-Up) Pages 5.2-1 through 5.2-3

TROUBLE ANALYSIS
Section 6.0 (Trouble Analysis Chart) Page 6.0-1
Section 6.1 (Chiller Starting Problems) Pages 6.1-1 and 6.1-2
Section 6.2 (Oil Pump Starting Problems) Pages 6.2-1 and 6.2-2
Section 6.3 (Starter Will Not Pull In) Page 6.3-1
Section 6.4 (Starter Will Not Transition) Pages 6.4-1 and 6.4-2
Section 6.5 (Fault Indicators On Starter Panel Trip) Pages 6.5-1 and 6.5-2
Section 6.6 (Control Panel Safety Indicators Trip) Pages 6.6-1 through 6.6-3
Section 6.7 (Purge System Trouble Analysis) Pages 6.7-1 through 6.7-3
Section 6.8 (Chiller W ater Control Trouble Analysis) Pages 6.8-1 and 6.8-2
Section 6.9 (Load Limit Trouble Analysis) Page 6.9-1
Section 6.10 (Chiller Will Not Load) Pages 6.10-1 and 6.10-2
Section 6.11 (Condenser Trouble Analysis) Pages 6.11-1 through 6.11-5
Section 6.12 (Evaporator Trouble Analysis) Pages 6.12-1 through 6.12-5
Section 6.13 (Compressor Trouble Analysis) Pages 6.13-1 through 6.13-4
Section 6.14 (Compressor Motor Trouble Analysis) Pages 6.14-1 through 6.14-5
Section 6.15 (Lubrication System Trouble Analysis) Pages 6.15-1 through 6.15-4
Section 6.16 (Open Rotor Trouble Analysis) Page 6.16-1
Section 6.17 (Water Leak Diagnosis) Pages 6.17-1 through 6.17-6

CONTROLS
Section 7.0 (Control Panel) Pages 7.0-1 through 7.0-4
Section 7.1 (Fuses) Page 7.1-1
Section 7.2 (High Condenser Pressure Control) Pages 7.2-1 and 7.2-2
Section 7.3 (Low Refrigerant Temperature Control) Page 7.3-1
Section 7.4 (Chilled Water Demand Control) Page 7.4-1
Section 7.5 (Anti-Recycle Timer) Page 7.5-1
Section 7.6 (Oil Pressure Control) Page 7.6-1 and 7.6-2
Section 7.7 (Oil Pump Timer) Page 7.7-1
Section 7.8 (Oil Temperature Control) Page 7.8-1
Section 7.9 (Off-Auto Switch) Page 7.9-1
Section 7.10 (Purge Unit High Pressure Control) Page 7.10-1
Section 7.11 (Purge Oil Separator Heater Control) Page 7.11-1
Section 7.12 (Capacity Control Module) Pages 7.12-1 through 7.12-9

1
 COKFIDETITIAIi'_
Use R e ; t,ricked
^ C o u r o O iid e r

Section 7.13 (Motor Protection Module) Pages 7.13-1 through 7.13-4

Section 7.14 (Factory Mounted Starter Panel) Pages 7.14-1 through 7.14-5
Section 7.15 (Electronic Motor Protection Module) Pages 7.15-1 through 7.15-7
Section 7.16 (Starter Circuit Breaker/Main Disconnect) Pages 7.16-1 through 7.16-3
Section 7.17 (Pilot Relays) Page 7.17-1
Section 7.18 (Starter Contactors) Pages 7.18-1 through 7.18-4
Section 7.19 (Transition Resistors) Page 7.19-1
Section 7.20 (Control Power Transformer) Page 7.20-1
Section 7.21 (Ground Fault Transformer) Page 7.21-1

REPAIR, REPLACEMENT, OVERHAUL

Section 8.0 (Oil Filter Replacement) Page 8.0-1
Section 8.1 (Oil Pump and Pump Motor Replacement) Pages 8.1-1 through 8.1-4
Section 8.2 (Compressor Disassembly) Pages 8.2-1 through 8.2-17
Section 8.3 (Compressor Reassembly) Pages 8.3-1 through 8.3-17
Section 8.4 (Compressor Motor Removal and Replacement) Pages 8.4-1 through 8.4-5
Section 8.5 (Compressor Motor Disassembly and Reassembly) Pages 8.5-1 through 8.5-26
Section 8.6 (Oil Pressure Regulator Repair) Pages 8.6-1 through 8.6-3
Section 8.7 (Economizer Removal) Pages 8.7-1 through 8.7-3

SPECIFICATIONS
Section 9.0 (Specifications) Pages 9.0-1 through 9.0-4
Section 9.1 (Model CVHE Tool Requirements) Pages 9.1-1 through 9.1-4

SERVICE BULLETINS
Section 10.0 (Recommended Service Bulletins) Page 10.0-1

2
 COTTFIDEITTI AL’_
Use R estricted
by Court Order

FOREWORD

This is the Trane Model CVHE Hermetic, Three-stage CenTraVac Service Guide. It is designed to be the reference book for ser­
vicing the Model CVHE Hermetic CenTraVac. This Service Guide describes and explains all phases of operation, installation,
maintenance, overhaul and trouble analysis.

The CVHE Service Guide is written for service personnel to aid them in providing the best possible service on this product.
 LITERATURE FILE NO. HCTV-SG-2

GENERAL SECTION
INFORMATION 1.0
FEBRUARY 1982
The Model CVHE CenTraVac is a hermetic centrifugal water crease in efficiency of the CenTraVac. The concept and oper­
chiller. It is equipped with a three stage compressor, an evapo­ ation of the economizer is discussed further in Section 2.0,
rator, water cooled condenser, economizer and an electronic "Operation.”
control panel. Cooling capacity of the product line ranges from
Heat removed from the cooling load and the heat of compression
140 through 1250 tons of refrigeration. Figures 1 and 2 illustrate
are rejected through the condenser which is of shell and tube de­
the chiller and point out the various components.
sign. Like the evaporator, water is circulated internally, through
The compressor incorporates three stages of compression utiliz­ the tubes. All system heat is transferred from the refrigerant,
ing R-11 refrigerant. The three impellers are directly driven by a through the tubes and to the water which is then pumped to a
hermetic, 2-pole, low slip, 3600 R.P.M. alternating current in­ cooling tower The use of a cooling tower may vary depending
duction motor. Motor bearings are lubricated by a positive pres­ upon system design. For example, some units may be equipped
sure oil pump and lubrication system. Motor cooling is provided with heat recovery or auxiliary condensers which put condenser
by spraying the rotor and stator area of the motor with liquid refrig­ heat to beneficial use.
erant. This absorbs the motor heat.
Capacity control of the CenTraVac chiller is accomplished
Chilled water is produced in a shell and tube evaporator of the through the use of variable position inlet guide vanes on the first
flooded design where refrigerant evaporates on the outside sur­ and third stage of the compressor. These guide vanes throttle the
face of the tubes, chilling water as it passes through the inside of gas flow rate through the compressor thereby controlling the
the tubes. Because R-11 is a low pressure refrigerant, operating amount of refrigeration produced. Section 2.0 describes in detail
pressures are below 15 psig. The machine is also equipped with CenTraVac chiller operation.
an economizer which may be of single or dual stage design de­
Figures 1 and 2 illustrate the various components and sub-as­
pending upon application. The economizer provides an increase
semblies of the chiller.
in overall refrigeration effect and, as a result, a significant in­

‘C 0 $ 1 ? T ‘D 3 1 irT IA Ij_

Use Restricted
f o r - C-StLC k-

CTHE TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A
1.0-1
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982 t ,t

3-STAGE COMPRESSOR FACTORY MOUNTED

STARTER (OPTIONAL)

COMPRESSOR SUCTION ELBOW

EVAPORATOR

FIGURE 1 - Model CVHE CenTraVac Chiller

1.0-2
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982
COUFIDENTIAE
Usa Ea,_...rioted
lay COui'G_Order

PRINTED BY PRODUCTION SERVICES — LA CROSSE FWB GNB

1.0-3
 LITERATURE FILE NO. HCTV-SG-2

SAFETY SECTION
PRECAUTIONS 1.1
FEBRUARY 1982

This section points out areas which may present hazards manual as applicable. It is good operating practice to read
to operating and service personnel. Also, precautions con­ and become thoroughly fam iliar with all the following pre­
cerning m echanical damage to the m achinery are given. c a u tio n s b e fo re p ro ce e d in g to operate and se rvice the
Appropriate precautions are em phasized throughout this equipment described in this manual.

CAUTION: POSSIBLE PHYSICAL INJURY -----------------------

Allow rotating or revolving equipment, such as fans, belts To avoid injury, keep hands away from the fans, sheaves,
and couplings to stop before servicing to avoid injury to belts and o th e r ro ta tin g e q u ipm e n t w hen the unit is
fingers and hands. Open the unit disconnect switch and operating.
lock in that position to prevent accidental start-up.
Never use a torch on a refrigerant line until it has been
Before working on this or any electrical equipment always determined that all gas has been eliminated from the line -
open and safety the unit disconnect switch. Failure to do unsafe p re ssu re s could result. Be sure area is well
so may result in personal injury or death by electric shock. ventilated.
Confirm that power is disconnected by using a voltmeter.
Do not apply flame to a refrigerant drum in an attempt to
Never leave the unit unattended with safety devices such increase drum pressure. Uncontrolled heat may cause ex­
as belt or coupling guards removed. cessive drum pressures and an explosion may result.

Keep work area as clean as possible to avoid slipping on Do not use oxygen or acetylene in place of dry nitrogen
pipes, oil or coils which may cause personal injury. for leak testing or pressurizing - a violent explosion will
result.
Before removing belt guard, or other unit safety devices,
open the unit disconnect switch and lock in that position to Alw ays use a pressure regulator, valves and gauges to
prevent injury by accidental starting of the unit. Do not control drum and line pressures when pressure testing the
leave the unit unattended with safety devices removed. system . E xce ssive pre ssu re s may cause line ruptures,
equipment damage or an explosion.
To avoid personal injury, never wear loose clothing while
working on or near roating machinery. Loose clothing may Should liquid refrigerant come in contact with the skin, the
become tangled in rotating parts causing injury or death. injury should be treated the same as though the skin has
been frost bitten or frozen. Wash affected area with luke­
In case of a motor burnout, w ear protective clothing and warm water.
do not allow the oil to contact the skin. Acidic conditions
will be present which can cause skin burn. Do not work in a closed area where refrigerant may be
leaking - a sufficient quantity of vapors may be present to
When cu ttin g sh e e t m etal, do not leave ragged edges cause personal injury. Provide adequate ventilation.
which may be harmful to personnel contacting them.
Pressurized cylinders (refrigerant, nitrogen) must always be
Do not use the shipping brackets for lifting or moving the stored, handled and used with caution. Follow accepted
unit. These brackets are not designed to support total unit safety p ra c tic e s -to avoid unsafe pre ssu re s w hich could
weight and may break causing hazardous conditions for result in a violent explosion.
personnel or unit damage.
Ventilate the equipment room when soldering, brazing, leak
testing or charging the unit.

CONFIDENTIAE
Use Restricted
by Court Order
®THE TRANE COMPANY 1962
COMMERCIAL AIR CONDITIONING DIVISION
LACROSSE, WISCONSIN 54601
PRINTED IN U S A 1.1*1
HERMETIC CENTRAVAC SERVICE GUIDE tT f S T T F T O T T T A l^
HCTV-SG-2
FEBRUARY 1982 ’u ;iute-C:
' .1 l Ordel.
CAUTION: POSSIBLE MECHANICAL DAMAGE

To provide proper operation, follow all piping recom m en­ necessary. The Trane Company assumes no responsibility
dations listed in this manual. for equipment failures which are the result of untreated or
improperly treated water.
Use only copper conductors for supply power wiring. Unit
terminals are not designed to accept other type wiring. Any repairs or alterations to ASME Coded Vessels must
be in strict accordance with ASME Codes and with coordi­
To prevent co m p re s s o r dam age, allow oil sum p te m ­ nation through the Trane CACD Service Departm ent, La
perature to reach 135 F before attempting to start the unit. Crosse, Wisconsin.
Do not use w ater on a m otor or electrical fire. Use CO 2 Do not, under any circumstances, meg or apply power to
(carbon dioxide) or Ansal (Dry chem ical) (C lass ABC or the w indings of a com pressor m otor w hile it is under a
BC). deep vacuum less than saturated refrigerant pressure. In
To prevent motor or bearing failures, inspect for proper lu­ the rarified atmosphere of a vacuum, the motor winding in­
brication before start-up. sulation will burn destroying the motor.

It is recommended that the owner consult a qualified water Never mix refrigerants or use the wrong refrigerant in a
treatment specialist to determ ine if any water treatment is system - use the type and co rre ct charge of refrigerant
specified. See unit nameplate.

PRINTED BY PRODUCTION SERVICES — LA CROSSE FWB /GNB

1.1-2
 LITERATURE FILE NO. HCTV-SG-2

O PER ATIO N SECTION

2 .0
FEBRUARY 1982
The basic components of the model CVHE CenTraVac chiller are connecting piping. Figure 1 is a cutaway view of the machine. The
the evaporator, the three stage compressor, the water cooled following discussion describes the components and refrigeration
condenser, the single or dual stage economizer and related inter­ cycle in detail.

"THE TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601 TrcomdmxAn
PRINTED IN U S A Use trieted
2.0-1 .^ ...C o u r t.0 ^
HERMETIC CENTRAVAC SERVICE GUIDE "a
HCTV-SG-2 ,js e 'S e B t r i0 t
FEBRUARY 1982

Refrigeration Cycle Refrigerant vapor drawn into the impellers is forced radially out­
ward and is compressed. The compressed discharge vapor is
Figure 2 is a schematic representation of the refrigeration cycle.
then drawn through the fixed second stage inlet guide vanes and
Liquid refrigerant is distributed along the length of the evaporator
into the second stage impeller where it is compressed again. The
and sprayed through orifices to uniformly coat each evaporator
vapor is then discharged to the third stage impeller where it is
tube with refrigerant, (refer to Figure 3). The evaporator tubes
compressed further before being discharged into the condenser.
carry the water which has absorbed the building cooling load and
this heat is in turn transferred through the tubes surfaces to the Relatively cold cooling tower water circulating through the con­
refrigerant. The chilled water exits the evaporator and is pumped denser tubes absorbs heat from the refrigerant vapor causing it to
through the building to again absorb heat and provide cooling. As condense. The resulting liquid refrigerant collects in the con­
the heat is transferred to the refrigerant, the refrigerant vapor denser and then is returned to the evaporator via an economizer.
rises and is drawn through the eliminators by the compressor. As the condensed refrigerant passes through the economizer, it
The eliminator is a screen mesh assembly which removes drop­ is subcooled through the action of orifices and connections to the
lets of the liquid refrigerant entrained in the vapor causing the compressor. A single stage or dual stage economizer may be
droplets to fall back into the refrigerant in the bottom of the used depending upon the options selected.
evaporator.
Figure 5 illustrates the construction of a dual stage economizer.
The refrigerant vapor which results from the evaporative process Liquid refrigerant from the condenser sump passes thrugh Orifice
is drawn through the first stage modulating inlet guide vanes. The A into Chamber A. Chamber A has a pressure equal to the third
first stage inlet guide vanes control the flow of refrigerant vapor in stage compressor suction. As liquid refrigerant passes through
response to system cooling capacity requirements. For example, Chamber A a portion of the liquid flashes into vapor cooling the
if there is a small demand for chilled water and cooling, the inlet remaining liquid refrigerant. The vapor which is generated is
vanes are throttled towards the closed position. As evaporator drawn directly into the third stage impeller. The remaining liquid
load increases, the inlet vanes will move towards the open posi­ refrigerant passes through Orifice B and into Chamber B. Cham­
tion. The inlet guide vanes also prerotate the refrigerant vapor al­ ber B is that interstage pressure which exists between the first
lowing it to enter the compressor’s impeller at the best angle for and second stage compressor sections. Again the lower pres­
maximum efficiency at all load conditions. Figure 4 illustrates the sure in this section causes some refrigerant to flash which cools
compressor and the inlet guide vane assemblies. the remaining refrigerant and the flash vapor is drawn directly into

COMPRESSED AND
SUPERHEATED
REFRIGERANT VAPOR

FIGURE 2 - Refrigeration Cycle Schematic

2.0-2
 HERMETIC CENTRAVAC SERVICE GUIDE
;
confidfittiae _ HCTV-SG-2
Use ,dieted FEBRUARY 1982

the second stage impeller. The benefits of the dual stage econo­ Motor
mizer are increased operating efficiency. By introducing refrig­
A cutaway view of the compressor motor is shown in Figure 6. It is
erant vapor at interstage areas instead of forcing all refrigerant
a hermetic two pole, low slip, 3600 rpm, squirrel cage induction
vapors through three stages of compression, compressor loading
motor. The CenTraVac motor is supplied in one of a number of
is reduced. The action of the economizer reduces the tem­
options. The 200 through 600 volt 3 phase 60 cycle motors are
perature of the refrigerant entering the evaporator which im­
supplied with 6 terminal posts for full voltage (across the line) or
proves the performance.
reduced voltage star delta or auto transformer starting. 2300
Some CenTraVac chillers may be equipped with a single stage through 4160 volt, three phase 60 cycle motors are equipped with
economizer. The principle and operation are similar to the dual three terminals for full voltage (across line for reduced voltage pri­
stage economizer except that all flash gas is directed to the suc­ mary reactor or auto transformer) starting. A CenTraVac chiller
tion of the third stage compressor. may be equipped with a remote starter as a factory option on units
up to 600 volts and 575 amps, see Page 7.14. Table 1 provides
The subcooled liquid refrigerant produced by the economizer compressor motor data.
flows to the evaporator to repeat the refrigeration cycle.
The rotor shaft is machined from heat treated carbon steel and
During the startup sequence of the chiller, the oil pump is ener­
gized 2 minutes prior to the start of the compressor motor. If the designed such that the first critical speed is well above the oper­
proper oil pressure has not been established after 2 minutes, the ating speed of the compressor. The shaft is supported by two
low oil pressure safety control will prevent the compressor motor bearings. At the terminal end of the motor is a double tapered
roller bearing. At the other end is a cylindrical roller bearing. The
from starting. Additionally the oil pump remains energized for 7
minutes following compressor motor shutdown. This insures that compressor impellers are keyed directly to the motor shaft and
the motor bearings are properly lubricated during shut down of locked in position. Nonferrous labyrinth seals minimize re­
the compressor. Refer to Page 2.0-10 for complete description of circulation and gas leakage between the compressor stages.
the CenTraVac Control System.

2.0-3
 C O ^ IT ^ T A *

HERMETIC CENTRAVAC SERVICE GUIDE —e s

R - l
\ise
HCTV-SG-2
FEBRUARY 1982

2.0-4
Compressor valve which maintains a net oil pressure to the bearings of ap­
proximately 15 psig. After passing through the oil pressure regu­
Two sets of fully modulating inlet guide vanes at the first and third lating valve which is located on the oil sump, the oil is filtered by
stage of the compressor provide chiller capacity control. (Refer to an inline replaceable element oil filter. The oil is filtered and then
Figure 4.) The guide vanes are activated by the externally moun­ passed to the bearings where the oil is sprayed over the bearings.
ted electric vane operator in response to evaporator load. The The oil then drains by gravity back to the oil sump through the oil
guide vanes also prerotate the refrigerant vapor so that it enters return lines which are fitted with sight glasses so that proper oil
the impellers efficiently. The fully shrouded impellers are made of flow may be verified. Oil flow must be visible in the sight glass
high strength aluminum alloy and are connected directly to the whenever the oil pump is energized and the CenTraVac is in
motor shaft. The impellers are statically and dynamically bal­ operation. The supply rate at each bearing is nominally 3 pints per
anced and over speed tested to 4200 rpm. Refrigerant is drawn minute of T exaco WF68 oil, 300 SSU per minute or equivalent. T o
into the center of the impeller, compressed and is discharged insure proper lubrication and to prevent refrigerant from condens­
radially outward into the volute. ing in the oil sump, a 750 watt electric resistant heater is attached
Lubrication System externally to the oil sump. The heater is controlled by the oil tem­
perature control and is energized as required to maintain the oil
Figure 7 illustrates the CenTraVac lubrication system. This sump temperature at 130 to 135 F when the machine is not oper­
system provides lubrication for the compressor motor bearings. ating. The oil sump is also vented to the compressor suction
Oil is pumped by an electric motor driven oil pump. Both the pump elbow to equalize the oil sump pressure. A drain line is attached to
and single phase electric motor are mounted inside the oil sump. the first stage suction cover to return oil from the refrigeration
Oil is discharged from the pump into an oil pressure regulating system to the oil sump.

2.0-5
 C O N F lE E N T lA i;
Use Restricted
Uv r.nurt^Qrdgx

FIGURE 7 - Lubrication System

Motor Cooling System The compressor motor is protected by a solid state module.
Three sensors located in the motor windings monitor the motor
Figure 8 illustrates a motor cooling system. The motor is hermetic temperature and should any one of the sensors defect an exces­
and is cooled with liquid refrigerant. The liquid refrigerant is sup­ sively high temperature a signal is sent to the motor temperature
plied to the motor from a sump in the evaporator. A set of fixed control module and the high motor fault indicator. The motor is de­
orifices maintains the constant flow of refrigerant to the motor. energized and the CenTraVac cannot be restarted until the fault
The liquid enters at the bottom of the motor and surrounds the trip indicator is manually reset and the motor temperature is
rotor and stator area. Liquid refrigerant is sprayed on to the rotor within acceptable limits. Also to prevent excessive heat buildup in
through the slot in the stator core. The liquid refrigerant absorbs the motor due to motor cycling an anti-recycle timer is employed.
heat and then drain from the ends of the motor assembly and is Thus 30 minutes must have elapsed from the time of the previous
returned to the evaporator. startup sequence.

2.0-6
 HERMETIC CENTRAVAC SERVICE GUIDE
) ] i r TT'>T?"T'r T i t HCTV-SG-2
,^ed FEBRUARY 1982
: -•
Purge System The heated vapor passes to the purge drum where the refrigerant
las “ -- water vapors are condensed on a chilled water coil within the
purge drum. The noncondensable gases remain at the top of the
Since the evaporator operates at less than atmospheric pres­
drum where they are vented off automatically by the purge relief
sures it is possible that air and moisture can leak into the ma­
valve when purge drum pressure reaches approximately 30 psig.
chine. If allowed to accumulate these noncondensables will
The water floats on top of the condensed refrigerant and appears
become trapped in the condenser reducing the total effective
as a distinct level in the purge drum sight glass. The water is re­
condensing area. The resulting increase in condensing pressure
moved by opening the manual blow-off valve. A mixture of refrig­
will result in inefficient compressor operation.
erant and water will flow from the drum.

Purge system operates periodically to remove noncondensables The purge unit may be operated either manually or automatically.
from the machine. Figure 9 is a schematic of the purge system. With the purge switch in the automatic position the purge com­
When in operation a mixture of refrigerant vapor and non­ pressor will run whenever the CenTraVac compressor is running
condensable gas is drawn from the condenser by the purge com­ and when purge drum pressure is below a preset value governed
pressor. The compressed gas is then discharged into the oil sep­ by the purge high pressure control. Operated manually the purge
arator tank where the gas is heated. Heating the gas effectively compressor will run when purge drum pressure is below the
separates any purge compressor oil from the gases and water preset high pressure control cutout value regardless of whether
vapor. The compressed gas is then discharged into the oil sepa­ the CenTraVac compressor is running or not. When purge drum
rator tank where the gas is heated. Heating the gas effectively pressure exceeds the HPC cutout, the purge compressor is shut
separates any purge compressor oil from the gases and water off or the purge system is operated manually or automatically.
vapor. Oil collects at the bottom of the tank and is returned to the Figure 10 illustrates a portion of a typical CVHE schematic wiring
purge compressor crankcase where a float valve and return tube. diagram and illustrates the purge system wiring.

FIGURE 9 - Purge System

K9

PURGE B3
MAIN S13 PURGE
28
- © ------------------ f t
o ----- <>
F4 S11 OFF
6 -------o L1
AUTO
o ------- o --------- \ v
29 K9
-K— "
PURGE

- m -

PURGE HEATER
FIGURE 10 - Purge System Schematic Wiring

Free Cooling 1. A refrigerant gas line including an electrically activated shut off
valve installed between evaporator and condenser.
Free cooling is an optional accessory available with the standard
2. A liquid return line including an electrically activated shut off
chiller. It adapts the basic chiller so that it functions like a simple
valve between the evaporator and condenser sump.
heat exchanger using the refrigerant as a heat transfer fluid with­
3. A liquid refrigerant storage vessel for added refrigerant
out compressor operation. The free cooling accessory consists of
charge.
the following factory installed or supplied components:
4. Free cooling selector switch.

2.0-7
 ‘S'OTT'FIDIEIT T X All
HERMETIC CENTRAVAC SERVICE GUIDE
tjse R e s t r i c t e d
HCTV-SG-2
FEBRUARY 1982 ■hy-r.Qurt Order
When condenser water is available at temperatures lower than exists between the condenser and the evaporator water. The
the required chilled water. Free cooling can provide up to 45% of amount of difference in temperature between the condenser
nominal chiller capacity. Free cooling operates on the principle water and evaporator determines the rate the refrigerant flow be­
that refrigerant flows through the area of lowest temperature in tween the two shelves and therefore the evaporator capacity.
the system. When cold condenser water is available, the operator Figure 1 illustrates this. It is important that there is available suf­
can stop the CenTraVac compressor and start the free cooling ficiently cold condenser water for free cooling operation.
refrigeration by simply pushing a switch located on the front of the
CenTraVac control panel. Adjustment must then be made to If the system load becomes greater than the free cooling system
supply cold condenser water the CenTraVac. Figure 11 illus­ capacity, or if condenser water becomes too warm the operator
trates the control panel of a CenTraVac equipped with the free must terminate free cooling operation by simply switching to off at
cooling option. Upon changeover to free cooling a shut off valve the control panel. The gas and liquid valves close and normal
and liquid line and gas line open and a lockout circuit prevents compressor operation will begin. Refrigerant gas is drawn out of
that compressor motor from starting. Figure 12 illustrates a por­ the evaporator by the compressor and is compressed and dis­
tion of the electrical schem atic diagram for a typical chiller charged through the condenser. Most of the condensed liquid
first takes the path of least resistance, by flowing into the storage
equipped with free cooling.
tank which is vented to the economizer sump through a small
Figure 13 is a schematic representation of the free cooling and bleed line. When the storage tank is full liquid refrigerant must
refrigeration cycle. Liquid refrigerant drains by garvity from the flow through the bleed line restriction. Pressure drop through the
storage tank into the evaporator flooding the tube bundle. Since bleed line is greater than through the orifice flow control device,
the refrigerant temperature and pressure will be higher in the therefore, liquid refrigerant flows normally from the condenser
evaporator then in the condenser due to the water temperature through the orifice system and into the economizer. During
different the refrigerant vaporized in the evaporator flows the con­ changeover to mechanical cooling the refrigerant transfer pro­
denser. The vapor is then condensed by the colder cooling tower cess requires approximately 3 minutes. The capacity control
water and flows by gravity back to the evaporator. This refrig­ loading ramp prevents evaporator carryover by slowing loading
eration cycle is sustained as long as a temperature difference the compressor.

FIGURE 11 - Control Panel With Free Cooling Switch

2.0-8
 TCOHFIDEHTIAE
HERMETIC CENTRAVAC SERVICE GUIDE
Use KeSuX'icted HCTV-SG-2
Court Order FEBRUARY 1982

7 —

FIGURE 12 - Free Cooling Schematic Wiring

FIGURE 13 - Free Cooling Cycle Schematic

2.0-9
HERMETIC CENTRAVAC SERVICE GUIDE C Q H F T 'D21T'nI A ‘L’
HCTV-SG-2 ..
FEBRUARY 1982 ^S6 ^ ^;
by Cnnrt Urge!
Heat Recovery Operation ing. It should be noted that in order to utilize heat recovery, there
must be a cooling load which is, in effect, the heat source.
The purpose of heat recovery operation is to recover heat nor­
mally rejected to the atmoshpere through the cooling tower and During heat recovery operation, the CenTraVac operates identi­
put that heat to beneficial use. This is accomplished by the addi­ cally to cooling only operation except that the cooling load heat is
tion of the heat recovery or auxiliary condenser to the refrig­ rejected to the heating water circuit instead of the cooling tower
eration system. This condenser is identical to the standard con­ water circuit. When hot water is required, the heating water circuit
denser except that it is piped to a heating circuit instead of the pumps are energized and flow is started through the heat recov­
cooling tower circuit. For example, during the winter months a ery condenser (or auxiliary condenser). This water absorbs cool­
high-rise office building may have simultaneous requirements for ing load heat through the tubes from the compressor hot gas dis­
cooling and heating. Through the use of the heat recovery con­ charge. The hot water is then put to use for heating or in the case
denser, heat removed from the building cooling load can be of units equipped with auxiliary condenser it is used for lavatory,
moved to that portion of the building which requires comfort heat­ kitchen or wherever hot water is required.

CENTRAVAC CONTROL SYSTEM 1. Pressure indicating gauges have no operating function. They
are used only to provide condenser, evaporator, lubricating oil
The Model CVHE CenT raVac is capable of continuous capacity and purge drum pressures.
modulation from 100% to 10% of full load at design conditions.
This is achieved through the electronic control panel which is il­ 2. System sequence status lights perform an important diagnos­
lustrated in Figure 15. Refer to Sections 7.0 through 7.21 for de­ tic function. A series of seven lights shows the progress of the
tailed individual control descriptions. CenTraVac starting sequence. As each of the seven circuit in­
terlocks is verified, its individual pilot light comes on. There­
CONTROL PANEL
fore, the reason for an aborted start can be determined by ob­
All safety and operating controls are housed in the CenTraVac serving the pilot lights and determining the point at which the
control panel. The panel functions are divided into four catego­ sequence was breached.
ries, as indicated by the external panel layout:

2.0-10
 'C O H P ir Z I T T I A ^ HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
Use Rescricoed FEBRUARY 1982
by Court didder

FIGURE 15 - Control Panel

3. Five fault trip indicators display the status of each safety cutout Electronic Control System
control. Circuit interrupters are used to open the circuit instead (Refer to Figure 16)
of relays because they will hold their position in the event of
A1 (line 9) is an electronic overload relay. Its purpose is to monitor
power interruption. Therefore, power failure does not require
the current draw of the compressor and to de-energize the com­
the manual resetting of all safeties. Additional alarm contacts
pressor starter if the current draw exceeds the setting of A 1.
on each of the fault trip indicators are brought to a terminal
strip for external connection. A3 (line 39) is the compressor inlet vane actuator electric motor.
4. The electronic capacity control system consists of three A3 end switch (line 26) is closed when the inlet vanes are full
elements: closed. A3 limit switch (line 38) is open when the inlet vanes are
full open. A3 limit switch (line 40) isopen when the inlet vanes are
a. Demand limiter
full closed.
b. Chilled water temperature control
c. Manual inlet vane control and status S4 (line 35) is a multi-program timer. It limits the compressor to
one start every 30 minutes and also provides the "start” signal to
The demand limiter control can be set to any value between 40
the compressor starter. S9 (line 43) is the oil pump timer. It keeps
and 100 percent of motor full load current. Motor current is
the oil pump motor energized for 7 minutes after the compressor
sensed by three current transformers and is processed into a pro­
starter is de-energized to provide lubrication during compressor
portional DC voltage by the CenTraVac motor overload. This
coast-down.
same DC voltage is monitored by the demand limiter. When the
set percentage of full load current is reached, the demand limiter 111 (line 37) is the capacity control module. It modulates the inlet
prohibits further opening of the inlet vanes. If the setting is ex­ vane actuator (A3, line 39) in response to leaving water tem ­
ceeded, the inlet vanes are moved toward the closed position. perature as sensed by sensor U3 (line 38). U1 also serves as a
load limiting device thru an input signal from the electronic over­
The chilled water temperature control module uses a solid
load relay. Power must be applied to terminal 84 (line 40) before
state temperature sensor to sense chilled water temperature.
U1 can open the inlet vanes.
Should this temperature vary from setpoint, an electronic control­
ler sends a pulsed signal to the inlet vane actuator. A combination U2 (line 35) is the compressor motor high temperature cut-out. Its
of proportional and floating control is used to provide high accu­ M1 -M2 contacts will close shortly after 115V is applied to termi­
racy and low sensitivity (hunting). nals T1 and T2.

2.0-11
 ,-f-rrr T V T ,

HERMETIC CENTRAVAC SERVICE GUIDE 'T La

HCTV-SG-2
FEBRUARY 1982

Sequence of Operation For Typical Start-Up K10 contact (line 34) closes to maintain power on timer S4
(Refer to Figure 16) through its entire timing cycle. A third K10 contact (line 29) opens
Energize the chilled water pump starter K12 (line 13). to interrupt the “ start” signal through S4 contacts (line 26). Thus
the original “start” signal through S4 (line 26) is maintained only
Set switch S6 (line 26) in the “ auto” position. long enough to energize the “ start" contactor of K1. If K1 drops
out for any reason, K1 stays de-energized until anti-recycle timer
Control power flows through the string of safety controls and
S4 completes its cycle. A third K1 “ start" contact (line 45) closes
safety lockout contacts (line 16). If all safeties are satisfied, light
to keep the oil pump energized as long as K1 contacts are closed.
DS1 (line 20) will light. Power flows on to the chilled water
demand switch S3 (line 26) whose temperature sensing element When K1 connects the compressor in the run configuration, K1
is located in the return water entering the chiller. Upon a rise in “ run” contacts (line 40) close feeding power to terminal 84 of the
return water temperature, S3 closes energizing light DS2 (line 20) capacity control module U1 (line 40) (if refrigerant temperature
and feeding power to timer contact S4. If 30 minutes or more have switch S2 is closed) thus allowing U1 to open the compressor
elapsed since the previous compressor start, timer contact S4 inlet vanes as necessary.
(line 26) feeds power to light DS3 (line 20). Power also flows
through compressor inlet vane end switch A3 (if vanes are When K1 is initially energized, relay K9 (line 26) is also energized.
closed), through relay K7 contacts (if compressor is off) to termi­ K9 contacts (line 25) open keeping relay K8 de-energized. This
nal 8. If chilled water flow is proven, power feeds through flow arms the starter fault safety circuit 15 seconds after the initial start
switch S5 to light DS4 (line 20). Power also feeds through switch pulse is sent to K1. S4 contacts (line 26) switch from 13-81 to 13-
S6 energizing relay K4 (line 19). K4 contacts (line 16) close to en­ 79, energizing relay K7 (line 24). K7 contacts (line25) close keep­
ergize the condenser water pump starter, K13. If condenser ing K7 energized and completing the arming of the starter fault
water flow is proven, power feeds through flow switch S7 (line 26) circuit. If K1 opens for any reason, contacts K1 (line 29) open de­
to light DS5 (line 20) and also energizes relay K5 (line 21). One energizing relay K9. K9 contacts (line 25) close energizing relay
set of K5 contacts (line 43) close energizing the oil pump timer S9. K8. K8 contacts (line 15) close tripping safety lockout CB5 and
In 40 seconds, timer S9 contacts (line 44) close energizing the oil locking the unit off. When there is no longer a call for cooling or if a
pump motor B2 (line 45). When oil pressure is established, oil safety opens, compressor starter K1 and relay K5 will be de-ener­
pressure switch S8 (line 26) closes, lighting DS6 (line 22) nd en­ gized. A contact of timer S9 (line 44) will keep timer S9 and oil
ergizing relay K6 (line 23). One set of K6 SPDT contacts (lines 14 pump motor B2 energized for 7 minutes to provide lubrication
and 15) switch to energize K3 (line 14). In turn K3 contacts (line during compressor coast-down.
16) close arming the low oil pressure circuit interrupter CB1 (line If ther is a loss of oil pressure while the compressor is running, oil
14). A second K6 contact (line 35) closes energizing timer S4. In pressure switch S8 (line 26) opens, stopping the compressor and
20 seconds S4 contacts (line 34) close. Five seconds later S4 de-energizing relay K6 (line 23). Power then feeds from terminal
contacts (line 28) close lighting DS7 (line 28), energizing K9 (line 12 (line 26) through contacts of K2 (line 16) and NC contacts o f K6
26) and initiating a compressor start by energizing K1 (line 29). (line 14) to trip safety lockout CB1, locking the compressor off.
One set of K1 “start” contacts (line 28) close to maintain power to
the compressor starter. Simultaneously, a second K1 “ start" con­ Alarm contacts (line 56) are factory wired using NC contacts of
tact (line 34) closes energizing K10. K10 contacts (line 32) close the control safety lockouts. NO alarm contacts may be used by
to maintain K10 for the duration of anti recycle timer S4. A second moving one wire on each safety lockout.

2.0-12
 C O T T F ir ' T - ' T T T A T . p HERMETIC CENTRAVAC SERVICE GUIDE
U se R es v.fic Lod HCTV-SG-2
fry Court Order FEBRUARY 1982
TABLE 1 - Compressor Motor Electrical Data
N O M IN A L V O L T A G E 200 208 440 460 480 575 600 2300 2400 4000 4160
U N IT A V A IL A B L E VO LTAG E
COMPRESSOR M OTOR M OTOR U T IL IZ A T IO N
D E S IG N A T IO N D E S IG N A T O R R A T IN G (K W ) rang e

jjL
187 2 2 9 187229 4 1 4 -5 0 6 4 1 4 -6 0 6 4 1 4 '5 0 6 54 0*66 0 5 4 0 .6 3 5 2 T B 0 2 6 4 C 2 1 6 0 2 6 4 L i7 4 4 '4 5 ? £

£
R a te d L o a ti A m p-. 914 90? •4 2 136 ’ 30 10" '•03
96
1 u c k e r l R o to r A n Ip ' ? 194 2240 999 1 040 10 85 7 63 796

R a te d l o a d A m p ; 94 ? 929 159 140 142 11 7 112

B 109
d e c k e d R o to r A n p ' 9 '9 4 2240 995 1040 10 85 763 796

R a te d l o a d A 'n p ' 979 964 17? 164 157 13' 126

118
l ■*. keel R o to ' Am p-. 9 1 94 2 ?d0 995 10 4 0 10 85 763 796

(,VH P R ailed L o a d Arr p ' 419 4m •y o 16? •7 4 146 140

[) 1 91
o n o?o 1 i n . r c t i P o lo ' i ' l l ! / 9194 2242 498 1.040 6086 763 796

R a te d l p a d A " ip '. 46 4 446 210 201 193 159 152

L 14?
1 o r.r.e d R o to r A m p ', 286? ?97fc ’ 299 1 2 95 t.351 950 1000

R a 'e d l o a d A r-ip ., 9U? 484 ?28 2 ' 8 20 9 1 73 166

199
1 rx > e d R o le A t ^ 286? 2976 12 9 9 12 95 1951 958 10 0 0

R a te d L e n d A m p s 959 99? 251 240 210 192 184

1 f?
1 iX .k e d R tV iy A fiip c 2862 2976 12 99 1295 1391 95 8 1000

R ate r) l o a d A /n p - 46 4 446 ?0 9 196 188 159 152

14?
1. o c k f id R o to r Am ps, 9014 9 ’ 95 1 949 •4 1 0 147: 1045 1 0 90

P a le d L o a d A t’ ip'-. 901 48? 22 4 214 205 173 166

; ( )C.k(!(! R rj'o r A rr'p s 901 4 9195 1.949 1410 1471 1045 '0 9 0

R ater) [ o i l ) A 'rip r, 951 5 9 ij 248 ?97 2? 7 192 184

1 7?
l CJokC'i) RolC>‘ A 'rip s 9014 9 '9 5 1 94 9 14 1O 14 71 1045 1 0 90

C ^H I R tV e .) i o a r) A m p s 60 4 58- ? 7? 260 ?49 206 197

H 184
o?? no? l 0 ( ty -d R o'r.r A ri.p s 4009 4 '6 ? 1 6 79 ’ 755 1831 1272 13 27

R a te d i o a d A m p s 662 69 7 29 9 286 2 74 228 218

J ?04
l fx .k e i t R o to r A m p ', 4009 4163 16 79 1 755 •8 3 ! 12 7 ? 1327

R iiie d l o si 1 A m p s 744 715 997 92? 909 257 240

„ ?90
t rx_ k e d R o to r A r r id 41)09 4169 16 79 ’ 755 1891 '2 7 2 132 7

R /tte o l oa r) A m p ' 820 788 79 357 94? 38 6 274

266
l o t.i-e i 1 R o to r A r i p ‘ . -8 8 0 4095 1 720 1 798 I8 7 h t? 6 1 1316

B a le d [ i.H ri A n .p - 654 629 296 282 2 70 22 5 216

204
l o r m td P o lo ' A m p -, 4 6 10 4 794 ’ 971 2060 2 ’ 50 1466 1 5 30

R a 'e d l o . x ! A m p '. 79? 704 333 918 3C5 254 243 h? 9 O' 2 36 7 t6 a
230
t , K.kt-d Ftolcif A n p 1. 4610 4 794 ■971 2060 ? ’ 50 i4 8 6 1530 a j" 36? 901 209

F a ile d I o d d A.■r ip ', 815 7B4 07 0 394 940 283 m 71 1 68 1 40 u 39 a

l 256
l lo c - e ') R u try A m i p '. 4610 4 744 1971 2060 ? 150 1 46c 1530 -4 ' 16? 201 20 9

CVHI P a le d l o a d A m p s 91b 881 41 5 ■797 ib o 31 6 90 9 "4 1 "6 4 4; r 498

M PH 4
Q:Tf> OSU l r 1 R o l l / Arr.p-. 4495 4675 ?; ;?9 2 115 220 7 ’ 550 16’ 7 a 7e -9? ? 1’ 2 ?h

F in e d L o a d A m p ', 1097 99 7 469 449 490 359 344 90 ' Bt: *. 8 49 8

n 3? 9
i r>r.kf‘ d R e tro A m [) c 4 4 9 -i 4675 2029 2H 5 2207 1 550 <617 40 8 4?6 ?d 7 ?'46

R ale , ] [ o n d A m p ', 62 5 5C2 481 40 ? 385 yy 4 9 5 '•< 6 7 ;■ 6i> A,

'* h l
1 o c .-e d R o to r A m p '. 2029 2115 2 2 07 1550 161? 485 506 ? fti .■■9?

R a te d 1 u a d A m p s 68C 555 57? 445 426 11 ’ 8 •1 7 - 64 1 td 8

H 400
L y o k e d R olcji A m p 1. 2 5 41 2697 7773 19 54 2039 64? 666 ) '4 ???■

p la te ;; l o a : ) Amp,., 10 18 979 46/ 442 424 359 344 89 8 86 1 51 7 49 7

rj V '■
1 iH .kei I Fki.itu' A .'iip '. 1)649 5875 2-.41 265 7 ? 7 73 1560 1HI 7 444 4h8 ? i.i: ? '3
H, ,'er 1 L o a d Am p* 615 493 4 72 40? 385 *9 4 as ' 1)!; 0
p 961
l (.e k e d Pr.iti.ir A m p s 25 41 2657 2 7 73 1550 16 17 486 506 281 ?9 ?

R a le :: i ■.ad A m p 1. 580 555 532 44; 4? 6 "1 8 dd I r-4 a A' 6

n
. O-r ke. ] R o to r A m p ' 254 1 265 7 7773 1954 3039 •4 . 5-0, 9 J 6 T,
C VH E R ate, 1 l u a i ) Arr p< 66 7 695 609 508 48" t.'A v ■?3 0 " 8 7’ 0
4 ' '*
08d , or - e d R o ’o r A m p ; 1426 94 7? 3528 2560 ? fi9 ? t '0 ‘ 6 ?d 946 96?

91 ' R a 'e ! [ o a rt A m p ' 75? 7 tu 689 5? 6 55. 145 ? 13 9 ? 83 7 80 b

L ix >e i R o to r A r,p « 9 6d 94 7 7 <628 2589 26 9. K" • 627 ■-48 36?

H a le d 1 ( a n Am p,'. fts n fi? 7 786 658 e 1' -. 4 16 8 0 95 ? 9’ 5

989.
[ ix b e d Ri )t: Arr i p ; M ,44 '.8 6 ? 4030 2 8 '6 2 9 -A 11 '9 1 406 42?

R a le ;: L o a d A m p s 45? 41 1 8 "9 7?7 69 ' 182 e 1 76 1.' '0 1 P

11 x*'i 1 R o to r A m p s 444: 536? 36’ 6 3 7 'a 8? 1 85 7 4’t 495

| t , i F itte d L o a d A m p s ■'49 ’ 4, 08 6 574 66? ’ 43 6 1 a ft , ■ 8? P 70 6

L rx. k e d R o to r An-p- 4448 • It,5.: 465? 3528 36 8 • "66 ’9 ' 44 , 46?

V 98n F ltl*': 1 L oa, i A m p '. 654 8‘ T ’ 83 655 6?0 4 ,4 a 1 58 0 94 r, bd ;j

L ■:H">e, t R o V jf A m p ' 4448 4 6 5 :; 4652 3528 368' "66 797 44/ 46..'

CVHI F! ite d 1 o a d A m p s A ..1 9 ’’ A7? 7;. 7 6 ;a ' 1 8? t? ’ '? 105 n 10-

t :
d fid 1 , 111 1 ■:I-L k e d R r:-|,- Am p< 444. 1 'm 5362 36’6 3 7" ■ 6. ' e.'--- 49, 49;

R a 'e d . Am p- 1" 8 " '" d 99C 83 0 ’ <• ” 6

l (ji. k e ; 1 R.. ,1 ■ pu 5h 18 f i t 28 4-7-4 4 ' •• rt4 ^ Abe 40 ' M l

Rote-d , i . . i d A m p 1 , 14 _■ 118b 1199 a* 1 4:3 .■90 •3 6 1d

. Fa : f-r 1.454 t,8 5 .' ’ 151■ •’4' 1 191 h r-' ' '6

d4 d , ■ - VT-, 1 ' V ■ .1' ' ■ d .-t ?r-,4 .■ ?6 ‘ 49

.............> 0 ,1.,' 7‘ 4 6 0 6 ;, 64 1 e -.heft Tk’ 4 -U ’ 1 19’ fifi’ 68"

2.0-13
 - 7 5 - THREE PHASE ^ » » P L ’ -" I" '
voltauc-cye -oro» * r'MorrR NA»re,L'
CIR C UIT RPF'

K I2
------- W ARNING!---------
START
OPEN DISCONNECT SWITCH STOP t

BEFORE SERVICING THE UNIT n

CHlLLl*2 HATER: co

o
m
— -0^ 0-—-o— 11— 0 '-+^—\ )--■
CONDENSER PJf*» CONT=:_ CONTACT <^9~|
CONDENSER WATER F--MP

NOTES:
V.UNLESS 0T>CRH1SE NOTED
ALL S M IT O tS ARE SH0M4
AT 2S -C 1 7 7 *F ) .A T
ATMOSPHERIC PRESSURE.
AT 50X R ELATIVE H U M ID IT Y .
W ITH ALL U T IL IT IE S TURhCS
! ■ y , « » L _ “ L _ OFF. AND AFTER A NORMAL
SHUTDOWN HAS OCCJ'R EO.
‘HI - C 'O i “ ' LCS CIL-1 2 . DASHE0 LIN E S INDICATE
RECOMm EMCEO F IE L D W IRIN G
L J L ; si _ , T“ s _J
b y o t h e r s , p h an to m l in e s
C62 ! r.3 1 INO I CATE ALTERNATE
I< S . 1 CIRCUITRY OR AVAILABLE
6 d 72 * s a l e s o p t io n s .
3 . NUH0CRS a lo n g t h e r ig h t

2.0-14
SID E OF THE SChCWATIC
DESIGNATE THE LOCATION ;JH P*
OF THE CONTACTS BY L IN E
NUMBERS. AN UNDERLINED
NUMBER IN DICATES A
NORMALLY C l o s e d CONTACT.
4 . MAXIMUM ANCIENT TEMPER­
ATURE SO*C U 2 0 « n
AVERAGE A IR TEMPERATURE
IN T )C IMMEDIATE ICIGHEKJR-
HOOO OF T « CONTROL PANEL.
< fT ]C IR C U IT BREAKERS C B I-C 0 5
— 3E)*»LOYED AS FAULT
INDICATORS IN ThC CONTROL
C IR C U IT ARE CFS1CNCD TO
BE SHUNT TR IP VOLTAGE
DEVICES (1 2 0 VAC AT U S X )
NOT CURRENT S E N S IT IV E
OEVICES AS NORMALLY
AP PLIED .A UX CONTACT ARE
LOCATEO ON L IN E S6
6. ALL F JE l O WIR IN G MUST
BE IN ACCORDANCE WITH T>€
n a t io n a l El e c t r i c a l c o d e
(N E C ), s t a t e a n d l o c a l
r e q u ir e m e n t s . o t >k r
COUNTRIES APPICAD l E
NATIONAL An D/OR l o c a l
REQUIREMENTS SHALL APPLY.
EXAMPLE : CAN.0D A-SHALL
CO*»LY WITH CANADIAN
STANOAROS ASSN. (CSA)
START-STOP SIGNAL TO K1
23,33 120 V O LT S .1 . 0 AMP INRUSH
" ^ V J * 5 (START) .5 A ) ^ CONTINUOUS (MAX)
c o ntact clo sed --------
40 (RUN)
W ITH REFERENCE < T 1 f o r t im in g seq u en c e of
VOLTAGE (1 2 0 VOLTS) TIM ERS S4 4 S 3 SEE TABLES
TO TERMINALS
< "9 ~ 1 *4 CONTACT RATEO AT 30 W
T1 AND T2
INRUSH 6 AH3 CONTINUOUS
120 VOLTS MAX)

(CONTINUED ON
NEXT PAGE)
1
 ( (

(CONTINUED FROM
PREVIOUS PAGE)

cl
CO r»y
ro o
© c i
o “ ■A
tn c
p
cl
sd
;c- >-
r- cr
o o ,ti
M, p u 1

=a
O
o

FIGURE 16 - Control System Schematic Wiring Diagram

-< 2 i
■i ««!
S 9 i

FWB L.LW
ro ro i
 LITERATURE FILE NO. HCTV-SG-2

IN S TA LLA TIO N
SECTION
3.0
FEBRUARY 1982

The following installation information was shipped with the Cen- with the background necessary to determine if the CenTraVac
TraVac chiller and was made available to the installing con­ has been properly installed. This is especially important when in­
tractor. It is presented here as reference material for the Trane specting the chiller prior to initial start-up and deciding if the chiller
Service Engineer. The purpose is to provide the service engineer is ready to be started.

'CONFIDENTI AT
Use Itcu ; v i .;t ;
by Court Oiuu

®THE TRANE COMPANY 1962

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A

3.0-1
 LITERATURE FILE NO. HCTV-SG-2

START-U P SECTION
4.0
FEBRUARY 1982
INTRODUCTION

The purpose of this Section is to describe the procedures and

techniques required by the Trane Sales Engineer and Service Ttottpiteittiat
Engineer to start a Model CVHE Water Cooled Centrifugal Liquid Use Ros'l_ L..'iu
Chiller equipped with or without the heat recovery option.
fry Court,

PRELIMINARY JOB CHECKOUT

The Sales Engineer is charged with specific responsibilities in­ Also check for correct wiring, control and piping diagrams at the
tended to ensure the readiness of all contracted assembly piping jobsite. Insure that these diagrams are for the job.
and wiring in addition to the actual checkout functions performed
by Trane representative. One of the greatest problems causing Check to see that the contractor has leveled the unit and that the
large machine start-up delays is contractor-caused delays re­ isolator pads are properly installed.
sulting from the lack of proper preliminary checks to ensure that Piping
the unit is indeed ready to start. Some offices have made in-
house arrangements to delegate this responsibility, but despite It is the Sales Engineer's responsibility to thoroughly review and
this, the ultimate responsibility for the preliminary job checkout check the design and lay out of the piping at the time of sale to see
still remains with the Sales Engineer who sold the unit. that both the design and layout will conform to The Trane Com­
pany's requirements for machine connection, control and service
It is to the Sales Engineer’s advantage to remain actively involved accessibility.
with the job even though some of the specific checks may be
delegated. The Sales Engineer has the essential customer con­ All heat exchangers should be piped with water flow entering at
tact, job specifics, and understanding of the application which can the bottom and leaving at the top.
maintain the continuity necessary to get the job done properly, or
Water pumps utilized should not be 3600 RPM as this speed will
to coordinate the necessary changes if the contractor work has
subject the installation to sympathetic beat frequency vibration
been done incorrectly.
from the close rotational frequency of the pumps and the com­
Prior to final scheduling of the Service Engineer supervised start­ pressor motor assembly. Most system designs now include pipe
up, the following checks should be made by the Sales Engineer to isolators on both the entering and leaving side of all pumps.
ensure that the job is ready to proceed. These can further reduce the transmission of pump-induced vi­
brational noise into the system.
UNIT CHECK: Sales Engineer Responsibility
In each piping circuit, the Sales Engineer should check and con­
A full inspection of the unit and all components should be made at firm the following specific items.
the time of equipment arrival so that any necessary shipping
claims can be made. The process of shipping, rigging and final A. Chilled Water Circuit
placement may have resulted in damage to the unit. Look for col­
B. Condenser Water Circuit
lision damage, scars, nicks, bent piping, or evidence of damage
1. In the condenser water circuit, check for proper installation
to any parts of the machine. Look carefully for damage resulting
of isolation valves, flow switches if specified, thermometer
from careless handling such as rigging slip-ups, dropping and so
wells, pressure taps, strainers, drain valves, vent cocks
forth. All units are factory inspected, therefore, any claims should
and working pressure specifications as before with the
be filed with the carrier.
evaporator water circuit.
All items ordered from Trane or through Trane on Direct Ship 2. Additionally, the condenser tubes are more susceptible to
(DS) orders should also be checked for completeness and any fouling due to the higher operating temperatures. Be sure
shipping damage. Check the amount of refrigerant shipped and that proper water treatment has been planned and will be
also look for damaged or partially full refrigerant drums. The re­ available prior to machine start-up. The Trane Company
frigerant and other DS items should be stored in a cool, dry area assumes no responsibility for poor equipment performance
until ready for use. or damage due to the absence of, or improperly applied
water treatment. Also, if required, ethylene glycol should be
added to the water circuit.
THE TRANE COMPANY 1962
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601
PRINTED IN U S A
4.0-1
HERMETIC CENTRAVAC SERVICE GUIDE w ? r Ai
h c t v - s g -2 c 0 1 ,r l'r'‘ r ' j,
FEBRUARY 1982 U s e itG!J t r i ' 5 u S d
by Court Oruer
C. Heat Recovery Units — F. Electrical Wiring
1. On heat recovery units the heating water circuits must also All wiring should be complete from the starter panel to the con­
have water treatment if water fouling factors exceed speci­ trol panel with all interlock control circuits. Copper lugs should
fications. Maximum allowable fouling factor is recorded on be attached to the flexible copper cables furnished for the
the sales order sheet. motor terminals. The motor leads should not be connected at
this point since the Service Engineer must dry run the starter
D. Auxiliary Water Piping
later. The motor must be disconnected for this check. For
The CenTraVac purge condenser must be supplied with suf­
CVHE machines with the heat recovery option, all heat recov­
ficient cooling water. Two (2) GPM with a 2 foot pressure drop
ery accessories should be checked for correct installation.
must be supplied. Piping the purge condenser across the
evaporator will supply this requirement while the unit is in This completes the preliminary job checkout which the Sales En­
operation. However, city water must be supplied to the unit gineer performs. If all of the preceding items have been com­
during shutdown periods. Also, the water must be 80 F or less pleted satisfactorily, the job can be scheduled for start-up with the
for proper purge operation. local Trane Service Company.

E. Pressure Relief Piping

FINAL CHECKOUT AND REVIEW 1. The chilled water and condenser water pump should be oper­
ated for 24 hours to insure that they perform satisfactorily and
The final checkout phase is intended to insure that all contractor
that all air is purged or vented from each system.
functions have been completed and that all equipment associ­
ated with the system is indeed operable. All changes required It is important that the entire system be circulated in this oper­
after the first unit check should be individually reviewed. This ation so that any foreign material will be brought back to the
checkout phase is extremely important to insure that the CVHE strainers. As a precaution, if the condenser or chilled water
start-up will not be delayed by minor equipment problems which systems are short looped, 24 hours of pump operation could
could abort the start-up and increase the chance for severe in­ increase water temperatures (through pumped water friction
convenience to the owner and the additional expense resulting heat) which could result in excessive unit pressures and possi­
from the delays and start-up rescheduling. bly cause rupture disc failure. To prevent this situation, it is
suggested that an aquastat interlock be installed. This will
It is possible that some of the items in this checkout phase have
sense excess chilled water loop temperature and stop the
been completed and checked earlier to the satisfaction of the
chilled water pump prior to causing rupture disc failure. After
Sales Engineer. The Sales Engineer should be convinced that
this 24 hour period, all system pumps and strainers must be
these areas have not been skipped and should recheck each
cleaned. By this time the system water should have had
area. This phase is primarily concerned with actual equipment
proper treatment to prevent system fouling.
functional checks as opposed to the installation checks com­
2. The refrigerant charge should be on the jobsite close to the
pleted earlier.
machine. The contractor is responsible for making the refrig­
Since the start-up date will now be quite close at hand, the Sales erant conveniently available. Be sure that sufficient refrigerant
Engineer and start-up Service Engineer should plan to meet to is available per the order writeup sheet. Also at this time, the
discuss the job and make required information available. remaining items in the loose parts box shipped with the unit
should be checked and parts made convenient to the unit.
The Sales Engineer and Service Engineer job review should be 3. Electrical supply power should be checked for availability. A
scheduled at least two weeks prior to the actual start-up. Design non-interruptable 120 volt AC source should be accessible
data on the order writeup should be discussed and a copy be near the machine for vacuum pumpout operation and other
made available for the Service Engineer. All interconnecting Service Engineer start-up needs.
wiring diagrams associated with this job and overall system elec­ 4. The cooling tower fans should be checked for proper rotation
trical and pneumatic diagrams should be reviewed and copies and operated for at least 24 hours. The tower fan should be
transferred. This includes any additional diagrams for heat recov­ operated this long to insure that proper fan pitch is set and that
ery controls. In addition, the heat recovery control scheme should the motors are not overloaded. In marginal cases a fan may
be thoroughly discussed to insure that the Service Engineer is fa­ operate several hours before the overloads trip. Cooling tower
miliar with and understands the control system. The design con­ controls should be checked for proper operation and thermo­
trol schedule for tower water temperature, heating load water and stats set for design temperatures. Final calibration will be done
hot gas bypass should be fully reviewed, along with suggestions by the start-up Service Engineer.
for minor control setting deviations in the event the design condi­ 5. A check should be made so that sufficient equipment room
tions cannot be met during start-up. All unit specials, such as unit heat will be available when needed during the machine startup
options or the addition of ethylene glycol, should also be dis­ so that proper evacuation and dehydration can be performed.
cussed at this time. A temperature of at least 70 F will be needed during evacu­
ation so that enough heat will be available to boil off any mois­
The Service Engineer is responsible for obtaining copies of the
ture in the machine. This provides a safe margin above freez­
appropriate installation, operation and sales literature which will
ing and also allows evacuation in the shortest possible time.
eventually be given to the customer or owner. This includes
6. To be certain that sufficient load will be available for the ma­
copies of suggested log forms which can be used by the operator.
chine at start-up, all system cooling load air handling units and
At the jobsite, the Sales Engineer is responsible for the following coils should be operable. In addition, a sufficient heating load
final checks prior to the scheduled start-up date. should be available if the unit is a heat recovery machine.

4.0-2
 COKFlPTruTn, HERMETIC CENTRAVAC SERVICE GUIDE
Use ' HCTV-SG-2
X FEBRUARY 1982

7. At some time during the final checkout p h a s ^ rffie -S a f^ e n - Ux 1%T>DAY

gineer should insure that arrangements have been made to
have the electrician, control representative and contractor re­ 7:00 to 8:00 - Travel to the Job: One hour has been allotted for this
presentatives available for the scheduled start-up time. The recognizing that some jobs may be closer or further than this. This
specific times should be arranged by the Sales Engineer for is an average time, plan arrival each day for 8:00 a.m.
each of these representatives with information provided by the 8:00 to 8:30 - Unload tools. Refer to the recommended tool list at
start-up Service Engineer. the end of this section. Since most jobsites should have an area
When the preceeding items have been completed to the Sales where tools may be temporarily stored, unload all the tools that
Engineer's satisfaction, the installation check sheet should be will normally be needed for the three day job. If storage is not
completed and signed by the contractor. With this form the con­ available, consider the use of some form of locking tool box with a
tractor certifies that the machine and all related systems are in­ suitable chain lock for attachment to a solid point at the machine
stalled properly and that he is satisfied that the machine is ready location. A tool inventory list is helpful to insure that all tools are
to start. This form, if used correctly places some responsibility on recovered upon leaving the job.
the contractor. If delays are caused in the start-up because of
8:30 to 8:45 - Relieve the holding charge at the compressor and
items certified to be complete and in fact are not complete, oil pump motors, close the purge valve, set the oil pressure con­
charge-backs to the contractor for delays may be in order.
trol, open the gauge valves and check and calibrate the high pres­
The following items should be checked and taken care of. sure control.

1. Prior to the scheduled start date the controls representative The holding charge on a CVHE as shipped is 4 to 8 psig. Although
should thoroughly check the control system. All controls this pressure may vary somewhat with temperature changes
should be checked for proper piping and wiring and should be there should be some positive charge remaining. If the holding
roughly calibrated with power to the system. charge has been lost, the unit must be pressure tested, leaks re­
2. All heat recovery controls should be similarly checked and paired and the locations and amounts of damages noted on the
calibrated. log. Leak testing is not a normal start-up procedure for CVHE ma­
3. Finally, if the building has special security requirements for ad­ chines and a separate time allowance should be made within this
mission the Service Engineer should have prior clearances ar­ procedure as necessary. Leak testing procedures are covered in
ranged for him for the days of the start-up. Section 5.2 of this Service Guide.
The CVHE motor should be tested using a megohm meter at the
START-UP: Trane Service Engineer Responsibility motor terminals with the power leads disconnected. This will pre­
As part of the Service Engineer’s preparation for the actual m a­ vent any interference to the test by potential mdtor lead insulation
chine start-up he should already have obtained the necessary weakness. Megging should test each phase to other phases and
design data, order writeup, wiring diagrams, control diagrams, all to ground per the start-up log. Be suspicious of any major
necessary interconnecting diagrams, heat recovery control dia­ megohm reading differences between phases or between a
grams with initial control settings and all necessary Sen/ice Lite­ phase and ground. A megohm resistance chart is in Section 5.3.
rature and applicable Service Bulletins. Motor megging must be done before evacuation and again after
the unit is charged with refrigerant.
In addition, the Service Engineer and Sales Engineer should
review the job materials together bringing the Service Engineer NOTE: Motors should never be megged in a vacuum, see Section
up-to-date on prestart checkout and any problems or delays en­ 5.3 for further information.
countered by the contractor which may need special attention. If the megohm readings are outside the limits given in Section 5.3,
They should also review the total system design. The Service En­ clean the motor terminal board with R -11 or denatured alcohol.
gineer should feel comfortable at this point that the job is indeed Any oil, grease or dirt on the board may contain sufficient mois­
ready for start-up. ture to give low megohm readings. After cleaning, the motor
should again be megged. If the readings are marginal, the motor
The start-up of a CVHE machine is planned for three days. Heat
itself may contain small amounts of moisture which should nor­
recovery options add about three and one half hours to the stan­
mally be removed with evacuation and refrigerant charging. This
dard CVHE start-up. Free cooling machines are started with the
can be assured with the second megohm test after the unit is
same time allowances as the standard machine because the ad­
charged.
ditional functions performed in the start-up can be accomplished
within the standard schedule. The High Pressure Control (HPC) can now be calibrated. The
HPC is a safety control which is connected directly with no inter­
One of the best ways to get a feeling for the planning involved in a
vening valve to the CenTraVac condenser. The purpose of this
CVHE start-up and, at the same time, become familiar with the
control is to stop compressor operation through a control relay in
efficient use of time is to follow an actual start-up through the full
the event of excessively high condenser pressure.
three day schedule.
Now remove the high pressure control line at the control panel.
On the day prior to the first day of start-up the Service Engineer
Connect a regulated cylinder of nitrogen or R-12 with a gauge and
should gather together all literature, wiring diagrams, control dia­
bleed valve to the control panel fitting.
grams and order writeup information. All tools required should be
gathered together. At the end of this section a recommended list Energize the panel by closing the fused disconnect. Increase test
of tools that should be available for the start-up is given. pressure to 15 psig. The HPC should operate at this point and the
high pressure fault indicator should operate. Recalibrate if neces-

4.0-3
 CONFIDENTIAL
HERMETIC CENTRAVAC SERVICE GUIDE USG .]I 3 $'!; j
r i .

HCTV-SG-2 10:00 to 10:30 - Pressure test the purge system. Refer to Section
b zJL os Oj -o r 5.2 of this Service Guide.
FEBRUARY 1982
sary. Now reduce the pressure to 10 psig, reset the Fault Indi­ 10:30 to 11:15 - Set the low temperature control, oil temperature
cator Circuit Breaker after the pressure bleeds down. The control control, and Chilled Water Demand control (Start-Stop). Setting
contacts should close at 10 psig. Again, recalibrate if necessary. and calibration of these controls are covered in Section 8.0 of this
Reconnect line to HPC. Service Guide.
8:45 to 9:00 - Connect and start vacuum pump. The vacuum LUNCH BREAK
pump should be connected to the charging valve located at the 12:15 to 12:45 - Check the starter to see that connections are
bottom of the evaporator. The vacuum pump used should be a 50 tight. Ring out motor leads.
cfm or larger two-stage pump capable of producing a one mm HG
or lower absolute blank-off pressure. Smaller pumps will take too With the main disconnect breaker “ off” and safety locked, check
long and single stage pumps will not achieve sufficient vacuum to each electrical connection in the starter panel. All terminals must
properly evacuate the machine. Be sure that the vacuum pump be tied in and leads properly connected. All leads should be iden­
power circuit is non-interruptable so that no one will be able to tified and checked with a continuity tester for correct phase. Final­
turn off the pump during the evening. ly, check that all power leads and conduit have balanced repres­
entation. Each conduit must contain an equal number of each
It is advisable to let the pump run overnight so that refrigerant en­ phase. Motor leads with two conduits must have leads 1 ,2 and 3
trained in the oil is removed. If, by the end of the first day, max­ in one conduit and leads 4, 5 and 6 in the other. Do not allow a
imum vacuum (1 mm HG absolute) has been achieved, turn the phase representation which is 1 , 2, 6 and 4 , 5 , 3 or any other com­
pump off prior to leaving. bination where unequal phase representation exists. Even
Proper use of the night running time to evacuate the machine is though each phase is represented, the leads are not on the same
important, so that refrigerant charging may begin early in the side of the closed transition starter and conduit heating will result
morning. from the imbalance. Additionally, this can cause phase imbal­
ance at the motor resulting in loss of efficiency.
9:00 to 9:45 - Check and adjust water flow rates (chilled water cir­
cuit, condenser water circuit, heating water circuit). 12:45 to 3:30 - The remainder of the first day is devoted to check­
out of the major controls for the machine. Check all interlocks, op­
Flow rates are determined by subtracting leaving pressure from tional flow switch wiring, control panel to starter panel inter­
entering pressure and converting the net pressure from psig to connecting wires and disconnect switch.
pressure in feet of water. (Multiply psig times 2.3). By using the
charts found in Section 9.0, flow rates in gallons per minute can If the unit is properly evcuated at this time, isolate the vacuum
be determined. The order specification sheet gives design net pump and turn it off. Record pressure on unit both now and in the
pressure required in feet of water and this should be all that will be morning to be assured of system integrity.
needed. All circuits must be trimmed per the order write-up and
In a twelve hour time period the pressure should not exceed 2.5
logged. If the system has multiple gauges at different elevations,
mm Hg absolute.
be sure to correct for the 1 psig per 2.3 foot water difference in
pressure. 3:30 to 3:45 - Cleanup of tools.
Since flow switches are usually included in the system design, 3:45 to 4:45 - Travel from job.
these will need to be adjusted at a reduced flow rate. A conser­ 2ND DAY
vative method is to allow the switches to open at the minimum
pressure drop or 50% of design, whichever is greater (if the flow The electrician and control representative should be available
switch is not adjutable be sure that it operates correctly within the today. The Sales Engineer should have already arranged for this.
desired flow range).
7:00 to 8:00 - Travel to the job.
Using the charts mentioned above and found in Section 9.0, the
8:00 to 8:15 - Check vacuum, start chilled water pump.
minimum pump flow rate can be converted to pressure differential
for both the evaporator and condenser. Adjust the flow to this cal­ The vacuum from yesterday should still be holding within limits.
culated pressure differential and adjust the flow switch to open at This reconfirms that the system integrity is intact. Start the chilled
this time. After calibration, retrim the flow rates to design. water pump to protect the tubes from potential freeze damage
while charging. Freeze damage potential is greatest during early
10:00 - Heat Loop: Add one quarter hour for checking and adjust­
ing heating water flow rates on heat recovery machines. stages of charging into a deep vacuum. On R-11 machines, for
example, the refrigerant vapor temperature will be below 32 F
9:45 to 10:30 - Energize Oil Heaters: This is an important time to until the evaporator pressure reaches 11.87 inches HG absolute.
do this because heating the oil will also assist in accelerating the Always vapor charge the unit until a pressure above 11.87 in Hg is
evacuation process. The oil sump temperature controller should obtained. Once the unit pressure is above the equivalent freezing
be set to cut in below 130 F. The oil heater wires will need to be temperature of water it is then safe to charge liquid into the
connected at the control panel and power supplied to the control machine.
panel. (Be sure that other control switches are set to OFF). 8:15 to 8:30 - Begin charging the machine. The required refrig­
erant amount should already have been checked by the Sales
WARNING: Be certain the control panel Is tie-energized Engineer during his prestart checks. The order specification has
before connecting and handling the oil heater wiring. Open a section which indicates the amount of refrigerant shipped. Re­
the main power supply disconnect switch and safety In the quired charge for standard machines is given in Sections 5.2 and
open position. Failure to do so may result In serious personal
9.0. The best method for charging all large chillers is a system
injury or death due to electric shock.___________________ using two drums of refrigerant and a driving charge of nitrogen.
4.0-4
 HERMETIC CENTRAVAC SERVICE GUIDE
This system is considerably faster than draw-in methods which HCTV-SG-2
rely on atmospheric pressure and negative machine pressures. It FEBRUARY 1982
requires assembly of suitable connectors and fittings and uses ni-
To illustrate this calculation further, take a look at a typical exam­
‘ rogen to positively drive the refrigerant into the machine. This is a
ple. Evaporator refrigerant pressure will slowly increase as the
necessity with R -11. Section 5.2 details the charging procedure.
evaporator is charged with refrigerant, but will stabilize as a func­
8:30 to 9:00 - Capacity Control Setup. The settings listed in Table tion of the temperature of the water circulating through the evapo­
1 are recommended starting points for the Capacity Control Mod­ rator. Assume that the water temperature and refrigerant pres­
ule. Once the system is under running conditions, the settings sure stabilize at 50 F and 12” Hg evaporator suction gauge. First,
may be changed for better performance. Suggestions for possi­ convert 12” Hg to "negative” psig by dividing by a conversion fac­
ble changes are given in Section 7.12 of this Service Guide. To tor. This factor is 29.92" Hg divided by 14.7 psi for a standard day
prepare the Module for machine start-up, make the settings as at sea level.
listed in Table 1. The factor would be 2.035” Hg per 1 psi. 12” Hg divided by 2.035
gives an equivalent minus 5.897 psi. The net oil pressure to open
NOTE: It is important to check the contactor wiring of the tem­ the OPC contacts is 5 psi net and to close contacts it is 9 psi net.
perature sensor(s). It must be wired with the correct polarity, i.e. The gauge will read as follows:
the black or negative wire must be on Terminal TS1, for correct
control operation. 5 PSI NET + (-5.897) = -.897 PSI
9 PSI NET + (-5.897) = +3.103 PSIG
9:00 - Add 1.25 hours for checking hot gas bypass (if applicable)
on heat recovery systems. The minus psi figure can be converted to gauge vacuum by m ulti­
plying by the conversion factor. This will give a vacuum of 1.825"
9:00 to 9:30 - Turn on the auxiliary water to the purge condenser, Hg for the open contact reading.
adjust the water regulating valve, check and adjust the Oil Pres­
Finally, with the OPC calibrated, raise the pressure to 18 psi net
sure Control (OPC).
pressure. This pressure, with the compressor off, corresponds to
The valves from the chilled water loop should be closed (two 12 psi net pressure with the compressor operating.
valves) and the auxiliary water valves opened to supply water to
Following the previous example, the 18 psi net pressure would be
the purge condenser. If the auxiliary water is piped from an ex­
calculated as follows:
tremely distant point it may take some time for the temperature of
the w ater to drop. Under these circumstances, special in­ 18 PSI NET + (-5.9) = 12.1 PSI GAUGE
structions may be required to be given to the operating personnel. or 12.1 PSI - (-5.9) = 18 PSI NET
Record the time required for the auxiliary water temperature to
drop at the purge inlet to normal supply temperature (80 F). Pass After the oil pressure is set, retighten the locking nut and turn off
this information on to the operating personnel as a special oper­ the oil pump.
ating instruction.
9:30 to 10:30 - The solid state overload relay setting should be
The OPC, located in the control panel, senses differential oil pres­ checked and the starter dry run at this time.
sure across the compressor bearings and prevents compressor
operation if the pressure should fall below the minimum setting of WARNING: Before working on this or any electrical equip­
5 psig. The control contacts should therefore open at 5 psig and ment, always disconnect the power supply. Failure to do so
close at 9 psig. The control is calibrated by adjusting the oil pres­ may result In serious personal Injury or death from electric
sure regulating valve located on the oil sump cover. With the oil shock. ______________________________________ _ _
pump switch set to “ MANUAL” , check for positive oil pressure, Before checking the overloads the starter should be inspected for
(correct oil pump rotation) and then decrease the oil pressure reg­
loose connections, loose controls and also for dirt and debris
ulating valve setting (after loosening the locknut). Monitor the oil
which may have fallen into the starter cabinet. All wire terminal
pressure at the control panel. The oil pressure gauge reading
joints should be tightened to the proper torque values as shown
must be corrected by subtracting the evaporator pressure to
on the chart on the starter panel door. This chart is also shown in
obtain the net oil pressure. Chart 1 reflects the following calcu­ Section 9 of this Service Guide. Any dirt or debris which is found
lations used to determine net oil pressure.
must be removed from the starter before proceeding.

TABLE 1 - Typical Base Settings for the Trane Capacity Control Module

Front Panel Adjustments Typical Settings

% Current Control Knob 100% or as desired
Control Point Desired Leavinq Water Temperature
Inlet Vane Control Knob ■AUTO"
Back of Panel Adjustments Typical Settings
Reset Gain Both off for no reset
Switches #1 & #2 If reset is used consult salesman for job specification
Dead Band Both on tor ±1.5 F
Switches #3 & #4 Dead Band
Load Delay #5 & #6 on for 30 seconds of delay
Switches #5 - #9

4.0-5

r
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

I
 HERMETIC CENTRAVAC SERVICE GUIDE
C0T7FTT>ETTIT AL’ HCTV-SG-2
U se u ../'.lo te d . FEBRUARY 1982
b^_Coai. L Order
12:00 to 1:00 - Lunch When the machine has stabilized (at design water flows, design
entering condenser w ater temperatures, and design leaving
1:00 to 2:45 - Fine tune all controls. As the system should now be chilled water temperature), take an accurate log of all tem­
stabilized, the controls should be fine tuned to maintain proper peratures, pressures, and other data. This log is required for re­
chilled water output with maximum efficiency. Check the water imbursement of start-up expense to the Sales office, but its func­
flow rates, water temperature control, and current control. tion is to provide an accurate record of actual performance which
2:45 to 3:45 - Stop the machine and clean up tools. Even though can be compared with later logs to determine possible problems
the unit is operating properly, do not allow it to run overnight. Start which may have developed with continued operation. This can be
essential to the service agency as well as the factory repres­
the machine in the morning with a full load pulldown. Some ser­
entatives in the event problems develop later.
vice engineers remove a key control wire in the panel to prevent
unauthorized operation. The log has places for five separate readings to be taken at 15
minute intervals at machine design conditions. Multiple readings
3RD DAY
are primarily useful in spotting any small performance drop which
7:00 to 8:00 - Travel to the job. could be caused by hard-to-detect obstructions, such as foreign
objects in water lines or heat exchangers, or for changes in oper­
8:00 to 10:00 - Start up and log the unit.
ation as the unit stabilizes at a typical load as opposed to "pull
down” operation.
To check the overload calibration the first step is to compare the
unit RLA and Solid State Overload Calibration figures listed on 12:00 - Add two hours for fine tuning heat recovery controls. A
the cover of the overload with the unit nameplate and order w rite­ heat load must be available to accurately fine-tune the control of
up data. The solid state overload is factory calibrated by the over­ the heat recovery functions.
load manufacturer but changes in the chiller design can cause the
calibration to be incorrect. The calibration of the overload should 10:00 to 12:00 - Instruct operating personnel.
be changed if necessary. In all cases, the setting of the solid state
In addition to machine operating service literature, an operating
overload current calibrator should be checked. Refer to Section
training seminar is available which explains the machine cycles,
7.12 of this Service Guide for the procedure.
standard controls, and routine operation and maintenance pro­
cedures. With heat recovery machines, special care must be
The starter should now be dry run to ensure that the starter is both
taken to ensure that the operator has an understanding of the
mechanically and electrically sound. The procedure is given in
heat recovery functions. If there is more than one machine oper­
Section 8.13 of this Service Guide.
ator, it may be more beneficial for the office and the owner to ar­
10:30 to 12:00 - Bump the motor over to confirm proper rotation range for a special seminar to instruct all operating personnel and
and proper motor cooling. their supervisor on equipment operation.

The motor leads can now be connected at the starter panel. Turn The operator training function is important. Instruct the personnel
the main disconnect off and safety lock. Connect the leads as on how to take proper log readings, recognize developing prob­
marked and checked earlier. Insure that the control panel lems, properly purge the machine, and to be aware of other spe­
switches are set properly and re-energize the main disconnect cific areas which could affect the life or performance of the unit.
and control panel. Start the oil pump and with the help of the own­
1:00 to 2:00 - Clean up tools. After lunch, pack tools and clean up
er’s representative, have him start the unit while observing the
any areas which may have been missed. Be sure to use the tool
machine for proper compressor rotation. Rotation of the com­
check list.
pressor shaft should be counterclockwise as viewed through the
shaft sight glass. 2:00 to 3:00 - Travel from the job.

In the event of improper rotation, two starter power leads (main The CVHE start-up procedures just concluded have made certain
power input leads) should be reversed. If this cannot be easily assumptions which have a direct bearing on the completion time.
done the motor leads may be reversed; however, if this is done, Virtually all of day # 3 is used for logging, fine tuning and operator
both sets of leads on a 6-lead motor must be changed. For exam­ training. This is in effect a buffer time period to provide sufficient
ple, if leads 1 and 2 are reversed, then leads 4 and 5 must also be flexibility in the event of minor delays.
reversed.
It is important for office reimbursement that any time items which
On R -11 machines, after ensuring correct rotation, let the com ­ belong in the shipped product defect program be seperated from
pressor run and check the motor cooling sight glass. The motor normal start-up items. The time allotted for start-up does not in­
must fill with liquid refrigerant within 2 minutes. If refrigerant clude time for repair of unit defects. By the same token, delays
cannot be seen within this time, stop the unit and determine the caused by poor contractor coordination do not belong in the al­
cause. lowance for start-up. Contractor delays as a result of last minute
scheduling problems or manpower delay are the responsibility of
The oil pressure should be rechecked in order to confirm running the contractor.
pressure at 12 psig net pressure. The pressure adjustment was
initially made with an 18 psig net differential with the compressor
stopped. By subtracting evaporator pressure from total oil pres­
sure, running net oil pressure of 12 psig results.

4.0-7
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
CONFIDENTIAL
FEBRUARY 1982 Use Re stricted
by Court Uiuer

Recommended Tool List For Model CVHE CenTraVac Start-

Up

1. Motor Megger
2. Volt-Ohm Meter (Digital)
3. Amprobe
4. Pressure gauge for setting controls
5. Mercury thermometers - 1/5° accuracy
6. Phillips and standard screwdrivers
7. Wrenches
8. Crescent wrenches
9. Refrigerant valve wrench
10. Socket set
11. Rags
12. Refrigerant charging hook-up
13. Nitrogen bottle pressure regulator
14. Refrigerant pressure - temperature chart
15. Vacuum pump
16. Vacuum gauge
17. Leak detector
18. Jumper wires
19. Trouble light or flashlight
20. Thermal conducting paste (for thermometers)

PRINTED BY PRODUCTION SERVICES LA CROSSE FWB KAP

4.0-8
 LITERATURE FILE NO. HCTV-SG-2

PERIODIC M AIN TEN AN CE SECTION

5.0
FEBRUARY 1982
PERIODIC MAINTENANCE will be noticed. For example, if over a period of a month, a gradual
increase in condensing pressure is noted, the probable cause
The purpose of this section is to provide a recommended periodic can be checked and corrected before a major problem occurs.
maintenance schedule and other maintenance information. Not only will a major problem be avoided, but the operating effi­
Some of the procedures, such as control checkout, are covered in ciency can be maintained at a high level. Also, the operating ex­
other sections found under the 'CONTROLS” tab. pense can be held at a minimum.
During the initial machine startup procedure, the Service En­
Daily Maintenance
gineer should acquaint the operating personnel with the mainte­
nance guidelines suggested in this Service Guide and which are 1. The operator should check the unit operating conditions
also in the CVHE Owner-Operator Guide (CVHE-M-1). A com­ against those given in Table 1 and in the Owner-Operator
plete periodic maintenance program is crucial in maintaining a guide. Readings should be recorded on the operating log.
machine so that it operates efficiently and reliably. Proper mainte­ 2. The oil sump oil level should be checked. There are two sight
nance will usually assure that minor problems do not develop into glasses on the oil sump head. The oil level must be main­
a costly machine shutdown during the cooling season. It is im­ tained between the sight glasses. If it is continually neces­
portant that operating personnel understand the concept of pre­ sary to add oil to the unit, unusual operating conditions or
ventive maintenance and that they adhere to the recommen­ compressor problems are indicated and must be corrected.
dations given in this Service Guide and the Owner-Operator
literature. Following is a recommended maintenance program. Weekly Maintenance

Operating Log 1. At weekly intervals the purge drum sight glass should be
checked for evidence of moisture. Water condensed in the
An important part of the CenTraVac maintenance program is the purge drum floats on the surface of the liquid refrigerant. Nor­
operating log. A typical log is shown on Page 5.0-2. The log mally a line of separation may be seen in the sight glass.
should be filled out by operating personnel on a predetermined Water is removed from the refrigerant side of the CenTraVac
schedule, usually on a daily basis. The biggest value of the oper­ system by operating the purge compressor until a positive
ating log is that over a period of time, trends in machine operation pressure of 5-10 psig is indicated on the purge drum pres-
TABLE 1 - Normal Operating Conditions

Evaporator Pressure 12 to 18 Inches Hg Vacuum

Condenser Pressure* 2 to 12 PSIG
Purge Drum Pressure 0 to 22 PSIG
Oil Sump Temperature
(Unit Not Running) 130 to 135 F
Oil Temperature
(Unit Running) 110 to 140 F
Net Oil Pressure** 12 to 18 PSIG
* Condenser pressure is dependent upon the temperature and GPM of
the condensing water. The pressure should be equal to the saturation
pressure of R-11 at a temperature 5 to 10 F above the leaving con­
denser water temperature.
" Net Oil Pressure (usable oil pressure is determined by subtracting Oil
Sump Pressure (Evaporator Pressure) from Oil Pressure Gauge.
Example:

Oil Pressure Gauge — 5 PSIG CONFI 7 1££

Evaporator Pressure — 18” Hg Vacuum U se K e c s ■j ;• -■-
First convert 18” Hg to PSIG iM L C o u r t _ O x v e *
18 : 2.03 (8.187) PSIG
'TH E TRANE COMPANY 1981 THEN,
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601 5 i 8.87 13.87 PSIG
PRINTED IN U S A

5. 0-1
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

T B a n e
CENTRAVAC OPERATING LOG # 4 ^ cOGomontmc

Unit Designation ________ Unit Serial No. _________ Date

Operator Time Started AM PM

r HOUR OR LOGGING TIME
STATION READING
1 2 3 4 5 6 7 8

Voltage

Amperage
— —

Oil Temp-Sump "F

Oil Level
- - - - - -----------------
Oil Gauge Pressure psig

Evap. Gauge Pressure psig

-- - —
Cond Gauge Pressure psig
—
- ..................
Purge Drum Pressure
(if operating) psig —
Condenser Water
Pressure Difference - psig
-- - ■ • - - - i — —
i
Condenser Water - In F i

Condenser Water - Out F

- — . 1 .....
Refrigerant Liquid Temp.
Condenser - °F
Chilled Water
Pressure Difference - psig — —
Chilled Water In - T

Chilled Water Out - °F

Refrigerant Liquid
Temperature Evaporator °F

% Current

OPERATORS REPORT
ENTER ALL STARTS-STOPS-PERIODIC MAINTENANCE CHECKS, MALFUNCTIONS. ETC

PERIODIC MAINTENANCE CHECKS

WEEKLY QUARTERLY FOR ANNUAL SERVICE INSPECTION
_____ Check oil in Purge Comp. IT IS RECOMMENDED
Operate Purge as needed ____ Oil Purge comp motor THAT THE LOCAL
Check Purge drum tor water ___ Check Purge belt tension TRANE SERVICE COMPANY
____ Clean all water strainers
BE CONTACTED

Ftefer to your Trane Owner-Operator Guide tor Complete Recommendations and Procedures.

5.0-2
 Co n f id e n t ia l ’ HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
Use Kootrieted FEBRUARY 1982
by Court Order
sure gauge. The purge compressor is then stopped and the Annual Maintenance
blow-off valve opened releasing the water and other non­
condensables. Moisture will enter the machine through WARNING:Toprevent seriouspersonal Injury, alwaysdis­
either a tube leak or air leak. Continuing accumulations of connect mainelectrical powerto (he unit whileservicing.
water in the purge drum indicates a need for acting to correct NeverworkonrotatingmachinerywhileIt Isinoperation.
the cause. It is recommended that the machine be shutdown for inspection
once each year to check the items indicated on the following
Every Three Months
checklist. If the system is to be off for an extended period of time,
WARNING:Toprevent seriouspersonal Injury, alwaysdis­ the purge unit must be operated for approximately 30 minutes
connect mainelectrical power to theunit whileservicing. every two weeks to keep the CenTraVac free of air and non­
NeverworkonrotatingmachinerywhileItIsInoperation. condensables. Since the machine is not providing chilled water,
cool water (less than 80 F) must be supplied to the purge con­
The following inspections and adjustments are recommended denser drum by adjusting the water valves to allow alternate
every three months. water flow through the purge condenser.
1. The purge compressor drive belt tension should be checked It will also be necessary to operate the oil pump for 10 minutes
and adjusted as necessary. The belt tension should be such every two weeks during the off period.
that the belt depresses approximately 1/2” to 3/4” under light
hand pressure. See Section 5.1 “ Maintenance Procedures.” If frequent purging is required the source of the air leak should be
identified and corrected as soon as possible. Moisture con­
If necessary, the belt tension is adjusted by loosening the
tamination through air leakage is detrimental to machine life.
motor mounting bolts and sliding the motor. Also check the
drive belt for excessive wear or damage. Other Maintenance Recommendations

2. The purge compressor motor bearings must be lubricated. 1. It is recommended that the condenser tubes be inspected
The motor bearings are lubricated with a good grade of SAE every three years through the use of an Eddy Current test.
20, non-detergent motor oil. 2. It is recommended that the evaporator tubes be inspected
3. Check the purge compressor crankcase oil level through the every 5 years with an Eddy Current test.
crankcase sight glass. With the compressor idle the oil level
should occupy 1/8 to 1/4 of the sight glass. If additional oil is NOTE: It may be desirable to perform an Eddy Current test
required Texaco WF-68 or Mobil Whiterex No. 425 should be on the components more frequently depending upon chiller
added. However, if more than 1/2 pint of oil is required, it is application. This is especially true of critical process
equipment.
possible that oil is being lost from the system. Refer to Sec­
tion for Trouble Analysis information. 3. Every 30,000 or 50,000 hours of operation it is recommen­
4. All system water strainers should be cleaned. ded that the outboard thrust bearing be examined. Look for
excessive wear, scratches, pitting and corrosion. If these
Every Six Months conditions are present it may be necessary to completely
overhaul the compressor. More frequent thrust bearing in­
WARNING:Toprevent seriouspersonal Injury, alwaysdis­ spection may be necessary if the unit has operated for ex­
connect mainelectrical power totheunit whileservicing. tended periods of time under surge conditions or very light
Neverworkonrotatingmachinerywhileit IsInoperation. load (10% or less).

1. Every six months lubricate the inlet vane control linkage Other conditions which may dictate more frequent thrust
bearings, ball joints, and pivot point with light machine oil. bearing inspection include:
Also apply one or two drops of light machine oil on the vane
a. Chronic air leaks. This will contribute to acidic conditions
actuator shaft and spread it into a very light film. This will pro­
in the compressor oil which may lead to premature bear­
tect the shaft from moisture and rust.
ing wear.
2. Inspect and clean the inside of the purge drum. Referto sec­
b. Evaporator or condenser water tube leak. If water enters
tion
the compressor oil the result may be pitting, corrosion, or
3. Cycle free cooling valves and check operation (if applicable).
excessive wear.
4. Flush oil separator. Refer to Section
5. All daily, weekly and three month maintenance procedures 4. R eferto Section for the procedure to be used in inspecting
should also be carried out at this time. the thrust bearing.

5.0-3
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982 MODEL CVHE CENTRAVAC
ANNUAL INSPECTION CHECKLIST AND REPORT

1. REVIEW UNIT WITH OPERATING PERSONNEL

2. COMPRESSOR MOTOR
___MOTOR CONTINUITY CHECK___GOOD __ OPEN
__ CHECK AND TIGHTEN MOTOR TERMINALS
__ MEG MOTOR__ PHASE 1 __ PHASE 2 ___PHASE 3
U se 'ilcz'y-1
__ CHECK NAMEPLATE AMP RATING__ AMPS
□y C p iii t
3. STARTER
__ CHECK OVERLOAD SETTING___ TRIP POINT, AMPS
__ TIGHTEN ALL TERMINALS
__ C H E C K C O N D IT IO N OF S TA R TE R
CONTACTS__ GOOD___ FAIR___REPLACE
4. OIL SUMP
__ CHANGE O IL___GALLONS (7 GALLONS REQUIRED)
__ CHECK OIL CONDITION__ .G OOD__ FAIR___POOR
__ CHECK OIL TEMPERATURE CONTROL SETTING___°F
__ OIL PUMP MOTOR CONTINUITY TEST__ . GOOD___OPEN
__ OIL PUMP MOTOR GROUND CHECK___ GOOD___BAD
__ CHECK MOTOR TERMINALS, TIGHTEN
__ CHECK MAGNETIC STARTER
__ CLEAN ALL STRAINERS
__ CHANGE HI-DENSITY FILTER
5. CONTROL CIRCUITS
__ LOW TEMPERATURE CONTROL CALIBRATION
__ SETPOINT TRIP-POINT (ICE WATER)
__ HIGH PRESSURE CONTROL CALIBRATION
__ SETPOINT TRIP-POINT (USE OIL-PUMPED DRY NITRO­
GEN TO CHECK)
__ OIL PRESSURE CONTROL CALIBRATION
__ CUT-OUT__ CUT-IN
__ CHECK ADJUSTMENT AND OPERATION OF DAMPER MOTOR
6. CONDENSER
__ VISUALLY INSPECT FOR SCALING IN TUBES, NOTE FINDINGS
AND MAKE RECOMMENDATIONS
7. LEAK TEST CHILLER
8. REFRIGERANT AND OIL ANALYSIS FOR ACID CONTENT
(ATTACH COPY OF ANALYSIS TO NEXT MONTHLY IN­
SPECTION REPORT)
— SAMPLE REFRIGERANT AND OIL FOR LABORATORY
ANALYSIS
9. PURGE UNIT
__ CHANGE OIL IN PURGE COMPRESSOR
__ CONDITION OF Oil____ CLEAR___DIRTY___ WET
__ CHECK CONDITION AND LEVEL OF FLOAT VALVE
__ MEG PURGE UNIT MOTOR___ TO GROUND
__ MOTOR CONDITION___ CLEAN___DIRTY
__ ADJUST BELT AND PULLEY___ REPLACED BELT
__ LUBRICATE MOTOR
___MAKE LEAK CHECK
__ CHECK AIR RELIEF SETTING
___CHECK COMPRESSOR EFFICIENCY
__ DISASSEMBLE AND CLEAN PURGE TANK AND COIL
10. COVER LOGS AND LOGGING SYSTEM WITH OPERATOR
___REVIEW PROPER LOGGING PROCEDURES WITH OPERATOR
11. COMMENTS

12. RECOMMENDATIONS
FWB 'LLW

5. 0-4
 LITERATURE FILE WO. HCTV-86-2

M AIN TEN AN C E SECTION

PR O C ED U RES
5.1
FEBRUARY 1982
MAINTENANCE PROCEDURES

This section describes in detail procedures to follow when per­

forming the recommended periodic maintenance. Included in this
section are procedures covering the following items:

Purge Unit
Lubrication
Refrigerant Level
Cleaning the Condenser
Cleaning the Auxiliaries
Compressor Oil

Other maintenance procedures are described in later sections of

this Service Guide.

PURGE UNIT (Refer to Figure 1)

WARNING:Beforeattemptingtoperformanymaintenance
onthepurgeunit,disconnecttheelectricalpowersupplyto
thepurgeunitheaterandthepurgecompressordrivemotor.
Beforeworkingonthisoranyequipmentalwaysdisconnect The procedure is as follows:
theelectrical power supply. Switchesshouldbelockedor 1. Stop purge unit operation.
Isafetledindie“OFF"position. Failuretodoso mayresultin
j accidental shockor dea thbyelectrocution.______________ WARNING: Before working on this equipment discon­
nect the electrical p o em to prevent personal Injury or fa­
DRIVE BELT tality caused by accidental electric shock or from be-
comlng entangled In the rotating parts._____________
Check and adjust the purge compressor drive belt tension. See
Figure 2. The belt should be adjusted so that it will depress ap­ 2. Remove the purge compressor drive belt.
proximately 1/2" to 3/4” under light hand pressure. Also inspect 3. Loosen the four motor mounting bolts at the base of the
the drive belt for excessive wear or damage. Replace as required. motor.

CTHE TRANE COMPANY 1981

COMMERCIAL AIR CONDITIONING DIVISION C O U P ID&flry T o r ­
LACROSSE, WISCONSIN 54601
PRINTED IN U S A t's e
^ -^ ■ ^ L Q rd a r
5.1-1
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982
4. Slide the motor away from the compressor to achieve the 2. P o u rl pint of Texaco CapellaW F-68 or Mobil 425 oil into the
proper belt tension. separator.
5. Retighten the motor mounting bolts. 3. Reinstall the line and fitting removed in Step 1.
6. Reinstall the drive belt guard. 4. Disconnect the oil return line connection at the compresso.
crankcase.
PURGE MOTOR BEARINGS 5. Cap the crankcase fitting and install a 2 or 3 foot piece of
The motor bearings are to be lubricated with a good grade of SAE tubing on the open end of the oil return line. Place the open
20 motor oil. This should be done on a three-month basis. Figure end at the tubing in a container.
3 illustrates the lubrication points. 6. With all the control panel switches in the “ Off" position, con­
nect the “ Purge Heater” and place the “ Purge Compressor”
PURGE COMPRESSOR CRANKCASE OIL LEVEL switch in the “ Manual" position, starting the purge com­
pressor. With the compressor in operation, oil will flow from
The oil level must be visible in the purge compressor sight glass
the separator into the container. When the flow of oil ceases,
shown in Figure 1.
stop the compressor.
NOTE: If more than 112 pint of oil is required to bring the level up
Repeat this procedure, each time adding new oil until the
to normal, check the oil separator heater and the separator float
separator has been thoroughly flushed.
valve. It may be possible that oil is not being returned to the com­
7. After the flushing procedure has been completed, tighten the
pressor from the separator. Do not run purge unit until the condi­
discharge line connections and reconnect the oil return line
tion has been corrected.
at the compressor crankcase.
PURGE UNIT OIL CHANGE
PURGE COMPRESSOR CRANKCASE
The purge unit must be isolated from the rest of the CenTraVac
1. Slowly remove the fill plug (see Figure t) from the com­
system while changing oil. To do this, close the purge outlet valve
pressor crankcase to allow the pressure in the system to
located on the side of the evaporator. Use the following in­
bleed off.
structions to remove and change the oil.
2. Siphon the oil from the crankcase.
OIL SEPARATOR 3. Refill the crankcase with Texaco Capella WF-68 Oil of Mobil
425.
1. Loosen the compressor discharge line connection at the top
of the oil separator shell to relieve the pressure. Move the PURGE DRUM CLEANING REFER TO SECTION
line enough to gain access to the oil separator.
PURGE DRUM WATER ELIMINATION

Water condensed in the purge drum will float on the surface of the
liquid refrigerant. Normally a line of separation can be seen
through the purge drum sight glass.

When water is observed, turn off the purge compressor and open
the blow-off valve (see Figure 1) until all of the water has been
drained.

LUBRICATION

The only points of the CenTraVac that require periodic lubri­

cation, other than the purge compressor motor, are the bearing
surfaces of the external vane linkage assembly.

Lubricate the vane shaft bearings and the rod end bearings on the
vane linkage with a few drops of light machine oil.

REFRIGERANT LEVEL

Refer to Figure 4.

To obtain the refrigerant level in the machine it is necessary to

FIGURE 3 - Purge Motor Lubrication Point

.-p T '

.* v ,.
— :

5. 1-2
 HERMETIC CENTRAVAC SERVICE GUIDE
*COHFID^lIT I AI.'_ HCTV-SG-2
Use Led FEBRUARY 1982
by Co u r t .Order

FIGURE 4 - Checking Refrigerant Level

TABLE 1 - Model CVHE Refrigerant Charges

NOMINAL TONS
200 315 500 “I 800 1250
EVAP
DESIGNATOR
1C 340 575 770 1075 —

2C 340 560 760 1000 —

3C 320 545 730 980 —

4C 300 525 700 950 _

5C 300 440 660 820 —

1D 450 750 1020 1400 2500

2D 450 750 1000 1320 2390
3D 425 675 975 1275 2360
4D 400 675 900 1250 2280
5D 400 620 870 1090 2140

1C 480 725 1200 1580 _

2C 480 715 1040 1480 —

3C 450 660 1000 1340

4C 400 660 920 1330 —
5C 400 610 870 1260 —
1D 640 1050 1580 2070 3450
2D 640 940 1370 1950 3260
3D 590 870 1300 1870 3125
4D 525 860 1210 1740 3020
5D 525 800 1140 1650 2770
Add for short or
long heat recovery 50 100 150 200 300
condenser
Add for auxiliary
condenser 50 50 50 50 50
_______

5.1-3
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 Use
FEBRUARY 1982 by Cou1 1
shut the unit oft. Also shut off the condenser and chilled water NOTE: If the compressor oil is to be changed at the time the
pumps. After 1-2 hours the refrigerant will have drained to the system is to be leaked tested, build a slightly positive pressure in
evaporator and the level may be checked. the system (2-5 psig) using dry nitrogen and then drain the oil
from the sump.
Attach one end of a length of clear tubing to the evaporator gauge
tubing connection on the evaporator. Attach the other end of the Pump the new oil into the sump before developing the full pres­
clear tubing to the valve at the bottom of the evaporator. sure necessary for the leak test.

Holding the tubing near the evaporator tube sheet and compare WARNING;DEENERGIZETHEOILSUMPHEATERBYOPEN­
the refrigerant level in the tube to the bench mark on the tube INGTHECONTROLPANELDISCONNECTSWITCH,BEFORE
sheet. Add or drain refrigerant as necessary to bring the level to DRAININGTHESUMP,OTHERWISETHEHEATERWILLBURN
the bench mark. Table 1 provides refrigerant charge amounts in OUT.________________________________________________
pounds of refrigerant.

C LEA N IN G T H E C O N D EN SER TABLE 2 - Oil Specifications

The formation of scale or sludge in the condenser water tubes is Viscosity at 100 F: 256-325 SSU
indicated by high condensing temperature and low temperature Viscosity at 210 F: 47-55 SSU
difference between the inlet and outlet water. Pour point: -20 F or Below
Floe Point: -40 F or Below
M EC H A N IC A L CLEA N IN G Aniline Point: 190-220 F
Moisture: 30 PPM Maximum
The mechanical method is used to remove sludge and loose ma­ Defoamant (DC 200): 0-30 PPM
terial from the condenser tubes. Remove the water box covers by Acid: .05 mg KOH/GRAM Based
removing the nuts and bolts and ease the covers off with a hoist. on Titration Method

Work a round nylon or bristle brush, attached to a rod, in and out

of the tubes to loosen the sludge. After the tubes have been DRAINING T H E O IL SUM P
cleaned, flush with clean water.
The saturation pressure of Refrigerant 11 is less than atmo­
C H EM IC A L CLEA N IN G spheric pressure at temperatures of less than 75 F. The satur­
ation pressure is greater than atmospheric pressure at tem­
Scale deposits are best removed by chemical means. The stan­ peratures greater than 75 F. If the ambient temperature is 75 F or
dard condenser water circuit is composed solely of copper and above, and the evaporator pressure gauge indicates a positive
cast iron. Any large chemical house in the area, knowing the pressure, simply open the oil sump charging valve located at the
chemistry of the water, will be able to recommend a cleaning solu­ rear of the oil sump and drain the oil into a suitable container.
tion suitable for the job. Figure 5 illustrates a typical chemical
cleaning setup. If the ambient temperature is less than 75 F and the evaporator
pressure gauge indicates a negative pressure, it will be neces­
All materials used in the external circulation system, quantity of sary to pump and draw the oil from the sump. This is done as
solution, duration of cleaning period and any required safety pre­ follows:
cautions should be approved by the company furnishing the ma­
terials or performing the cleaning. 1. Connect a line from an auxiliary oil pump to the oil charging
valve located at the rear of the oil sump.
The Trane Company assumes no liability for equipment damage 2. Operate the pump and then open the charging valve.
caused by improper chemical cleaning procedures or methods. 3. After the oil has been removed from the sump, close the
charging valve.
CLEA N IN G TH E AU XILIA R IES As an alternate procedure, it is possible to build a slight positive
The coils of the purge unit will be subject to the same type of scal­ pressure in the CenTraVac using dry nitrogen. This will force the
ing as the condenser, if they are supplied with the same water oil out, making an auxiliary pump unnecessary.
source. However, if the auxiliaries are connected up to the chilled
FILLING THE O IL SUM P
water circuit, cleaning will usually not be required.
To prevent dirt and other foreign matter from entering the sump,
If the auxiliaries are to be cleaned, use the same chemical meth­ charge the oil directly from the container in which it was shipped.
ods described under “ Cleaning the Condenser” .
1. Connect a clean piece of copper tubing to the oil charging
Thoroughly flush cleaned parts with clear water before con­
valve.
necting them to the remainder of the water circuit. 2. Submerge the open end of the tubing in the container of oil.
C O M PR ESSO R O IL 3. Open the oil charging valve. If the system is under vacuum,
the oil will be readily drawn from the container.
The approved oils for the Model CVHE CenTraVac units are
Mobil 425 and Texaco Capella WF-68. The design oil charge for CAUTION:Topreventtheentryofair, makecertainthat
theopenendof thetuberemainssubmergedIntheoil
all units is 7 gallons. If these oils cannot be obtained refrigeration
oil which meets the specifications given in Table 2 may be used. duringtheentirechargingprocess. Closethecharging
valvebeforeraisingthetubeabovethesurfaceoftheoil.
5. 1-4
 HERMETIC CENTRAVAC SERVICE GUIDE
n O ? 7P ID ^T T T IA L ' HCTV-SG-2
FEBRUARY 1982
L eg - i; o te d
b ^_ _ C u a n
Order
4. After the sump has been filled, energize the oil sump heater NOTE:The above procedure applies only if the system is under a
by closing the control panel disconnect switch. vacuum. If ambient temperature conditions and evaporator
pressure gauge reading indicate a positive pressure, pump the
oil into the system.

FWB LLW

1.1-5
 LITERATURE FILE NO. HCTV-SG-2

PURGE DRUM SECTION

C LEA N -U P
5.2
FEBRUARY 1982
PURGE DRUM CLEAN-UP 1. Stop purge unit operation. When the purge unit is stopped the
purge compressor suction solenoid valve will close isolating
It is recommended that the purge drum be disassembled annually the purge unit from the refrigerant. Confirm that the solenoid
for cleaning and maintenance. To do this, first remove the purge valve is closed by first relieving purge drum pressure, then ob­
drum from the machine using the following procedure. See Figure serve the purge drum pressure gauge. If the pressure does not
1. increase the solenoid valve is holding pressure. If pressure in­
creases the valve is not holding. This will require that the oil
To do this, first remove the purge drum from the machine using
separator connection supplying the purge drum be capped to
the following procedure.
prevent loss of refrigerant. Also, the solenoid valve will have to
WARNING:Moreworkingonthisoranymachinery,always be replaced.
disconnectallelectricalpower topreventpersonalInjuryor 2. Close the purge liquid return valve at the bottom of the
fatllltyduetoaccidental electricshockorentanglement In evaporator.
rotatingparts. 3. Close all water supply and return valves to the purge drum and

WATER CONNECTIONS

END PLATE

FIGURE 1 - Purge Drum FIGURE 2 - Endplate, Coll and Gasket

disconnect the water connections at the purge drum. Refer to 3. Clean the outside of the coil with a brush or solvent. Do not use
Figure 1. a wire brush as this will damage the coil. See Figure 3.
4. Disconnect the evaporator liquid return line connection at the 4. Clean the inside of the purge drum with solvent. Again, do not
purge drum. use a wire brush. See Figure 4.
5. Disconnect the purge drum gas inlet line. 5. Clean out and check to be sure the small vent hole at the top of
6. Remove the 4 purge drum baseplate retaining screws. the divider plate is open. See Figure 4.
6. Clean the inside of the water coil by circulation of a chemical
To clean the water coil:
cleaning solution to remove scale, etc. from the internal
1. Remove the 6 end plate retaining screws. See Figure 1.
surfaces.
2. Remove the end plate with coil and gasket. See Figure 2.
C O T T F ID E U T T A E

•THE TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601
PRINTED IN U S A.

5. 2-1
 - - \ iJ
c o w 'I I W
HERMETIC CENTRAVAC SERVICE GUIDE ,:d
HCTV-SG-2 Use £f
FEBRUARY 1982 C u u ^

remove the float seat retaining nut.

To clean the float valve assembly: 3. Examine the rubber valve (Figure 10) and replace if cracked or
1. Remove the six end plate retaining bolts. See Figure 5.
hardened.
2. Remove the end plate and gasket as shown in Figure 6. 4. If necessary, the float may be replaced by removing the re­
3. Clean the inside of the purge drum using solvent. Do not use a
taining screw shown in Figure 11.
wire brush as this will damage the purge drum. See Figure 4.
Check to be sure the small hole at the top of the divider plate Reassemble the unit in the reverse order of disassembly. Use
and the slot at the bottom are open. new gaskets on end plates - do not use oil or grease on gas­
kets or flanges. Tighten end plate bolts evenly and just until the
To disassemble the float valve: gaskets begin to protrude between the flanges.
1. Remove the cotter pin. See Figure 7.
2. Clean or replace the valve seat shown in Figure 8. To remove Pressure test all joints at 30 psig using dry nitrogen and Refrig­
the seat, remove the 1/4” angle fitting shown in Figure 9. Next, erant 12 as a tracer.

REFRIGERANT END PLATE

RETURN CONNECTION
FIGURE S - Float Valve End of Purge Drum FIGURE 6 - Float Valve Assembly and Gasket

5. 2-2
 CONFIDENTIAL HERMETIC CENTRAVAC SERVICE GUIDE
Use HCTV-SG-2

FIGURE 7 - Cotter Pin FIGURE 8 - Float Valve Seat

5. 2-3
 LITERATURE FILE NO. HCTV-SG-2

TR O U B LE A N A LYS IS SECTION
C H A R TS
6.0
FEBRUARY 1982

The following sections are designed to allow the Trane Service MENDED ACTION. The POSSIBLE CAUSE and corresponding
Engineer to diagnose and correct any operating problems which RECOMMENDED ACTION columns are arranged so that the
may occur. These Trouble Analysis charts consist of three parts: most likely POSSIBLE CAUSE appears first and the least likely
COMPLAINT-SYMPTOM, POSSIBLE CAUSE and RECOM­ appears last.

^ O N F I B E I f T J AT,'
The following trouble analysis sections are: T, , L
SECTION NUMBER TITLE C o u r t ie r

6.1 Chiller Starting Problems

6.2 Oil Pump Starting Problems
6.3 Starter Will Not Pull In, No Fault Indicators Tripped On Starter Panel
6.4 Starter Will Not Transition
6.5 Fault Indicators On Starter Panel Trip
6.6 Control Panel Safety Indicators Trip
6.7 Purge System Trouble Analysis
6.8 Chilled Water Control Trouble Analysis
6.9 Load Limit Trouble Analysis
6.10 Chiller Will Not Load
6.11 Condenser Trouble Analysis and Supplementary Notes
6.12 Evaporator Trouble Analysis and Supplementary Notes
6.13 Compressor Trouble Analysis and Supplementary Notes
6.14 Compressor Motor Trouble Analysis and Supplementary Notes
6.15 Lubrication System Trouble Analysis and Supplementary Notes
6.16 Open Rotor Trouble Analysis
6.17 Locating A Water Leak

®THE TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601
PRINTED IN U S A.

6 .0-1
 LITERATURE FILE NO. HCTV-SG-2

CH ILLER S TA R TIN G SECTION

PROBLEM S
6.1
TROUBLE ANALYSIS FEBRUARY 1982
CHILLER STARTING PROBLEMS
COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
No control panel lights on. Main power disconnect switch open Close disconnect switch

Main power supply interrupted Check power supply wiring and

switches

Control fuse (F1) blown Check fuses

Loose wire in starter or panel Check continuity of circuits to locate

and repair as necessary

Capacity control unload light on only One or more fault trip indicators Reset fault trip indicator
tripped

Loose wire in panel Check continuity of circuits to locate

and repair as necessary

Customer supplied interlock open Check continuity of interlock con­

tacts, repair s necessary

Safeties satisfied light (DS1) on, no No cooling required Wait for cooling load to develop
further lights on

Start-stop control (S3) misadjusted Check chilled water demand control,

or defective see Section 7.4

Loose wire in panel Check circuit continuity to locate,

repair as necessary

Cooling required light (DS2) on, no Anti-recycle timer not timed out Wait 30-minutes between attempted
further lights on starts

Anti-recycle timer defective Check anti-recycle timer, see Sec­

tion 7.5

Loose wire in panel Check circuit continuity to locate,

repair as necessary
Restart time elapsed light (DS3) on, Evaporator flow switch not closed Check continuity of water pump aux
no further lights on contacts and flow switch

Compressor inlet vanes not fully Wait for vanes to be fully closed, see
closed Section 2.0

Inlet vane motor end switch mis­ Readjust vane motor end switch, see
adjusted or defective Section 2.0

Loose wire in panel Check circuit continuity to locate,

repair as necessary

Customer supplied interlock open Check continuity of interlock con­

tacts, repair as necessary

Control contact (K7) not closed Check continuity of control contacts,

repair as necessary
r THE TRANE COMPANY 1982
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
I- . L
PRINTED IN U S A. 7
6.1-1
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Chilled water pump light (DS4) on, no Off-Auto switch in off position Place switch in auto position
further lights on

Condenser water flow switch not Check continuity of water pump aux.
made contacts and flow switch

Off-Auto switch defective Check continuity of switch, replace

as required

Loose wire in panel Check circuit continuity to locate,

repair as necessary

Customer supplied interlock open Check continuity of interlock con­

tacts, repair as necessary
Condenser water pump light (DS5) Oil pump not operating Refer to Section 6.2
on, no further lights on

Oil pressure not sufficient Refer to lubrication system chart

Oil pressure control (S8) misadjusted Check oil pressure control, refer to
or defective Section 7.6

Loose wire in panel Check circuit continuity to locate,

repair as necessary
Oil pump light (DS6) on, no further Anti-recycle timer (S4) not timed out Wait 30-minutes between attempted
lights on starts

Anti-recycle timer defective Check anti-recycle timer, refer to

Section 7.5

Starter not receiving/accepting start Refer to Sections 6.3, 6.4, 6.5 and
signal 6.6

Loose wire between panel and Check continuity of circuits to locate,

starter repair as necessary

Loose wire in panel Check circuit continuity to locate,

repair as necessary

Control contact (K10 Line 29) not Check continuity of control contacts
closed in circuit, repair as necessary
System light (DS7) on, chiller not Starter not receiving/accepting start See Sections 6.3, 6.4, 6.5 and 6.6
starting signal

Loose wire in panel or starter Check continuity of circuit to locate,

repair as necessary

Loose wire in panel Check circuit continuity to locate,

repair as necessary

FWB /LLW

6.1-2
 LITERATURE FILE NO. HCTV-SG-2

O IL PUM P SECTION
S TA R TIN G PR O B LEM S
6.2
FEBRUARY 1982

NOTE: Before using this chart, perform the checks found in Trouble Analysis Section 6.1. Also, in order to use this chart, it is
necessary to disconnect the wire lead at Terminal 14 of the compressor motor starter. Disconnect the wire and tape the end of the
connector on the wire. Next, install a jumper wire between Terminal F1 and Terminal 12 in the control panel. This will energize the
control circuit but prevent the starter from being energized. After the testing is complete it may be necessary to wait thirty minutes
which will allow the anti-recycle timer to time out. It will then be possible to restart the chiller.

OIL PUMP STARTING PROBLEMS

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Oil pump will not start, no power at Disconnect switch open Close disconnect switch
Terminal 12 in control panel on termi­
nal board

Supply power interrupted Check power supply wiring and

switches

Control Fuse F1 blown Replace fuse

Loose wire to Terminal F1 in starter Check continuity of control circuit to

or control panel locate, repair as necessary.

Loose wire in control panel Check continuity of control circuit to

locate, repair as necessary

Oil pump will not start, no power at Loose wire in control panel Check continuity of control circuit to
either terminal C on control Relay K5 locate, repair as necessary

Oil pump will not start, power to Relay Defective relay Check relay operation and continuity
K5, relay not energized through contacts, clean/replace as
necessary

Oil pump will not start, control relay Control relay contacts dirty or burnt Check continuity across contacts,
K5 made, no continuity across K5 clean/replace as necessary
N.O. contacts

Defective control relay Check relay operation and continuity

through contacts, replace as
necessary

Oil pump will not start, control relay Loose wire in control panel Check continuity of control circuit to
K5 makes, S9 oil pump timer does locate, repair as necessary
not run

Control Fuse F2 blown Replace fuse

Control relay contacts dirty or burnt Check continuity through contacts,

clean/replace as necessary

Oil pump timer defective See Section 7.7

S9 Timer motor defective Refer to Section 7.7

"THE TRANE COMPANY (982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601 COITFTPF.II'TIAL'
PRINTED IN U S A.
Uso ii y -y -n -Lobod
6.2-1 py L,_uu J u . . t".r
 C O T ^ E E H T IA E .
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 Use
O r c ie £ .
FEBRUARY 1982
OIL PUMP STARTING PROBLEMS
COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDEO ACTION

Oil pump will not start, S9 timer runs, Loose wire in control panel Check continuity of control circuit to
power not received at Terminal 21 in locate, repair as necessary
control panel

S9 Timer contacts defective Refer to Section 7.7

S9 Timer motor defective See Section 7.7

Oil pump does not run, control panel Loose wire in control panel Check continuity of control circuit to
power to Terminal 21 locate, repair as necessary

Control relay contacts dirty or burnt Clean/replace contacts as necessary

(K14)

Loose wire between control panel Check continuity of circuit, repair as

and oil sump necessary
Oil pump will not run, power to oil Oil pump motor defective Replace motor, see Section 8.1
sump terminal block

Oil pump jammed or seized Replace/free oil pump

Oil pump to motor coupling broken Replace coupling

FWB /LLW

6.2-2
 LITERATURE FILE NO. HCTV-SG-2

S TA R TE R W IL L N O T PU LL IN,
NO F A U L T IN D IC ATO R S SECTION
TR IP P E D ON S TA R TE R PAN EL 6.3
FEBRUARY 1982

STARTER WILL NOT PULL IN, NO FAULT INDICATOR TRIPPED ON STARTER PANEL
COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Starter not receiving start signal at Loose wire between control panel Check circuit continuity, repair as
Terminal 14 and starter necessary

Control panel not sending start signal See chart labelled “ Chiller Will Not
Start" Section 6.1

Pilot relays not pulling in Loose wire in starter Check circuit continuity, repair as
necessary

Both pilot relays defective Check operation, replace as

necessary

K25 (S) contactor not pulling in Loose wire in starter Check circuit continuity, repair as
necessary

Burned out contactor coil Check operation, replace as

necessary

Defective contact on pilot relay Check operation, replace as

necessary

Defective NC contact on K26 or K28 Check operation, repair or replace as

necessary

Defective fault trip indicator Check operation, replace as

necessary

K27 (1M) contactor not pulling in Loose wire in starter Check circuit continuity, repair as
necessary

Defective NO auxiliary contact on Check operation, repair or replace as

K25 (S) necessary

Burned out contactor coil Check operation, replace as

necessary

'c o n f i d e i t t i a t ;
Uoe R c a t - i ■ iv .ic l

co ur l_ Or d. c r

°THE TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A. F W B ,LLW

6.3-1
 LITERATURE FILE NO. HCTV-SG-2

S TA R TE R W IL L N O T SECTION
TR A N S ITIO N
6.4
FEBRUARY 1982

STARTER TROUBLE ANALYSIS - STARTER WILL NOT TRANSITION (STAR-DELTA)

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Motor current does not drop from Compressor inlet vanes not com­ Check vanes and vane linkage, inlet
LRA, motor not up to speed pletely closed vanes should be closed

Extreme voltage drop during start-up Contact power company

Refrigerant carryover during start Refer to evaporator trouble analysis

chart

Components rubbing in com­ Check compressor/motor assembly,

pressor/motor assembly eliminate interference
Motor current does drop below chiller Loose wire in starter transition con­ Check continuity of circuit, repair as
RLA trol circuit necessary

Burned out contactor coil on K26 Check operation, replace as

necessary

Defective auxiliary contact on K25 or Check operation, repair or replace as

K27 necessary

No control power to X1 and X2 in Check circuitry, repair

motor protection module

Motor protection module improperly Recalibrate as necessary

calibrated

Defective transition relay in motor Check operation, replace as neces­

protection module sary, refer to Section 7.13

Defective motor protection module Check operation, replace as neces­

sary, see Section 7.13
Distribution fault indicator trips at Actual distribution fault occurring, Contact power company
transition complete loss of voltage for more
than 1-1/2 cycles

Motor current drops below 15% of Contact La Crosse Service

chiller RLA

Chattering starter contactor Check operation, repair or replace as

necessary

Starter open transitioning Check starter, repair as necessary

Fault trip indicator CB15 defective Check operation, replace as

necessary

Defective transition relay in motor Check operation, replace as neces­

protection module sary, see Section 7.13

°THE TRANE COMPANY 1982

CONFIDENTIAL
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601
Use Kcsr-lrLotoT
PRINTED IN U S A Uy 0 o <x . o U'x i i l' i.
j

6.4-1
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 Use R e s i- - 1 ; i
FEBRUARY 1982

STARTER TROUBLE ANALYSIS - STARTER WILL NOT TRANSITION (STAR-DELTA)

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Motor overload fault indicator trips at Refrigerant carryover occur at start­ Refer to evaporator trouble analysis
transition up chart

Motor acceleration too slow See compressor/motor trouble anal­

ysis chart

Starter transition sequence too slow Contact starter vendor

Power factor correction capacitors Refer to Section 7.13

incorrectly installed

Fault trip indicator CB11 defective Check operation, replace as

necessary

Defective transition relay in motor Check operation, replace as neces­

protection module sary, refer to Section 7.13
Starter fault indicator trips at Loose wire in starter transition con­ Check continuity of circuit, repair as
transition trol circuit necessary

Auxiliary contact on transition re­ Check operation, repairor replace as

sistors staying in circuit necessary

Transition resistors staying in circuit Check operation, repairor replace as

necessary

Defective pilot relay contact K23, Check operation, repairor replace as

K24 necessary

Fault trip indicator CB13 defective Check operation, replace as

necessary

FWB'LLW

6.4-2
 LITERATURE FILE NO. HCTV-SG-2

FA U LT IN D ICATO R S
SECTION
ON S TA R TE R PAN EL TR IP
6.5
FEBRUARY 1982
FAULT INDICATORS ON STARTER PANEL TRIP
COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Motor overload indicator tripping im­ L.R.A. potentiometer set too low Reset as necessary, refer to Section
mediately upon call for start 7.13

Incorrect current calibrator adjust­ Adjust as necessary, refer to Section

ment or installation 7.13

Locked rotor trip time set incorrectly Reset as necessary, see Section
7.13

Current transformers incorrectly Check circuit

wired

Fault trip indicator CB11 defective Check operation, replace as

necessary

Defective motor protector module Check operation, replace as neces­

sary, see Section 7.13

Motor overload indicator trips at L.R.A. potentiometer set too low Reset as necessary, refer to Section
transition 7.13

Locked rotor trip time set incorrectly Reset as necessary, see Section
7.13

Current transformers incorrectly Check circuit

wired

Motor acceleration time too long Refer to compressor and motor trou­
ble analysis chart

Starter transition sequence occurring Check operation, contact La Crosse

slowly Service

Power factor correction capacitors Check circuits, see Section 7.13

installed incorrectly

Fault trip indicator CB11 defective Check operation, replace as

necessary

Defective motor protection module Check operation, replace as neces­

sary, see Section 7.13

Motor overload indicator trips while Incorrect current calibrator adjust­ Adjust as necessary, see Section
chiller is running normally ment or installation 7.13

Power factor correction capacitors Check circuits, see Section 7.13

installed incorrectly

Fault trip indicator DB11 defective Check operation, replace as

necessary

Defective motor protection module Check operation, replace as neces­

sary, see Section 7.13
'TH E THANE COMPANY 1902
COMMERCIAL AIR CONDITIONING DIVISION C O 'T F X D F ^T T T A T.
LA CROSSE. WISCONSIN 54601 „ . . ^ ' ' ''

6.5-1
"by C cii-i-'L. l .. c | '
 'COWIDETTTIAL_
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 Use R e s t r i c t e d
FEBRUARY 1982 ^ C o u rt^ O ra e r

FAULT INDICATORS ON STARTER PANEL TRIP

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Distribution fault indicator trips during Actual distribution fault occurring, Contact power company
start complete loss of voltage for more
than 1-1/2 cycles

Chattering 2M (K28) auxiliary or main Check operation, repair or replace as

contactor necessary, see Section 7.18

Starter open transition Check starter operation, repair as

necessary

Motor current drops below 15% of Contact La Crosse Service

chiller R.L.A.

Fault trip indicator CB15 defective Check operation, replace as

necessary

Defective motor protection module Check operation, replace as neces­

sary, see Section 7.13

Starter fault indicator trips during Loose wire to pilot relay coil Check circuit continuity, repair as
start necessary

Loose wire to pilot relay contact Check circuit continuity, repair as

necessary

Defective pilot relay coils (K23 - K24) Check operation, repair or replace as
necessary

Burned contact on pilot relay Check contact continuity, repair or

replace as necessary

Transition resistor contactor staying Check operation, repair or replace as

in circuit necessary

Auxiliary contact on transition re­ Check operation, repair or replace as

sistor staying in circuit necessary

Defective auxiliary contact on starter Check operation, repair or replace as

contactor (K26 - K28) necessary

Burned out contactor coil Check operation, replace as

necessary

Starter fault indicator trips during Loose wire to pilot relay coil Check circuit continuity, repair as
normal chiller operation necessary

Loose wire on pilot relay contact Check circuit continuity. Repair as

necessary

Welded pilot relay contacts (K23 - Check operation, repair or replace as

K24) necessary

Defective pilot relay coils (K23 - K24) Check operation, repair or replace as
necessary

Transition resistor contactor staying Check operation, repairor replace as

in circuit necessary

Auxiliary contact on transition re­ Check operation, repairor replace as

sistor contactor staying in circuit necessary

I Fault indicator defective (CB13) Check operation, repair or replace as

i necessary

FWB ,'LLW

6.5-2
 LITERATURE FILE NO. HCTV-SG-2

C O N TR O L PAN EL SECTION
S A F E TY IN D IC ATO R S T R IP
6.6
FEBRUARY 1982

CONTROL PANEL SAFETY INDICATORS TRIP

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Low oil pressure indicator trips, oil
pump will not start Oil pump overload fuse blown Replace fuse

Loose wire in control panel (F2) Check continuity of control circuit to

locate, repair as necessary

Oil pump timer (S9) defective Check oil pump timer operation, see
Section 7.7

Control relay defective Check relay operation and continuity

th r o u g h c o n t a c t s , r e p l a c e as
necessary

Low oil pressure indicator trips, oil Oil pressure regulator misadjusted Readjust regulator
pressure low

Oil filter plugged Replace filter, see Section 8.0

Oil pump problem See Section 6.15

Oil pressure satisfactory, low oil Oil pressure control (S8) misadjusted Readjust or replace control as neces­
pressure fault indicator trips or defective sary, see Section 7.6

Loose control panel wire Check continuity of control circuit to

locate, repair as required

Control relay (K6 or K3) defective Check relay operation and continuity
through contacts, replace as
necessary

Fault indicator circuit breaker (CB1) Check fault indicator operation and
defective continuity through contacts, replace
as necessary
Oil pump starts, then stops, low oil Oil pump overload fuse blown Replace fuse
pressure indicator trips

Loose wiring Check continuity of circuit to locate,

repair as required

Oil pump timer (S9) defective Check oil pump timer operation, see
Section 7.7

Control relay defective Check operation of relay and con­

tinuity through contacts, replace as
necessary
High condenser pressure indicator Heat transfer problem See trouble analysis chart 6.11
trips, high condenser pressure

Hot gas bypass operating incorrectly Adjust hot gas bypass

l
'TH E TRANE COMPANY 1982
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A. cofr?IM;rTI,J;
6.6-1
&£-C 0U rt_
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982
COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Condensing pressure satisfactory, High condenser pressure control Readjust or replace control as neces­
condenser pressure indicator trips misadjusted or defective sary, see Section 7.2

Fault indicator circuit breaker (CB2) Check fault indicator operation and
defective continuity through contacts, replace
as necessary
Low refrigerant temperature indi­ Evaporator refrigerant flow problem See trouble analysis Section 6.12
cator trips, low refrigerant
temperature
Low refrigerant temperature indi­ Low refrigerant temperature control Readjust control or replace as neces­
cator trips, refrigerant temperature (S2) misadjusted or defective sary, see Section 7.3
satisfactory

Fault indicator/circuit breaker (CB3) Check fault indicator operation and

defective continuity through contacts, replace
as necessary
High motor temperature indicator Motor cooling problem Refer to Section 6.14
trips, motor hot
High motor temperature indicator Motor protection module (U2) Refer to Sections 6.14 and 7.15
trips, motor not overheated defective

Motor temperature sensor defective Refer to Sections 6.14 and 7.15

Loose wire in control panel Check continuity of control circuit to

locate, repair as necessary

Control relay (K11) defective Check relay operation and continuity

through contacts, replace as
necessary

Fault indicator circuit breaker (CB4) Check fault indicator operation and
defective continuity through contacts, replace
as necessary

Starter fault indicator on control Starter problem See Sections 6.3, 6.4, 6.5
panel trips, fault indicator on starter
trips

Starter fault indicator on control Loose wire in control panel Check continuity of control circuit to
panel trips before starter pulls in; locate, repair as necessary
starter circuit fault indicator on starter
not tripped

Loose wire between control panel Check continuity of circuits to locate,

and starter repair as necessary

System light not on, anti-recycle Check anti-recycle timer operation,

timer (S4) defective see Section 7.5

Control relay K10 or K8 defective Check relay operation and continuity

through contacts, replace as
necessary

System light comes on, starter See Sections 6.3, 6.4, 6.5
problem

Fault indicator circuit breaker CB5 Check fault indicator operation and
defective continuity through contacts, replace
as necessary

6.6-2
 p O T im M T IA L ' HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
Use IU.c.... - - ' c 1 FEBRUARY 1982
Uy Cc u u . jUL,

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Starter fault indicator on control Loose wire in control panel Check continuity of control circuit to
panel trips 15 seconds after start has locate, repair as necessary
occurred, starter circuitfault indicator
on starter not tripped

Loose wire between control panel Check continuity of circuits to locate,

and starter repair as necessary

Control relay K9 defective Check relay operation and continuity

through contacts, replace as
necessary

Starter interlock not making or drop­ Check operation and continuity of

ping out starter contact interlocks, replace as
necessary

Fault indicator circuit breaker CB5 Check fault indicator operation and
defective continuity through contacts, replace
as necessary

Starter fault indicator on control Loose wire in control panel Check continuity of control circuit to
panel trips intermittently during locate, repair as necessary
chiller operation, starter circuit fault
indicator on starter not tripped

Loose wire between control panel Check continuity of circuits to locate,

and starter repair as necessary

Control relay K9 defective Check relay operation and continuity

through contacts, replace as
necessary

Starter interlock not making or drop­ Check operation and continuity of

ping out starter interlock contacts, repair or
replace as necessary

System light comes on, starter See Sections 6.3, 6.4, 6.5
problem

Fault indicator circuit breaker CB5 Check fault indicator operation and
defective continuity through contacts, replace
as necessary

FWB :LLW

6.6-3
 LITERATURE FILE NO. HCTV-SG-2

PURGE S YS TE M SECTION
TR O U B LE A N A LYS IS
6.7
FEBRUARY 1982

PURGE SYSTEM TROUBLE ANALYSIS

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Purge unit will not run No power to purge motor, fuse blown, Identify problem, correct
loose wiring or terminals

Panel switch in off position Set switch to on position

Panel switch defective Replace switch

Purge compressor drive belt broken Replace drive belt

Purge motor defective Replace

Purge compressor seized Replace

Purge relief valve discharges con­ No water flow through purge drum Coil plugged, open valves to allow
tinuously while purge unit is running coil flow through coil. If coil is fouled,
clean.

Water temperature in purge drum coil Allow water to flow long enough to
too warm attain 80 F or lower

Relief valve setting too low Readjust relief valve

Relief valve defective Replace

Chiller has large amount of air in it Purge unit is operating normally

Air leaking into chiller faster than Determine source of leaks and repair
purge unit can remove it
Purge drum pressure higher than Water temperature in purge drum coil Allow water to flow long enough to
normal while purge unit is running too warm attain 80 F or lower

No water flow through purge drum Coil plugged, open valves to allow
coil flow through coil. If coil is fouled,
clean.

Relief valve out of adjustment Readjust relief valve setting

Faulty gauge Replace gauge

Vent hole in drum baffle clogged Disassemble drum, clear vent hole

Float valve stuck shut in drum Repair or replace

I Purge compressor leaks oil Bad shaft seal Replace seal

Leaking sight glass Replace sight glass

Head or valve plate gasket bad Replace

Purge compressor base plate gasket Replace

bad

Purge compressor housing cracked Replace compressor

c o m r m iA r
L- u L; l : 1' b i . i .! c i e d
 C 0 D F I DM T T IA L
HERMETIC CENTRAVAC SERVICE GUIDE TTo _ r, ; : 1
HCTV-SG-2 use/ ;‘ h ; .
FEBRUARY 1982
COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Purge compressor or motor exces­ Sheave or belt rubbing against belt Replace sheave, rework belt guard to
sively noisy while in operation guard or other portion of purge unit avoid contact with belt

Purge motor defective Replace motor

Worn out purge compressor Rebuild or replace

Water noted in purge drum sight Purge drum coil leaking Replace coil
glass

Low side air leak in chiller with very Repair low side leak, insulate sweat­
humid conditions ing areas

Evaporator or condenser tube leak Replace or plug faulty tubes

No refrigerant level noted in purge No power purge compressor drive Identify problem, correct
drum sight glass motor, blown fuse, loose wiring or
terminals

Purge switch in off position Switch to on position

Purge switch defective Replace switch

Purge compressor drive belt broken Replace belt

Purge motor defective Replace motor

Solenoid valve bad Replace solenoid valve

Purge drum leaks Repair or replace

Float valve in purge drum stuck open Repair or replace

or defective
Purge drive makes squealing noise Drive belt loose Adjust belt tightness

Drive belt worn out Replace belt

Bad sheave Replace sheave

Purge compressor seized Replace purge compressor

Condensation forms on outside of Normal condition, indicates humid Insulate to correct
purge drum conditions and cold water inside of
purge drum
Condensation forms on 1/4 inch line Cold refrigerant returning to evapo­ Insulate to correct
between purge drum and evaporator rator causing humidity to condense
on line
Water or refrigerant leaking from Refrigerant leak - leaking gaskets on Tighten head bolts or replace
purge drum purge drum heads gaskets

Water leak - purge drum coil con­ Repair leaking joint or replace coil
nection leak

Sight glass leaking Replace sight glass

Drum is porous due to acid corrosion Replace purge drum, more frequent
clean out recommended

Oil level in purge compressor is over Too much oil in compressor or oil Remove excess oil
top of compressor crankcase sight separator
glass

Excessive refrigerant in oil Determine source and correct

Oil separator heater or thermostat Replace heater or thermostat

defective

6.7-2
 O T F iiB im A i;
HERMETIC CENTRAVAC SERVICE GUIDE
Use t i ■•' HCTV-SG-2
f r ^ _ C g u r x ,0_41^S,£,
FEBRUARY 1982
COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Oil in purge compressor sight glass is Oil separator thermostat set too high, Reset thermostat
black, may be observed during oil burning oil
change

Excessive moisture/acid in oil Change oil more often

Incorrect oil or noncompatible oils Change oil, use WF-68 oil

mixed
Oil removed from oil separator is Oil separator thermostat is set too Reset thermostat
black high

Hard black carbon deposits found on Oil too hot, oil separator thermostat Repair or replace heater thermostat
walls of oil separator when defective
disassembled

Oil separator thermostat set too high Reset thermostat

FW B /LLW

6.7-3
 LITERATURE FILE NO. HCTV-SG-2

CH ILLER W A TE R C O N TR O L SECTION
TR O U B LE A N A LYS IS
6.8
FEBRUARY 1982
CHILLER DOES NOT CONTROL CHILLED WATER TEMPERATURE
COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Chiller does not load up Refer to Section 6.10

Chiller control hunts excessively Low water flow through chiller Check water flow, adjust to design
conditions

Water flow through chiller varies Check water flow, stabilize at design
conditions

Polarity of water temperature sensor Check sensor wiring, correct as

reversed necessary

Loose wire in vane motor circuit in Check circuit continuity, repair as

control panel necessary

Low refrigerant temperature switch Check control operation, repair or re­

opening intermittently place as necessary

Starter auxiliary contactor (K28) Check operation, repair or replace as

opening intermittently necessary

Loose wire between terminal F1 and Check circuit continuity, repair as

84 in control panel necessary

Loose wire between control module Check circuit continuity, repair as

and temperature sensor necessary

Sensor wells not sufficiently deep in Install deeper sensor wells

water piping

Supply water temperature sensors Check sensor operation, replace as

defective necessary
Chiller consistently controls several Chiller controlling at deadband limits Normal condition, if tighter tem­
degrees from setpoint perature control is required, set the
deadband limits narrower

Control point knob not in correct Adjust knob position as necessary

position

Control module automatically re­ Normal operation, see Section 7.12

setting the control point from return
water temperature

Low water flow through chiller Check water flow, adjust to design
conditions

Control point reset from external cus­ Consult with customer

tomer source

Control module defective Replace control module as neces­

sary, see Section 7.12

®THE TRANE COMPANY 1902

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601 'COUFII521TTIAL'
PRINTED IN U S A
Use ReSw-ji-^tcd
6.8-1 ^L_C ourt Order
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982 r i j i - . .e jL

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Inlet vane motor does not respond to Loose wire in vane motor circuit in Check circuit continuity, repair as
control module signals control panel necessary

Inlet vane motor tripping thermal Check inlet vane motor for binding
overload linkage, repair or replace as
necessary

FWB 'LLW

6.8-2
 LITERATURE FILE NO. HCTV-SG-2

LOAD LIM IT
SECTION
TR O U B LE A N A LY S IS
6.9
FEBRUARY 1982

CHILLER LOAD LIMIT FUNCTION NOT OPERATING

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Chiller will not load limit, overload Loose wire between solid state over­ Check circuit continuity, repair as
trips while chiller is still calling for load and capacity control module necessary
loading, voltage between Terminals
V 1 and V2 of capacity control module
does not reach 8.25 V.D.C.

Mis-wiring (cross) between V1 and Check circuit wiring, repair as

V2 in starter and control panel necessary

Solid state overload not operating Refer to Section 7.13

properly

Chiller will not load limit, overload Mis-wiring (cross) between V1 and Check circuit wiring, repair as
trips while chiller is still calling for V2 in starter and control panel necessary
loading, voltage between Terminals
V1 and V2 reaches 8.25 V.D.C.

Capacity control module not oper­ Refer to Section 7.12

ating correctly

^ O T T P Itn ^ T IA T i

Use
hv C ourt 0rd e r

'TH E TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601
PRINTED IN U S A. FW B LLW

6.9-1
 LITERATURE FILE NO. HCTV-SG-2

C H ILLER W IL L N O T LO AD SECTION
6.10
FEBRUARY 1982

TROUBLE ANALYSIS - CHILLER WILL NOT LOAD

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Load light on, power to Terminal M2 Loose wire between control panel Check continuity of circuit, repair as
and inlet vane motor necessary

Inlet vane motor thermal overload Wait for motor to cool and overload to
tripped reset

Inlet vane motor or vane linkage Disconnect linkage from vane motor
jammed and free

Vane motor end switch stuck Remove cover from end switch as­
sembly and free

Inlet vane motor burned out Check motor, replace as necessary

No capacity control lights on Chiller control point temperature Readjust control point to get output
satisfied action

Manual-Auto knob in the hold Change control knob setting as

position required

Capacity control on automatic reset Change control knob setting as

required

No power to control module, fuse Check fuse continuity, replace as

blown necessary

No power to control module, loose Check power supply wiring, repair

wire

Control module defective Check operation, replace as neces­

sary, refer to Section 7.12

Chiller will not load, current control Capacity control module controlling Change control knob settings as re­
light on current quired to load chiller

% current knob set low Change control knob settings as

required

Electronic overload emitting exces­ Check operation, see Section 7.13

sive voltage

External load limiter causing current Check external load limiter operation
control (If used)

Control module defective Check operation, see section 7.12

CTHE TRANE COMPANY 1982

COIO'irsiTTIAI
COMMERCIAL AIR CONDITIONING DIVISION fr s e H e s i; . . i. L
LA CROSSE. WISCONSIN 54601
PRINTED IN U S A. by Coui' L
- Crcie^
6.10-1
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Unload light only on Manual-Auto knob in unload position Change control knob settings as re­
quired to load chiller

Chiller unloading because water Wait for load to increase or change

temperature below setpoint control knob setting as required

Low temperature override not made Check operation of low temperature

override, see Section 7.3

Starter auxiliary K28 not made Check operation of starter auxilia­

ries, repair or replace as necessary

Loose wire circuit between Terminal Check continuity of circuit, repair as

F1 and Terminal 84 on capacity con­ necessary
trol module

Capacity control on automatic reset Change control knob settings as

required

Return or supply water temperature Check wiring, repair, see Section

sensor wired with incorrect polarity 7.12

Reset dip switch on back of capacity Check control setting, see Section
control module in the ON position 7.12
with no return water temperature
sensor attached

Leaving chilled water temperature Check continuity of circuit, repair as

sensor circuit (TS1 - TS2) open necessary

Supply water temperature sensor Check and replace sensor as re­

defective quired, see Section 7.12

Return water temperature sensor cir­ Check continuity of circuit, repair as

cuit (TS1 - TS3) open necessary

Return water temperature sensor Check and replace sensor as re­

defective quired, see Section 7.12

Current control and unload lights on Capacity control module controlling Change control knob settings as
current required

% current knob set low Change control knob setting as

required

Electronic overload emitting exces­ Check operation, see Section 7.13

sive V1 - V2 voltage

External load limiter causing current Check external load limiter operation
control (If used)

Control module defective Check operation, replace as neces­

sary, see Section 7.13

Chiller will not load, load light on, no Control module output relay Replace or switch output relays
power at terminal M2 of capacity con­ defective
trol module

Control module defective Check operation, replace as neces­

sary, see Section 7.13

C O T IF IO T T T J AT,
Use Uestx

FWB LLW

6.10-2
 LITERATURE FILE NO. HCTV-SG-2
CONDENSER
TR O U B LE A N A LY S IS SECTION
AN D S U P P LE M E N TA R Y
N O TES 6.11
FEBRUARY 1982

CONDENSER TROUBLE ANALYSIS CHART

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Unit will not produce full load tonnage Water entering condenser too warm Readjust cooling tower controls refer
to supplementary note no. 1

Water flow rates not correct Reset per order write-up refer to sup­
plementary note no. 2

Condenser tubes fouled Clean tubes, refer to supplementary

note no. 3

Noncondensables in condenser Operate purge unit to remove refer to

supplementary note no. 4

Problem not caused by condenser Refer to other trouble analysis charts

Motor amperage fluctuates, random Chiller in near surge condition Refer to other possible causes
or synchronous fluctuations

Condenser tubes fouled Clean condenser tubes, refer to sup­

plementary note no. 2

Entering condenser water tem­ Readjust cooling tower controls, see

perature too high supplementary note no. 1

Varying condenser water flow Diagnose cause, correct, see sup­

plementary note no. 2

Problem not caused by condenser Refer to other trouble analysis charts

Inlet vanes constantly modulating, Varying condenser water Adjust cooling tower controls, see
chiller does not operate stably temperature supplementary note no. 1

Varying condenser water flow rate Adjust cooling tower controls, see
supplementary note no. 2

Problem source not in condenser Refer to other trouble analysis charts

Condenser leaks air, water Bad o-ring Test for leaks, replace

Leaking threaded joint Test for leaks, repair

Poor solder joint Test for leaks, repair

O-ring groove pitted Clean groove, repair with solder

Porous casting Clean, repair with solder or replace

casting
Moisture and condensation forming Condenser water temperature very Adjust cooling tower controls, see
on outside of condenser cold supplementary note no. 1

Condenser needs insulation Insulate condenser

* SUPPLEMENTARY NOTES FOUND AT END OF SECTION

«THE TRANE COMPANY 1982
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601 Use
PRINTED IN U S A.
C our c j j i je r
6.11-1
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Chiller runs quieter than usual Refrigerant carryover Refer to evaporator trouble analysis
operation charts. See supplementary note no.
6

Condenser rattles with chiller com­ Air in water piping Vent air from pumps and pipes, see
pressor off supplementary note no. 12

Water hammer Correct water system problems

Condenser tubes worn in tube sup­ Inspect supports/replace tubes, see

port areas supplementary note no. 5
Rattling noise from condenser while Condenser tubes fouled Clean tubes, see supplementary
chiller is in operation note no. 3

Non-condensables in condenser Operate purge to remove non-con­

densables, see supplementary note
no. 4

Chiller operating outside of design Obtain order write-up, readjust water

conditions temps, etc. at jobsite, see supple­
mentary note no. 8.

Broken condenser baffle, loose Repair as necessary, see supple­

tubes mentary note no. 5

Air in water piping Vent air from pumps and pipes, see
supplementary note no. 12

High condenser water temperature Adjust cooling tower controls, see

supplementary note no. 1

Poor equipment isolation Install or replace isolators

Condenser needs insulation Insulate condenser

Condenser pressure higher than nor­ Non-condensables in condenser Operate purge unit to remove non­
mal, higher than observed on pre­ condensables
vious logs
Tubes fouled or plugged Check condenser approach, clean or
replace tubes, see supplementary
note no. 3

Temperature of water entering con­ Adjust cooling tower controls, see

denser above design supplementary note no. 1

Condenser pressure lower than nor­ Temperature of water entering con­ Adjust cooling tower controls, see
mal, lower than previously observed denser too low supplementary note no. 1
on logs

Light load on chiller Normal; condenser pressure will be

lower with light load, see supple­
mentary note no. 7

Condenser tubes recently cleaned Normal; condenser pressure will be

lower following tube cleaning, see
supplementary note no. 9

Faulty pressure gauge Replace gauge

CONFIDENT TAT/
Use He;: .
 HERMETIC CENTRAVAC SERVICE GUIDE
COITFIT51DNTTATT_ HCTV-SG-2
U s^ u u o V i'iu t e d FEBRUARY 1982
h y Court Order

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Condenser temperature higher than Temperature of water entering con­ Adjust cooling tower controls, see
normal; higher than observed on pre­ denser too high supplementary note no. 1
vious logs

Condenser tubes fouled Clean condenser tubes, see supple­

mentary note no. 3
Condenser temperature lower than Temperature of water entering con­ Adjust cooling tower controls, see
normal; lower than observed on pre­ denser too low supplementary note no. 1
vious logs

Light load on chiller Normal; condenser pressure will be

lower with light load, see supple­
mentary note no. 7

Condenser tubes recently cleaned Normal; condenser pressure will be

lower following tube cleaning, see
supplementary note no. 9

Faulty pressure gauge Replace gauge

Pressure-temperature relationship of Non-condensables in condenser Operate purge unit to remove non­
condenser not in agreement with re­ condensables, see supplementary
frigerant pressure temperature chart note no. 4
while chiller is in operation

Wrong or mixed refrigerant in chiller Remove refrigerant, evacuate, re­

charge with correct refrigerant, see
supplementary note no. 10

Leaving condenser water tem ­ Condenser tubes fouled or plugged Check condenser approach, clean or
perature vs. refrigerant temperature replace tubes, see supplementary
(approach) greater than normal; note no. 3
greater than observed on previous
logs

Glycol or other additives in water Flush water system only if glycol not
system requied, see supplementary note no.
13
Leaving condenser water tem­ Light load on chiller Normal; approach will be less at light
perature vs. refrigerant temperature chiller loads, see supplementary
(approach) lower than normal; lower note no. 7
than observed on previous logs

Tubes recently cleaned or replaced Normal; approach will be less follow­

ing condenser tube cleaning or re­
placement, see supplementary note
no. 9
Water entering condenser not at Cooling tower controls misadjusted, Readjust cooling tower controls,
proper design temperature cooling tower malfunction repair cooling tower, see supple­
mentary note no. 1
Water temperature leaving con­ Chiller operating at partial load Normal; leaving condenser water
denser not per order write-up temperature will be lower at partial
specifications chiller load, see supplementary note
no. 7

Cooling tower controls misadjusted Adjust cooling tower controls as nec­

essary, see supplementary note no.
1

6.11-3
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Condenser water pressure drop not Too much or too little water flow Adjust balancing valves as neces­
per order write-up specifications through condenser sary to achieve proper flow rate and
pressure drop, see supplementary
note no. 2

Condenser tubes fouled or plugged Check condenser approach, clean or

replace tubes, see supplementary
note no. 3

Pass to pass leakage Repair, replace water box gaskets or

water boxes, see supplementary
note no. 14

Restriction in condenser water Clean water system, see supple­

system mentary note no. 11.

Mis-matched pressure gauges Use a single gauge to measure pres­

sures, see supplementary note no. 2

SUPPLEMENTARY NOTES TO CONDENSER TROUBLE

ANALYSIS CHART 5. If a rattling noise is heard from the condenser and a broken
1. Obtain an operating log of the machine. Compare Item 11, baffle is suspected, it will be necessary to try to pinpoint the
location of the break by using a stethoscope. This should be
shown in Table 1 which lists the various log readings, to the
done while the unit is running. After isolating the areas of rat­
chiller order write-up conditions. If Item 11, entering con­
tle, it will be necessary to remove the refrigerant from the
denser water temperature, is higher or lower than the order
chiller, evacuate to remove refrigerant vapor, and then pres­
write-up conditions, readjust the cooling tower controls so
surize the unit with dry nitrogen to 0 psig. Next, cut holes in
that the entering condenser water temperature is at design
specifications. the condenser to examine and repair all cracks and breaks in
the baffle assembly. All cracks or broken welds must be re­
2. Obtain an operating log of the machine and compare Item 10
welded and strengthening material or braces added as re­
to the order write-up condition. Convert the water pressure to
flow in Gallons Per Minute (GPM). If the water flow rate is not quired to prevent future breakage.
If rattling tubes are suspected to be the cause of the con­
in accordance with the order write-up specification, adjust
denser noise, the stethoscope can be used to pinpoint the
the balancing valves to obtain the correct flow rate.
area where tubes or tube supports may be worn. The refrig­
3. Obtain an operating log of the machine and refer to log read­
erant must be removed, evacuated and then the chiller pres­
ing Items 12 and 13. Items 12 and 13 refer to the condenser
surized to 0 psig using dry nitrogen. Cut an appropriately
approach. The approach is obtained by subtracting the Re­
sized hole to gain access to the tubes or tube supports. Mea­
frigerant Liquid Temperature (Item 13) from the temperature
sure the tube to tube hole clearance by inserting a feeler
of the water leaving the condenser. If the approach tem ­
perature is greater than normal, condenser tube fouling may gauge between the tube and tube hole surfaces. The max­
imum allowable clearance is .016 inch. If tube wear is the
be the cause. The normal approach temperature for a partic­
source of the problem these tubes should be pulled and re­
ular machine may be obtained from previous logs taken
when it is known that the tubes were clean such s just after placed with new tubes.
the initial start-up of the unit. A log taken after annual mainte­ 6. Obtain a complete operating log of the machine. Refrigerant
nance will also provide this information if tube cleaning is part carryovercan bediagnosed by taking a temperature reading
of the maintenance program. of the compressor discharge and comparing with the con­
4. Obtain a complete operating log of the machine and then densing temperature, Item 13. At full load conditions the
refer to Items 8 and 13. If noncondensables are present in compressor discharge temperature should be approxi­
the condenser, Items 8 and 13 will not agree according to a mately 35 F hotter than the condensing temperature. At part
Pressure - Temperature chart. Noncondensables are indi­ load conditions the discharge temperature may be as much
cated by condenser pressure that is greater than the pres­ as 50 or 60 F hotter than the condensing temperature. If car­
sure called for on a Pressure-Temperature chart for a cor­ ryover is occurring, the compressor discharge temperature
responding temperature. For example, in the Refrigerant 11 will be less than 35 F hotter than the condensing tem ­
pressure - temperature chart, if the condensing temperature perature. It is essential that an accurate thermometer and
is 94 F the condenser pressure should be 6.5 psig. However, heat conducting paste be used on the compressor discharge
if the condenser pressure gauge reads 10 psig it may be as­ connection. Insulate around the thermometer with Armaflex
sumed that there are noncondensables in the chiller. or equivalent.
C O 'T F I F U 'T 'r T A * '

Use P• . 6 .1 1 -4
by Cqiu’ L ui
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

7. Obtain a complete log of the machine paying particular atten­ bly, the water pump will cavitate. This will necessitate that all
tion to Items 2 ,1 1 ,1 2 ,1 5 and 16. It will be necessary to com­ bleed valves in the system be opened (at high points of the
pare these items with the same items on the order write-up to system and on the water boxes) to remove the trapped air.
determine the amount of load on the chiller. For example, if 13. Obtain a complete operating log of the machine. Pay particu­
the order write-up specifies that the temperature differential lar attention to Items 1 1 ,1 2 ,1 3 and 10. By looking at these
between water in and water out of the evaporator to 10 F, and items it would appear that the water side of the condenser
the log reading indicates only 1 F difference, a machine load tube surfaces are fouled. However, glycol in the water
of 10% is indicated, assuming that the water flow rates are system will have this affect. Unless glycol is desired in the
correct. If allowed to operate at less than 10% load condi­ system and the chiller is derated, it will be necessary to drain
tions, baffle breakage may occur. It is recommended that Hot the entire system and flush with water and then refill.
Gas Bypass be added to the machine or that the chilled 14. If a chiller is equipped with multiple pass arrangements on
water demand switch (S3) be readjusted. the condenser or evaporator and the baffle or gasket be­
8. Obtain a complete operating log of the machine and pay par­ tween the water passes fails, it will be possible for the water
ticular attention to Ite m s 2 ,1 0 ,1 2 ,1 4 ,1 5 and 16. Also adjust to short circuit between the passes. This causes insufficient
the evaporator and condenser water flow rates to the order water flow through the tubes. To verify that this situation
write-up specifications and adjust the condenser entering exists pressure drop readings must be taken on the con­
water temperature controls to the value specified. Also denser or evaporator between the entering water pressure,
adjust the leaving chilled water temperature control to the leaving water pressure, and at the end of each water pass.
order write-up specification. On a two pass evaporator the water pressure drop at the end
9. Obtain a complete operating log of the machine paying par­ of one water pass should equal one-half of the total pressure
ticular attention to log reading items 12,13 and 8. If the con­ drop across the evaporator. This relationship holds true for
denser tubes have been recently cleaned the leaving con­ three or four pass evaporators and condensers as well. Each
denser water temperature and the condenser liquid water pass would have one-third or one-fourth, respectively,
refrigerant temperature (approach) may be closer together of the total pressure drop across the vessel, assuming that
compared with logs taken previously. The normal tem­ there is no pass-to-pass leakage. Use only a single gauge
perature difference can be obtained from the initial start-up when taking pressure drop readings. The air vents or drain
log or a log taken immediately after the tubes have been valves can be used for attaching the pressure gauge when
cleaned (such as after annual maintenance). taking readings.
10. Make a complete operating log of the machine paying partic­
ular attention to items 7, 8, 13 and 17. It will also be neces­ TABLE 1 - Operating Conditions
sary to refer to a Refrigerant 11 Pressure-Temperature LOG
chart. Compare the evaporator pressure gauge reading with ITEM READING
the refrigerant liquid temperature in the evaporator and also 1. Voltage
compare the condenser pressure gauge reading with the 2. Amperage
liquid refrigerant temperature from the condenser. If a mix­ 3. Oil Temp. - Sump - °F
ture of refrigerants is in the chiller, the pressure - tem­ 4. Oil Level
5. Oil Gauge Pressure PSIG
perature relationships of these readings will not coincide.
6. Evap. Gauge Pressure PSIG
11. Make a complete operating log of the machine. Pay particu­
7. Cond. Gauge Pressure
lar attention to Item 10. If the condenser water pressure dif­ 8. Purge Pump Pressure (If Operating) PSIG
ferential cannot be balanced or adjusted to the value speci­ 9. Condenser Water Pressure Diff. PSIG
fied on the order write-up, a restriction in the water piping 10. Condenser Water In - °F
system or in the condenser may be present. This will neces­ 11. Condenser Water Out - °F
sitate cleaning the water strainers or the condenser tubes to 12. Refrigerant Liquid Temp. Cond. - °F
correct the flow problem. 13. Chilled Water Pressure Diff. PSIG
12. Air in the water piping is not generally detectable with the 14. Chilled Water In - °F
operating log. Air in the water system can be heard as a gur­ 15. Chilled Water Out - °F
gling or bubbling noise at a high point in the water system. In 16. Refrigerant Liquid Temp. Evap. - °F
17. % Current Control
extreme cases, flow switch flutter will occur and also, possi­

n o K P i T > r : : T T . ‘ T,

Use I,:.0 .. ,
Uy Court

FWB'LLW

6.11-5
 LITERATURE FILE NO. HCTV-SG-2
EVA P O R A TO R
T R O U B L E A N A L Y S IS SECTION
AN D S U P P LEM EN TA R Y
N O TE S 6.12
FEBRUARY 1982

EVAPORATOR TROUBLE ANALYSIS

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Chiller does not produce required ca­ W ater flow rates through evaporator Readjust per order write-up, see sup­
pacity, motor running at full load not correct plementary note no. 1
amperage

Chiller low on refrigerant Check refrigerant level, add refrig­

erant, see supplementary note no. 1

Tubes fouled (Waterside) Diagnose, clean tubes, see supple­

mentary note no. 1

Tubes fouled (Refrigerant side) oil in Distill the refrigerant charge.

refrigerant

Glycol or other contaminants in water Replace charge, flush system to

system remove.

Refrigerant carryover Diagnose and correct, see supple­

mentary note no. 1, also Section 6.11

Restriction in refrigerant piping, ori­ Disassemble to clean out piping or

fice or distributor orifice, cut hole in evaporator to clean
out distributor

Surge operation Determine cause and correct, see

Section 6.11

Wrong or mixed refrigerants Remove refrigerant, evacuate, and

recharge with correct refrigerant

Water box baffle leakage Diagnose, replace box or gasket, see

supplementary note no. 1

Machine is not level Check level, relevel unit

Chiller does not produce required ca­ Chiller low on refrigerant Check refrigerant level, add
pacity, motor will not run at full load refrigerant
amperage

Tubes fouled (Waterside) Diagnose, clean tubes

Tubes fouled (Refrigerant Side) oil in Distill the refrigerant charge, install a
refrigerant clean up system to remove con­
taminants, retube evaporator

Restriction in refrigerant piping, ori­ Disassemble to clean out piping or

fice or distributor orifice, cut hole in evaporator to clean
out distributors

* SUPPLEMENTARY NOTES FOUND AT END OF SECTION

'T H E TRANE COMPANY 1982 C077 T777 TTAL

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601 Use If'-:. -*
PRINTED IN U.S.A
by J j v V W- u - ■
L-
6.12-1
HERMETIC CENTRAVAC SERVICE GUIDE f n ^ T T ^Ti,'T7 T f i r
HCTV-SG-2 - ' "7
FEBRUARY 1982 L 3 e il ; r - 1 e d
by Gour c_yx- a or

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Chiller does not produce required ca­ Glycol in water system Flush out glycol or derate the chiller
pacity, motor will not run at full load
First and second stage inlet vanes Readjust inlet vanes
amperage
not scheduled properly

Refrigerant carryover Diagnose and correct, see supple­

mentary note no. 1, also Section 6.11

Capacity control load limiting See Section 6.9

Motor amperage fluctuates may be Water flow rate varies due to adjust­ Adjust valves, check pumps, check
random or synchronous oscillations ing valve problem, water pump prob­ air handling units
lem, or air handling unit problem

Refrigerant shortage Check refrigerant level, add if neces­

sary, see supplementary note no. 1

Near surge condition Diagnose, correct, refer to chart cov­

ering, see Section 6.11

Refrigerant carryover Diagnose, correct, see supple­

mentary note no. 1, see Section 6.11
Inlet vanes hunt, constantly opening Chiller low on refrigerant, unit ap­ Add refrigerant, see supplementary
and closing, do not find a stable point proaches LTC cut out override pre­ note no. 1
vents cut out

Water flow varies Diagnose and correct system, see

supplementary note no. 1

Changes in evaporator load Not a problem

Refrigerant, oil or water seen leaking Bad O-ring Test for leaks, replace
from joints, Audible air leak into unit

Leaking threaded joint Test for leaks, repair

Poor solder joint Test for leaks, repair

Sight glass leaks Test for leaks, replace

O-ring groove pitted Clean groove, repair with solder

Porous casting Clean, repair with solder or replace

casting

Unit makes unusual noise (squeal­ Broken baffle in condenser Repair as necessary
ing, knocking, hammering, etc.)

Rattle Loose or worn tubes in tube supports Eddy Current Check tubes, replace
or reroll tubes

Squeal Surge operation See Section 6.11

Moisture condensation forming on High humidity Condition normal, insulate
evaporator shell evaporator

Moisture condensation forming on High humidity Condition normal, insulate suction

suction elbow elbow

Refrigerant carryover Determine cause, correct, see sup­

plementary note no. 1, also Section
6.11

6.12-2
 CONFIDENTIAL_ HERMETIC CENTRAVAC SERVICE GUIDE
U s 6 iiS S u J . HCTV-SG-2
Uy Court; order FEBRUARY 1982

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Frost on all or part of evaporator shell Low temperature glycol system Normal condition possibly de­
being used pendent upon solution temperature
and approach

Chiller low on refrigerant and LTC Check for frozen tubes, replace con­
and override not functioning trols, add refrigerant

Inlet vanes jammed open, LTC and Check for frozen tubes, repair inlet
override not functioning vanes, replace controls

Evaporator shell rusting Refer to same complaint on com ­

pressor trouble analysis chart

Chiller runs unusually quiet Refrigerant carryover Diagnose, correct, refer to

Unit running backwards Reverse two power leads at starter

Refrigerant level too high in Refrigerant overcharge Diagnose, remove excess refrig­
evaporator erant, see supplementary note no. 1

Unit not stabilized after shutdown, re­ Allow time for unit stabilization,
frigerant still boiling recheck

Oil or other contaminants in Distill or replace refrigerant

refrigerant

Chiller not level Check level, correct

Unit is equipped with free cooling Overcharge is normal

Refrigerant level too low in Leak in chiller Pressure test, repair leaks, operate
evaporator purge unit

Insufficient refrigerant charge Add refrigerant

Chiller not level Re-level chiller

Evaporator suction temperature Chiller low on refrigerant Refer to recommended action for
lower than normal “ Refrigerant Level Too Low In
Evaporator”

Fouled evaporator tubes Clean tubes

High water flow rate Diagnose, lower flow rate, see sup­
plementary note no. 2

Leaving water temperature lower Readjust or repair capacity control

than normal module

Glycol in system Normal result of adding glycol

Evaporator suction pressure lower Contaminated refrigerant Distill or replace refrigerant
than normal

Erroneous reading taken during pull­ Let unit stabilize, then measure suc­
down condition tion pressure

Faulty gauge Replace or recalibrate

Chiller low on refrigerant Refer to recommended action for

“ Refrigerant Level Too Low In
Evaporator”

6.12-3
 COTIFir^IJTTAL'
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 Use icted
FEBRUARY 1982 uy Court Order
COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDS) ACTION
Evaporator suction temperature Light load on unit compared to pre­ Normal condition
higher than normal vious reading

Leaving water temperature too high Readjust or repair water temperature

controller

Evaporator water flow rate too low Determine cause, correct

Water box pass-to-pass leakage Diagnose and repair water box, see
supplementary note no. 1
Evaporator suction pressure higher Refer to “ Evaporator Suction Tem ­
than normal perature Higher Than Normal”

Faulty evaporator pressure gauge Recalibrate or replace

Suction pressure and temperature Faulty gauge or thermometer Recalibrate or replace
relationship not in agreement

Pressure reading not adjusted for Adjust reading

altitude

Refrigerant contaminated Distill refrigerant or replace

Refrigerants mixed Replace refrigerant

Leaving water temperature vs. refrig­ Chiller low on refrigerant Check refrigerant level, add
erant temperature higher than refrigerant
normal

Readings taken during pulldown Allow unit to stabilize, take new

readings

Water flow rate high Normal condition

Contaminated refrigerant Distill or replace refrigerant

Fouled tubes Clean tubes

Glycol added to evaporator water Normal condition

Evaporator converted to single pass Normal condition

Evaporator leaving water tem­ If temperature is higher than design, Check building for open windows,
perature not at design building load is too great for chiller doors, etc. and warm air infiltration
refer to “ Chiller Does Not Produce
Required Capacity” column

If water temperature is lower than de­ Readjust temperature controller

sign, temperature controller is out of
adjustment

Evaporator entering water tem­ Reading taken at pull down Allow system to stabilize, take new
perature not at design readings

Low evaporator water flow Check pump, system, readjust

valves, correct

Less than full load on machine Normal condition

Evaporator water pressure drop not Water flow rate too high or too low Readjust balancing valves, pump not
at design properly sized

Evaporator pass-to-pass leakage Diagnose, repair water box

Plugged evaporator tubes Clean tubes

Two gauges used to take readings Use one gauge only

6 .1 2 -4
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
EOimBMTTAT; FEBRUARY 1982
U se J 'JuOd
fry C ourt Order

SUPPLEMENTARY NOTES TO EVAPORATOR TROUBLE ANALYSIS CHART

1. Chiller cannot make capacity due to: rator has a three pass arrangement the pressure drop
a. Improper water flow rates. Obtain a log of the operating after one pass should equal one-third of the total pres­
conditions (see Table 1) and compare Item 14 with the sure drop. If the pressure drop measured across one
order write-up for the chiller. Readjust the water flow pass is not correct, then water box baffle leakage is to be
rates to agree with those shown on the order write-up. suspected.
b. Shortage of refrigerant in chiller. Obtain a log of the 2. Suction temperature lower than normal due to high water
operating conditions. Look at Items 16 and 17 (Table 1). flow rate. Obtain a complete log of the chiller operating con­
The approach will be wider than established as normal. ditions. Compare Item 14 (Table 1), CHILLED WATER IN,
Use a sight tube assembly to check the refrigerant level with the chiller order write-up. If the reading and order write­
in the evaporator. If the refrigerant level is correct the up do not agree, adjust the entering evaporator water flow
level will align with the punch marks on the evaporator rate to agree with the order write-up.
tube sheet.
c. Water side of the evaporator tubes are fouled. This diag­
TABLE 1 - Operating Conditions
nosis is arrived at in the same manner as “b” preceding. LOG
Clean the tubes using a brush or using a chemical ITEM READING
means. 1. Voltage
d. Refrigerant side of the evaporator tubes are fouled . This 2. Amperage
diagnosis is arrived at in the same manner as “ b” pre­ 3. Oil Temp. - Sump - °F
ceding. Refrigerant carryover may also result. One per­ 4. Oil Level
cent by weight of oil in the refrigerant is the maximum 5. Oil Gauge Pressure PSIG
allowable concentration before operating problems 6. Evap. Gauge Pressure PSIG
such as carryover or heat transfer problems will occur. 7. Cond. Gauge Pressure
8. Purge Pump Pressure (If Operating) PSIG
e. Restriction in orifice or distributor. This diagnosis is also
9. Condenser Water Pressure Diff. PSIG
arrived at in the same manner as in “ b” preceding. Condenser Water In - °F
10.
f. Baffle leakage in waterboxes. Obtain a complete log of 11. Condenser Water Out - °F
the operating conditions as in Table 1. Look at Item 14, 12. Refrigerant Liquid Temp. Cond. - °F
CHILLED WATER IN. If this is per the order write-up, 13. Chilled Water Pressure Diff. PSIG
obtain the pressure drop after one pass of a multiple 14. Chilled Water In - °F
pass arrangement. If the evaporator has a two pass ar­ 15. Chilled Water Out - °F
rangement the pressure drop after one pass should 16. Refrigerant Liquid Temp. Evap. - °F
equal one-half of the total pressure drop. If the evapo­ 17. % Current Control

FWB LIW

6.12-5
 LITERATURE FILE NO. HCTV-SG-2

C O M P R ES S O R
TR O U B L E A N A L Y S IS SECTION
AN D S U P P LEM EN TA R Y
NOTES 6.13
FEBRUARY 1982
COMPRESSOR TROUBLE ANALYSIS
COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Oil level in oil sump lowers as unit Oil supply line leaks Repair or replace, see supple­
runs, oil level not stable mentary note no. 1

Oil return line leaks Repair or replace, see supple­

mentary note no. 1

Oil sump leaks (high pressure line in Repair - see lubrication system trou­
oil sump) ble analysis chart, Section 6.15

Oil return line plugged Clean out or replace

Excessive refrigerant and foaming in Refer to lubrication system trouble

sump analysis chart, Section 6.15

Oil leakage past labyrinth seal Adjust cooling tower controls, see
caused by low condenser water supplementary note no. 1
temperature

Labyrinth seal gasket leak Replace gasket

Excessive labyrinth seal clearance Replace seal, see supplementary

note no. 1

Labyrinth seal bolts loose Tighten bolts

Labyrinth seal not positioned Reposition seal with oil drain hole on
correctly bottom, see Figure 25, Section 8.5

Noise and unstable operation while Light load, low condenser water Increase condenser water tem­
unit is running temperature perature, shut unit off to avoid low
load operation, see supplementary
note no. 2

Faulty journal bearing Replace bearing, see Section 8.5

Excessive thrust clearance Replace or readjust thrust bearing,

see Section 8.5

Open rotor Perform open rotor test, repair or re­

place rotor

Bent motor shaft Straighten or replace motor shaft,

see Section 8.5

Inlet vanes misadjusted Readjust inlet vanes, see Section 8.4

Evaporator or condenser water Change pumps to lower RPM models

pump running at 3600 RPM

Unit in surge operating condition Determine cause, correct

Refrigerant carryover Determine cause, correct

Impeller imbalance Replace or rebalance impeller

©THE TRANE COMPANY 1982 * SUPPLEMENTARY NOTES FOUND AT END OF SECTION
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601 COTTPTTEITTTAll
PRINTED IN U.S.A.
6.13-1
Use R estricted
by Court_uruer
HERMETIC CENTRAVAC SERVICE GUIDE U e;.,; H o o t i i c t e d
HCTV-SG-2
FEBRUARY 1982 t, ■ court Order

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Chiller will not produce design full Refrigerant carryover Diagnose, correct, see Section 6.12
lo a d to n n a g e , e v a p o ra to r, te m ­
perature differential not per design

Compressor surge Diagnose, correct, see Section 6.11

Compressor rotating backwards Reverse two power leads to motor,

see supplementary note no. 3

Inlet vanes not opening or not prop­ Repair or resynchronize, see Section
erly synchronized 8.4

Excessive labyrinth seal clearance Replace seal, see Section 8.4

on impeller

Impeller incorrectly positioned Shim impellers correctly, see Section

against vane plates 8.4

Impellers positioned incorrectly on Reassemble compressor correctly,

compressor shaft (1st stage in 3rd see Section 8.4
stage position, etc.)

Motor amperage not stable during Compressor surge Determine cause, correct see Sec­
unit operation, may be random or tion 6.11
synchronized oscillations

Refrigerant carryover Determine cause, correct see Sec­

tion 6.12

Inlet vanes hunting Determine cause, correct see Sec­

tion 6.11 also supplementary note
no. 4

Machine low on refrigerant Repair leaks, add refrigerant, see

Section 6.12 and also supplementary
note no. 5

Internal components rubbing Disassemble compressor, replace

faulty components, see Section 8.3

Inlet vanes constantly opening and Refer to evaporator and condenser

closing, will not find a stable point charts, sections 6.11 and 6.12

Refrigerant, oil or water seen leaking Bad O-ring Replace O-ring, see Section 8.4
out of compressor, see supple­
mentary note no. 6.

Bad gasket Replace gasket, see Section 8.4

Poor solder joint Repair joint, see Section 8.4

Threaded joint leaking Repair joint, see Section 8.4

Broken sight glass Replace glass, see Section 8.4

Rusty or corroded O-ring groove or Clean thoroughly, fill pitted areas

gasket surface with solder or replace casting

6.13-2
 'C O I 'I ? ! — T"’TAT:
HERMETIC CENTRAVAC SERVICE GUIDE
U se - HCTV-SG-2
U y _Cg U iro^O rd.e r^ FEBRUARY 1982

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Unusual noise from unit while run­ Surge operation Determine cause, correct, see Sec­
ning (squealing, knocking, hammer­ tion 6.11
ing, clatter, buzz)

Low condenser water temperature Adjust cooling tower controls, see

supplementary note no. 7

Faulty roller bearing Replace bearing, see Section 8.5

Internal components rubbing Disassemble, correct cause replace

faulty components, see Section 8.3

Inlet vane broken off Retrieve broken parts, repair as nec­

essary, see Sections 8.3 and 8.4

External noise transmitted to unit Determine noise source, isolate and

correct
Paint seen to flake or peel off of unit Corrosive atmosphere Paint unit with corrosive atmosphere
resistant paint

Solvent splashed on unit Clean and repaint

Paint worn or scraped off Clean and repaint

Dirty surface under paint Clean and repaint

Rust forming on unit Paint was removed from surface of Determine cause of paint removal,
unit clean and repaint

Condensation seen forming on vari­ High relative humidity of ambient air Normal condition with high humidity,
ous portions of compressor housing insulate to prevent condition

Low suction pressure/temperature Possibly a normal condition for appli­

cation, refer to evaporator chart, see
Section 6.12 and also supplementary
note no. 8

Refrigerant carryover Determine cause, correct see Sec­

tion 6.12

Low condenser water temperature Adjust cooling tower controls, see

causing low interstage supplementary note no. 9
pressure/temperature
Machine operating quieter than Refrigerant carryover Determine cause, correct, see Sec­
normal tion 6.12

Change in machine load from normal Change in unit sound normal

External noise masking noise of unit Determine source of other noise,

correct

Machine coasting down Normal

6.13-3
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 C O ItfF T jT ^ T A t;
FEBRUARY 1982 Use Ll :. • .. .. -d
by C o u i> _ _v x ; d e g
SUPPLEMENTARY NOTES TO COMPRESSOR TROUBLE
ANALYSIS CHART
1. Oil level in the oil sump lowers as the chiller runs. The follow­ 6. Refrigerant, oil or water seen leaking from the compressor.
ing notes will help determine the cause of this situation. This may be the result of several of the listed POSSIBLE
a. Oil loss due to bearing oil supply or drain line leakage. CAUSES. Pressure test the chiller to determine the exact
Inspect the oil supply and drain lines for leakage. On the source of the leak. Disassemble and repair as necessary.
compressor end of the motor a portion of the oil lines are 7. Unusual noise due to low condenser water temperature.
internal. This will require that the compressor be disas­ Obtain a log of the operating conditions of the chiller. Look at
sembled to inspect and repair the oil lines. At the motor Items 11 and 12 (Table 1). If these are lower than design
end, all of the oil lines can be inspected externally. (from order write-up), readjust the cooling tower controls so
b. Oil loss due to leakage past the labyrinth seals as a the inlet water temperature is at design specifications. Also,
result of low condenser pressure. To a large extent, the low condenser water temperature can cause unstable gas
condenser water temperature governs the condensing flow in the chiller resulting in noise and unstable operation.
pressure of the chiller. Adequate condenser pressure 8. Condensation due to low suction pressure and temperature.
places a differential pressure cross the labyrinth seals in Obtain a log of the operating conditions of the chiller and look
the motor to contain oil in the bearing cavities. If ade­ at Items 7 and 17. These conditions may be low due to low
quate differential pressure across the labyrinth seals is chilled water temperature as dictated by the design. This can
not present then oil will seep past the seals and motor reduce economizer pressures and temperatures to below
shaft and be lost in the refrigerant side of the system. the dew point.
See Figure 1. 9. Condensation due to low condenser water temperature.
2. Abnormal or excessive vibration while unit is running caused Obtain a log of the chiller operating conditions and look at
by light load or low condenser water temperature. Obtain a Items 11 and 12 (Table 1). If these are lower than design
complete log of the operating conditions of the chiller. Com­ specifications adjust the cooling tower controls so that the
pare items 11,12,15,16 and 2 with the chiller order write-up entering condenser water temperature is according to that
specifications. (See Table 1.) If the log readings indicate an specified on the order write-up.
extremely light load (10 percent or less) combined with low
condenser water temperature, readjust the condenser water
controls and recalibrate switch S-3 to cycle the chiller off. It is TABLE 1 - Operating Conditions
possibly normal for the chiller to operate unstably at very light LOG
load conditions. ITEM READING
3. Chiller does not produce full load tonnage due to compressor 1. Voltage
operating in reverse. Observe the motor shaft rotation 2. Amperage
through the sight glass at the terminal end of the motor. The 3. Oil Temp. - Sump - °F
correct rotation of the shaft is clockwise as viewed from that 4. Oil Level
5. Oil Gauge Pressure PSIG
end.
6. Evap. Gauge Pressure PSIG
4. Compressor motor amperage not stable due to inlet vanes
7. Cond. Gauge Pressure
hunting. Obtain a log of the operating conditions of the
8. Purge Pump Pressure (If Operating) PSIG
chiller. Observe Items 16 and 2 (Table 1). Amperage will vary 9. Condenser Water Pressure Diff. PSIG
with inlet vane position. The leaving chilled water tem­ 10. Condenser Water In - °F
perature may also vary indicating a problem with the water 11. Condenser Water Out - °F
temperature controller. Recalibrate the control for less sensi­ 12. Refrigerant Liquid Temp. Cond. - °F
tivity or replace the control. Refer to Section 7.12. 13. Chilled Water Pressure Diff. PSIG
5. Amperage unstable due to shortage of refrigerant. Obtain a 14. Chilled Water In - °F
complete log of the operating conditions of the chiller. Look 15. Chilled Water Out - °F
at Items 16 and 17 (Table 1). The approach will appear wider 16. Refrigerant Liquid Temp. Evap. - °F
17. % Current Control
than normal as the Low Refrigerant Temperature Override is
unloading the chiller. This will occur if the chiller is low on re­
frigerant. Add refrigerant.

6.13-4
 LITERATURE FILE NO. HCTV-SG-2

COM PRESSOR M O TO R
TR O U B LE A N A LYS IS AN D SECTION
S U P P LE M E N TA R Y N O TES 6.14
FEBRUARY 1982
COMPRESSOR MOTOR PROBLEMS
COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Oil level in sump lowers as unit runs, Unit losing oil Refer to same complaint on com­
oil level not stable pressor charts
Excessive vibration while unit is Refer to compressor charts
running
Unit won’t make cooling capacity, Inlet vanes not opening Determine cause, correct
motor won’t draw full load amps

Refer to evaporator, condenser, ca­

pacity controller charts

Motor amperage fluctuates randomly Voltage fluctuation Check voltages with voltmeter, have
or in uniform oscillations power company correct

Open rotor Diagnose, repair or replace rotor

Amperage imbalance over 3 phases Supply voltage imbalance Have power company correct, see
supplementary note no. 1

Unequal phase representation in Re-route motor or main power leads

power lead conduits for equal phase representation in
each conduit

Resistance in starter or wiring caus­ Diagnose, correct, see supple­

ing a voltage drop mentary note no. 2
Refrigerant or oil leaking from motor, Defective O-ring Diagnose, replace
air leak into motor

Leaking threaded joint Diagnose, repair

Leaking sweat joint Diagnose, repair

Leaking sight glass Diagnose, repair or replace

Pitted O-ring groove Clean up, fill with soft solder

Porous casting Replace or clean and solder

Unusual noise - vibration Bad bearings Replace, determine reason for fail­
ure, see supplementary note no. 3
Unusual noise - constant hum Overvoltage at motor Have power company correct 10%
above nameplate is max.

Motor locked up, won't spin Disassemble compressor and motor

to determine cause, correct

Unusual noise - periodic hum Open rotor Repair or replace rotor

Carryover Refer to evaporator charts

Motor accelerating Possibly normal

"THE TRANE c o m p a n y 1982 ' SUPPLEMENTARY NOTES FOUND AT END OF SECTION

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
'C O N F I D E N T I A L
6.14-1
Use R estricted
by Court Order
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Refrigerant sample or refrigerant in Soot from previous motor burnout Install filter-dryer to clean up and/or
sight glass appears dark in color replace refrigerant
Motor excessively hot No cooling to motor, refrigerant Clean orifice or strainer
supply orifice or strainer restricted
Motor barrel rusty Refer to compressor chart
Condensation forming on motor High relative humidity in ambient air Normal condition
barrel

Excessively cold refrigerant from Refer to ‘‘Condenser Problems”

condenser, low condenser chart
temperature

Insulation megohm test low Dirt, moisture, oil on terminal board Clean off with solvent, re-meg motor,
or terminals see supplementary note no. 4

Moisture on motor windings Dry out, re-meg motor

Windings going bad Remove terminal board, meg leads

to confirm, replace or rewind motor

Terminal board bad Replace

Solid state overload (SSOL) trips at SSOL miscalibrated Recalibrate
start-up

Motor windings shorted Meg to confirm, rewind or replace

motor

Solid state overload (SSOL) trips at SSOL miscalibrated Recalibrate

transition

Motor not up to speed Readjust SSOL

Open circuit transition Faulty resistors, faulty contactor,

wrong starter sequence

Solid state overload (SSOL) trips SSOL miscalibrated Recalibrate

while unit is running

Motor amps exceed 107% of FLA Determine reason for excess amp
draw, correct

Motor barrel hot to touch Insufficient coolant supply, clogged Clean strainer
strainer

Clogged orifice in motor cooling line Remove orifice, clean

Machine running at very light load Increase cooling tower water tem ­
with low condenser water tem­ perature and/or cycle unit off
perature unit surging

Third stage inlet vanes misadjusted Repair and/or readjust vanes

Motor temperature control trips MTC defective Diagnose, replace

Winding sensor defective Diagnose, install resistor to

compensate

Motor overheating - no coolant See excessive cycling

supply

Excessive cycling, insufficient load Shut unit off

for machine

6.14-2
 A l HERMETIC CENTRAVAC SERVICE GUIDE
,.■34 HCTV-SG-2
U se -■ 1 FEBRUARY 1982
C o u i i 4 *^

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Oil supply lines hot Oil sump problem See "Lubrication System Problems”
chart

Oil drain lines hot Low oil flow through bearing, re­ Clean restrictions from lines
striction in supply or drain lines

Oil drain lines cold Motor bearing cap leaking Disassemble, repair, or replace bear­
ing cap or gasket

Oil supply temperatues too cold, re­ Diagnose oil sump problem, correct
frigerant leakage into bearings - see
compressor chart

Motor barrel cold Excessively cold condenser water Increase temperature of cooling
tower water. This could possibly be a
normal condition

Excess refrigerant in oil sump Oil temperature control set too low Reset control

Refrigerant carryover Refer to “ Evaporator Trouble Anal­

ysis” Chart

Oil drain lines different temperatures; One motor bearing cap leaking Disassemble, correct problem
one cold, one normal
Oil drain lines different temperatures; Marginal cooling supply to motor, Clean strainer, line, and orifice
one hot, one normal strainer clogged, restriction in supply
line, orifice at motor clogged

Excessive seal leakage into com ­ Disassemble compressor, replace

pressor side bearing cavity seal and gasket

No oil flow in drain lines Restriction in bearing Determine source of restriction,

correct

Internal oil line broken Disassemble, repair

Faulty gasket on internal compressor Disassemble, repair

plate

Drain line sight glass clouded Replace sight glass

Restriction in supply line Disassemble, correct

No oil flow in supply line Oil inlet orifices plugged Disassemble, correct

Oil filter plugged Replace

Oil pressure regulating valve Remove, disassemble and remove

restricted restriction or replace

Faulty oil pump or pump motor Replace

Oil pump motor running backwards Reverse two power leads

Oil pressure regulating valve Repair or replace

defective

No oil in sump Add oil, determine cause of oil loss

Broken oil pump discharge line Disassemble and repair

6.14-3
HERMETIC CENTRAVAC SERVICE GUIDE ftOHFIEETTTTA]?
HCTV-SG-2 Use He ted
FEBRUARY 1982 D;; Court Order

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

No refrigerant in motor coolant Restriction in collant supply line Disassemble and clean strainer, ori­
supply line fice at motor barrel, line at condenser
liquid connection

No refrigerant in condenser, unit low Add refrigerant, determine cause of

on refrigerant shortage
No refrigerant in collant drain lines, No refrigerant in supply lines Repeat action - call out
motor too hot

Drain lines restricted Determine source of restriction,

correct

Unit cycling excessively causing hot Determine reason for cycling, correct
motor and vaporization of refrigerant
in motor barrel
Measured oil flow through bearings Oil filter plugged, oil line inlet re­ Replace oil filter, clean out restrictors
too low strictors plugged

Oil too cold, oil sump not at 130 -135 Repair or replace heater or tem ­
F perature control

Oil pump not supplying proper Replace oil pump

volume

Leak in internal oil pump discharge Disassemble and repair

line
Measured oil flow rate through bear­ Oil pressure too high Reset oil pressure regulating valve
ings higher than maximum

Oil diluted with refrigerant Distill refrigerant from oil or change

oil

No restrictors in oil inlet fittings Install restrictors

Motor locked up or will not spin easily Bearings locked up Replace bearings
by hand

Bearing worn out, shaft dropped, Disassemble, replace faulty

rotor jammed against stator components

Compressor seal rubbed Disassemble, replace or reposition

as necessary

Motor shaft bent, locking motor Straight or replace shaft

against seal

Motor shaft rotation stops very Operating at high load, high con­ Normal condition
quickly after disconnecting power denser pressure when shut off

Seal rubbing in compressor or motor Disassemble, replace faulty

components

Motor shaft bent Disassemble, straighten or replace

shaft

Motor shaft rotation is reversed Electric wiring not properly phased Reverse two power leads

6 .1 4 -4
 'CC/KT?IT ® TTI Ali HERMETIC CENTRAVAC SERVICE GUIDE
Use RoG.-i-Cued HCTV-SG-2
FEBRUARY 1982
-- ---- —
COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Motor journal bearing clearance ex­ Bearing worn out Replace bearing
ceeds maximum allowance, bearing
worn out

Acidic oil Install filter dryer

Shaft vibration, impeller imbalance Replace impeller

Carryover Determine cause, correct

Motor thrust/end play exceeds rec­ Worn out bearing Replace

ommended maximum

Surge operation See surge complaint

Bearing not correctly installed Readjust thrust bearing

Thrust bearing outer race retainer Replace ortighten bolts securing ring
ring loose
Motor journal bearing clearance too Mis-machined bearing Measure and replace
small

Material buildup on rollers of bearing Replace bearing

or race
Motor thrust clearance too tight Mis-machined bearing Measure and replace

Material build-up on bearing rollers Replace bearing

SUPPLEMENTARY NOTES TO COMPRESSOR MOTOR TROUBLE ANALYSIS CHART

1. Amperage imbalance due to voltage imbalance. Several job 2. Amperage imbalance due to high resistance is starter.
site or installation procedures can also cause amperage im­ Check the voltage drop through the starter from the con­
balance, such as: nection of one phase at circuit breaker to the same phase
a. Extreme difference (12 inches or more) in either line to connection at the motor terminal. This measures voltage
starter or starter to motor terminal lead lengths. drop through at all wire terminations, contactors, etc. The
b. Different conductor sizes between phases. normal voltage drop will be one to two volts A.C . If the starter
c. Unequal phase representation of conductors in a con­ contactors are burned, dirty or if the wire connections are
duit. This procedure will also cause excessive tem­ loose, then the voltage drop through the starter will be
peratures due to unbalanced magnetic flux which is greater than two volts. Systematically work through the
present on all current carrying conductors. starter to find the high resistance point and take the appropri­
ate corrective action.
The theoretical definition of voltage imbalance is rather in­
volved. However, within the range of limits which are satis­ 3. Unusual noise due to bad bearings. If this is apparent it will
factory for successful motor operation, the following defini­ be necessary to disassemble the compressor so that the
tion gives results which are sufficiently accurate. bearings can be inspected. Refer to Section 8.3. Examine
the bearings for signs of pitting, wear, corrosion or over­
The percentage of voltage imbalance may be defined as 100
heating. If there are excessive air leaks in the chiller, pitting
times the sum of the deviation of the voltages from the aver­
and corrosion due to acidic conditions can result. Wear and
age without regard to sign, divided by twice the average volt­
overheating are the result of poor lubrication due to a lubri­
age. This can be illustrated by the following example of a 220
cation system problem. This may be a restriction in the oil
volt system. If the voltages between lines of an unbalanced
supply or the oil drain at the bearing. Also check the oil filter
system are 213,219 and 222 volts, the percent of imbalance
for restriction.
is calculated as follows:

213 + 219 + 222 = 218 (AVG.) 4. Low megohm reading due to moisture in the windings of the
3 motor. Remove the refrigerant from the chiller and then
locate and repair any air leaks or tube leaks. Evacuate the
(218-213) + (219-218 )+ (222-218)x100 = 2.29% chiller thoroughly. Break the vacuum using dry nitrogen and
2 x 218 then make another megohm check of the motor. Also, if the
refrigerant is contaminated with moisture or water, replace
The maximum allowable voltage imbalance is one percent. If with clean dry refrigerant.
the voltage imbalance is greater than this, contact the local
power company.
FWB 1LW

6.14-5
 LITERATURE FILE NO. HCTV-SG-2
LU BRICATION S YS TEM
TR O U B LE A N A LYS IS SECTION
AN D S U P P LE M E N TA R Y
N O TES 6.15
FEBRUARY 1982

LUBRICATION SYSTEM PROBLEMS

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION
Oil pressure fluctuates, randomly or Faulty oil pressure regulator valve Repair or replace
in sync with motor amperage
fluctuation

Faulty oil pressure gauge Replace

Excessive refrigerant in oil sump - Determine faulty component, re­

defective oil heater, thermostat, laby­ place, see supplementary note no. 1
rinth seal leak

Open rotor Diagnose, repair or replace rotor

Gauge on panel fluctuating from Determine cause of vibration correct

panel vibration or isolate panel

Oil pump running, but no oil pressure Faulty oil pressure gauge Replace
indication on gauge

Faulty oil pressure regulator Replace or repair

Oil pump defective Replace

Pump motor running wrong direction Reverse two leads

- (3 phase motor only)

Motor to pump connection broken Replace faulty parts, see supple­

mentary note no. 2

Internal oil line from pump to regu­ Repair or replace broken line, see
lator broken supplementary note no. 3

No oil in sump Add oil, correct cause of oil loss

Excessive refrigerant in oil sump - Determine faulty component, replace

defective sump heater, defective
thermostat, labyrinth seal leak

Pump suction clogged with debris Disassemble, remove debris

Line to panel clogged or pump dis­ Disassemble, remove debris

charge clogged
Oil pump runs, oil pressure normal, Faulty oil pressure regulator Repair or replace regulator
noise from oil pressure regulator

Excessive refrigerant in oil - defective Determine faulty component, replace

sump heater, detective thermostat,
labyrinth seal leak

Oil level in sump too low, pump Add oil, determine cause of tow oil
cavitating level

®THE TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
SUPPLEMENTARY NOTES FOUND AT END OF SECTION
LA CROSSE, WISCONSIN 54601 CONFIDENTTAX,'
PRINTED IN U S A.
U se R e s tric te d
6.15-1
R l-C o u r X O rd er
 C O tfF IB E flT T K n
HERMETIC CENTRAVAC SERVICE GUIDE
Use
HCTV-SG-2
FEBRUARY 1982 by C u u r O r d e x

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Oil sample or oil in sight glass ap­ Excessive heat in oil sump burning oil Repair or replace oil temperature
pears dark in color control

Excessive moisture in system Determine cause, repair leaks, see

supplementary note no. 4

Wrong oil or mixture of incompatible Change oil to correct type

oils

Contaminated oil due to con­ Change oil, clean refrigerant, see

taminated refrigerant supplementary note no. 5

Excessive heat from compressor Correct motor cooling problem

motor and bearings
Oil pump doesn't run, no oil pressure No power to oil pump motor Correct electrical problems

Pump motor failure Check, replace motor

Pump or motor locked up Determine cause, replace bad part

Oil sump leaks, oil dripping from Faulty gasket on sump head Replace gasket
sump or connections on the head.

Sump head bolts loose Tighten head bolts

Crack in oil sump Drain oil, reweld crack

Oil leak from other source Determine source, repair

Oil leaks from pressure regulator Gasket between sump head and reg­ Replace gasket
ulator defective

Oil pressure regulator defective Repair or replace

Connection at regulator defective Repair flare joint or pipe joint

Leak from other source Determine source, repair

Oil pump motor phase imbalance (3 Imbalanced voltage at motor Correct voltage problem
phase pumps only)

Excessive voltage to motor (over Correct voltage problem

10% of normal)

Defective oil pump motor Replace motor

Improper phase representation in Correct

conduit to motor

Loose electrical connection to motor Correct

Excessive oil mist seen in oil sump Broken oil pump discharge line Repair or replace line
sight glass

Regulator bypass deflection baffle Disassemble oil sump, locate broken

broken piece, repair, or replace oil sump
head

6.15-2
 •VTtr L/C
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
U se
R FEBRUARY 1982

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Metal chips found in oil filter or seen Excessive bearing wear (steel chips) Replace bearings, determine cause
in sump sight glass of wear

Impeller/seal wear (aluminum chips) Replace faulty parts, determine

cause of wear

Tube surface particles (copper chips) A very small amount is norm al-in­
sertion of tubes during manufacture -
clean up system.

Rust particles from walls or vessels, Correct water leak, clean up system -
oxidation due to water in system replace plug tubes
Oil sump sight glass discolored, can't Soot or carbon on inside of sight Clean or replace glass, determine
see through glass cause of sooting, correct

Glass chemically etched from acid Replace glass, correct high acid con­
condition dition, see supplementary note no. 6

Cracks in glass Replace glass

Oil level above sight glass Excessive oil in sump Remove excess oil

Excessive refrigerant in oil sump - Determine faulty component, replace

defective sump heater, defective
water, labyrinth seal leak

Water in oil sump Drain sump, clean, repair water leak

Sight glass leaks oil Defective glass Replace or repair

Sight glass flange not tight enough (if Tighten sight glass flange bolts (if
applicable) applicable)

Leakage from other source Determine source, repair

Defective oil sump head, porous Replace oil sump head

metal
Carbon caked on inside of oil sump Overheated oil - defective oil sump Check heater operation, repair or re­
heater, thermostat place temperature control

Wrong oil or incompatible mixture in Change oil to correct type

oil sump

Oil dripping from filter, or seepage Defective oil filter gasket Replace gasket or tighten oil filter
noted on filter and surrounding areas canister

Leakage from oil filter canister fittings Repair broken fittings or lines

Cracked filter housing or canister Replace housing or canister

Leakage from other source Determine source, repair

Oil pump stops operating with com­ Loose wire in control panel Check continuity of control circuit to
pressor motor de-energization, S9 locate, repair as necessary
timer does not begin to run

Control relay contacts dirty or burnt Clean/replace contacts as necessary

(K5)

Defective control relay (K5) Check operation, repair/replace as

necessary

Oil sump timer (S9) contacts not Refer to Section 7.7

made

6.15-3
HERMETIC CENTRAVAC SERVICE GUIDE C 0 ^ ^ ;-a !
HCTV-SG-2 t p t 0
Feb r u a r y 1982 / - o u r t_ O r d e r

COMPLAINT - SYMPTOM POSSIBLE CAUSE RECOMMENDED ACTION

Oil pump stops operating with com­ Loose wire in control panel Check continuity of control circuit to
pressor motor de-energization, S9 locate, repair as necessary
timer does run

Control relay contacts dirty or burnt Clean/replace contacts as necessary

(K14)

Oil pump timer (S9) contacts not Refer to Section 7.7

made
Oil pump continues to run following Loose wire in control panel Check continuity of control circuit to
compressor de-energization and locate, repair as necessary
post-lube time period, S9 timer does
not run

Oil pump timer (S9) defective or See Section 7.7

jammed

Starter auxiliary contact welded Check operation, replace as

necessary

Oil pump continues to run following Purge switch in the manual position Turn purge unit off
compressor de-energization and
post lube time period, S9 timer does
run after shutdown

Oil pump timer (S9) contacts welded Refer to Section 7.7

Starter auxiliary contact welded Check operation, replace as

necessary

Defective control relay (K14) Check operation, repair or replace as

necessary

SUPPLEMENTARY NOTES FOR LUBRICATION SYSTEM

TROUBLE ANALYSIS CHART

1. Excessive refrigerant in oil sump due to labyrinth seal wear. 4. Oil sample or oil in sight glass appears dark in color due to
Since the motor is cooled with liquid refrigerant, an exces­ excessive moisture in system. This may be caused by either
sive amount of labyrinth seal clearance will allow refrigerant an air leak or a water leak in the machine. If an air leak is indi­
to enter the bearing cavities and become mixed with the oil. cated, pressure test the chiller and replace bad O-rings, gas­
This will cause cold oil, excessive foaming of the oil and pos­ kets as necessary. If a water leak is indicated, pressure test
sibly oil loss, and also oil pressure fluctuation. If refrigerant is the chiller and plug or replace leaking tubes. Modify the
entering the lubrication system, the oil drain line temperature water treatment program or remove tube obstructions as
at the defective seal end of the motor will be cooler than the necessary to avoid a tube erosion problem.
opposite drain line. If a defective seal is diagnosed, it will be 5. Oil sample or oil in sight glass appears dark in color due to
necessary to disassemble the compressor and motor. Refer contaminated refrigerant. This is likely due to a motor burn­
to Sections 8.3, 8.4 and 8.5. out. Remove and replace refrigerant, filtering the refrigerant
2. Oil pump running but no oil pressure due to broken motor to through a filter-drier to remove the contamination. Or, install
pump connection. Drain the oil sump and replace the broken a refrigerant pump with a filter-drier to clean the refrigerant
oil pump or motor. Try to determine if the tang breakage is while the chiller is in operation.
due to debris becoming jammed in the oil pump. Correct as 6. Oil sump sight glass discolored due to acidic condition.
necessary. Highly acidic conditions result from excessive moisture in the
3. Oil pump running but no oil pressure due to internal oil line lubrication or refrigerant system. The moisture may be the
between pump and pressure regulator broken. Drain the oil result of a tube leak or an air leak. Pressure test the chiller
sump, remove the oil sump head and repair or replace the and repair air leaks and/or tube leaks. Tubes may also be
broken oil line. plugged.

FW B-LLW

6.15-4
 LITERATURE FILE NO. HCTV-SG-2

OPEN R O TO R SECTION
TR O U B LE A N A LYS IS
6.16
FEBRUARY 1982

Open Rotor Diagnosis

Early diagnosis and motor replacement is important since pro­ To confirm that an open rotor exists the following items will be
longed operation of a motor with an open rotor condition can needed:
result in:
1. Multi-amp relay tester or an amperage source with a max­
1. Stator burn out due to rotor bars contacting the stator core. imum output of 110/60/1 and fused for a maximum 5 amp
2. Compressor failure due to accelerated bearing wear and dis­ output.
tortion of the rotor shaft. This may cause rubbing of impellers 2. An accurate A.C. voltmeter.
on labyrinth seals or the shaft on the bearing cover. 3. An accurate low scale ammeter.
Following are four symptoms which are indicative of an open rotor The procedure is (refer to Figure 1):
condition:
1. Open the unit disconnect switch. Verify that there is no power
1. Fluctuating amperage under constant load conditions. available to the unit starter.
2. The amplitude of the fluctuations increase as load gets
heavier. WARNING: Beforeworking on this or anyelectrical
3. Oil pressure may fluctuate at the same frequency as the equipment, alwaysdisconnecttheunitelectricalpower
current. source. Failuretodosomayresultinseriouspersonal
4. There may be mechanical vibration and an audible growling injuryordeathbyelectrocution.
of the same frequency.
2. Evacuate the unit and remove the refrigerant charge.
3. Remove the compressor suction elbow or second stage suc­
CenTraVac chiller motors use a cast aluminum rotor bar. The tion cover as applicable to machine.
open condition is the result of a micro-fracture in a rotor bar cre­ 4. Apply 5 to 100 volts across one winding of the motor. Control
ating a high resistance point in the bar. When current flows the output at 4 amps.
through the bar localized heating results which can cause further 5. Slowly rotate the rotor by hand.
deterioration of that bar or adjacent bars. 6. An amperage fluctuation of greater than 1/4 amp indicates
an open rotor.
The fluctuating amperage is the result of an open circuit as the
Corrective Action:
fractured bar passes the power pole of the field.
If an open rotor is confirmed the condition must be corrected im­
Oil pressure fluctuation is the result of the rotor shaft "dropping” mediately. The rotor, bearings, and slingers must be replaced.
in the bearing at the moment power is lost when the bar with the Contact the La Crosse Service Department with complete motor
open circuit passes the power pole of the field. and unit information for further instructions.

5 o!TFidetttxat;
Use flea crioted
by Court Oru.ar

eTHE TRANE COMPANY 1902

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601
PRNTED IN U.S.A. FWB LLW

6.16-1
 LITERATURE FILE NO. HCTV-SG-2

TR O U B LE A N A L Y S IS - SECTION
W A T E R LEAK D IA G N O SIS
6.17
FEBRUARY 1982

The purpose of this section is to provide the necessary infor­ (When it has been confirmed that the chiller is accumulating ex­
mation for the diagnosis of a water leak in a CenTraVac chiller cessive amounts of water under no circumstances should an
and determination of the proper corrective procedures. attempt be made to start the chiller motor. Possible motor fail­
ure could result.
When it is suspected that a chiller has a water leak, it is important
that this condition be confirmed and rectified as quickly as possi­ Locating A Water Leak
ble. The extent of the evacuation and dehydration process re­
quired to dry the chiller out is directly proportional to the amount of There are two areas which must be checked for leaks: the purge
water allowed to leak into the refrigerant in the chiller. A thor­ unit and the evaporator and condenser. A step-by-step pro­
oughly wet chiller may require a considerable amount of “ drying cedure for locating the source of a water leak is outlined in the
following paragraphs.
out" time. It is also important to follow good repair procedures in
order to minimize the formation of rust inside the chiller. 1. Close the inlet and outlet valves on both the evaporator and
condenser and then drain the water from the tubes and water
boxes. It is important to do this quickly to prevent further ac­
Confirming A Water Leak
cumulation of water in the refrigerant side of the chiller. Do
The purge system will give an indication of an excessive accumu­ not allow any additional water to enter the tubes or water
lation of water. By observing the sight glass on the side of the boxes until the chiller is repaired.
purge drum, it is possible to detect the accumulation of water. The 2. As soon as possible, hand pump at least one gallon of oil
w ater will lie in a definitive milky white layer on top of the through each motor bearing to flush it of water and to coat the
refrigerant. journal of the shaft with oil. Another method of flushing the
bearings is to run the oil pump. However, if water has accu­
The function of the purge system is to remove water vapor from
mulated in the oil sump it is recommended that the oil sump
the refrigerant side of the chiller along with non-condensables
be drained and recharged with fresh oil. If the oil pump motor
that may leak in because the chiller is normally operating under a
meg-ohm readings are acceptable operate the oil pump
vacuum. Generally, water from an air leak will accumulate slowly.
several hours and while continuing to locate the source of the
Water will initially appear in the purge drum as globules of milky water leak.
liquid on the surface of the refrigerant. A tube related water leak is 3. Discharge the refrigerant and oil from the chiller. The refrig­
not likely to be present if no more than six ounces of water is erant is best removed by forcing it out with nitrogen gas. Do
drained from the purge unit every three or four weeks. This not use more than 5 psig pressure to do this.
amount could leak in as water vapor. It is important to find such an
WARNING: Useonly dry nitrogen topressurize the
air leak as soon as possible because it affects the condensing
chiller. Theuseofoxygenoracetylenemaycause a vio­
temperature and, therefore, the power that the chiller requires for
lentexplosionwhichcouldcauseseriouspersonalinjury
operation. Additionally, extended operation with air leakage may
result in rust which may retard the heat transfer in the chiller,
ordeath._________________________________________
damage the motor, evaporator eliminators and also the com­ The refrigerant, being heavier than water, will lie in the
pressor components. bottom of the evaporator. When the refrigerant is removed
through the charging valve on the bottom of the evaporator,
When moisture is detected in the purge drum, operate the purge the refrigerant will be discharged first. The refrigerant should
compressor by setting the purge switch to the AUTO position. Ob­ be stored in drums until it can be distilled and reused. Refer
serve the inside of the purge drum every hour. If water accumu­ to “ Distilling the Refrigerant” found later in this section.
lates, blow it off and determine the quantity. As the water is re­ When the refrigerant has been removed and only water is
moved from the purge drum a mixture of refrigerant and water will being discharged, the w ater may be disposed of in any
come off together. Watch the purge drum sight glass and the con­ manner suitable.
tainer into which the mixture is being collected to determine when 4. Check the purge unit.
all water has been removed. If the water accumulates at an ap­ a. Close the evaporator and condenser purge connection
proximate rate of 'A pint per hour, there is a water leak in the valves, isolating the purge unit from the refrigerant side
chiller. of the chiller.

®THE TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
T T / t"
PRINTED IN U S A.
Use ’
6.17-1 fry C o
 :r
/, s t r i c t efl-
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 ( i • : x*ij
I I . Or d e r
:L
FEBRUARY 1982
b. Remove the purge condenser coil and pressurize the CAUTION: Be sure the electrical pow er disconnect switch o r '
water side of the coil to 150 psig using dry nitrogen. circuit breaker Is open before making any connections. Also
Check for leaks by submerging the coil in water and do not use a D C type welder. Use o f a D C type w elder m ayj
watching for bubbles. An alternate test method is to cause equipment damage. ______ ____________________ ]
pressurize the coil with dry nitrogen and a small amount
After the source of the water leak has been determined, steps one
of Refrigerant 12 and use a refrigerant leak detector to
find any leaks. through three which follow must be taken immediately to mini­
mize rusting of internal surfaces and the time required to evacu­
W ARNM&Uasontydry nitrogen toproaauretaettha ate the chiller.
coH.The usedoxygen or acetylene may causeevlo-
1. Plug or remove the source of the water leak. If the purge coil
lent explosion resulting la serious personal Injury or
is leaking, it should be isolated from the chiller so that evacu­
death. ■■■■ 0 ■■■: - 0 : ■ . ■;. ■
ation can begin immediately.
WARNING: Always use a pressure regulating valve 2. If the failure is found in the evaporator or condenser, the
on the nitrogen cylinder when pressure testing. Fad- decision must be made whether to plug or replace tubes.
ure to do so may causa the coH to rupture. Serious Generally, if there are less than 10 percent tubes leaking or
personal Injury or death could result____________ questionable tubes in a given pass, they may be plugged.
Suitable tapered plugs can be made in a local machine shop
c. Repair any leaks that are found. Any holes that are
or obtained from the factory. The plug for % inch O.D. tubes
found in the coil can be brazed or soldered to stop the is Trane part number PLU-158. UNDER NO CONDITIONS
leak. SHOULD MORE THAN 10 PERCENT OF THE TUBES IN
5. Check the evaporator and condenser for leaks.
ANY GIVEN PASS OF THE CHILLER BE PLUGGED.
a. Remove the rupture disc and replace it with blank-off 3. Any decision to replace tubes should be based upon an eddy
plate or cap. Pressurize the refrigerant side of the chiller current tube test and metalurgical inspection of a failed tube
using dry nitrogen with Refrigerant 12 as a tracer. Pres­ sample. Before tubes are replaced in the evaporator or con­
surize the chiller to 15 psig. denser, the chiller must be evacuated to remove moisture
b. After pressurizing the chiller, allow it to stand for 15 to 30 and to minimize rusting. Temporary plugging of the failed
minutes. Make a preliminary leak test of the evaporator tubes is recommended using the brass plugs (PLU-158) or
and condenser by opening the drain valves on each of rubber stoppers which can be purchased locally. Always
the water boxes and testing with a halide torch or similar evacuate the chiller as soon as possible to remove moisture
leak detector. A tube leak of the magnitude generally prior to opening the chiller. The evacuation time can be rr
encountered will be indicated by this test. duced by taking some or all of the following steps:
c. For a suspected leak in the evaporator or condenser, it a. W herever possible, the liquid lines between the con­
will be necessary to remove both water boxes or covers denser, econom izer and evaporator should be re­
to gain access to the tube sheets. With a leak detector,
moved. With the piping removed any standing water can
locate the tubes which are leaking. It is important to de­ be cleaned from the liquid sumps and piping. When fin­
termine the number of leaking tubes and also the reason ished, replace the pipes immediately.
for the tube failure. Removal of a failed tube for metal- b. Drill and tap any low points in volutes and suction covers
urgical analysis is recommended. To help in identifying or where water may be standing in low points. Figure 1
the exact number of leaking tubes, remove any residual illustrates where to drill and tap the compressor for
water from the inside of the tubes using compressed air. water removal.
Each tube should then be plugged using rubber stop­ c. Remove any other compressor and oil sump piping
pers at each end. If small leaks are suspected the chiller where water may be standing in low points. Remove
should be allowed to stand several hours before re­ immediately.
moving any of the plugs to check individual tubes. Leak d. After the majority of standing water has been elimi­
test each tube separately by removing only the plug of nated, the chiller should be evacuated immediately.
the tube to be checked. Do not remove all the plugs at 4. Evacuate the chiller.
once as this will not give an accurate indication of which a. Use the largest vacuum pump available. The free air ca­
tube is leaking. A soap solution may be used for identi­ pacity of the vacuum pump should be a minimum of 20
fying roll joint leaks between the tube and tube sheet. to 30 CFM although 100 CFM is preferable. If a large
d. Eddy Current analysis should be considered to aid in single is not available, use two or more pumps, each
identifying other questionable which may nee3 to be
connected to its own opening in the chiller.
replaced. b. The suction line between the chiller and the vacuum
pump should be as short as possible and as large, or
Repair Procedure preferably one size larger than the suction connection of
the vacuum pump.
WARNING: B ato n working on this or arqr electrical equlp- c. If a single large vacuum pump is used, it will be neces­
ment, always disconnect the electrical power to d ie equip­
sary to have a large connection at the chiller. Use the
ment. Failure to do so may result In serious personal Injury or rupture disc connection on the compressor suctior
death due to electric s h o c k . __________________ elbow for this purpose. Figure 2 illustrates this cor

6.17-2
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

nOKFID^'TTIAL
U se R e s tn ^ te d
Uy Cour t Order

FIGURE 1 - Drain Points for CVHE Units

nection which can be left on the chiller permanently for g. An AC arc welder can be used to heat the compressor
evacuation. When not in use, the connection must be motor windings to help vaporize moisture in this area.
capped. Apply no more than 50% of nameplate current at no
d. The dehydration time of a wet chiller can be reduced by more than 10% of the motor nameplate voltage. The
using a water freezeout chamber between the chiller welder may be connected to any two of three phase ter­
and the vacuum pump. This can be built using a refrig­ minals of the standard motor. If the motor is arranged for
erant drum that is clean. It is important that the inlet be wye - delta starting, temporarily connect the windings
placed within six to eight inches of the bottom of the for delta, or block the run contactor of the starter in the
drum. See Figure 3. Install shutoff valves as shown so operating position and connect the welder to two of the
that the water freezeout drum can be removed and line terminals of the starter.
drained. It will be necessary to keep renewing the dry ice h. During the drying out process, use an insulation tester to
to keep the water in the drum frozen. dete rm in e m otor w inding insulation resistance to
e. For accurate high vacuum readings, it is recommended ground. A series of these readings will indicate when the
that a U-tube Meriam mercury manometer or electronic motor windings are free of moisture.
vacuum gauge be used. Connect the gauge directly to
the shell rather than to the suction line of the vacuum CAUTION:Whenthesystemandthemotorareunder
pump. highvacuum,thevoltageappliedbytheInsulation
f. When a freezeout chamber is not used, the oil in the teetermust not exceed100voltstorreliablereadi­
vacuum pumps must be changed frequently (every four ngs.Severemotorwindingdamagemayresultfrom
hours) to maintain pump effectiveness. With a freezeout applyingavoltagegreaterthan100voltsto amotor
chamber on the suction side of the vacuum pump the thatIsunderahighvacuum.Thisprecludestheuse
time between oil changes can be increased. In all cases, ofaconventionalmeggar.Aninsulationtester such
the condition of the oil should be checked periodically asaWestonModel799oraconventionalVolt-Ohm-
and changed when necessary. Milliammetermaybeused.________________
6.17-3
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

RUPTURE

COKFIDETTTIAL
U se I 5 ; 3 !. .. ..

U UOu L> y i C.OI"

FIGURE 2 - Vacuum Pump Connection

F IG U R E 3 - D ry Ice W a te r F re e z e o u t V a c u u m C h am b e r

6.17-4
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

Characteristically, during the evacuation and dehy­ Distilling The Refrigerant

dration period the insulation resistance will increase as
Distilling the refrigerant to remove moisture and allow reuse of the
the moisture is removed. When the chiller has been
refrigerant can be accomplished using two Refrigerant 11 drums
evacuated the insulation resistance should be in ac­
and a roll of copper tubing. As shown in Figure 5, the warm water
cordance with the curve shown in Figure 4.
will cause the refrigerant to boil in drum A. The refrigerant will con­
i. During the evacuation and dehydration process run
dense in the tank containing the condensing coil which is main­
warm water, if available, through the evaporator and
tained at a lower pressure than drum A.
condenser tubes. The temperature of the water should
not exceed 125 F entering the chiller. WARNING: Always open the shutoff valves before filling the
j. Evacuate the chiller to 2.5 mm Hg or lower. After evacu­ tank with warm water. Exheme care must be exercised to pre­
ation, the chiller should be returned to atmospheric vent over-pressurization and rupture o f the distilling drums.
pressure using dry nitrogen. Serious injury or death could result. A relief device as
shown
in Figure S must be used to prevent over-pressurization o f the
5. After the chiller has been evacuated and returned to atmo­ drums.
spheric pressure with dry nitrogen, the chiller can be opened
for major repairs such as retubing, bearing replacement, etc. After the refrigerant has been completely distilled it may be
charged into the chiller.

I- tilii
LLI
X
2
LLI
cr
i
<
Li_ -: T
CO tjlj
LLI
W 7n
CC llll
0
LLI
t* i
LU l.-tj
t i(l
D
<
X
0.
LU

20 30 40 50
INSULATION RESISTANCE - MEGOHMS

F IG U R E 4 - M o to r W in d in g In s u la tio n R es is ta n ce Vs. T em p e ra tu re

COTTFIB^TTIAL
Use Res o i _
by Cour t __D_x;^ex
6.17-5
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982
U se
hv

FIGURE 5 - Refrigerant Distillation Set Up

FWB LLW

6.17-6
 LITERATURE FILE NO. HCTV-SG-2

C O N TR O L PANEL
SECTION
7.0
FEBRUARY 1982

The purpose of this section and the following sections is to de­ 2. System Status Lights
scribe the Model CVHE CenTraVac chiller control panel and its 3. Unit Switches and Safety Indicators
components. The sections include a description of the function, 4. Capacity Control Group
location, setting and calibration, and maintenance of each oper­
ating indicator and control. 1. PRESSURE GAUGES:
The pressure gauges at the left side of the panel provide the
CONTROL PANEL
following information:
The control panel may be divided into four functional groups as
shown in Figure 1. The groups are: Condenser Pressure Gauge - This gauge indicates the pres­
sure within the condenser. Normal condenser pressure is 2
1. Pressure Gauges to 13 psig.

__ FIGURE 1 - Control Panel

®THE TRANE COMPANY 1982 CO’ :” ' — TTTAL
COMMERCIAL AIR CONDITIONING DIVISION
U lJ G j ■ >. ‘ L u t l *3(1
LA CROSSE. WISCONSIN 54601
7. 0-1
PRINTED IN U S A.
by Co art
 C O M M I T I AT j\
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 .o r\
FEBRUARY 1982
Use if--c - - - 0~u
U y _ C o u i ; '0 . aU £
Evaporator Pressure Gauge - This gauge indicates the pres­ will be low when there are no noncondensables present in
sure within the evaporator. Normal evaporator pressure is 12 the m achine and the gauge will read high when non­
to 18 inches Hg vacuum. condensables are present.

Oil Pressure Gauge - This gauge indicates the pressure of oil 2. SYSTEM STATUS LIGHTS:
being pumped to the CenTraVac motor bearings relative to The system status lights on the left side of the control panel
atmospheric pressure. Normal oil pressure gauge readings door indicate the progress of the CenTraVac starting se­
are in the 3 to 9 psig range. quence. Refer to Figure 2. As each system running require­
ment is satisfied the appropriate light will come on in se­
NOTE: CenTraVac chillers are designed to operate with a quence. If the CenTraVac will not start, the system status
net oil pressure of approximately 12 to 15 psig. Net oil pres­ lights may be used to determine what condition is preventing
sure is determined by subtracting the oil pressure gauge the start-up. During a normal start-up, each of the lights must
reading from the evaporator pressure gauge reading. Fol­ come on, in order, from top to bottom. No light can come on
lowing is an example of this calculation. before the light above it. If this were to occur, it would indicate
that the upper light is burned out.

Evaporator Pressure Reading - 15” Hg vacuum An example of this would be that the COND WATER PUMP
Oil Pressure Gauge Reading - 6.5 psig light could not come on before the CHILLED WATER PUMP
light. If this occurred, it would indicate that the CHILLED
First, it is necessary to convert 15” Hg to psig. This is done as
WATER PUMP light is burned out.
follows:

15" Hg - 2.03 = 7.4

NOTE: After a start-up and whenver the CenTraVac is oper­
ating, all lights will remain on except the "RESTART-TIME
2.03 is a constant used to convert inches Hg to psig. Since ELAPSED" light. This light will go off for thirty minutes follow­
vacuum is expressed as a negative, the equation to deter­ ing a start. While the light is off it indicates that the machine
mine net oil pressure is: cannot be restarted. Normally after the light comes back on,
indicating the anti-recycle time is completed, the machine
6.5 - (-7.4) = Net Oil Pressure may be stopped and restarted at any time.
When subtracting a negative value, addition is used, The status lights and their function are as follows.
6.5 + 7.4 = 13.9 psig net oil pressure A. SAFETIES SATISFIED - This light, when off, indicates
that either one of the SAFETY INDICATORS is tripped
Purge Pressure Gauge - This gauge indicates the pressure or that there is no control power to the unit. To continue
within the purge drum. Normal purge gauge pressure will the start sequence the safety must be reset or control
range from 0 to 22 psig with the purge running. The pressure power be restored.

F IG U R E 2 - C o n tro l P an el

7 . 0-2
 ■ TA L
5. HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982
B. COOLING REQUIRED - This light, when off, indicates CAUTION: Do not run the purge In the manual posi­
that the chilled water demand switch setting in the con­ tion without water flow through the purge drum
trol panel is satisfied. The start sequence will continue since this m ay causa refrigerant to be purged from
when the chilled w ater tem perature increases suf­ the machine. For proper purge operation refer to
ficiently for the demand switch to call for cooling. Section 5.1
o f this service guide.________________

C. RESTART-TIME ELAPSED - When this light is off, the NOTE:When the CenTraVac is running, all safety indi­
thirty minute timer is in its timing period and will not allow cators will be in the reset position. All safety indicators
the unit to be restarted. The start sequence will continue
are manual reset switches. After a tripout, the unit
when the timer has timed out, which is thirty minutes cannot be restarted until the indicators are reset. If the
after the last start. CenTraVac is shut down due to a safety control, the
reason for the shut down should be determined and
corrected before the machine is restarted and left to run
D. CHILLED WATER PUMP - This light, when off, indi­ unattended.
cates that the water flow through the evaporator is insuf­
ficient to satisfy the setting of the flow sensing device in C. LOW OIL PRESSURE - The circuit breaker, when
the evaporator water circuit. The flow rate must be in­ tripped, indicates that the CenTraVac has experienced
creased to the design requirements of the CenTraVac a decrease or loss of oil pressure while running. Refer to
before the start sequence can be continued. Section 6.12, "Trouble Analysis” , for recommended
action.

E. CONDENSER WATER PUMP - This light, when off, in­

D. HIGH CONDENSER PRESSURE - The circuit breaker,
dicates that the water flow through the condenser is in­
when tripped, indicates that the CenTraVac has experi­
sufficient to satisfy the setting of the flow sensing device enced high condenser pressure while running. Refer to
in the condenser water circuit, or it may indicate that the
the Trouble Analysis section of this service guide for
unit AUTO-OFF switch is in the off position. The flow
recommended action.
rate must be increased sufficiently to meet the require­
ments of the CenTraVac before the start sequence can E. LOW REFRIGERANT TEMPERATURE - The circuit
be completed. Or, the AUTO-OFF switch must be breaker, when tripped, indicates that the CenTraVac
placed in the on position. has experienced e xce s s iv e ly low evaporator tem ­
perature. Refer to the Trouble Analysis section of this
service guide for recommended action.
F. OIL PUMP - This light, when off, indicates that the net oil
pressure is too low for the CenTraVac to be started. The F. HIGH MOTOR TEMPERATURE - The circuit breaker,
oil pressure must be increased to the design require­ when tripped, indicates that the CenTraVac motor has
ments before the start sequence can be completed. experienced excessively high winding temperatures.
Refer to the Trouble Analysis section of this service
guide for recommended action.
G. SYSTEM - This light comes on when the CenTraVac
starter is energized. It remains on as long as the Cen­ G. STARTER FAULT - The circuit breaker, when tripped,
TraVac is running. indicates that the starter did not energize or was de-en-
ergized while the control system was calling for the Cen­
3. UNIT SWITCHES AND SAFETY INDICATORS:
TraVac to run. The safety indicators on the starter door
These switches are located in the center of the control panel
should be checked to determine the cause of the starter
door. Refer to Figure 2. The switches perform the following
shutdown If none of the safety indicators are tripped,
functions:
refer to the Trouble Analysis section of this service
A. UNIT AUTO-OFF SWITCH - This switch allows the guide for recommended action.
CenT raVac to be manually turned off by switching to the
4. CAPACITY CONTROL GROUP:
off position. When in the auto position the CenTraVac
will operate in response to all the safeties and controls These knobs are located on the right side of the panel and
on the chiller. The unit will not automatically start unless perform the following functions:
all start-up safety conditions are satisfied and cooling is A. % CURRENT - This knob sets the highest running cur­
required. The switch is normally left in the auto position rent level at which the capacity control module will allow
when cooling is needed. the CenTraVac to operate. The numerals around the
knob represent the percent of the unit design RLA at
B. PURGE OPERATION SWITCH - This switch controls
which the control module will limit. If turned to 100% the
the operation of the purge compressor. When in the off
unit will be able to operate at the full design RLA. If set at
position the purge will not operate. When in the auto
50% the unit will limit at 50% of the unit RLA.
position it will operate only when the CenTraVac is run­
ning. With the switch in the manual position, the purge B. CONTROL POINT - The Control Point knob establishes
com pressor will run continuously. When the purge the chilled water temperature set point which the chiller
switch is in the MANUAL position, the oil pump will also will attempt to maintain. Its setting is determined by the
run. original design conditions for the CenTraVac chiller.

7 . 0-3
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 UE3 ' J' * " " " ' .
FEBRUARY 1982 iDXJLcurt Order,
C. LOAD-HOLD-UNLOAD-AUTO - This switch is called RENT knob. The vanes are holding in the position
the “ Function Control Switch" because it controls the they are in.
function of the capacity control module. This knob is left 3. Unloading Light On - With this light on, the Cen­
in the auto position for normal operation. It should only TraVac is producing chilled water at a temperature
be put in any of the other positions for service work. Re­ colder than that called for by the CONTROL POINT
gardless of the position the knob is in, the safety controls knob. The compressor inlet vanes will be closing to
will be able to override its setting and stop loading, un­ reduce the capacity of the chiller and to produce less
load, or shut the CenTraVac off. The safety controls will chilled water.
be able to do whatever is necessary to protect the Cen­
TraVac from dangerous operating conditions.
NOTE: The unloading light will always be on when­
ever the Cen TraVac is not operating. When the Cen­
D. INDICATOR LIGHTS - The lights on the capacity control TraVac is off there is a continous unload signal to the
section of the control panel indicate the mode of capac­ vane operator to insure that the inlet vanes are
ity control operation and the signal being sent to the closed for the next start sequence.
compressor inlet vane operator. The signals are as
4. Current Control and Unloading Lights On - With
follows:
these lights on, the CenTraVac has loaded to beyond
1. No Lights On - If none of the lights are on, the unit the current control load point as established by the %
chilled water temperature setpoint is satisfied and CURRENT knob. The vanes are closing to reduce
the compressor inlet vanes are holding in the posi­ the chiller capacity and reduce the current draw.
tion they are in. 5. Loading Light On - The CenTraVac is not producing
2. Current Control Light On - With this light on, the Cen- chilled water cold enough, as called for by the setting
TraVac is at its current control load point as estab­ of the CONTROL POINT knob, and the inlet vanes
lished by the unit RLA and the setting of the % CUR­ are opening to increase chiller capacity.

PRINTED BY PRODUCTION SERVICES — LA CROSSE FWB /DJL

7. 0-4
 LITERATURE FILE NO. HCTV-SG-2

FUSES (F1-F4) SECTION

7.1
FEBRUARY 1982

pOtfFI!T'TTXAL'
Use i- . - -- >.ed
Uy C o u.1 ^

D ESC RIPTIO N

The fuses are located on the door of the factory mounted starter.
They provide protection for the chiller control circuit, oil pump cir­
cuit, oil heater circuit, and the purge unit circuit. Each circuit is
protected by a 15 amp fuse. Spare fuses are included in a holder
on the inside of the starter door.

S P E C IFIC A TIO N S

Current Rating 15 Amperes, Time Delay

Type SC
Fuse Class G
Length 1 5/16”
Diameter 3/8”

C H E C K O U T P R O C ED U R E

To determine the condition of a fuse, check the continuity of the

fuse. If the fuse isopen, replace the fuse. Determine the cause of
the fuse burn-out before putting the chiller back in service.

'T H E TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A 7. 1-1
 LITERATURE FILE NO. HCTV-SG-2

HIGH CONDENSER SECTION

PRESSURE CO N TROL (S1)
7.2
D E S C R IP TIO N FEBRUARY 1982

The Condenser High Pressure Control is a single stage control

with a set of normally open contacts. The closing of the NO con­
tacts trips the high condenser pressure fault indicator. The control
contacts automatically reset while the fault indicator provides for
manual safety reset. Figure 1 illustrates the control. M AIN CONTACTS (LINE-M2) CLOSE HIGH; OPEN LOW
B CUTOUT SETTING A RANGE ADJUSTING SCREW
S P E C IF IC A T IO N S :

Cut Out 15 PSIG ± 1

Differential Fixed 5 PSIG ± 1

Maximum Allowable Pressure 325 PSIG

FLA @ 120 VAC Line 2 - M2 (m ain): 16.0

Amps
Line 1 - M1 (auxiliary): 6.0
Amps

LRA @ 120 VAC Line 2 - M2 (m ain): 96.0

Amps
Line 1 - M1 (auxiliary): 36.0
Amps

Pilot Duty (Both Poles) 125 VA 120 to 600 VAC

Terminal Connection 0 .25 inches m ale spade

quick connect
FIGURE 1 - Condenser High Pressure Control
Connecting Tubing Length 12 inches (nut to nut)

Fitting Size 0 .25 inches fem ale SAE r /i - r

Flare

C A LIB R A T IO N A N D C H E C K O U T PR O C E D U R E

1. Isolate the control from the condenser by disconnecting the 4. Energize the chiller control panel but leave the unit OFF-
pressure sensing line at the condenser. Cap the condenser AUTO switch in the OFF position.
connection. 5. Slowly open the valve on the nitrogen cylinder, putting the
2. Disconnect the control flare connection at the chiller control control under pressure. When the line pressure gauge indi­
panel. cates 15 psig, the main control contacts (L1-M1, shown in
3. Connect a cylinder of dry nitrogren to the flare adapter of the Figure 3) will close, tripping the High Condenser Pressure
control. Figure 2 illustrates the testing hookup. Fault Trip Indicator.

WARNING:Useonlynitrogenforpressuretesting. The 6. Close the nitrogen cylinder valve and slightly open the bleed

useof oxygen or acetylenemayresult Inaviolet ex- line in the pressure line. W hen the test pressure drops to 10

plosioncausingseriouspersonal injuryordeath. psig the control contacts should open.

7. If the control does not operate properly it should be adjusted
WARNING:ThenitrogencylinderMUSThaveapressure or replaced as necessary.
regulatingvalveattached. Donot connectthenitrogen 8. Remove the nitrogen cylinder and test equipment. Recon­
cylinderdirectlyasthiswillsubjectthecontroltoexces­ nect the control as originally installed.
sivepressures. Thismaycausedamagetothecontrol
andioranexplosioncausingseriouspersonal Injuryor
death.____________________________________________
CTHE TRANE COMPANY 1982
COMMERCIAL AIR CONDITIONING DIVISION
■LA CROSSE. WISCONSIN 54601
PRINTED IN U S A 7 . 2-1
HERMETIC CENTRAVAC SERVICE GUIDE A r,
HCTV-SG-2 x t -- , t r , ': —
FEBRUARY 1982 u'" '. r ox^aS i
^ 7 C o j i 1- - - " ' -----

CYLINDER
PRESSURE
GAUGE

FIGURE 3 - Contact Arrangement, High

Pressure Control

MAINTENANCE
It is recommended thatthe control be checked annually for proper
operation. If the control does not function as specified it should be
FIGURE 2 - Pressure Test Hookup replaced.

PRINTED BY PRODUCTION SERVICES — LA CROSSE FWB /DJL

7 . 2-2
 LITERATURE FILE NO. HCTV-SG-2

L O W R E FR IG E R A N T SECTION
TE M P E R A TU R E C O N TR O L (S2)
7.3
'T
J .I! f'j FEBRUARY 1982
Use h.,e ted
DESCRIPTION accuracy thermometer. Add ice, stir continuously and observe
by Co ur y order
control operation to see that contacts switch as specified above.
The Low Refrigerant Temperature Control is a two-stage control Remove bulb from ice bath to see that contacts remake as
with its sensing bulb located in a well in the bottom of the evapo­ specified.
rator. The control has one set of normally closed and one set nor­
mally open contacts which switch on a drop in refrigerant tem ­ The differential between stages can be adjusted by rotating the
perature and reset on a temperature increase. Upon the opening adjusting cam as shown in Figure 2. Recheck control setting after
of the first control contact, the compressor inlet vanes will be making adjustments.
throttled towards the closed position, unloading the machine. If
the refrigerant temperature continues to decrease, the control’s
MAINTENANCE
second set of contacts will close tripping the low refrigerant tem­ It is recommended that the function of the control be checked an­
perature fault indicator, de-energizing the compressor and stop­ nually. If the control does not function as specified, it should be
ping machine operation. replaced.
The control is equipped with a low limit stop to prevent setting the
control at less than 30 F. SET POINT TEMPERATURE

SPECIFICATIONS

Actuation Temperature C lose on rise in refrigerant

temperature
First Stage: 35.5 F
Second Stage: 33.5 F

Deactuation Temperature O pen on fa ll in re frig e ra n t

temperature
First Stage: 34 F
Second Stage: 32 F

Temperature Range 20 F to 90 F

Low Limit Stop Setting 30 F

Max Bulb Temperature 140 F

FLA @ 120 VAC 16.0 Amps

FIGURE 1 - Low Refrigerant Temperature Switch
LRA @ 120 VAC 96.0 Amps

Pilot Duty 125 VA - 24/600 VAC

Terminal Connection Size 0.25 inches male spade quick

connect

Capillary Length 15 feet

Bulb Size 0.375 inches x 5 inches

CALIBRATION AND CHECKOUT PROCEDURE:

The low refrigerant temperature control is calibrated by com­

paring the indicated temperature setting against the actual bulb
temperature when the bulb is placed in a container of ice. The low
refrigerant temperature control is normally set at 32 F. To cali­
brate the control, place the sensing bulb in water along with a high
'TH E TRANE COMPANY 1982
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601 FIGURE 2 - Stage Differential Adjustment
PRINTED IN U S A.

PRINTED BY PRODUCTION SERVICES - LA CROSSE 7. 3-1

FWB.DJL
 LITERATURE FILE NO. HCTV-SG-2

C H ILLED W A T E R D EM AND SECTION

C O N TR O L (S3)
7.4
FEBRUARY 1982
DESCRIPTION CALIBRATION AND CHECKOUT PROCEDURE

The Chilled Water Demand Control, labled START-STOP on The chilled water demand control is calibrated by comparing the
wiring diagrams, senses return chilled water temperature through indicated tem perature setting against the actual bulb tem ­
a bulb located in the return water piping. The control opens and perature when the bulb is placed in water. The bulb is placed in
closes its contacts to start and stop the chiller in response to the water with a high accuracy thermometer. Add ice to the water,
chilled watertem perature change. Figure 1 illustrates the control. stir continously, and observe the control action to see that the
contacts open as specified. Remove the bulb from the ice water
SPECIFICATIONS or add warm water to see that the contacts reclose as specified.
Set Point range 20 to 80 F The control should be replaced if it does not function as specified.

Differential range 3.5 to 14 F The differential of this control can be adjusted from a minimum of
3.5 F to a maximum of 14 F. The differential can be increased by
Standard Differential Setting 5.0 F sliding the tab, located on the right side of the control next to the
mounting base, in the upward direction. Refer to Figure 2. The
Maximum Bulb Temperature 140 F
differential can be decreased by sliding this tab down.
FLA 16.0 Amps @ 120 VAC
The standard differential on this control is 5 F.
LRA 96.0 Amps @ 120 VAC
This control is typically set up with its cut in 4 F above the CON­
Pilot Duty 125 VA @ 24 - 600 VAC TROL POINT setting of the capacity control module. With the
standard 5 F differential the cut out will then be 1 F below the
Terminal Connection 0.25 inch male spade quick CONTROL POINT setting.
connect

Capillary Length 15 feet

Bulb Size 0.375 inch x 4.25 inch

D IFFE R EN TIA L
ADJUSTING LEVER

FIGURE 1 - Chilled Water Demand Control FIGURE 2 - Adjusting Control Differential

PRINTED BY PRODUCTION SERVICES — LA CROSSE 'C0JTPTD5ITTIAI' FWB.DJL

®THE TRANE COMPANY 1982 Use icted

COMMERCIAL AIR CONDITIONING DIVISION
LACROSSE. WISCONSIN 54601 Ox'der
PRINTED IN U S A. 7 . 4-1
 LITERATURE FILE NO. HCTV-SG-2

A N TI-R E C Y C L E TIM E R (S-4) SECTION

7.5
FEBRUARY 1982

DESCRIPTION CHECKOUT PROCEDURE

The Anti-Recycle Timer is a mechanically driven cam timer. It The operation of the timer is checked by energizing the timer
controls the starting sequence of the control panel and limits the motor leads. Each set of terminal leads is then monitored to see
number of chiller starts to one start each 30 minutes. that the contacts (Figure 1) operate correctly. Figure 2 illustrates
the timing sequence of the timer. If any of the contacts fail to oper­
SPECIFICATIONS ate as illustrated in Figure 2, the timer should be replaced.
Voltage: 115V ± 10% @ 6 0 cycles NOTE: Timer Terminal Contact 7 - 8 (wire numbers F1 -51) must
Switch Rating: 15 AMP @ 220 VAC close before Terminal Contact 1 - 3 (wire numbers 81 -82).

Motor Speed: 2/15 RPM MAINTENANCE

Cycle Time: 30 minutes No adjustments or maintenance are possible on this timer. If the
timer fails to function properly it should be replaced.
Terminal Connection Size: 0.25 in spade_____________

o o
CNJ t-
t- in lO CM
S4 +1 +1 +1
+1 +1 +1 +1 o
SECONDS § £ oTj- o o

05 O
MINUTES C\J CO

F1-52 HOLD
81-82 "I PULSE TIMER
VMOTOR RUN
|I 13-81
13-79
J CONTACT
STARTER FAULT AND
76-4 COUNTER PULSE
START LRT BY-PASS
76-88

-START PULSE
— ARM STARTER FAULT

-PRE-LUBE

HEAVY LINE INDICATES CONTACT CLOSED

60 HERTZ TIMING SHOWN
50 HERTZ TIMING WILL BE 6/5 OF THAT SHOWN

FIGURE 1 - Wiring Diagram for Anti-Recycle Timer (S4) FIGURE 2 - Timer Contact Timing Chart

C O N F I D E N T 1 4 .E
PRINTED BY PRODUCTION SERVICES — LA CROSSE TT_ „ ., . * ■ FW B'DJL
use HeGLi-icted
®THE TRANE COMPANY 1982 ]U L C o u r t O rd e r
COMMERCIAL AIR CONDITIONING DIVISION -------
LA CROSSE, WISCONSIN 54601
PRINTED IN U.S.A. 7.5-1
 LITERATURE FILE NO. HCTV-SG-2

O IL PR ESSU R E SECTION
C O N TR O L (S8)
7.6
D ES CR IP TIO N DECEMBER 1982

The oil pressure control is a single stage control with a normally CALIBRATION AND CHECKOUT PROCEDURE
open, single throw contact. Its contacts close when the net oil
1. Start the oil pump. This can be accomplished by setting the
pressure rises to 15 psig and reopens if the oil pressure falls to 8
purge switch at the MANUAL position. This can also be ac­
psig. With the chiller in a vacuum, the net oil pressure can be de­
complished by placing a jum per between Terminals F2 and
termined by dividing the reading on the evaporator pressure
21 in the control panel.
gauge (Inches-Hg) by two and adding that number to the reading
2. Decrease the oil pressure by adjusting the oil pressure regu­
on the oil pressure gauge. For example:
lating valve. Refer to Section 8.1, OIL PRESSURE REGU­
16 Inches Hg -p 2 -= 8 PSI equivalent. Adding 8 PSIG to the oil
LATING VALVE.
pressure gauge reading (7 PSIG) gives an actual net oil pres­
3. When the net oil pressure drops to 8 psig the contacts of the
sure of 15 PSIG.
control should open.
Figure 1 illustrates the contact arrangement and Figure 2 illus­ 4. Increase the net oil pressure to 15 psig. The contacts should
trates the control adjustments. Figure 3 is used to determine ac­ close. If the control fails to function as specified, the cut-in
ceptable net oil pressure over a range of machine load condi­ and cut-out points should be changed as required and the
tions. The opening of the control contacts de-energizes the control operation checked again.
compressor and trips the low oil pressure fault circuit breaker.
To adjust the cut-out point:
The oil pressure control contacts close on a net oil pressure in­
crease to 15 psig. The fault circuit breaker must be manually reset 1. Adjust nut “ A” while observing the cut-out pointer. See
before machine operation can be resumed. Figure 2.
2. Clockwise nut rotation (viewed from top) lowers the cut-out
SPECIFICATIONS setting.
Cut-Out Pressure 8 psig ± 1 above Evaporator 3. Counter-clockwise rotation raises the cut-out setting.
Pressure
To adjust the cut-in setting:
Cut-In Pressure 15 psig ± 1 above Evapo­
rator Pressure 1. Adjust cam “ B" while observing the cut-in pointer. Refer to
Figure 2.
Maximum Allowable Pressure 325 psig 2. Clockwise cam rotation (viewed from the top) raises the cut-
in and the cut-out settings.
FLA @ 120 Volts AC 20.0 Amps 3. Counter-clockwise rotation lowers both the cut-out and the
LRA @ 120 Volts AC 120.0 Amps cut-in setting.
4. Whenever the cut-in point is adjusted, the cut-out point will
Pilot Duty 125 VAC @ to 600 VAC a ls o h a ve to be re a d ju s te d . R e fe r to c u t-o u t p o in t
adjustment.
Terminal Connection 0.25 inch male spade quick
connect If the control cannot be set as specified, it should be replaced.

Connecting Tubing Length Flare connected

Fitting Size 0.25 inch female SAE flare

ADJUSTING i
CAM B

ADJUSTING, .CONTACT
fTOTIFIDTni'Tt Ia l ' NUT A BLOCK
TERMINALS
Use lies loti-‘d CUT-OUT CUT-IN
by Com L Uraer POINTER' POINTER

FIGURE 1 - Contact Arrangement of Oil

Pressure Control
'TH E TRANE COMPANY 1982 FIGURE 2 - Control Adjustments
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601
PRINTED IN U S A 7.6-1
 3! x x
™n m
™ -H 30
C ■ 2
30 < p 3
-< ro n
_ l n
to m
oo
ro
z
-H

n
eo

PRINTED BY PRODUCTION SERVICES

m
o

LA CROSSE
C:> C l
\r i
\c

L i

S G <
p o a
n p^1

FIGURE 3 - Net Oil Pressure Limits

FWB/DJL
 LITERATURE FILE NO. HCTV-SG-2

O IL PU M P TIM E R (S9)
SECTION
7.7
FEBRUARY 1982

DESCRIPTION CHECKOUT PROCEDURE

The oil pump motor timer provides for starting the oil pump motor. To check the operation of the oil pump motor timer, run the timer
It also keeps the oil pump energized for 7 minutes following shut­ by energizing the motor leads. Each set of terminals is then mon­
down of the CenTraVac compressor. This maintains a supply of itored to insure that the contacts operate as described in Figure 2.
oil to the compressor motor bearings during coastdown of the If any of the contacts do not operate as specified, replace the
compressor. timer.

SPECIFICATIONS MAINTENANCE

Voltage: 1 1 5 V ± 10% @ 60 cycles Ther are no adjustments or maintenance possible on this timer.

Switch Rating: 15 AMPs @ 220 VAC

Motor Speed: 4 RPM

Cycle Time: 8 minutes

Use . •... ioTcd
Terminal Connection Size: 0.25 inch spade
hy

co r-
cm in co
S9 +i +i +i
20
20

SECONDS o < 0

MINUTES u•> CC
£5 3 f 10-12 START
M l 7-8 OIL PUMP RUN

cc POST LUBE
I- L— TIMER HOLD FOR
l start shutdow n

HEAVY LINE INDICATES CONTACT CLOSED

60 HERTZ TIMING SHOWN
50 HERTZ TIMING WILL BE 6/5 OF THAT SHOWN.

FIGURE 2 - Contact Timing Chart

PRINTED BY PRODUCTION SERVICES LA CROSSE FWB DJL

'T H E TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A. 7 . 7-1
 LITERATURE FILE NO. HCTV-SG-2

O IL TE M P E R A TU R E SECTION
C O N TR O L (S10)
7.8
FEBRUARY 1982
DESCRIPTION CALIBRATION AND CHECKOUT PROCEDURE

The Oil Temperature Control senses oil temperature through a The oil temperature control is a fixed differential switch. To check
bulb located in the oil sump and energizes the oil sump heater to its operation, power must be applied to the starter panel. The con­
maintain a set oil temperature. By maintaining the oil temperature trol should be set at 135 F and the oil temperature thermometer
between 130 and 135 F when the CenTraVac is not running, the watched. Oil temperature should stablize between 130 and 135
accumulation of liquid refrigerant in the oil sump is prevented. F. If the oil temperature does not stabilize at this temperature, the
Power to the control is supplied through Fuse F3 in the Cen­ control should be adjusted by resetting the dial as necessary and
TraVac starter. The control is illustrated in Figure 1. the oil temperature rechecked. If the control does not function as
specified, it should be replaced.
SPECIFICATIONS
MAINTENANCE
Set Point 135 F ± 5 F
No internal adjustments are possible with this control. It is recom­
Differential (Fixed) 5 F + 2 F mended that the cut-in and cut-out temperatures be checked
Temperature Range 100 to 250 F annually.

Maximum Bulb Temp. 290 F

FLA 16.0 Amps @ 120 VAC

LRA 96.0 Amps @ 120 VAC Use Ueou.. - - ^

X>v C o u r t _ ^ p>'
Pilot Duty 125 VA @ 24 to 600 VAC

Terminal Connection 0 .2 5 in c h e s m a le s p a d e q u ic k
connect

Capillary Length 15 feet

Bulb Size 0.375 inches x 4.25 inches

*THE TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A. 7. 8-1
 LITERATURE FILE NO. HCTV-SG-2

O FF - A U TO S W ITC H (S-11)
SECTION
7.9
FEBRUARY 1982

DESCRIPTION SPECIFICATIONS

The OFF - AUTO Switch (S-11) is a single pole, single throw, Number of Poles 1
rocker switch used to manually turn the machine OFF or to allow
Switch Rating 15 Amps @ 125 VAC
the machine to operate in the automatic mode. In the automatic
3/4 HP @ 250 VAC
mode the machine will operate in response to demand for chilled
water and system safeties. Figure 1 illustrates the wiring of this Terminal Connection 0.25 inch male spade quick connect
switch.
MAINTENANCE

There are no adjustments which may be made to this control.

COtfFIDM'TIAL
Use icii j I
Court, w'i uer

FIGURE 1 - Wiring of OFF-AUTO Switch (S-11)

PRINTED BY PRODUCTION SERVICES — LA CROSSE FWB,DJL

'T H E TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A. 7.9-1
 LITERATURE FILE NO. HCTV-SG-2

PU RG E U N IT
HIGH P R ES S U R E C O N TR O L SECTION
(S-13) 7.10
FEBRUARY 1982

DESCRIPTION WARNING:Useonlydrynitrogenforpressuretesting.
TheuseofoxygenoracetylenemayresultInaviolentex­
The Purge Unit High Pressure Control senses the purge com­
pressor discharge pressure and shuts the purge compressor off
plosioncausingseriouspersonalinjuryor death.
whenever this pressure exceeds the normal control setting of 30 WARNING:Thenitrogencylindermusthaveapressure
psig. This is a safety control which prevents excessive pressure regulatingvalveattached. Donotconnectthenitrogen
from building in the purge system. cylinder directlytothecontrol asthiswill subject the
control toexcessivepressures. Thismaydamagedie
SPECIFICATIONS
controlandmayalsoresultInanexplosioncausingseri­
Set Point 30 psig Maximum ouspersonal Injuryordeath.
Differential 10 psig ± 2 psi
3. Slowly open the pressure regulating valve on the nitrogen
Pressure Range 15 " Hg Vacuum to 50 psig cylinder putting the control under pressure. Listen for control
operation. When the line pressure gauge indicates 30 psig,
Maximum Pressure 250 psig
the control contacts should open.
Full Load Amps at 120 VAC 20 Amperes 4. Close the regulating valve on the nitrogen cylinder and then
slightly open the bleed valve in the pressure line. When the
LRA at 120 VAC 120 Amperes test pressure drops to 20 psig the control contacts should
Pilot Duty close.
125 VAC
5. If the control does not function properly it should be adjusted
Terminal Size #8-32 Screws or replaced.
6. Remove the nitrogen cylinder and test hook-up equipment.
CALIBRATION AND CHECKOUT PROCEDURE Reconnect the control as originally installed.
1. Isolate the control from the purge condenser by discon­ MAINTENANCE
necting the pressure sensing line at the purge compressor.
2. Connect a cylinder of dry nitrogen with regulator to the flare It is recommended that the control be checked annually for proper
adapter of the control. Figure 1 illustrates the testing hook­ operation. If the control does not function as specified it should be
up. replaced.

CONFIDENTIAL
Use Re st ri ct ed
fry

6THE TRANE COMPANY 1982 FIGURE 1 - Pressure Test Hookup

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A. 7. 10-1
 LITERATURE FILE NO. HCTV-SG-2

PURGE O IL S E P A R A TO R SECTION
H EA TER C O N TR O L (S-14)
7.11
FEBRUARY 1982

DESCRIPTION CALIBRATION AND CHECKOUT PROCEDURE

The purge oil separator heater control senses the purge oil sepa­ The oil separator heater control is calibrated by comparing the in­
rator temperature through a bulb attached to the oil separator dicated temperature setting with the actual temperature of the oil
drum. The control is mounted on the outside of the purge oil sepa­ within the separator drum. The control should open its contacts
rator. This control energizes and de-energizes the oil separator and de-energize the oil separator heater when the oil tem ­
heater to maintain the oil separator temperature at between 120 F perature reaches approximately 135 F. It should reclose its con­
and 135 F. tacts at approximately 8 F below this temperature. To calibrate
this control, place a high accuracy thermometer in the top of the
The power for this control is supplied through Fuse F4 in the com­
oil separator being sure the thermometer bulb is immersed in the
pressor starter.
oil. One of the male pipe to flare fittings on top of the separator
SPECIFICATIONS should be removed so the thermometer can be inserted into sep­
arator. Observe the control action to see that it operates as speci­
Set Point (Open on rise above) 135 F ± 5 F fied; adjust as necessary. If the control cannot be made to oper­
ate as specified it should be replaced.
Differential 8 F (Fixed)
MAINTENANCE
Switch Action Open on Rise - SPST
It is recommended that the control be checked annually for proper
Temperature Range 100 F to 300 F
operation.
FLA at 120 VAC 7.4 Amps

LRA at 120 VAC 44.5 Amps

Terminals #8-32 Screws

C C t tF ir r o r c r A B

Use ie..j... -.luted

u_uxjL- CJivi nr

PRINTED BY PRODUCTION SERVICES — LA CROSSE FWB ,'DJL

*THE TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A. 7. 11-1
 LITERATURE FILE NO. HCTV-SG-2

C A P A C ITY C O N TR O L SECTION
M O D U LE U - V , .
Use I ■• i- - vtU.
Ui' C e u L L ui'iier
7.12
D ES C R IP TIO N FEBRUARY 1982
The Trane Electronic Capacity Control Module is located on the The current limiting setting is continously adjustable from 100%
door of the control panel. It operates the electric inlet vane motor down to MIN. The control module will automatically limit the chiller
to load or unload the CenTraVac chiller. It controls the chiller in inlet vane opening to prevent current draw from exceeding the se­
such a way as to maintain the leaving chilled water temperature at lected value.
the setting on the CONTROL POINT dial on the front of the chiller
control panel. See Figure 1. The control point is continuously ad­ The capacity control module also has a knob called the FUNC­
justable between 35 F and 55 F. TION CONTROL SWITCH which enables the chiller to be m anu­
ally loaded, unloaded, held at a set load, or operated auto­
The capacity control module receives its chilled water tem­
matically in response to chilled water temperature, as required,
perature indication from a sensor located in the leaving chilled
Refer to Figure 1. Operation in all these control modes is auto­
water stream. The module also receives signals from the Elec­
matically overridden and the chiller unloaded in the event of a
tronic Overload (A1) in the starter, the low evaporator tem­
compressor motor overload, low evaporator refrigerant, or if the
perature control (S2), and the starter 2M (K28) auxiliary contacts.
starter is de-energized.
It will load limit or unload the chiller when any of these indicates a
condition that is hazardous to the chiller. There are three lights on the front of the control panel door which
indicate if the chiller is loading, unloading, holding with no vane
The capacity control module limits the maximum load on the
movement, or limiting the chiller capacity based on compressor
chiller based on compressor motor current draw. This is accom­
motor current draw. See Figure 1. All other operational character­
plished by setting the knob on the control panel marked % CUR­
istics of the capacity control module are set on the back of the
RENT to the maximum current draw desired. Refer to Figure 1.
module. Refer to Figure 2. Also refer to "O perating C har­
acteristics.”

FIGURE 1 - Trane Electronic Capacity Control Module

•THE TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
FIGURE 2 - Trane Electronic Capacity Control Module
LA CROSSE, WISCONSIN 54601
PRINTED IN U.S.A. 7.12-1
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 C O W IO T T T A tf
FEBRUARY 1982 Use Rcsxrioted
t L i d e r OPERATING CHARACTERISTICS
SPECIFICATIONS

Set Point Range 35 F to 55 F Loading: The capacity control module loads the machine using
variable duration “ pulses." The length of the load pulse is deter­
Ambient Operating Range 0 F to 150 F mined based on two conditions: 1) the deviation of the leaving
Current Limiting Adjustment 40% to 100% chilled water temperature from the dead band around the set-
poing; and 2) the motor current draw as a percentage of the set­
Operating Voltage 120 VAC ± 15%, 60 or 50 Hz ting on the % CURRENT knob.

Output Relay Rating 5 Amps @ 120 VAC Figures 3 and 4 show the length of load pulse given by the capac­
ity control module when under temperature control and when ap-

LENGTH OF LOAD/UNLOAD PULSE VS.

LEAVING WATER TEMPERATURE
DEVIATION FROM DEAD BAND
( ■>
1

i
LENGTH OF
LOAD/UNLOAD
PULSE (SECONDS)

/
/
/|
.25 -
0
C .! 2 1(
LEAVING WATER TEMPE RATUR ; DE VIAT ION FRO VI DE AD
DEAD BANC BAND (EIT HER AE OVE O R BELO W, DEGR EES FAH REN HEIT)
LIM IT

FIGURE 3 - Graph of Load/Unload Pulse Schedule When Under Temperature Control

7. 12-2
 IAJ-* ... W L HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982
proaching current control, respectively. The actual load pulse Load Delay: The length of time that the capacity control module
time given will be the shorter of the times indicated on the two waits between load pulses (load delay) is set using DIP Switches
charts. 5 through 9 on the back of the capacity control module. Refer to
Figure 5. The load delay time can be set at from 10 seconds to
Example: A chiller is set up and is operating with the following 310 seconds.
conditions:
The load delay is set by turning on the combination of switches
CONTROL POINT setting 45 F which equals the amount of delay time desired. See Figure 5 and
% CURRENT setting 100 % Table 1.

± 1F Example: The desired load delay is 110 seconds. To achieve this

Dead Band setting
time, Switches Numbered 5 ,6 and 8 would be turned on. This can
Leaving Chilled W ater Temperature 51 F be seen by adding the time indicated on each switch.

10 seconds + 20 seconds + 80 seconds = 110 seconds

The machine is operating at 90% of the % CURRENT knob set­
Dead Band : The capacity control module may be set with a dead
ting. What is the length of the load pulse?
band, or sensitivity of ± 0.25, ± 0.50, ± 1.0 F, or ± 1.5 F around
From the temperature given it is seen that the leaving chilled the control point. Refer to Figure 6. The dead band is the tem ­
water temperature is 5 F away from the dead band around the perature range around the control point in which the capacity con­
CONTROL POINT setting. Figure 3 shows that this would pro­ trol module will not give a load or unload pulse signal. It considers
duce a 1 second load pulse. However, the current draw is 90% of the load satisfied as long as the leaving chilled water temperature
the % CURRENT knob setting. Figure 4 dictates that a 0.5 is within the dead band.
second load pulse be given because the capacity control module
The dead band is set using DIP Switches Number 3 and 4 on the
always gives the shorter of the two pulses (compare Figure 3 with
back of the capacity control module. See Figure 5. Table 2 gives
Figure 4).
the switch combinations necessary to set the different dead
If the current draw had been 80% or less of the % CURRENT bands. The module reaction to this calibration is illustrated in Fig­
knob setting, a 1 second load pulse would have been given. ures 3 and 4.

FIGURE 5 - Capacity Control Module Rear Adjustments

TABLE 1 - Function of DIP Switches and Jumpers (Refer to Figure 5)

SWITCH NUMBER FUNCTION NORMAL SETTING
1+ 2 Automatic Setback of Optional
Chilled Water Temperature
3 + 4 Set Dead Band or Sensitivity ± 1.5 F
of Temperature Control Switch No. 4 and No. 5 on
5-9 Set Amount of Time Between 30 Seconds
Load Pulses Switches No. 5 and No. 6
7.12-3
 HERMETIC CENTRAVAC SERVICE GUIDE Unloading: The capacity control module unloads the chiller
HCTV-SG-2 based on the deviation from the dead band around the setpoint
FEBRUARY 1982 and on the motor current draw.
TABLE 2 - Control Point Sensitivity Settings
When under temperature control, the capacity control module
SWITCH #3 SWITCH #4
POSITION POSITION SENSITIVITY
pulse unloads the chiller as shown in Figure 3. The hold time be­
OFF OFF ± 0.25 F tween unload pulses is the time set on the DIP Switches Number
ON OFF ± 0.5 F 5 through 9 (see Figure 5) just as in the case of loading.
OFF ON ± 1.0 F
Current Control: The following paragraphs and Figure 7 discuss
ON ON ± 1.5 F
the operation of the Trane capacity control module as it ap­
proaches 100% load.

OUTSIDE DEAD BAND THE CONTROL WILL

LOAD/UNLOAD AS SHOWN IN FIGURES 3 AND 4

DEAD BAND
UJ LIMITS
cc
z>
h-
<
CC CONTROL
LU
0- POINT
2
UJ
DEAD BAND
LIMITS

NOTE: DEAD BAND LIMITS ARE ADJUSTABLE FROM

0.25 F TO 1.5 F AROUND CONTROL POINT SETTING
CONFIDENTIAL
Use Restricted
by Court Order
FIGURE 6 - Graph Showing Module Operation Around Control Point Setting

-OVERLOAD TRIP POINT

107^

105% -

103%'
CURRENT DRAW
AS A
PERCENTAGE
OF THE %
CURRENT KNOB
SETTING
100%

95% - ■

CAPACITY CONTROL MODULE

FIGURE 7 - Graph Showing Module Operation Under Current Control

7. 12-4
 HERMETIC CENTRAVAC SERVICE GUIDE
^ O T IF lT ) E T IT T A Ii_ h c t v - s g -2
n , p ric ts d FEBRUARY 1982
^ C o u r i i ^
It must be understood that whatever position the % CURRENT
'mob is set at, is considered the 100% current draw point as far as
ie capacity control module is concerned. contacts and the machine will load normally. If the evaporator
When the current draw of the compressor motor reaches 100% of temperature continues to drop, the second stage of the low evap­
the % CURRENT setting, the current control light on the control orator temperature control will trip and shut the chiller down. The
panel door will come on and the chiller will stop loading. chiller will then be locked off and require manual resetting of the
fault trip indicator.
When the current draw reaches 103% of the % CURRENT set­
ting, the unload and current control lights will both be on and the F. Chilled water reset - The Trane Electronic Capacity Con­
capacity control module will give 0.25 second unload pulses until trol, with the addition of a return chilled water temperature
the machine is unloaded to the 100% point. sensor, will automatically reset the leaving chilled water tem ­
perature upward as the return chilled water temperature de­
When the current draw exceeds 105% of the % CURRENT set­ creases. Decreasing return chilled water temperature indi­
ting, the unload and current control lights will both be on and the cates a decreasing cooling load. By resetting the chilled
capacity control module will give a continuous unload signal until water tem perature upward the chiller will unload some
the current draw has dropped to 95%. The control module will amount and thus save energy. The amount of reset is adjust­
then reload the chiller as shown in Figures 3 and 4. able, and its setting is dependent upon the application of the
chiller. The capacity control module is designed to begin au­
INDICATOR LIGHTS tomatic reset when the return water temperature comes
The lights on the capacity control module indicate the mode of within 10 F of the CONTROL POINT knob setting. Figures 8,
operation and type of signal being sent to the compressor inlet 9 and 10 graphically illustrate the effects of different reset
vane operator. The indications are as follows: ratios.

A. No lights on - If none of the lights are on, the chilled water If reset is desired, a w ater temperature sensor must be in­
temperature setpoint is satisfied and the compressor inlet stalled in the return chilled water and should be wired across
vanes are holding in position. terminals TS-1 and TS-3 as shown in Figure 11. The reset
ratio should then be determined with Switches 1 and 2. Table
B. Current control light on - The chiller is at its current control 3 provides the degrees of reset which will occur with the dif­
load point as established by the setting of the % CURRENT ferent combinations of Switches 1 and 2.
knob. The inlet vanes are holding in position.
The settings listed in Table 4 are recommended starting points.
1. Unloading light on - The chiller is producing chilled water Once the chiller system is operating under full running conditions,
„__, colder than called for by the setting of the CONTROL POINT the capacity control module may be adjusted for better operation.
knob. The inlet vanes are closing to reduce chiller capacity. Some suggestions for possible changes are as follows.

NOTE: The UNLOADING light will always be on when the If the customer desires slow loading to prevent the chiller from
chiller is off. The capacity control module continuously going to full load immediately on start-up and pull down, time may
sends an unload signal to the inlet vane operator so that the be added to the Load Delay. This may save the custom er energy
inlet vanes are closed for the next chiller start. costs by preventing high demand charges during pull down.

D. Current control and unloading lights on - The chiller has If there is a short cooling loop which experiences rapid changes in
loaded beyond the current control point as established by the load, the Load Delay should be set for a short time. This will
chiller RLA and the setting of the % CURRENT knob. The enable the control to better follow the changes in system load.
inlet vanes are closing to reduce the chiller capacity and cur­
rent draw. If the cooling loop is long, more Load Delay time may be added to
the control. This will help slow the control action better matching
E. Loading light on - The chiller is not producing chilled water the control response to the large thermal inertia in the system.
as cold as called for by the setting of the CONTROL POINT This will prevent over-chilling the water and will save energy.
knob. The inlet vanes are being opened to increase the
chiller capacity and reduce the chilled water temperature. The Dead Band should be set as wide as possible on each partic­
ular system. This will help system stability.
OPERATING SAFETIES
The Reset Ratio setting should be established by the job en­
When either the starter (K1) is de-energized or the low evaporator gineer. In the event that no particular gain is specified, the control
temperature control (S2) opens its first stage contacts, the circuit should be set with a Reset Ratio of one (1). This is the most typical
between terminals 84 and F1 on the capacity control module is setting.
opened (see Figure 11) and the control module sends a con­
tinuous unload signal to the inlet vane operator. This is done for CAUTION:Thetemperaturesensors used withtheTraneCa­
two reasons: 1) if the starter is de-energized the unload signal is pacityControlModuleerepolarized. TheymustbeInstalled
sent so that the vanes will be closed when a restart is attempted, withthecorrectpolarity.Thenegativelead(s)(black)mustbe
and 2) if the low evaporator temperature control (S2) trips its first attachedtotheTSIterminalofdmmodule.Thepositivelead-
stage contacts the machine is unloaded to allow the evaporator fa)(red)ofdiesupplychittedwarier temperaturesensor and
temperature to increase to a safe level and keep the machine run- diereturnwatertemperaturesensor (Ifused)shouldbeat­
ning. When the evaporator temperature increases to an accept­ tachedtothecapacitycontrolmoduleterminalsTS-2andTS-
able level the low evaporator temperature control will close its 3respectively.
7 . 12-5
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 tr0 iT 7 T T J H 7 rT T A T ?
FEBRUARY 1982 Doe P , v; :d
by Court wrcisr

F IG U R E 8 - R e s e t R a tio o f 2.0, G ra p h o f C h ille d W a te r T e m p e ra tu re V s. C h ille r L o ad U s in g 1.0 F A u to m a tic R e s e t o f th e S u p p ly

C h ille d W a te r S e tp o in t P e r 2 F D ro p in R etu rn C h ille d W a te r T em p e ra tu re .

7.12-6
 ' C O r ^ T T " 7- ^ &E HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
, io te d
u FEBRUARY 1982
irder

FIG U R E 9 - R eset R a tio o f 1.0, G rap h o f R eturn C h illed W a ter T em p e ra tu re V s. S e tp o in t U sing 1 F o f A u to m a tic R eset o f th e S u pp ly
C h illed W a ter S etpo int Per 1 F D rop in R eturn C h illed W a te r T em p e ra tu re

7. 12-7
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 c o jr F T O T 7 r ffl;
FEBRUARY 1982
Use her t r i c t e d
by Cour t Order

F IG U R E 10 - R eset R atio o f 0.5, G rap h o f R eturn C h illed W a ter T e m p e ra tu re V s. C h ille r L oad U sing 1 F of A u to m a tic R eset o f th e S u p p ly
C h ille d W ater S e tp o in t P er 0 .5 F D rop In R eturn C h ille d W a te r T e m p e ra tu re

7.12-8
 c o u p ie m t ia E HERMETIC CENTRAVAC SERVICE GUIDE
Us- — -i-icted HCTV-SG-2
ixrt Order FEBRUARY 1982
TABLE 4 - Typical Base Settings for the Trane Electronic
TABLE 3 - Degrees of Automatic Reset Capacity Control Module
SWITCH NO. 1 SWITCH NO. 2 DEGREE OF RESET FRONT PANEL ADJUSTMENTS TYPICAL SETTINGS
OFF OFF 0F % CURRENT CONTROL KNOB 100% OR AS DESIRED
ON OFF 0.5 F CONTROL POINT DESIRED LEAVING
OFF ON 1.0 F WATER TEMPERATURE
ON ON 2.0 F INLET VANE CONTROL KNOB AUTO
The degree of reset establishes the amount of reset the control will pro­ BACK OF PANEL ADJUSTMENTS TYPICAL SETTINGS
vide with each degree of temperature drop of the return water tem­ RESET GAIN SWITCHES BOTH OFF FOR NO RESET.
perature. See Figure 9. NO. 1, 2 IF RESET IS USED, CONSULT
SALESMAN FOR JOB
Example: If switch No. 1 is OFF and switch No. 2 is ON, with every degree
SPECIFICATION
reduction from 10 the return water temperature comes to the established
DEAD BAND SWITCHES BOTH ON FOR ± 1.5 F
setpoint, the capacity control module resets the setpoint from that shown
NO. 3, 4 DEAD BAND
on the "CONTROL POINT" knob one degree up. This would be a 1 to 1
LOAD DELAY SWITCHES 5 AND 6 ON FOR 30
reset ratio. See Figure 8.
NO. 5-9 SECONDS OF DELAY

MAINTENANCE voltage between M1 and ground should be the same as con­

trol voltage.
There are no internal adjustments which can be made to this 3. If the contacts appear to be severely burned or if no voltage
control.
appears at the output terminal M1 or M2 the output relays
should be changed.
The only annual maintenance which needs to be performed on
this control is a check of the ouput relay contacts. This may be OUTPUT RELAY CHANGE
accomplished as follows:
The output relays are double-pole, double-throw type relays. One
controls the pulsing action of the control while the other controls
f . Visually inspect the relays for signs of contact burning. the unload and load functions. The opposite set of contacts on
2. Load and unload the chiller while measuring the voltage these relays are used for each of these functions. This means that
output on Terminals M1 and M2 to ground. When the control if one set of contacts is found to be burned the two relays may be
module is giving a load pulse the voltage between Terminal interchanged with one another. When this is done the previously
M2 and ground should be the same as control voltage (115 unused contact will be put into service. This effectively doubles
VAC). When the control module is giving an unload pulse the the life of the relays.

PRINTED BY PRODUCTION SERVICES — LA CROSSE FWB DJL

7. 12-9
 LITERATURE FILE NO. HCTV-SG-2

M O TO R P R O TE C TO R SECTION
M O D U LE (U2)
7.13
FEBRUARY 1982

DESCRIPTION SPECIFICATIONS

The Robertshaw Motor Protector Module MP23, shown in Figure Cut-out Temperature 265 F ± 5F
1, is a solid state control which protects the compressor motor
Cut-in Temperature 235 F + 5 F,
windings against overheating. It does this by monitoring the re­
-0 F Fixed Differential
sistance of three thermistor type temperature sensors. These
sensors are embedded in each of the stator phase windings. The Voltage 1 1 5 V A C @ 5 0 /6 0
resistance of each sensor varies in direct relation to the motor cycles
tem perature (refer to Figure 2). Because of this direct re­
lationship, the MP23 module can monitor the motor temperature. Voltage Tolerance + 10%, -15%

Maximum Control Circuit Load (VA) 300 V A @ 115 VAC

Ambient Temperature Limits -30 F to 150 F

Terminal Connection Size 0.25 inch male, spade

(T1, T2, M1, M2) quick connect

CONNECTION DIAGRAM

FIGURE 1 - Solid State Motor Protector Module

CONFTIIE'X T I A Z
Use i?
Ujf C o u r t OiT*
®THE TRANE COMPANY 1962
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A 7 . 13-1
HERMETIC CENTRAVAC SERVICE GUIDE COTTFIDEUTIAl
HCTV-SG-2
FEBRUARY 1982
Use Rest. i o"fce cL
by Coui o. ___ c r
CALIBRATION AND CHECKOUT PROCECURE If two winding temperature sensors are found to be defective, use
the preceeding procedure for both sensors and the following
If the MP23 module is determined to be the cause of chiller lock­
procedure.
out problems, (refer to Trouble Analysis Section) the following
checkout procedure should be used. The MP23 may keep the 1. Install two W hite - Rodgers Motor Temperature Controls
chiller from starting for any of the following reasons. (Trane part No. CNT-322) set to cut-out at 120 F.
2. Attach the temperature sensing bulbs of the controls to each
1. The motor windings are overheated.
of the motor refrigerant drain lines as close to the motor as
2. Power has been lost or there is a loose wire on Terminals T 1
possible. Insulate around the bulbs and lines to assure accu­
or T2. rate temperature sensing.
3. The MP23 module is defective.
3. Wire the contacts of the controls in series with the M1 termi­
4. O ne or m ore o f the w in d in g te m p e ra tu re se n s o rs is
nal of the MP23 module.
defective.
With this arrangement, any loss of motor cooling will result in in­
After the first two possibilities have been ruled out, the winding
creased temperature in the refrigerant drain lines and at the set
temperature sensors and control module should be checked out
temperature the compressor motor will be shut off.
using the following procedures.
MP23 MODULE CHECKOUT
SENSOR CHECKOUT
If the temperature sensors checkout satisfactorily but the control
1. If, after allowing sufficient time for the motor to cool (several module will not reset, or it will not reset even after corrective
hours or longer), the tem perature lockout will not reset, the action on a defective sensor, the MP23 module should be re­
motor winding temperature sensors should be checked. moved and bench checked as follows.

a. Remove the wiring connections from the sensor and 1. To properly test the control module it will be necessary to
common terminals (23 - 26) on the control panel term i­ construct a test board as shown in Figure 3. The materials
nal board. required to construct the test board are:

a. 1/2 watt, 100 ohm ± 5% carbon resistors - 3 required

CAUTION: Use a standard ohmmatar, such as a Sim­ b. 0 to 25 ohm variable resistors - 3 required
pson 160 or 260, for chocking tho winding sensors. c. 120 volt AC pilot relay or small contactor - 1 required
D o not use any othor type of equlpmont. The sensors d. Terminal strip, six terminals - 1 required
can be damaged by high test voltage such as those e. Miscellaneous wire and connectors
developed by a test lamp or meggar. NEVER USE A
Before testing can begin, the test board must be accurately
VOLTMETER OR MEGGAR WHICH PRODUCES HIGH
calibrated. Using a high quality ohmmeter (digital preferred)
VOLTAGE WHEN TESTING THESE SENSORS.
the total resistance value of each series resistor circuit (100
SENSOR DAMAGE WILL RESULT.________________
ohm plus 0 - 25 ohm) should be adjusted to 115 ohms. The
b. Measure the resistance between each sensor lead and position of the variable resistor shaft should be marked. The
the common lead. The sensor resistance reading, with same should be done for the 109 ohm position. Once cali­
the motor cooled to room temperature, should cor­ brated, proceed with step 2.
respond to the temperature - resistance chart in Figure 2. Connect the MP23 module to the test board as shown in
2. Each of three sensors should have a resistance which Figure 3. Adjust all the variable resistors to their minimum
is within the allowable range as shown in Figure 2. value.
3. Energize the test board by connecting it to a 120 VAC power
2. Resistance readings approaching zero ohms indicates a
source. Once voltage is applied the module should close the
short; resistance approaching infinity indicates an open con­
M1 - M2 circuit and energize the control relay.
nection. The sensors are connected in a bridge circuit, there­
4. Using one variable resistor at a time, increase the resistance
fore proper operation o f the motor protection system is de­
to the sensor terminals on the module to 115 ohms. The
pendent upon the correct operation of all three sensors.
module should then open the M1 - M2 circuit and de-ener­
If one of the sensors is found to be defective (having an ab­ gize the control relay. Decrease the resistance to approxi­
normally high or low resistance) the MP23 module will pre­ mately 109 ohms. The module should close the M1 - M2 cir­
vent compressor operation even though there may not be cuit and re-energize the control relay. Each of the sensor
any malfunction within the CenTraVac motor. In this situation inputs should be checked in this manner. If the M1 - M2 cir­
the CenTraVac motor may be made to run by replacing the cuit opens before 110 ohms is reached the module is de­
defective sensor with a Vi watt, 100 ohm ± 5%, carbon re­ fective and should be replaced. If the module does not open
sistor (available through most electronic supply shops). The the M1 - M2 circuit before 120 ohms is reached on any of the
resistor is wired across the MP23 module’s defective sensor sensor circuits the m odule is defective and should be
and common terminals, leaving the defective sensor discon­ replaced.
nected. This bypasses the defective resistor and allows con­
MAINTENANCE
tinued compressor operation with two rather than three wind­
ing tem p e ra tu re sensors. T h is provides fo r continued There are no internal adjustments which can be made to this
operation with a satisfactory degree of safety. control.

7. 13-2
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982
COUFIDUTITIAL'
Use lies'.cicted
curt Order
RESISTANCE - OHMS

FIGURE 2 - Temperature Vs. Resistance Graph for Motor Protector Positive Temperature Coefficient Sensors

7 . 13-3
HERMETIC CENTRAVAC SERVICE GUIDE 'COITFTI'E'i TI AL_
HCTV-SG-2
FEBRUARY 1982 Use Ret.trioted
^ ^ C o u rt U in ie r

FIGURE 3 - Test Board Wiring

PRINTED BY PRODUCTION SERVICES LA CROSSE FWB/DJL

7 . 13-4
 LITERATURE FILE NO. HCTV-SG-2

F A C TO R Y M O U N TED SECTION
S T A R T E R P A N EL (K1)
7.14
FEBRUARY 1982

This section describes the factory mounted starter panel used STARTER PANEL DOOR
with the Model CVHE CenTraVac chiller. Included is a description
The front of the starter panel door may be divided into three func­
of the function, location and proper setting of each of the controls
tional groups. These groups include:
found within the starter.
1. Circuit Breaker/Disconnect Handle
The schematic and connection wiring diagrams illustrate the
wiring used in the starter panel along with the relative location of 2. Meters
3. Safety Fault Indicators and Fuses
each control. Also illustrated is each wire number attached to
each terminal on each control. Refer to Figure 1. C O N F I D E 7 - t 47-
U se ]r,x

FIGURE 1 - Starter Panel Door Controls

*THE TRANE COMPANY 1982
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

1. Circuit Breaker/Disconnect Handle - This is located on the Refer to the Trouble Analysis section of this Service
left side of the starter panel door. When in the off position, Guide for additional information.
main power is disconnected from the starter and control d. Distribution Fault - this indicator, when tripped, indicates
panel circuits. that the CenTraVac has experienced an electrical distri­
bution fault. R eferto the Trouble Analysis section of this
WARNING: Baton working onthis or any electrical Service Guide for more information.
equipment, alwaysdisconnect themainpowersupply. e. Starter Circuit Fault - this indicator, when tripped, indi­
FailuretodosomayresultinseriouspersonalInjuryor cates that there is a problem with the starter pilot relays
deathdmtoelectricshock. or transition resistors. Refer to the Trouble Analysis sec­
tion of this Service Guide for additional information.
Morethanonedisconnectswitchmayherequiredtoda-
energizethisequipment.TheGroundFaultIndicatorand Following is a list of the controls in the Factory Mounted Starter
transformerarenot deenergizedbyopeningthemain control panel as shown in Figure 2. A description of the function
starter circuit breaker. Failuretoopenall disconnect and maintenance of each control is found in other sections of this
switchesmayresultInseriouspersonalInjuryordeath Service Guide.
dueto electricshock. 1. Ground Fault Indicator Transformer (T5)
2. Main Power Disconnect/Circuit Breaker (CB10)
The disconnect handle must be in the OFF position to open 3. Current Transformers (T2, T3, T4)
the starter door. In the event of a Ground Fault or Circuit 4. Control Power Transformer (T1)
Breaker trip, the handle will move to a position between ON 5. Electronic Motor Protection Module (A1)
and OFF. The handle must be moved to the OFF position to 6. Pilot Relays (K23 & K24)
reset the circuit breaker before it is moved back to the ON 7. Terminal Board (TB1)
position. 8. Transition Resistor Contactor (K26-1A)
2. Meters - The meters are located on the upper right side of the 9. Shorting Contactor (K25-S)
panel door. Refer to Figure 1. They may include voltmeters 10. Main Contactor (K28-2M)
and/or ammeters. 11. Main Contactor (K27-1M)
12. Transition Resistors (R2-R10)
The voltmeters indicate directly in A.C. volts.
FACTORY MOUNTED STARTER PANEL SEQUENCE OF
The ammeter readings must be multiplied by the number lo­
OPERATION (REFER TO FIGURE 3)
cated in the upper left corner of the meter to determine the
actual compressor motor current draw. When the safety controls are satisfied and the system is calling
3. Fault Trip Indicators and Fuses - These are located on the for cooling, a signal from the chiller control panel will be received
right side of the panel door. Refer to Figure 1. They perform at Terminal 14, line 23, energizing the K23 and K24 relays. This
the following functions: closes the Normally Open (NO) contacts on line 34 and com­
pletes the circuit to the main starter sequence. Also, contacts on
a. Ground Fault Indicator - when a ground fault trip occurs, lines 31 and 32 monitor the two relays (K23 and K24) assuring
the light in the indicator will be on and the disconnect proper interlock between them. If one relay does not energize
handle will be in the tripped position. The disconnect
within two seconds of the other, CB13 will shut the unit down.
must be reset and the indicator light must be pushed to
reset the system. The indicator light and relay may be With K23 and K24 energized, the signal will energize K25 relay
tested by pushing in the light. (line 36). This closes NO contacts (lines 4, 5) in the star config­
b. Fuses - the fuses protect their respective circuits from uration of the starter. Also, the Normally Closed (NC) contact on
current overloads. All are 15 amp fuses. Extra fuses are line 39 opens and NO contact on line 38 closes, energizing the
located in a holder on the inside of the starter door. After K27 relay. K27 contacts on lines 2, 5 and 8 all close connecting
a fuse has blown, the cause of the circuit overload the motor to the line in a star configuration. The K27 contact on
should be found and corrected before the CenTraVac is line 27 closes keeping the oil pump energized as long as the K27
allowed to run unattended. contactor is closed. The K27 contact, NO, on line 39 also closes,
c. Compressor Motor Current Overload - this indicator, interlocking the K27 contactor with itself. The NO K27 contacts on
when tripped, indicates that the CenTraVac has experi­ line 34 close, arming the Solid State Overload relay (A1 on line
enced current draw in excess of the set overload RLA. 32).

7 . 14-2
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

FIGURE 2 - Internal Starter Panel Controls

With the motor connected in the star configuration and A1 ener­ The K26 NC contact on line 36 opens with the energizing of K26
gized, the solid state overload current transformers (lines 2 ,5 and contactor. This de-energizes K25, allowing the NC contacts in
8 ) will monitor the current to the motor. When the current drops to line 39 to close, energizing the K28 delta contactor. With K25 de­
approximately 85% of RLA, the transition sequence will begin energized and K28 energized, the unit is connected in the delta
with the closing of a normally open contact on the A1 relay (D 1 - configuration with the resistors in series with the motor windings.
D2) on line 37. The K26 transition contactor will energize, closing The NC K28 contacts on line 36 open after K28 energizes thus
NO contacts on lines 3, 6 and 9. The motor is now connected in dropping out K26 and taking the resistors off the line. The final
the star configuration with the resistors connected in star and in result is the motor connected in the delta run configuration with
parallel with the motor windings. The NO K26 contact on line 30 full voltage applied.
closes. If this contact stays closed for more than a period of 2 sec­
onds, the starter fault contactor CB13 will trip, shutting the unit
down.

7.14-3
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 W ARNING!-
FEBRUARY 1982 OPEN DISCONNECT SWITCH
THREE PHASE SUPPLY NOTES DCSICNEO TO 9E USEO BEFORE SERVICING THE UNIT
PER STARTER NAMEPLATE H ITH CONTROL PANEL
fSY OTHERS! PER H IR IN G DIAGRAM NO.
0 EARTH CROUNO EX3 5 4 7 0 3 0 2 A E X 35470303
L3| 12 | LI [ AS REQUIRED
/ — I — I BY OTHERS)
- <? $ <JJ T4
LL3
L31 L21 L I1 L31 L2*A n 'A
N N * Ifl
£ l «4 ttc X,2?
----------- ? b -------------------------------------------------------
, q T3 f r t l i
r iT f t i]
' hi H2 H3 H4 HS Hs )

4 ---- I p rw w w ^ i
r ~ ~ i 2 K,2,7 T2 T2/ s V M i r i
-
L f . _____ h *J
L
1------------ ' ' --------------f ---------------------------------------6 ^ K2S
I
! C3o 0 6C4 j 1 TT4 V ,B •A A A '4 3 S . l CROUNO FAULT
2! 6 6 6 !
TRANSFORMER

LL1A*I
L L 2 A .B

MORE THAN ONE DISCONNECT

SWITCH MAY BE REQUIRED
TO DE-ENERGIZE T H IS
EQUIPMENT FOR SERV IC IN G
TRANSFORMER i QPOUNO
FAULT INDICATOR NOT
DE-ENERCIZED BY
STARTER MAIN C IR C U IT
BREAKER
NOTES:
1 . UNLESS OTHERNISE NOTED
ALL SNITCHES ARE SHOMN
AT 2 5 * C ( 7 7 * F ) « AT
ATMOSPHERIC PRESSURE*
AT SOX R ELATIVE H U M ID ITY*
HJTH ALL U T IL IT IE S TURNEO
OFF* AND AFTER A NORMAL
SHUTDOHN HAS OCCURED.
2 . DASHED L IN E S INOICATE
RECOMHENOED F IE L D H IR IN G
’T A t
BY OTHERS* PHANTOM LIN E S
INOICATE ALTERNATE
C IRCUITRY OR AVAILABLE
SALES OPTIONS.
3 . NUMBERS ALONG THE RIGHT
SID E OF THE SCHEMATIC
DESIGNATE THE LOCATION
OF THE CONTACTS BY L IN E
NUMBERS. AN UNDERLINED
NUMBER IN D IC ATES A
NORMALLY CLOSEO CONTACT.
4 . MAXIMUM AMBIENT TEMPER­
ATURE SO 'C 11 2 0 *F )
AVERAGE A IR TEMPERATURE
IN THE IM MEDIATE NEIGHBOR-
__ HOOO OF THE CONTROL PANEL.
C IR C U IT BREAKERS CBJ1 4
CB15 (5 0 VOLTS OCI & CB13
(1 2 0 VOLTS AC) EMPLOYED AS
FAULT INDICATORS IN THE
CONTROL C IR C U IT ARE
OESICNEO TO BE SHUNT TR IP
VOLTAGE OEVICES NOT
CURRENT S E N S IT IV E DEVICES
AS NORMALLY A P P L IE D .
ALL F IE L O H IR IN G MUST BE
IN ACCORDANCE H IT H THE
NATIONAL ELECTRICAL COOE

COUNTRIES APPLICABLE
NATIONAL ANO/OR LOCAL
REQUIREMENTS SMALL APPLY.
EXAMPLE: CANAQA-SHALL
(CONTINUED ON
COMPLY M1TH CANADIAN
STANDARDS ASSN. (CSAJ
STARTER OESICNEO AT NEMA
NEXT PAGE)
RECOMMENOEO VOLTAGES AS
FOLLOWS:
20 0 VO LTS'^ ♦ ic v
5“ volt! / 6 0 HERTZ

SALES OPTIONAL AMMETERS

AND OR VOLTMETERS IN
DOOR* WHEN AMMETERS
ARE REQUIRED CONNECT
IN SERIES H IT H - C T 'S ’ ANO
OVERLOAD RELAY ( A ) ) .
SALES OPTIONAL C IR C U IT
BREAKER - C B IO ' REPLACES
TERMINAL BOARO * T B 2 * .
FOUR STYLES OF C IR C U IT
BREAKERS OFFERED:
STANOARD INTERRUPTING
CAPACITY
HICH INTERRUPTING
CAPACITY
STANDARO INTERRUPTION
CAPACITY H IT H CROUNO
FAULT.
HIGH INTERRUPTING
CAPACITY H IT H CROUNO
FAULT
A GROUND FAULT INDICATOR
IN DOOR IS FURNISHED
WITH A GROUND FAULT
STYLE C IR C U IT BREAKER.

COMPONENT
LAST USEO UNUSED
T S n RIO K 2 .K 2 9
F4 At C8I THRU CM .C812.C BH
CB1S Bi k 1 *k3 th r u K22
K20 DS9 R1
0S1 THRU 0S8

FIGURE 3 - Factory Mounted Starter Schematic and Connection Wiring Diagram

7.14-4
 HERMETIC CENTRAVAC SERVICE GUIDE
------- W ARNING!-------- HCTV-SG-2
FEBRUARY 1982
'" ” "TAT7 ' OPEN DISCONNECT SWITCH
u - te d ' BEFORE SERVICING THE UNIT
JLl - ....... - - a e jg
CONNECTION DIAGRAM

PRINTED BY PRODUCTION SERVICES LA CROSSE FWB DJL

7.14-5
 LITERATURE FILE NO. HCTV-SG-2

ELEC TR O N IC M O TO R SECTION
P R O TE C TIO N M O D U LE (A1)
7.15
FEBRUARY 1982
DESCRIPTION

The Trane Electronic Motor Protection Module (MPM), also SPECIFICATIONS

called the Electronic Overload, provides the following functions
Voltage 115 VAC ± 10%
and features:
Transition Relay Contact 3 Amps at 115 VAC
1 . Provides precise compressor motor overload protection.
2. Protects against excessive locked rotor (in-rush) current Proportional Load Signal 8.25 VDC at Full Load
draw. Output (Terminals V1-V2)
3. Limits the length of time that in-rush current may be drawn.
4. Protects the unit from damage caused by an electrical distri­ Operating Frequency 50 or 60 Hz
bution fault.
Required Transformer Output 2 to 5 Amps at Unit RLA
NOTE: A distribution fault is defined as a complete loss of at Unit RLA
line voltage for a period of less than 60 cycles.
Point of Transition Initiation 85% ± 5% of Unit RLA
5. The module initiates starter transition when the compressor
Ambient Temperature Limit 160 F
reaches full speed.
6 . Provides a DC signal which is proportional to load.
7. Can be adjusted to compensate for high line voltage.
8 . Is adjustable for 50 or 60 cycle operation.

F IG U R E 1 - M o to r P ro tectio n M o d u le

*THE TRANE COMPANY 1982 CONPIDSTITTAr

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601 7.15-1 Use Itee ll-j.ij. ted
PRINTED IN U S A.
by Court jux- ^ ”
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982 C O'TT T T AE_
ii.-.r., r, , j ' / r i o t e d
ly _ c o u r t . O r d e jfc ,
CALIBRATION AND CHECKOUT PROCEDURE^ site voltage is either lower or equal to the specified volt­
age rating shown on the unit nameplate, the current
WARNtNQ: Whenever working on the MPM, as with any elec­ calibrator setting can be established based on the
trical equipment, stop the motor amt Oaconnect ail power to nameplate RLA.
the untt. FaMuro to do so may reoult In accidental shock or
death by electrocu tion. Prevent personal Injury by always
When the actual voltage is higher than the specified
disconnecting electrical power before working on electrical
voltage, refer to "High Voltage Compensation” later in
equipment.______________________________________ _ this section.
In order to accomplish the MPM calibration, the small circuit
board mounted in the center of the MPM must be tilted outward. If the unit is equipped with power factor correction ca­
This is done by gently pulling on the black tabs located on the top pacitors which are connected on the load side of the
of the circuit board, and tilting it down on its hinges. overload current transformers, and the capacitor leads
are not run through the current transform ers with the
1. Line Frequnecy Adjustment motor leads, the RLA shown on the unit nameplate will
The MPM can operate on either 50 or 60 Hz electrical sys­ have to be recalculated for the purpose of setting the
tems. The line frequency is set as follows: overloads. If the capacitor leads are run through the
a. First, determine the installation of line frequency. (60 Hz current transfomers the unit RLA will not have to be re­
for all U.S. installations.) calculated. On CenTraVacs shipped with factory in­
b. Set the frequency switch to the position which cor­ stalled pow er fa c to r cap a cito rs, the adjusted RLA
responds to the installation frequency. Refer to Figures should be shown on the electronic overload cover and
1 and 2 .
the overload set accordingly.
c. Write in the setting on the MPM nameplate. See Figure
3.
To determine the adjusted RLA on other units, the ma­
2. Compressor Motor Overload Calibration
chine should be run to full load and amperage readings
The overload is set by adjusting the resistance of the current
taken on the load and line sides of the capacitor terminal
calibrator. The MPM is designed so that with the current cali­
points. The nameplate RLA should be multiplied by the
brator correctly set, the overload will trip at 107% of the motor
ratio of the current measured on the line side of the ca­
rated load current. The use of a 107% trip point prevents nui­
pacitors to the current measured on the load side of the
sance full load tripouts while still protecting the motor from
capacitors. This gives the adjusted RLA to be used to
potentially damaging overloads.
set the current calibrator. Refer to the equation and ex­
The correct procedure for setting the current calibrator is as ample following.
follows:
a. Determine the Rated Load Current (RLA) and the cur­ Adjusted RLA = Nameplate RLA x current.
rent transform er ratio for the unit. Where the actual job- load side current

FIGURE 2 - Line Frequency Adjustment Switch

TRANE NO.
CALIBRATOR NO.
CALIBRATOR OHMS C.T. RATIO /5
MOTOR I RA
KA III
MOTOR R IA

L.R. TRIP TIME SEC. 50|_ 60 HZ

F IG U R E 3 - M .P .M . N a m e p la te
7.15-2
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
C o W T O T IA t
FEBRUARY 1982
i O T G&
Example: U se NOTE: When doughnut type current transformers
Motor Rating (RLA) = 100 Amps fo y C o u rt Urcler are used, the wires passed through them are some­
Current on line side of capacitors = fw A m p s times wrapped around and passed through more
Current on load side of capacitors = 92 Amps than once. When this is done, the CT ratio is effec­
tively divided by the number o f times the wire
Adjusted RLA = 100 Amps x — - = 91 Amps passes through the CT. This means that a 20015 CT
' 92 Amps
with the wire passed through it twice should be
If the power factor capacitors on the line side of the treated as a 100/5 CT.
MPM current transformers or if the capacitor leads are
c. With the I sec value found, use Table 1 to determine the
run through the current transformers with the motor correct current calibrator and its setting. For the pre­
leads, as described above, the RLA should not be ad­ ceding example in which the line current is being mon­
justed. The motor nameplate RLA should be used to set itored (I sec = 4.55), the correct current calibrator would
the current calibrator in this case. be H818. The correct calibrator setting would be 82.6
b. Once the correct RLA has been determined, the rated
ohms. With the calibrator setting adjusted in this man­
load secondary current (I sec) from the current trans­ ner, the overload trip point would be 107% of the name­
former can be determined. The value of I sec at full load
plate RLA.
is dependent upon the location of the current trans­ d. To set the current calibrator, it must be removed from
formers. The correct methods of determining the value the module. Using a digital ohmmeter (3 1/2 digit mini­
of I sec follows. mum accuracy), set the resistance of the calibrator to
the value taken from Table 1.
1. Current Transfomer Monitoring Line Current
e. Replace the current calibrator in the module. Write the
If the current transformers are located such that they
adjusted RLA, calibrator number and its setting on the
monitor line current, the vale of I sec is determined by
MPM nameplate.
dividing the current transfomer ratio into the RLA.
Refer to the equation and example which follow. NOTE: With the current calibrator set correctly and the
unit operating at full load, a DC voltage of approxi­
I sec = RLA -f- (CT Ratio)
mately 8.25 VDC should exist across Terminals VI and
Example RLA = 91 Amps V2 in the MPM.
CT Ratio = 1^0
5 3. Locked Rotor Current Lockout Adjustment
The MPM protects the compressor motor from excessive
LRA current draw during start-up. It does this by tripping the
motor overload circuit breaker any time the set LRA is ex­
ceeded. The correct procedure for setting the LRA trip point
I sec = 4.55 is as follows:
2. Current Transformers Monitoring Phase Current a. The LRA current trip point setting is dependent upon the
If the current transformers are located in a starter type of starter being used with the CenTraVac com ­
such that they monitor phase current, the value of I pressor motor.
sec is determined by dividing the current transformer b. The LRA current trip point is set using the LRA set po­
ratio into the RLA and multiplying this quantity by tentiom eter (Figure 1).
0.58. Refer to the equation and example following. c. The correct setting positions for the LRA set poten­
Example: RLA = 91 Amps tiometer as applied to different types of starters are
shown in Figure 4.
100
CT Ratio = d. To set the LRA potentiometer, insert a screw driver in
5
the adjusting slot and turn potentiometer to the fully
100 counter-clockwise (CCW) stop. This establishes a refer­
I sec = 191 I x 0.58
5 ence position. From this point, the potentiometer should
be rotated clockwise to the position, shown in Figure 4,
I sec = 2.64 which corresponds to the compressor motor starter
being used.

FIGURE 4 - LRA Set Potentiometer Positions For Different Type Starters

7.15-3
HERMETIC CENTRAVAC SERVICE GUIDE ^
HCTV-SG-2 C' '■
FEBRUARY 1982 ^ ,
. o rd e r

TABLE 1 - Current Calibrator Table

POTENTIOMETER POTENTIOMETER
f SEC ‘ NUMBER ON ADJUSTMENT I SEC NUMBER ON ADJUSTMENT
AMPERE RATING CURRENT RESISTANCE AMPERE RATING CURRENT RESISTANCE
MIN. MAX. CALIBRATOR (OHMS) MIN. MAX. CALIBRATOR (OHMS)
2.01 2.05 H816 185 3.51 3.55 H817 106
2.06 2.10 H816 180 3.56 3.60 H817 105
2.11 2.15 H816 176 3.61 3.65 H817 103
2.16 2.20 H816 172 3.66 3.70 H818 102
2.21 2.25 H816 168 3.71 3.75 H818 101
2.26 2.30 H816 165 3.76 3.80 H818 99.2
2.31 2.35 H816 161 3.81 3.85 H818 97.9
2.36 2.40 H816 158 3.86 3.90 H818 96.6
2.41 2.45 H816 155 3.91 3.95 H818 95.4
2.46 2.50 H816 151 3.96 4.00 H818 94.2
2.51 2.55 H817 148 4.01 4.05 H818 93.0
2.56 2.60 H817 146 4.06 4.10 H818 91.8
2.61 2.65 H817 143 4.11 4.15 H818 90.7
2.66 2.70 H817 140 4.16 4.20 H818 89.6
2.71 2.75 H817 138 4.21 4.25 H818 88.5
2.76 2.80 H817 135 4.26 4.30 H818 87.5
2.81 2.85 H817 133 4.31 4.35 H818 86.5
2.86 2.90 H817 130 4.36 4.40 H818 85.5
2.91 2.95 H817 128 4.41 4.45 H818 84.5
2.96 3.00 H817 126 4.46 4.50 H818 83.5
3.01 3.05 H817 124 4.51 4.55 H818 82.6
3.06 3.10 H817 122 4.56 4.60 H818 81.7
3.11 3.15 H817 120 4.61 4.65 H818 80.8
3.16 3.20 H817 118 4.66 4.70 H818 79.9
3.21 3.25 H817 116 4.71 4.75 H818 79.1
3.26 3.30 H817 114 4.76 4.80 H818 78.2
3.31 3.35 H817 113 4.81 4.85 H818 77.4
3.36 3.40 H817 111 4.86 4.90 H818 76.6
3.41 3.45 H817 109 4.91 4.95 H818 75.8
3.46 3.50 H817 108 4.96 5.00 H818 75.1
* The V Trane Port Numbers are as follows: H816 - PNT 9
H817 - PNT 10
H818 - PNT 11

TABLE 2 - Starting Characteristics for Various Types of Motor Starters

STARTING CHARACTERISTICS - % OF RATED VALUE
MOTOR MOTOR LRA MOTOR
TYPE OF STARTER % TAP VOLTAGE CURRENT TORQUE
Full Voltage Type N/A 100 100 100
Magnetic - X - Line
Reduced Voltate Types
Auto-Transformer 80 80 80 64
65 65 65 42
50 50 50 25
Primary Reactor 80 80 80 64
65 65 65 42
50 50 50 25
Reduced - Inrush Types
Star-Delta N/A 100 33 33
Open or Closed
Transition N/A 100 33 33

7.15-4
 e. As can fc>e seen by the calibration markings on the LRA HERMETIC CENTRAVAC SERVICE GUIDE
set potentiometer, this is a rough setting only. If it is HCTV-SG-2
found that the "M otor Overload” circuit breaker trips im­ FEBRUARY 1982
mediately upon energization of the starter, the LRA cur­ jobside conditions. It should be set, based on the typical
rent trip point may have to be set higher. Doing this will acceleration time for the particular unit and jobsite
not harm the operation of the MPM or the compressor conditions.
motor. b. Once the desired value is known, the combination of
f. Write the nameplate LRA and the nameplate RLA on the switches on the maximum acceleration time adjustment
MPM nameplate. See Figure 3. which add to this value should be switched to the “ ON”
g. Calculate the RATIO % using the formula below. Write position (see Figure 5).
this on the nameplate. See Figure 3.
NOTE: If none of the switches are in the “ON" position,
Ratio % = Motor LRA‘ x 100%
the unit will not start. The MPM allows no acceleration
Motor RLA time in this situation and the “ Motor Overload" circuit
breaker will trip immediately upon attempted start-up.
Example: Motor RLA - 100 AMPS
c. Write the LRA time adjustment setting on the MPM
Motor LRA = 200 AMPS
nameplate. See Figure 3.
200 AMPS 10Q% = Ratjo 200%
5. High Voltage Compensation:
100 AMPS
The RLA shown on the unit nameplate is based on original
* Locked rotor amperes (LRA) is the reduced value ob­ design conditions and the nominal voltage ordered. The
tained depending on the method of starting. See Table actual jobsite voltage quite often varies from the nominal.
2. Higher than nominal line voltage permits the motor to pro­
duce higher than rated horsepower without motor current
4. Maximum Acceleration Time Set draw in excess of nameplate. To prevent overloading of the
The MPM limits the maximum acceleration time the motor motor due to higher than rated voltage, the MPM should be
can undergo by tripping the "Motor Overload” circuit break­ recalibrated. This can be done in either of two ways:
er, locking the machine off, whenever the machine does not
transition in the time period set on the acceleration time ad­ a. By removal of the 10% current reset jumper from termi­
justment (Figure 1). This prevents the motor from drawing nals J1 - J2 in the MPM (see Figure 1), the module is
LRA for an excessive period of time and overheating the TABLE 3 - Typical Maximum Acceleration Time Settings
motor. The maximum acceleration time is set as follows: RECOMMENDED MAXIMUM
STARTER
a. Determine the desired maximum acceleration time (be­ TYPE ACCELERATION TIME SETTINGS
tween 1 and 63 seconds) for the unit. Table 3 gives rec­ Star-Delta 40 Seconds
ommended settings for typical units. This setting may Auto-Transformer 22 Seconds
vary, depending on the type of unit, type of starter and Across-The-Line 12 Seconds

12 SECONDS = 8 + 4
TURN ON SWITCHES 3 & 4

F IG U R E 5 - M ax im u m A c c e le ra tio n T im e A d ju stm en t

7.15-5

Dy i ou ri u x 'd iii'
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982
automatically recalibrated so that approximately 90% of This occurs because the distibution fault trip is initiated when
the motor nameplate current rating is the new “ rated” the motor current drops below 15% of RLA with the M 1 cor
current for the application. The MPM should be setup tactor energized. S eethe "Distribution Fault Trip Operatior.
normally as removal of the jumper recalibrates all func­ section below for the reasoning behind this. The only times
tions of the MPM. the above circumstances can occur is during an actual distri­
b. The MPM can also be recalibrated to compensate for bution fault or a starter dry run.
high voltage by resetting the current calibrator. The 2. The other difference which will be noticed is that immediately
proper value is determined by multiplying the I sec upon energization of the dry run, the starter will go through
value, determined in the Compressor Motor Overload transition.
setup portion of this section, by the ratio of the rated volt­
This happens because the MPM initiates transition on the
age to the actual line voltage. Refer to the equation and
the example following. basis of motor current draw. During a normal start-up, the
vanes are closed which allows the motor current to drop from
rated voltage
New I sec = I sec x LRA to a vlue below RLA. When the motor current drops from
actual line voltage
LRA to 85% of RLA during start, the MPM initiates transition.
During a dry run, there is no current draw, so the MPM imme­
Example: Original I sec = 4.55 diately initiates transition.
Rated Voltage = 460 volts DISTRIBUTION FAULT CIRCUIT BREAKER OPERATION
Actual line voltage = 485 volts
A distribution fault is defined as a loss of lin e voltage for less than
460 volts 60 electrical cycles. This type of short duration power interruption
New I sec = 4.55 x 4.32 can be damaging to many types of induction motor driven
485 volts
equipment.
The new I sec value is then used to enter Table 1 and
determine a new current calibrator setting. The cali­ The damage occurs because an induction motor acts as a gener­
brator should be reset to this value. This will calibrate all ator for several seconds after power is disconnected. The voltage
other MPM functions, compensating for the high voltage generated by the motor can hold in control relays and starter con­
condition. tactors when a voltage loss occurs. The period of time the con­
tactors are held in is approximately 60 electrical cycles or 1
c. Whenever the MPM is recalibrated for high voltage second for a Water Cooled CenTraVac, and 20 cycles or 1/3 sec­
compensation, the LRA potentiometer should be turned ond, for an Air Cooled CenTraVac.
up one space higher than shown in Figure 4. This is to
prevent tripouts at start-up. This is because the high If line voltage is re-established during the period of time the con­
voltage causes higher than nameplate LRA current tactors are being held in by the motor generated voltage, and the
draw to occur. This must be compensated for, therefore two voltages are out of phase, motor torques may occur which are
the LRA potentiometer must be turned up. 6 to 10 times normal running torques. These torques occur as the
motor is pulled into phase and may be in either the forward or re­
Any calibration of the module, such as removal of the J1 verse direction. These high torques cause severe overloading of
- J2 jumper or recalibration of the current calibrator, the impeller hub area, with resultant upsetting of the impeller
should be noted on the MPM cover along with the keyway and, in severe cases, cracking or destruction of the im­
reason for recalibration. pellers can occur.
6 . CVHE Load Limiting Control Calibration
The MPM detects a distribution fault by monitoring current draw
On CVHE CenTraVac chillers, the MPM controls the load
and the M 1 contactor. The tripping of the Distribution Fault Circuit
limiting of the motor through a load proportional DC voltage
Breaker is initiated because in normal operation, only during the
which it sends directly to the Capacity Control Module (U1).
occurrence of an actual distribution fault (line voltage loss) is it
The load proportional DC voltage can be measured across
found that the motor current draw is less than 15% of RLA and the
terminals V1 and V2 of the MPM. At rated load, this voltage
M1 contactor is energized at the same time. An induction motor
will be 8.25 VDC. This voltage varies linearly with the ma­
will normally always draw over 15% of RLA, even when com­
chine running amperage.
pletely unloaded; and whenever the M1 contactor is energized
Example: 100% RLA = 8.25 VDC the motor is running. The only exceptions are when there is a dis­
98% RLA = 8.25 x .98 = 8.09 VDC tribution fault or the starter is being dry run.

DRY RUNNING STARTERS EQUIPPED WITH THE MOTOR The distribution fault lockout is initiated when the motor current
PROTECTION MODULE drops below 15% of RLA with the M1 contactor energized. The
MPM senses this set of conditions to be a voltage loss for the rea­
Starters equipped with the Motor Protection Module can be dry sons explained previously Tripping of the Distribution Fault Cir­
run at start-up in the same manner as starters not so equipped. cuit Breaker is completed within 6 electrical cycles (1 /10 of a sec­
There are two differences which should be noted: ond) of the time when the voltage loss occurs.
1. Before the starter can be dry run, the Distribution Fault Cir­
cuit Breaker must be disconnected. This can be done by It should be noted that this provides a way of checking for proper
simply removing a wire from the Distribution Fault Circuit operation of the distribution fault function of the MPM. The Distri­
Breaker. If this is not done, the starter will not sequence, but bution Fault Circuit Breaker should trip instantly if it is left con­
will lockout on distribution fault instantly upon initiation of the nected during a starter dry run.
start. C O T T F T T r’T T T IA L
7. 15-6
U S &K l . !j u j .' i v. u S d
by C uuij/ v 1 ~d. s i*
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982
MOTOR PROTECTION MODULE WIRING MAINTENANCE

Figure 6 illustrates the wiring of the MPM. Trouble Analysis charts On an annual basis the MPM should be opened and any dirt
are found in Section 6 of this Service Guide. cleaned out. This is best accomplished with a vacuum cleaner.
Also, the current calibrator should be removed and its resistance
checked to see that it has not varied. If its setting has changed, it
should be recalibrated and replaced in the module.

FIGURE 6 - Motor Protection Module Interconnections

PRINTED BY PRODUCTION SERVICES LA CROSSE FWB D J I
c o iT F iT m ? :7 iA r
7 . 15-7
Use Ks^ti'icted
by Court Order
 LITERATURE FILE NO. HCTV-SG-2

S T A R T E R C IR C U IT
BREAKER/MAIN D IS C O N N E C T
SECTION
(CB10) 7.16
FEBRUARY 1982

D ES C R IP TIO N 2. Overload Protection - the circuit breaker will trip in the event
of a sustained overload. The time required to trip is de­
The Starter Circuit Breaker/Main Disconnect, when the starter is
pendent upon the magnitude of the overload.
so equipped, provides branch circuit protection at the incoming
3. Ground Fault Protection (optional) - the circuit breaker will
power lines and a means of disconnecting the unit from line trip instantly in the event of a ground fault current exceeding
power. Refer to Figure 1. the set pick-up point.
WARNING: Always disconnect all power before working on When the circuit breaker trips for any reason, the disconnect
this or any electrical equipment Failure todoso may result In handle will move to a position that is halfway between off and on.
serious personal Injury or death due to electric shock. More To reset the circuit breaker the handle must first be moved to the
than one disconnect switch may be required to de-energize full off position and then returned to the on position.
this equipment Auxiliary circuits and ground fault Indicators
may not be de-energized by the starter main disconnect cir­ In the event the circuit breaker is tripped due to a ground fault, the
cuit breaker. lamp in the ground fault indicator will be on and the disconnect
handle will be tripped. See Figure 2. To reset the circuit breaker,
The circuit breaker can provide three types of branch circuit pro­ the ground fault indicator light/button must be pushed in, in addi­
tection. These are: tion to the normal resetting of the circuit breaker with the discon­
1. Short Circuit Protection - the circuit breaker will trip instantly nect handle.
in the event of a phase-to-phase short circuit.

FIGURE 1 - Seltronlc Circuit Breaker/Main Disconnect

COITFT r p T T i A r
F IG U R E 2 - G ro u n d F a u lt In d ic a to r L ig h t/R e s e t B u tton
CTHE TRANE COMPANY 1982
COMMERCIAL AIR CONDITIONING DIVISION
■ oted
LA CROSSE, WISCONSIN 54601 --U1-Order
PRINTED IN U S A 7.16-1
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 pOU 'J - i iI A T j

FEBRUARY 1982 UOO 1 j : ictod

SPECIFICATIONS "T*------------- CALIBRATION AND CHECKOUT PROCEDURE

Circuit Breaker Westinghouse Seltronic The circuit breaker will have either one or three adjustments, de­
pending upon whether it is equipped with ground fault protection.
Maximum Voltage 600 VAC See Figure 3.
Asymetrical Amperes Interrupting Capacity A circuit breaker not equipped with ground fault protection will re­
VOLTAGE quire only one adjustment. This is the setting for the Short Circuit
200 460 575 Trip Point. The adjustment for this is made on the front of the cir­
VAC VAC VAC cuit breaker and should be set to the minimum position. This set­
CIRCUIT BREAKER TYPE ting provides the maximum protection.
STD INTERRUPT CAPACITY 42,000 30,000 2 2 ,0 0 0
Ground Fault, when applied to a 3-wire, floating ground, 3-phase
HIGH INTERRUPT CAPACITY 65,000 35,000 25,000
system, protects against faults or shorts which occur around the
circuit breaker between different phases (shown as A to B in
Figure 4) or from one load system to another (shown as A to C in
Line Power Wire Lug Sizes Figure 4). Grounding one leg of the system does not cause a
ground fault trip since this merely changes the 3-wire floating
POWER WIRING ACCEPTED
ground distribution system to a 3-wire grounded system. Ground
UNIT RATED LOAD BY STANDARD
Fault equipped circuit breakers will require two adjustments in ad­
(AMPS) LUGS* - NUMBER AND SIZE
dition to the adjustment for short circuit trip point. These adjust­
----------5 4 ^ 5 5 0 ------------ 1 - 4 TO 250 MClYl
ments are the Current Pick-up and the Time Delay. Both of these
1 - 000 TO 600 MCM
should be set to the maximum position.
250.1 - 400 1 - 000 TO 350 MCM
1 - 000 TO 500 MCM Any other settings of the circuit breaker adjustments should be
400.1 - 550 2 - 00 TO 500 MCM determined by the jobsite electrical engineer.
550.1 - 650 3 - 000 TO 500 MCM
* COPPER CONDUCTORS ONLY MAINTENANCE

There are no internal adjustments which can be made in this cir­

cuit breaker. On an annual basis the circuit breaker should be ex­
Maximum Continuous Trip Setting - Rating Plug Sizes ercised. This includes the following:
MAX. CONTINUOUSCIRCUIT BREAKER 1. Turn the circuit breaker off and on several times to insure that
UNIT RATED AMPS (RATING FRAME RATING the disconnect mechanism is free.
LOAD (AMPS) PLUG SIZE) (AMPS) 2. Trip the circuit breaker with the PUSH TO TRIP button on the
64 - 90 150 400 front panel of the circuit breaker. Do this several times to
90.1 - 110 175 400 insure that the trip mechanism is free and operating properly.
110.1 - 130 200 400 Refer to Figure 3.
130.1 - 140 225 400
140.1 - 150 250 400 NOTE: Steps One, Two and Three must be performed with
150.1 -2 0 0 300 400 the compressor motor de-energized to prevent unneces­
200.1 - 225 350 400 sary wear of the circuit breaker. This can be done by leaving
225.1 - 250 400 400 the system switch on the unit control panel in the off position.
250.1 - 275 450 600
WARNING: Before w orking on tf»f* o r any electrical
275.1 - 325 500 600
equipment always d b co n n ec t a ll electrical power. A b o,
325.1 -4 0 0 600 600
the line tid e remains energized when the disconnect In
400.1 - 425 700 800
the starter /s de-energized. The m ain line {Reconnect to
425.1 - 550 800 800 the unit m ust be d e + n e rg b e d and aafcd a d (p ad lo cke4
550.1 - 650 1000 1200
before any work I t done on the circuit breaker . Prevent
p erso n al Injury by alw ays d isco n n ecting e le c tric a l
pow er before working on electrical equipment. Failure
Short Circuit Trip Point A d ju sta b le from 5 to 10 T im es
to disconnect electrical power may result In serious per­
Ampere Rating of Installed Rating
sonal Injury or death due to electric shock.
Plug
3. Test the Ground Fault indicator, on units so equipped, by
Ground Fault Trip Point Adjustable from 0.2 to 1.0 Times pushing the test button on the front of the starter panel door.
Circuit Breaker Frame Rating 4. Tighten all electrical connections on the circuit breaker. In
some cases it may be necessary to remove terminal lug
Ground Fault Time Delay Adjustable from 0 (No Delay) to 0.5 shields and the disconnect handle mechanism in order to
Seconds (30 Cycles) gain access to the lug bolts.

7. 16-2
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

Ground F»ui! Tnp Magnetic Trip Breaker

J' -3 times Ampere r ■ Test
Ten.* 1- ,4 ratin* , Push to Trip ICS 600 I Ratirg Plugs
Seconds ," 5 *«*i h»t snows rr pximum
!* * I« * ‘ "> continue s Ampere
rating
Amperes ^ „ 9'
Ground F tult
480 , ; 240 ‘ est
See I L 1184 360 Wester {house Electric Corporation 135P193H04

1
GROUND FAULT TRIP MAGNETIC PUSH-TO-TEST RATING TEST PLUG OPENINGS:
TIME DELAY PICK-UP BUTTON PLUG INSTANTANEOUS TRIP
ADJUSTMENT ADJUSTMENT LONG DELAY TRIP

GROUND FAULT TRIP TEST PLUG OPENINGS:

CURRENT PICK-UP GROUND FAULT TRIP
ADJUSTMENT

FIGURE 3 - Seltronic Circuit Breaker Adjustments, Front Panel

PHASE TO PHASE SHORT CIRCUIT GROUND FAULT FAILURES

FIGURE 4 - Protection Provided by Circuit Breaker

PRINTED BY PRODUCTION SERVICES — LA CROSSE CONFIDENTIAL' FWB/DJL
7. 16-3 Use lice i.t*j c ted
SiL-C curt order
 LITERATURE FILE NO. HCTV-SG-2

P ILO T R E LA YS SECTION
(K23 AN D K24)
7.17
FEBRUARY 1982

DESCRIPTION CHECKOUT PROCEDURE

The pilot relays are located in the bottom of the starter next to the To check this relay, measure the continuity across the contacts. If
terminal board. The relays are wired in series with each other to the normally open and normally closed contacts operate correctly
assure shutdown of the chiller if one of the relays sticks or welds. when the relay is energized and de-energized, the relay is ac­
The relays also monitor each other and will give a STARTER ceptable for use. If the contacts do not operate properly or if the
FAULT trip if one of the relays sticks, welds, or fails to operate relay chatters when powered by design voltage it should be re­
properly. placed. Figure 1 illustrates the relay contact configuration and ter­
minal numbers.
SPECIFICATIONS

Contact Arrangement D ouble-P ole, D ouble- MAINTENANCE

Throw
There are no adjustments or repairs which can be made to this
Inductive FLA Rating at 125 VAC 12 Amps control.
Inductive LRA Rating at 125 VAC 60 Amps

Terminals 0 .2 5 in c h , S ta b -o n ,
Quick Connect

Coil Voltage Rating 120 VAC (+10% ,-15% )

Coil Insulation Class B

FIGURE 1 - Relay Contact Configuration and Terminal Numbers, K24 and K25 Relays
•THE TRANE COMPANY 1982
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601
PRINTED IN U S A CTTTAr
U i e lie s
c:c: cze-i
7.17-1
 LITERATURE FILE NO. HCTV-SG-2

S T A R T E R C O N TA C TO R S
SECTION
(K25, K26, K28, K27)
7.18
FEBRUARY 1982

DESCRIPTION

The starter contactors used in the Trane factory mounted starter Refer to the factory mounted starter panel section for the con­
panel are Definite Purpose (DP) rated contactors. Size 2 DP nection and schematic diagrams. These diagrams give the lo­
through Size 5 DP contactors are used depending upon the cation of contactors and how they are wired.
Rated Load Amps (RLA) of the CenTraVac and the specific func­
tion which the contactor is performing. The four starter contactors
SPECIFICATIONS
provided are:
The following Table lists contactor size and function.
1. Main compressor motor contactor K27 (1M)
2. Main compressor motor contactor K28 (2M)
3. Star (wye) connection contactor K25 (S)
4. Transition resistor contactor K26 (1A)

TABLE 1 - Specifications
DEFINITE PURPOSE CONTACTOR SIZE
130, 2 3 4 5
NO. OF POLES 3 3 3 3
LUG SIZE 4-14 3/0-14 350 MCM 750 MCM
CONTINUOUS RLA RATING 60 120 200 350
LRA RATING AT 460 V — 800 1500 2320
COIL APPD CLASS INSUL. B B B B
MAX. COIL IN RUSH AT
120 V - 60 Hz 391 VA 1034 VA 1034 VA 1034 VA
MAX. SEALED AT 120 V - 60 Hz 55 VA 80 VA 80 VA 80 VA
AUX. SWITCH RATING 10 AMPS 10 AMPS 10 AMPS 10 AMPS

TABLE 2 - Contactor Size and Function

UNIT SIZE CONTACTOR SIZE
VOLTAGE RLA K27 (1M) K28 (2M) K25 (S) K26(1A)
440-600 84-140 3DP 3DP 3DP 2DP
440-480 140.1-200 3DP 3DP 3DP 2DP
575-600 140.1-200 4DP 4DP 3DP 2DP
ALL 200.1-325 4DP 4DP 3DP 2DP
ALL 325.1-650 5DP 5DP 4DP 3DP

®THE TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A.

7 . 18-1
 C O N F ID E N T IA L
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 Use Ilestribtod
FEBRUARY 1982 ~by C o u . y O r a e r
MAINTENANCE 1. Remove the power head from the contactor body by re­
moving the copper colored screws. Refer to Figures 1 and 2.
Contactors normally require very little maintenance. However,
2. Clean the contactor with a small brush or rag and then
the following is a list of recommended annual maintenance which
vacuum to remove all dirt and debris. Never use pressurized
should be carried out.
gas or air to blow particles out as they may become lodged in
WARNING:Beforeworkingonthisor anyelectrical equip­ the contactor.
ment alwaysdisconnect theelectrical powersupply. More 3. Visually inspect the power head and contactor base for signs
thanonedisconnectmayneed(o bede-energizedtoremove of overheating.
allpowerfromthestarterpanel.FailuretodosomayresultIn Indications of overheating include discoloration of any com ­
seriouspersonal Injuryordeathduetoelectricshock. ponent or part and also cracking or hardening of wire lead
insulation. If there are indications of overheating, determine
the cause and correct. Some of the causes of overheating
are loose connections, corrosion, overloading and dirty or
high resistance connections.
4. Visually inspect the contact surfaces as described in “ Con­
tact Inspection” which follows in this section. DO NO FILE
THE CONTACTS. Filing or dressing the contacts only re­
duces the service life and is not needed.
5. Inspect the auxiliary contacts for looseness and damage.
6. Tighten all electrical and mechanical connections in and on
the contactor. Refer to Table 3 for wire lug torque values.
7. Reassemble the contactor. DO NOT OIL OR GREASE ANY
CONTACTOR COMPONENT.
8 . Inspect the contactor for contact wear allowance as de­
scribed under “ Contact Inspection" which follows in this
section.
9. Replace the contacts as necessary as determined by the
visual and wear allowance checks.

NOTE: When replacing moveable contacts, the contactor

holder must be removed from the power head. Refer to
Figure 2. The contactor holder has a specific orientation in
the power head. Do not force into position. If installed incor­
rectly the contactor may malfunction causing potential
hazard to personnel and property.

10. Check the functioning of the auxiliary contact to insure that it

FIGURE 1 - Size 4 Cutler Hammer Definite Purpose Contactor
operates correctly.

F IG U R E 2 - T y p ic a l D is a s s e m b le d C o n ta c to r

7.18-2
 C O N F IT ^ T T A L
HERMETIC CENTRAVAC SERVICE GUIDE
Use Herjtricted HCTV-SG-2
Order^regularity FEBRUARY 1982
TABLE 3 - Contactor Torques
CONTACTOR TORQUE (INCH-LBS.)
isUL O Ui-
WIRE LUG
of contour usually involves a slantwise type of wear.
As an example, one comer of a contact may wear more quickly
SIZE LUG HOLDING SCREWS SCREWS that the other three corners. This type of wear is normal. EVEN
2 15-20 50 THOUGH THE WEAR ALLOWANCE OF THE CONTACT MAY
3 40 150 NOT Y E T BE R EAC H ED , C O N TA C TS SHO ULD BE RE­
4 40 200
PLACED IF IT IS NOTED THAT ONE CONTACT WILL BE
5 65-85 300 MAKING CONTACT WITH THE PLATE. The plate is the material
on which the contacts are fastened. If the plate material is con­
INTERLOCK INSPECTION
tacted, the contacts may weld together.
The mechanical interlock is located between the K25 and K28
Pitting is caused by melting and vaporization of the contact mate­
contacts. After removing both power heads the interlock should
rial. The pitted surface has high and low spots, and tests indicate
be inspected. It is a pendulum type mechanism with nylon rollers
that such a surface provides better contact than a smooth sur­
on each side. When one or the other contactors is energized the
face. The size of a pit mark, or crater, is proportional to the am­
pendulum swings under the armature of the other contactor pre­
peres of the arcing current. On a high amperage contact the pit
venting its movement. The mechanism should be inspected for
marks will be larger than on a low amperage contact. Pitting of a
signs of wear or looseness and should be repaired if necessary.
contact that is wearing well will show a uniform texture. WHEN IT
CONTACT INSPECTION APPEARS THAT CHUNKS ARE BEING TORN AWAY FROM
THE ARCING SURFACES, IT IS ADVISABLE TO REPLACE
In establishing and interrupting motor currents, contacts are sub­ THE CONTACT.
jected to both mechanical and electrical wear. Normally, mechan­
ical wear is insignificant. Electrical wear, caused by arcing, CURLING OF A CONTACT IS A CONDITION IN WHICH THE
erodes the contacts; and during arcing a small part of each con­ CORNERS OF THE CONTACT SEPARATE FROM THE PLATE
tact is vaporized and blown away. TO WHICH THE CONTACTS ARE FASTENED. IF SUCH A
SEPARATION OCCURS, THE CONTACT SHOULD BE RE­
Accurate determination of the time to replace contacts should ac­ PLACED. Curling is usually the product of service that produces
tually combine measurement of wear allowance and judgement high heat. An example of such service is severe jogging or inch­
regarding the appearance of the contacts. ing of the contactor, or when the device is subjected to fault condi­
tions that occur from short circuits or grounds in the system. If the
condition continues to exist with each replacement of the con­
VISUAL CONTACT INSPECTION
tacts, the application should be carefully checked to determine if
WARNING:Beforeworkingonthisoranyelectrical equip­ the contactor is properly rated for the application and whether as­
ment, alwaysdisconnect theelectricalpowersupply. More sociated equipment is operating properly.
thanonedisconnectmayneedtobede-energizedtoremove
allpowerfromthestarterpanel.FailuretodosomayresultIn Inspection of contacts is a simple maintenance operation. Simply
seriouspersonalInjuryor deathdueto electricshock. remove the contact block cover and slide out the moveable con­
tact bar. Where periodic maintenance is performed regularly, in­
As contacts continually make and interrupt current, the surface of spection of the moveable contacts alone will provide sufficient in­
the contact will change in color, contour and smoothness, re­ dication of the condition of the contacts. If the moveable contacts
sulting in discolorations, irregularity of surface and pitting. Nor­ are in reasonably good condition, then it may be safely assumed
mally, a new contact has a uniform silver color. As electrical wear that the stationary contacts are also in good condition. If the
occurs, the color may change to blue, brown or black. The black moveable contacts appear questionable, check the stationary
color is due primarily to the oxidation of the silver which is bene­ contacts also. Also, check the wear allowance as described in the
fic ia l to contact operation. The presence of small black em­ following portion of this section. With experience, it will be possi­
bedded granules in the contacts indicates the presence of cad­ ble to judge the condition of contacts by appearance and to avoid
mium oxide which is an excellent electrical conductor. the needless waste of throwing away good contacts.

F IG U R E 3 - E x a m p le s o f C o n ta ct W e a r C o n d itio n s

7.18-3
HERMETIC CENTRAVAC SERVICE GUIDE O T F ID T T ^ IA E
HCTV-SG-2 U se i a . ’ , U' d
FEBRUARY 1982 Court. Order
MEASUREMENT OF WEAR ALLOWANCE WHEN TO REPLACE CONTACTS
Wear allowance of a contact is defined as the total thickness of Determination of when to replace contacts should combine visual
contact material which may be worn away before the contact is inspection with wear allowance measurement. If there is extreme
unable to carry the rated current. Generally, a contact is ser­ pitting and curling of the corners, of if the contact has eroded at
viceable as long as the remaining wear allowance is not less than the corners to a point where the contacts bridge is beginning to
a specified minimum value. Usually this minimum value is on the show, the contacts should be replaced. Even with contacts
order of 0.015 inch. whose appearance is good, however, they should be replaced if
they do not check out satisfactorily on measurement of wear
On a contactor, the means of determining the wear allowance an allowance.
arrangement of contacts has remaining is to insert a 1/32 inch
DO NOT FILE SILVER CONTACTS, AS THIS ONLY REMOVES
feeler gauge between the armature and magnet frame, and move
USEFUL LIFE OF THE CONTACT! Filing of the contacts will nei­
the armature towards the sealed position until it comes to rest
ther improve performance nor extend the life of the contact.
against the feeler gauge. At this point, if the contacts are touch­
ing, the wear allowance of the contacts has not been exceeded, REPLACEMENT OF CONTACTS
and the contacts are still useable.
WARNING:ContactsshouldneverbeInspectedorreplaced
In many instances, visual inspection of the contacts during mea­ without first disconnectingthepowersupplyat themotor
surement of wear allowance may be difficult. A more reliable branchcircuit disconnectingdevice. Instartersequipped
method of determining whether the contacts are or are not touch­ withaseparatelowvoltagesupply, Onseparatecontrol
ing, is to use a continuity tester. There should be continuity with supplyshouldalsobedisconnected. Failuretodosomay
the armature against the 1/32 inch feeler gauge. It is advisable to result Inseriouspersonal Injuryor deathduetoelectric
use a wide feeler gauge to avoid the possibility of tilting the arma­ shock._______________________________________________
ture while holding it closed.
When it is determined that the contacts should be replaced, it is
required that the stationary contact, moveable contact, and the
If the continuity tester indicates continuity, the contacts have suf­ moveable contact spring all be replaced. Also, if a device is used
ficient w ear allowance to still be useable. If there is no continuity, to control a three-phase motor, it is required that all of the power
the contacts should be replaced. Be sure to check the continuity pole contacts be replaced when any one of the power pole con­
tester for proper operation. tacts require replacement. Contact kits are readily available con­
taining all the necessary contacts and springs to make this
replacement.

FWB /LLW

7. 18-4
 UTERATURE FILE NO. HCTV-SG-2

TR A N S ITIO N R ES IS TO R S SECTION
(R1 - R10)
7.19
FEBRUARY 1982
pOTTFXTVFTTT7AII_
Us • J.' ■cued
by Cuu-'L
DESCRIPTION CALIBRATION AND CHECKOUT PROCEDURE

The transition resistors are located in the top of the starter. Their The only check which can be made on the resistors is to check for
purpose is to provide closed transition starting of the CenTraVac continuity. The resistance across the resistors will vary between
compressor motor. They are energized by the K26 (1 A) contactor 0.5 and 10 ohms, depending upon the size of the resistor. If any
during the starter transition sequence. resistor is open it must be replaced.

SPECIFICATIONS MAINTENANCE

Resistance 0.5 to 10.0 Ohms No adjustments or repairs can be made to the resistors. During
annual maintenance they should be gently cleaned by vacu­
Base Material Porcelain uming any dirt or debris from them. The wire terminals should be
checked for tightness.

"HINTED BY PRODUCTION SERVICES — LA CROSSE FWB /DJL

®THE TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A 7. 19-1
 LITERATURE FILE NO. HCTV-SG-2

C O N TR O L PO W ER SECTION
TR A N S FO R M E R (T1)
7.20
FEBRUARY 1982
Co n f id e n t ia t
Use H'. 'j.. .1^ted
d e s c r ip t io n by Couri; Order CALIBRATION AND CHECKOUT PROCEDURE

The Control Power Transformer is located in the bottom of the Check to see that the transformer has the correct input and output
factory mounted starter panel. It reduces the line voltage to 120 voltages according to the manner in which it is wired. Figure 1 il­
volts AC. This transformer powers the control circuits, oil pump, lustrates the terminal numbering of the control power trans­
oil heater, and purge unit. former. Wiring diagrams for each design voltage are located on
the starter wiring diagrams. If the voltages measured are incor­
SPECIFICATIONS rect for the wiring used, replace the transformer since repair is not
Power Rating 3 KVA possible.

Primary Voltages 200 - 460 - 575 VAC MAINTENANCE

Secondary Voltage 120 VAC ± 10% Check the terminal connection tightness annually.

Frequency 50/60 Hz

Terminal Size 0.25 inch diameter

FIGURE 1 - Control Power Transformer

Terminal Numbers

PRINTED BY PRODUCTION SERVICES LA CROSSE FWB/DJL

‘ THE TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601
PRINTED IN U S A 7 . 20-1
 LITERATURE FILE NO. HCTV-SG-2

GROUND FAU LT SECTION

TRANSFORM ER (T5)
7.21
FEBRUARY 1982
bOIFIMTTTTAl_
Use Kosuricted
DESCRIPTION SPECIFICATIONS
by Court Order
The Ground Fault Transformer is located irTthe top of the factory Power Rating 40 VA
mounted starter. It powers the ground fault indicator when the cir­
Primary Voltages 200, 230, 400, 460, 575 VAC
cuit breaker trips.

WARNING:ThegroundfaulttransformercircuitIsnotde-en- Secondary Voltage 120 VAC

arglzedwhenthestarterpaneldisconnectisshutoff.Asepa­ Frequency 50/60 Hz
ratesystemdisconnect mustbeshutofftode-energizethis
dlrcutt. TopreventpersonalInjury,alwaysopenallelectrical CALIBRATION AND CHECKOUT PROCEDURE
power disconnect switchesMore workingontideorany
electrical equipment Failuretodosomayresulttoserious Check to see that the transformer has the correct input and output

personalInjuryordeathfromelectricshock. voltages according to the manner in which it is wired. Figure 1 il­

lustrates the correct wiring for each primary voltage. There are no
repairs which may be made to this transformer. If the voltages
measured are correct for the particular wiring scheme, replace
the transformer.

FIGURE 1 - Ground Fault Transformer Wiring and Terminal Numbers

’ RINTED BY PRODUCTION SERVICES — LA CROSSE FWB ;DJL

®THE TRANE COMPANY 1962

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601
PRINTED IN U S A
7.21-1
 LITERATURE FILE NO. HCTV-SG-2

O IL F ILTE R SECTION
R EP LA C EM EN T
8.0
FEBRUARY 198Z

Typically, the oil filter is to be changed during annual mainte­ 2. Increase the oil sump pressure to 0 psig by pressurizing the
nance. However, should the oil become contaminated due to ex­ chiller with dry nitrogen. This may also be accomplished by
cessive air leakage, moisture, or a motor burnout, more frequent allowing the chiller to warm up to the temperature where the
oil and oil filter changes will be necessary. This section describes chiller’s internal pressure reaches 0 psig.
the procedure for changing the oil filter.
WARNING:Uaeonlydrynitrogen.Donotuseoxygenor
1. Shut the CenTraVac off by turning the system switch to the acetylene.TheuseofoxygenoracetylenemayresultIna
OFF position. violent explosioncausingseriouspersonal injury or
death.___________________________________________
WARNING:Preventpersonalinjurybyde-energizingthe 3. Loosen the bolt on top of the oil filter housing. Refer to Figure
oilpumpbeforeworkingonthelubricationsystem.The 1. Do not completely remove oil filter bowl until all pressure is
unitmaindisconnectswitchmustbeopenedtoprevent removed from within the unit.
accidental oil pumpoperationduringservicepro­ 4. Separate the filter housing and then replace the filter. See
cedures.Disassemblyofdieoil fitterwhiletheoilpump Figure 2.
isrunningwillresultInasprayofhotoilpossiblycausing 5. Lightly oil the new filter housing gasket before reassembling.
seriousbumsandpersonalInjury. 6 . Operate the purge unit as necessary to remove the dry nitro­
gen from the chiller.

FIGURE 1 - Loosening Bolt on Filter Housing FIGURE 2 - Filter Element

®THE TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601 FWB /SPS
PRINTED IN U SA. 8.0-1
 LITERATURE FILE NO. HCTV-SG-2

O IL PU M P AN D PUM P SECTION
M O TO R R EP LA C EM EN T
8.1
FEBRUARY 1982

In the event of an oil pump or pump motor failure, use the follow­ 2. Remove the refrigerant charge.
ing procedure for replacement of the components. 3. Drain the oil from the sump as described in Section 8.0.
4. Loosen the nut at the connection of the oil line to oil filter
1. Shut the CenTraVac off and allow the oil pump to stop housing. See Figure 1.
operating. 5. Remove the two bolts on the oil sump cover plate and insert
WARNING: Prevent personal injury by de-energizing the threaded guide rods. See Figure 2.
o il pum p before m a k in g on the lubrication system. The 6 . Remove all remaining cover plate bolts and slide the cover

chiller main disconnect tw itch m u tt b e opened to pre ­ plate away from the oil sump approximately 2 inches. Refer
vent accidental o il pum p operation during a a n lc a pro - to Figure 3.
cedurea. Disassembly o f the lubrication system while the 7. Attach a lifting fixture through the top hole in the cover plate
o ilp u m p lao pera tin g w iltres u ltln aa p ray o th o to ilp o s s i- and remove the cover plate. The cover plate, oil pump and
bty causing serious burns and personal Injury._______ pump motor will be removed as an assembly. Refer to Fig­
ures 4 and 5.
WARNING: Beforeworkingon thlaor anyelectrical 8 . Cut the oil line as shown in Figure 6 .
equipmentalwaysdisconnectall electricalpower. Fail­ 9. Remove the three bolts which secure the oil pump to the
uretodosomayresult Inseriouspersonal Infuryor motor housing. See Figure 7.
deathfromelectricshock. ___

FIGURE 1 - OH Line Disconnection FIGURE 2 - Guide Rod Insertion

C O ITFID E N TIA E
Use Resti'icted
bT
V Court Order

®THE TRANE COMPANY 1962

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A. 8.1-1
 C O T T F lO T T T T .A 'L

HERMETIC CENTRAVAC SERVICE GUIDE

U se i'--' /
HCTV-SG-2
FEBRUARY 1982

FIGURE 5 - Lifting Cover, Oil Pump and Pump Motor Assembly

Clear of Sump

1 0.Remove the oil pump. Refer to Figure 8 . 13. Before replacing the oil pump assembly on the oil sump
11. To replace the oil pump it is necessary to remove the fitting cover, clean the cover plate O-ring groove with emery cloth.
with the oil line stub attached and thread it into the new oil Lightly grease the new O-ring with Lubriplate or equivalent.
pump. Use a % inch copper coupling to reconnect the oil line. 14. Using guide rods, slide the assembly on the oil sump. Refer
Braze the coupling with Sil-Fos or equivalent. to Figure 5.
12. When installing the new oil pump, be certain the oil pump 15. Tighten the cover plate retaining bolts to approximately 100
drive fits into the slotted shaft of the motor. See Figure 9. ft.-lbs. torque.

8.1-2
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

K
Vi

FIGURE 9 - Reinstalling Oil Pump

8 .1-3
 'C O T T F T O T T T J a
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 Us o it o ^t. r i o t e d
FEBRUARY 1982 tiu.jct Order

Oil Pump Motor Replacement Reassembly

1. Reattach the motor power leads to the terminals on the cover

plate.
2. Install the oil pump as previously desribed in this section.
3. Before installing the assembly, clean the O-ring groove in the
cover plate with emery cloth. Lightly grease the new O-ring
with Lubriplate or equivalent.
4. Install the assembly using guide rods for support. See Figure
5.
5. Tighten the cover plate retaining bolts to appoximately 100
ft.-lbs. torque.
6 . Evacuate the chiller. Also charge the chiller using the pro­
cedures found in the same section.
1 . Remove the oil pump as previously described in this section.
2. Remove the motor power leads from the terminals in the
cover plate. Refer to Figure 10.
3. Remove the four motor mounting bolts from the mounting
plate. See Figure 11.
4. Remove the motor as shown in Figure 12.

8 .1 -4
 C O FFT D E F T IA L ’ HERMETIC CENTRAVAC SERVICE GUIDE
T1 ^ ...... - HCTV-SG-2
UoG K e ^ o X ' l c t e a FEBRUARY 1982
by Court Qi-deg

PRINTED BY PRODUCTION SERVICES — LA CROSSE FWB/KAP

8.1 -5
 CONI’'-•• • ■•
Use R e s tilu te d
P i-m i r*T. U x '^ e X L

J — ......... — ■ ... ... ! M ill" ------

LITERATURE FILE NO. HCTV-SG-2

M O D E L CVH E
C E N TR A V A C C O M P R ES S O R SECTION
D IS A S S E M B LY 8 .2
FEBRUARY 1982

The purpose of this section is to describe the disassembly of the

Model CVHE CenTraVac compressor. The procedures given
may be used for com pressors in the 013 through 080 size range
and the 089 through 125 size range with certain variations. Steps
1 through 9 and 11 through 27 under “ Disassembly" are identical,
however at step 10 there are differences. For the weights of vari­
ous compressor components refer to Section 9.0.

D isassem bly
WARNING:Beforeworkingonthisor anyelectrical equip­
ment,alwaysdisconnecttheelectricpowersupply.Failureto
dosomayresult Inseriouspersonal Injuryor deathfrom
electricshock.
1. Disconnect all electrical power. Before starting disassembly
it is first necessary to remove all the refrigerant from the
chiller. After the refrigerant has been removed, evacuate the
chiller to 4 mm Hg to remove all refrigerant vapor. After the
chiller has been evacuated, pressurize the chiller with dry ni­
trogen until the evaporator pressure gauge reads 0 psi.
Refer to Figures 1 , 2 and 3.

WARNING:Useonlydrynitrogenwhenpressurizingthe
chiller. Theuseofoxygenoracetylenemaycauseavio­ FIGURE 2 • Pressurizing With Dry Nitrogen
lent explosionresultingInseriouspersonal Injuryor
death.

FIGURE 1 - Removing Refrigerant

CTHE TRANE COMPANY 1982
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U.S.A.

8.2-1
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

2. Mark and disconnect all power leads to the inlet vane actu­
ator motor. Remove the conduit assembly from the actuator
motor. See Figure 4.
3. Remove the inlet vane actuator linkages. This is accom­
plished as follows:
a. Disconnect the universal joints at the first and third
stage inlet vane operator levers. See Figures 4 and 5.
b. Remove four 5/8” -11x2” hex head bolts securing the
vane drive support assemblies to the castings. See
Figure 4.
c. Remove the cotter pin securing the vane operator stud.
d. Slide the vane motor off the stud and remove the entire
vane linkage assembly and vane motor from the chiller.
e. Remove the linkage assembly from the vane motor.
This is done by removing the cotter pin. The vane motor
is now free and can be removed.
4. Scribe a line on the exterior of all the compressor castings in
two locations which are 90 degrees apart. This must be done
so that precise alignment of all components can be made
when reassembling the compressor. Failure to complete this
step may result in misalignment of the suction elbow and
FIGURE 5 - Disconnecting Linkage
possible distortion of the compressor. This may result in im-
peller-to-seal interference and/or impeller failure. b. D isconnect and rem ove the control panel support
5. Remove or loosen the economizer for compressor volute bracket. See Figure 9.
clearance. See Figure 6 . Also refer to Section 8.7 which pro­ c. Attach a sling with overhead chain hoist to the suction
vides the complete procedure for economizer removal. elbow to support its weight.
6 . Remove the compressor suction elbow. d. Remove the bolts on the suction cover and evaporator
a. Cut the 7/8 inch vent line to the oil sump. Sand all the connections. Remove the suction elbow. See Figure 10
paint off the pipe at the point where the cut is to be m ade, e. Cover the evaporator suction pipe with plywood to p rt
before making the cut. Make the cut using a tube cutter vent entry of dirt and debris into the evaporator. Refer to
in a straight section of pipe. This will facilitate reas­ Figure 11. Also, coat all bare metal surfaces with a light
sembly with a sweat connection. coat of com pressor oil to prevent the formation of rust.

INLET VANE
MOTOR

ARM

UNIVERSAL JOINT

ROD ASSEMBLY

UNIVERSAL JOINT

F IG U R E 4 - C o m p re s s o r In le t V a n e L in k a g e A s s e m b ly

8.2-2
 CONFIDENTIAL'
Use K e sjricte d HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
U. Court Order FEBRUARY 1982

FIGURE 10 - Suction Elbow Connections FIGURE 11 - Suction Elbow Evaporator Connection With
Protective Cover

8.2-3
 rOTTFIDETTTTAL'
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 iioyv.-ioied
FEBRUARY 1982 by Court, order
7. Remove the first stage inlet vane assembly. positioned around the pipe as close as possible to the
a. Loosen and remove the 5/16 inch - 1 8 x 1 inch hex head vane housing. The pipe is used as a fulcrum to lift the
bolts and lockwashers securing the tang operator to the weight o f the inlet vane assembly and then slide the as­
suction cover. See Figure 12. Remove the tang operator sembly out of the suction cover a short distance. A chain
assembly. See Figure 13. or sling can then be wrapped around the housing just
b. Remove the 5/16 ” -18x3/8” set screws countersunk in inside the flanged outer portion while the assembly is al­
the suction cover. lowed to rest on the inside of the suction cover. The
c. Remove the inlet vane assembly. The tool shown in housing should then be lifted slightly and removed from
Figure 14 is for production purposes. For field removal the suction cover. The weight o f the assembly is given in
of the inlet vane assembly a 5 foot section of heavy duty Section 9.0, “ Specifications” , in this Service Guide. Re­
pipe is used. Slide the pipe between the vane blades at moval of the inlet vane assembly requires two men.
the top of the vane housing. A chain or sling should be Refer to Figure 15.

FIGURE 12 - Tang Operator Retaining Bolt Removal FIGURE 13 - Tang Operator

F IG U R E 14 - In le t V a n e R e m o v a l F IG U R E 15 - In le t V a n e A s s e m b ly

8.2-4
 HERMETIC CENTRAVAC SERVICE GUIDE
IJfcO
HCTV-SG-2
FEBRUARY 1982
8 . Remove the first stage impeller nose seal. Refer to Figure
16.
a. Check and record the seal clearance for indication of ex­
cessive wear. Figure 17 illustrates this measurement.
Mark the seal for TOP and FIRST STAGE. See Table 1 A
for correct clearances.
b. Bend the tabwashers to remove the hex head bolts : v
' 4 -
which hold the seal in place. See Figures 18 and 19.
c. Remove the seal. '>*

FIGURE 18 - Tabwashers

FIGURE 19 - Removing Seal Retaining Bolts

TABLE 1 - Clearances
IMPELLER SEAL RING CLEARANCE
COM PR SIZE 1ST STG 2ND STG 3RD STG
013 THRU 014 .0295/.0195 .024/.0165 .024/.0165
015 THRU 020
022
.0295/.0195
!
.0295/.0195
023 THRU 032 l
.033/.022
035
f .033/.022
036 THRU 045
049 THRU 050
I T
.0365/.0245

1 .033/022
055 .0365/0245
056 THRU 071 T
043/.0285
' '

079 THRU 080 f

f .0365/.0245

r ~_t_ ♦
089 THRU 112 .046/.031 .043/.0285
125 .043/.0285
SEAL TO SHAFT .0005/.003 ALL SIZES

8.2-5
 'C 0 f l F lE * U : C --
HERMETIC CENTRAVAC SERVICE GUIDE U ss R o 3 r io te d
HCTV-SG-2
FEBRUARY 1982 order.
9. Remove the suction cover and O-ring. d. Remove all bolts except the one at the top and two b o ltf
a. Disconnect the 1/4” oil drain line between the bottom of near the bottom. See Figure 20.
the first stage suction cover and the oil sump. e. Loosen the upper bolt and the lower bolts. Pry the cover
b. Attach rigging to the suction cover for lifting. Remove away at the top and loosen the top bolt enough to attach
two bolts from the suction cover, 180 degrees apart on the lifting tool. See Figure 23.
the horizontal centerline, and insert guide pins. A lifting f. Attach the overhead hoist, take the weight off the re­
tool (TOL-89) is available from the Service Marketing maining bolts, remove the bolts and then carefully
Department. The tool shown in Figures 20 and 21 is not remove the suction cover. See Figure 23. Also remove
available, however Figure 22 illustrates the proper tool. the suction cover O-ring. Lightly coat all bare metal sur­
c. Remove a bolt near the top of the suction cover and faces with compressor oil.
insert a long bolt as shown in Figure 21.

FIGURE 20 - First Stage Suction Cover FIGURE 21 - Suction Cover Removal

F IG U R E 2 2 - S u c tio n C o v e r L iftin g T oo l F IG U R E 2 3 - P re p a rin g S u c tio n C o v e r F o r L iftin g

8.2-6
 COTTFIDEUTIAI HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
Use Bostx’xotod FEBRUARY 1982
10. Remove the first stage impeller. Q iJL ouL't Order e. Remove the impeller. It may be necessary to use a pull­
er. Mark the impeller FIRST STAGE. See Figure 27.
NOTE: SEPARATE PROCEDURES FOR CVHE 013
f. Remove the impeller key and shims from behind the im­
THROUGH 080 SIZE RANGE AND CVHE 089 AND 125 peller. See Figure 28. Lighly coat each com ponent with
SIZE RANGE. BE SURE TO LOCATE AND FOLLOW THE compressor oil for protection from corrosion.
APPROPRIATE PROCEDURES AS DESCRIBED BELOW.
AFTER THE FIRST STAGE IMPELLER IS REMOVED, THE CVHE 089 THROUGH 125
SUBSEQUENT PROCEDURES ARE THE SAME. a. Bend the locking tab which secures the impeller locknut.
b. Remove the impeller locknut and lockwasher.
CVHE 013 THROUGH 080
c. Remove the springwasher.
a. Bend the lock tab securing the impeller locknut. See
d. Remove the impeller. It may be necessary to use a pull­
Figure 24. er. Mark the impeller FIRST STAGE.
b. Remove the impeller locknut and lockwasher. Use a
e. Remove the impeller key and shims from behing the im­
spanner. See Figures 25 and 26. This has right-hand
peller. Lightly coat each component with compressor
threads. oil.
c. Remove the springwasher.
f. Remove the spacer. (Remove the additional spacer
d. Remove the spacer. found on CVHE 089 and 090 units).

FIGURE 25 - Locknut Removal

F IG U R E 2 6 - L o c k w a s h e r F IG U R E 2 7 - Im p e lle r R e m o v a l

8.2-7
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982 r

FIGURE 28 - Impeller Shims

11. Remove the first stage shaft seal. a. Remove two 3/8” x16 socket head capscrews, 180 de­
a. Check the seal clearance for wear and record reading. grees apart.
The proper clearances are given in Table 1. Refer to b. Mark the diffuser plate for TOP and FIRST STAGE.
Figure 29. Mark the seal for TOP and FIRST STAGE. c. Install two 3/8” -16x6” or longer guide rods in the two bolt
b. Loosen and remove the 3/8” -16x1” bolts and tab- holes. See Figure 33.
washers which secure the seal to the vane plate. See d. Remove the remaining socket head capscrews.
Figure 30. e. Back the plate away far enough to attach the lifting rig.
c. Remove the seal. Support the plate on the guide rods. Lifting the plate can
12. Remove the shaft spacer. Refer to Figure 31. be accomplished by using a nylon sling, rope or steel
a. Removal may require the use of a puller. See Figure 32. cable instead of the lifting tool shown in Figure 34. Insert
Lightly coat the spacer with compressor oil. the sling or cable through the center of the plate and
13. Remove the first stage diffuser plate. See Figures 33 and 34. through the clearance between the shaft and hole in
plate. Lift the plate directly by the sling or cable.

H-

• * ► ’
I r
%

W ii

F IG U R E 2 9 - C h e c k in g F irs t S ta g e S h a ft S e a l C le a ra n c e F IG U R E 3 0 - R e m o v in g F irs t S ta g e S h a ft S e a l R e ta in in g B o lts

FIGURE 31 - Shaft Spacer Removal FIGURE 32 - Shaft Spacer Pulling Holes

FIGURE 34 • Lifting the First Stage Diffuser Plate

14. Remove the second stage shroud assembly. Refer to Figure 15. Remove the second stage impeller nose seal. Refer to
35. Figure 37.
a. Leave the guide rods from the previous step in place. a. Measure and record the seal clearance for wear indi­
b. Mark the top o f the shroud assembly. c a tio n . S ee F ig u re 38. S ee T a b le 1 fo r p ro p e r
c. Remove the 1/4’,-20x3/4" flat head screws securing the clearances.
shroud assembly. See Figure 35. b. Mark the seal for TOP and SECOND STAGE.
c. Bend back the tabwashers and remove the 3/8” -16x1 ”
1. Attach the lifting sling or cable as in step 13E. Remove the
hex head capscrews which secure the seal.
shroud, guiding it clear with the guide rods. See Figure 36.
d. Remove the seal. See Figure 39.
Lightly coat the shroud with compressor oil.

8.2-9
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

FIGURE 35 - Removing the Second Stage Shroud Retaining Bolts

FIGURE 36 - Lifting the Second Stage Shroud

F IG U R E 3 8 - M e a s u rin g th e S e a l C le a ra n c e F IG U R E 3 9 - S e a l R e m o v a l

8.2-10
 O T 7 T . D ^ T T t A Tj
HERMETIC CENTRAVAC SERVICE GUIDE
Use HCTV-SG-2
^ C o u r t .O rd e r:
FEBRUARY 1962
16. Remove the second stage suction cover and O-ring. b.Mark the impeller SECOND STAGE.
a. Scribe two marks, 90 degrees apart on the outer surface c.Remove the key and shims behind the impeller. These
of the casting and the mating casting. This will facilitate must also be marked SECOND STAGE. Lightly coat the
precise alig n m e n t of the com ponents when reas­ components with compressor oil.
sembling the compressor. 18. Mark and remove the second stage shaft seal.
b. Remove two 5/8” -1 1x2” bolts and insert two guide rods, a. Measure the seal clearance and record for wear indi­
180 degrees apart. See Figure 40. cation. The proper clearances are given in Table 1. See
c. Attach the lifting rig to the suction cover. Remove the re­ Figure 43.
maining bolts securing the volute and remove. Coat all b. Mark the seal for TOP.
bare metal surfaces with compressor oil for protection c. Bend back the tabwashers and then loosen and remove
from corrosion. See Figure 41. the 3/8” -16x1" bolts that secure the seal to the vane
17. Remove the second stage impeller. Refer to Figure 42. plate. See Figure 44.
a. It may be necessary to use a puller for removal. d. Remove the seal. See Figure 45.

FIGURE 40 - Second Stage Suction Cover Casting FIGURE 41 - Second Stage Suction Cover Casting Removal

F IG U R E 4 2 - S e c o n d S ta g e Im p e lle r F IG U R E 4 3 - M ea s u rin g S e c o n d S ta g e S h a ft S e a l C le a ra n c e

8.2-11
 'C 0 ’ ^ T " " ’ T T T A T j
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 Use i. -- - od
FEBRUARY 1982 •j-iv ' r |~- o r d e r

19. Remove the shaft spacer. It may be necessary to use a puller grees apart, and insert 3/8” -16x6” guide rods. Refer to
for this operation. See Figure 45. Figure 46.
20 . Remove the second stage diffuser plate. c. Remove the remaining socket head capscrews.
a. Mark the plate for TOP. d. Attach a lifting rig or sling as in Step 13E and remove the
b. Remove two 3/8” -16 socket head capscrews, 180 de­ vane plate. Lightly coat the plate with compressor oil.

FIGURE 46 - Guide Rods Installed for Second Stage Diffuser FIGURE 47 - Second Stage Diffuser Plate Removed
Plate Removal

8.2-12
 fOTJFI® TT M ^
HERMETIC CENTRAVAC SERVICE GUIDE
U se R e s Vi - V V U -
HCTV-SG-2
FEBRUARY 1982
1yG j

21. Remove the third stage vane operator assembly. Refer to ring the vane operator assembly. Refer to Figure 50.
Figures 48, 49, 50 and 51. b. Remove the vane operator and gasket. See Figure 51.
a. Remove the 1/2” -13x1-1/2" hex head capscrews secu­ Lightly coat all bare metal surfaces with compressor oil.

8.2-13
 TTottt?t bit : t t al"
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 Use i ' o : vi 1e t e d
FEBRUARY 1982 by Court Order
22. Remove the third stage shroud and vane assembly. 23. Remove the third stage impeller nose seal.
a. Mark the assembly for TOP. a. Mark the seal for TOP and THIRD STAGE.
b. Leave the guide rods installed in Step 20 in place. See b. Measure and record seal clearance for wear indication.
Figure 52. Table 1 provides the proper clearances. Figure 55 illus­
c. Remove the 1/4"-20x3/4’' flathead screws securing the trates the clearance being measured. Measure the
shroud. Refer to Figure 53. clearance all the way around the seal.
d . Attach a sling or cable as in Step 13E to the shroud and c. Remove the 3/8” -16x1" hex head capscrews and tab-
remove the shroud and vane assembly. See Figure 54. washers. See Figure 56.
Lightly coat the components with compressor oil. d . Remove the seal. Lightly coat the seal with compressor
oil.

FIGURE 53 - Removing Retaining Screws

F IG U R E 54 - T h ird S ta g e S h ro u d an d V a n e A s s e m b ly R em o val F IG U R E 5 5 - C h e c k in g T h ird S ta g e Im p e lle r N o se S eal C le a ra n ce

8.2-14
 {To n f id e ittia l ' HERMETIC CENTRAVAC SERVICE GUIDE
Use R c ;jz r i c t e d HCTV-SG-2
by Court Order FEBRUARY 1982

FIGURE 56 - Bending Tabwashers on Retaining Bolts

24. Scribe two marks, 90 degrees apart, in the third stage suc­ b. Attach lifting rig to the suction cover.
tion cover casting and the mating casting. This will facilitate c. Remove the remaining bolts securing the suction cover
proper alignment of the components upon reassembly of the and remove. See Figure 58. Lightly coat all bare metal
compressor. Remove the third stage suction casting and CD- su rfa c e s w ith co m p re s s o r o il fo r protection from
ring. corrosion.
a. Remove two 5/8” -1 1x2” bolts, 180 degrees apart, and
insert 5/8’ -11x6” guide rods as shown in Figure 57.

8.2-15
HERMETIC CENTRAVAC SERVICE GUIDE
TOTT1?TT'T'T'T’T
’ TAI
HCTV-SG-2
FEBRUARY 1982 Use I;,.., tod
by Co l, u .L -d e .r
25. Remove the third stage impeller. See F igure’5 a T ' 27. Remove the bearing oil seal mounting plate and gasket,
a. Mark the impeller for THIRD STAGE. a. Mark the plate for TOP.
b. The use of a puller may be required for removal. b. Remove tw o 3/8” -16x1" socket head capscrews and
c. Remove the key and shims from behing the impeller. insert two guide rods.
Lightly coat all com ponents with com pressor oil. c. Remove the remaining capscrews and remove the plate
26. Remove the bearing oil seal and gasket. and gasket. Use a nylon rope to lift the plate as de­
a. Measure and record the seal clearance fo r w ear indi­ scribed in Step 13E. Place a container under the plate
cation. Refer to Figures 60 and 61. Measure the seal as oil will drain out. Lightly coat the plate with com ­
clearance all the way around as shown. Proper clear­ pressor oil.
ances are 0.0005” minimum and 0.003” maximum
b. Check the clearance all the way around the shaft as This ends the disassem bly procedure. Inspect all the com­
shown. ponents for damage o r excessive wear. Do not reassemble the
c. Mark the seal for TOP. This is important since the seal unit using faulty components. Also, clean each component and
has a small oil drain hole in the back which must be cor­ apply a light coat of refrigerant oil to protect the components from
rectly aligned during reassem bly. This is shown in moisture and corrosion (especially O-ring and gasket surfaces).
Figure 62.
d. Remove the hex head capscrews and tabwashers se­ Refer to Section 8.3 for reassembly procedures.
curing the seal. Remove the seal and gasket. See
Figure 63.

F IG U R E 61 - B e a rin g O il S e a l C le a ra n c e M e a s u re m e n t F IG U R E 6 2 - O il D rain H o le in B e a rin g O il S e a l

8.2-16
 ■COirFIElflTlATj HERMETIC CENTRAVAC SERVICE GUIDE
U se R c tj - c r i t 5 ' t e d HCTV-SG-2
^ y C o u r tJ ) £ i® £ FEBRUARY 1982

FIGURE 63 - Bending Tabwasher on Oil Seal Retaining Bolts FIGURE 64 - Bearing Oil Seal Mounting Plate

FWB /LLW

8.2-17
 LITERATURE FILE NO. HCTV-SG-2

M O D EL CVHE
C E N TR A V A C C O M PR ES SO R SECTION
R EA S S EM B LY 8.3
FEBRUARY 1982

This section describes the reassembly of the Model CVHE Cen- 2. Install the bearing oil seal. Refer to Figure 2.
a. Check the shaft runout with a dial indicator. The max­
TraVac compressor and assumes that the motor has been in­
im um allow able runout is 0 .0 0 1 2 " Total Indicated
stalled. Notice that at Step 15 two different procedures are given
Runout (T.I.R.). See Figure 3. Also refer to Section 8.5,
depending upon the size of the compressor.
Compressor Motor Reassembly, for details on how to
measure shaft runout and end float. It is necessary to
NOTE: Figure 62, found on page 8.3-17, at the end of the section preload the shaft to obtain accurate indication of Total
is a cutaway view of the CVHE compressor. Refer to this Figure Indicated Runout.
while reassembling the compressor. b. Install the seal with a new gasket using the tabwashers
and bolts. INSTALL THE SEAL WITH THE SMALL OIL
DRAIN HOLE IN THE BACKSIDE OF THE SEAL
1. Install the bearing oil seal mounting plate as shown in FACING DOWN AND TOWARDS THE MOTOR. Refer
Figure 1. to Figure 2.
a. Thoroughly clean all dirt and debris from the plate. c. Tighten the retaining bolts very lightly.
b. Install the plate with a new gasket. Be certain the TOP is d. Set the seal to shaft clearance at 0.0005” minimum and
in the correct position. 0.003” maximum. See Figures 4 and 5.
c. Tighten the 3/8” -16x1" socket head screws to 24 ft.-lbs. e. Tighten the retaining bolts to 24 ft.-lbs. and then recheck
torque. the clearance.
f. Bend the tabwashers to secure the bolts. See Figure 6 .

FIGURE 2 - Bearing Oil Seal

C O N F ID E N T IA L

Use Restricted
5THE TRANE COMPANY 1982
bg. Court QxAftr
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601
PRINTED IN U.S.A.

8.3-1
FIGURE 3 - Measuring Compressor Shaft Runout FIGURE 4 - Measuring Shaft to Seal Clearance

FIGURE 5 - Measuring Shaft to Seal Clearance FIGURE 6 - Bending the Tabwashers

3. Install the third stage impeller. See Figure 7. surface for defects. If there are scratches deeper than
a. Thoroughly clean the impeller, compressor shaft, im­ 1 /16” , do not use the impeller, replace it.
peller key, and shims to remove all dirt, debris, ox­ b. Lubricate the shaft and/or impeller bore with Lubriplate
idation, etc. Examine the impeller carefully for defects. lubricant or equivalent.
Inspect the impeller key with dye penetrant indicator for c. Measure the shaft Outside Diameter (O.D.) and the im­
cracks. Use the following dye penetrant components to peller bore Inside Diameter (I.D.). The clearance must
inspect the impeller: not be less than 0.0005” or greater than 0.0025” .
- Manufacturer: Magnaflux d. Slide the impeller on the shaft.
- Brand Name: “ SpotCheck” e. Add shims as necessary to line up the innermost dis­
- Penetrant Number: SKL-HF/SKL-S charge surface of the impeller with the diffuser plate as
- Developer Number: SKVD-NF shown in Figure 8 . The surfaces must be level with one
- Cleaner Number: SKC-NF another or at most, the impeller surface may be no more
Discard the impeller if cracks are found. Do not attempt than 0.005" above the diffuser plate surface.
to repair any cracks in the impeller. Examine the seal f. Insert the impeller key and install the impeller.

8.3-2
 c o w i ^ T T v T; , HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
U se FEBRUARY 1982

9- Measure the impeller nose runout. Mount th d o ia l indi­ impeller is 0.003". If the runout exceeds 0.003” the
cator as shown in Figure 9. Also check the runout at the
shims should be inspected for burrs or foreign material
very end of the shaft to insure that the shaft is true.
between the shims. Refer to Figure 10. Recheck the
Rotate the impeller/shaft by hand and observe the dial runout. Replace the impeller if runout is still excessive.
indicator. The maximum allowable nose runout on the

FIGURE 7 - Third Stage Impeller FIGURE 8 - Aligning Third Stage Impeller Discharge with
Diffuser Plate

8.3-3
 C O N F ID E N T IA L '
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
Use R e stricte d
FEBRUARY 1982 by Cour t Order
sanded with sandpaper to achieve the proper clear­
4. Install the third stage suction cover casting. Align the scribe
ance. Refer to Figure 12.
marks which were made during disassembly. See Figure 11.
e. Tighten the seal bolts to 24 ft.-lbs. torque and recheck
a. Thoroughly clean all dirt, debris, oxidation, etc., from the
the radial clearance. Readjust as necessary.
cover. Pay particular attention to the O-ring groove. Also
f . Bend the tabwashers to secure the bolts. See Figure 13.
clean the mating discharge volute surface.
6 . Install the third stage inlet vane assembly. Refer to Figure
b. Lubricate the new O-ring with Lubriplate or equivalent.
14.
c. In se rt the new O -rin g and p o sitio n the co ve r fo r
a. Thoroughly clean all surfaces of the assembly. If any of
assembly.
the inlet vane assembly components are worn exces­
d. Use guide rods as in the disassembly to guide the cover
sively, replace them.
into position.
b. This assembly may be lifted into position by two men, or
e. Insert the retaining bolts and tighten to 150 ft.-lbs.
a nylon sling or cable through the center of the assembly
torque.
can be used to lift the component.
5. Install the impeller nose seal.
c. Install the assembly with the TOP in the proper position.
a. Thoroughly clean the seal of all dirt, debris, oxidation,
Position the inlet vanes on the suction cover casting and
etc. Inspect the labyrinth seal grooves for wear, debris,
secure with 1/4” -20x3/4” flathead screws. See Figure
etc. Replace the seal if cracked, warped or worn beyond
15.
clearance tolerances.
d. With the inlet vane assembly installed, the vane oper­
b. If the old seal is reused, make sure the TOP is in the
ator arm will be visible through the tang operator hole.
same location.
See Figure 16.
c. Install the seal and lightly tighten the bolts with the
e. Tighten the screws to 6 ft.-lbs. torque. The head of these
tabwashers.
screws must not protrude into the diffuser passage. See
d. Set the radial seal clearance according to Table 1. If the
Figure 15.
new seal clearance is too tight, the seal may be lightly

F IG U R E 13 - B e n d in g T a b w a s h e rs F IG U R E 14 - T h ird S ta g e In le t V a n e A s s e m b ly In s ta llatio n

8.3-4
 C O m O T T IA B
HERMETIC CENTRAVAC SERVICE GUIDE
Use Res.ox'ioted HCTV-SG-2
^ _ g o u rt_ O rd e r FEBRUARY 1982

FIGURE 15 - Tightening Third Stage Inlet Vane Assembly FIGURE 16 - Inlet Vane Operator
Retaining Screws

a. Thoroughly clean the plate and mating surface to

7. Install the third stage vane operator assembly.
remove all dirt, debris, oxidation, etc.
a. Clean the operator assembly.
b. Using guide rods, move the diffuser plate into position.
b. Insert the vane operator into the suction cover and con­
Use the second stage impeller to center the plate. See
nect to the inlet vanes. Use a new gasket on the oper­
Figure 18. The diffuser plate may be lifted by a nylon
ator flange. Refer to Figure 16.
sling or cable through the center of the assembly.
c. Tighten the retaining bolts to approximately 60 ft.-lbs.
c. Secure the diffuser plate with socket head capscrews
torque or until the gasket just begins to extrude from be­
and tighten to 24 ft.-lbs. torque. Refer to Figure 19.
tween the flanges.
9. Install the impeller spacer. Refer to Figure 20.
d. Operate the vane assembly with the external operator to
a. Thorougly clean the spacer.
v e rify th a t th e a s s e m b ly w o rk s and is p ro p e rly
b. Lubricate the spacer with Lubriplate or an equivalent
positioned.
lubricant.
8 . Install the second stage diffuser plate. Make sure the TOP is
c. Install the spacer with the pull-off holes away from the
in the proper location.
motor. See Figure 2 1 .

FIGURE 17 - Tightening Inlet Vane Operator Retaining Screws FIGURE 18 - Guide Rods Installed for Third Stage Diffuser
Plate Installation

8.3-5
HERMETIC CENTRAVAC SERVICE GUIDE ^ T F ID E IT T T A E

HCTV-SG-2 U se H esi:ri oted

FIGURE 19 - Third Stage Diffuser Plate Installed FIGURE 20 • Impeller Spacer Installation

10. Install the second stage shaft seal. e. If a new seal is used and the clearance is too tight the
a. Thoroughly clean the seal and inspect the labyrinth seal may be lightly sanded with sandpaper to achieve
grooves for excessive wear. the required clearance.
b. Install the seal with the TOP in the correct position. f. After the proper clearance is set, tighten the retaining
Refer to Figure 20. bolts to 24 ft.-lbs. torque.
c. Secure the seal loosely with bolts and tabwashers. g. Recheck the seal clearance.
d. Set the seal clearance at 0.018” minimum and 0.024” h. Bend the tabwashers to secure the bolts. See Figure 23.
maximum radial clearance. See Figure 22.

FIGURE 21 - Spacer Pull-Off Holes FIGURE 22 - Measuring for Correct Second Stage Shaft Seal
Clearance

8.3-6
 C O N F ID E N T IA L HERMETIC CENTRAVAC SERVICE GUIDE
Use R estricted HCTV-SG-2
FEBRUARY 1982
1SJLCourt Order
TABLE 1 - Clearances
IMPELLER SEAL RING CLEARANCE
CGMPR SIZE 1ST STG 2ND STG 3RD STG
013 THRU 014 .0295/.0195 .024/0165 .024/.0165
015 THRU 020 .0295/.0195
f
022 .0295/0195
023 THRU 032 .033/022 T
035 .033/. 022
1
036 THRU 045 .0365/.0245
___ !'
049 THRU 050 .033/.022
1
055 f .0365/.0245
056 THRU 071 .043/0285
079 THRU 080
» ? .0365/0245
089 THRU 112 .046/031 043/.0285 ♦
125 * " ___t .043/0285
SEAL TO SHAFT .0005/.003 ALL SIZES

FIGURE 23 - Bending the Tabwashers

11. Install the second stage impeller.
a. Thoroughly clean the impeller and compressor shaft. In­ d. Install the second stage suction cover. Match the scribe
spect the impeller for wear, cracks, warpage, etc. Exam­ marks on the outside of the cover with the scribe marks
ine the seal surface for scratches. If there are any on the outside of the third stage suction cover. These
scratches deeper than 1/16” , impeller replacement is marks were made during disassembly to aid in the
recommended. Use dye penetrant as described in Step proper realignment of the components during reas­
3. sembly. See Figures 26 and 27.
b. Lubricate the impeller bore or shaft with Lubriplate or 1. Thoroughly clean all surfaces. Pay particular atten­
equivalent lubricant. tion to O-ring grooves.
c. Add shims as necessary behind the impeller to line up 2. Lubricate the new O-ring with Lubriplate or an
the innermost discharge surface of the impeller with the equivalent lubricant.
diffuser plate surface. The surfaces must be level with 3. Lift the suction cover and using guide rods, move it
one another or at most, the impeller surface may be no into position.
more than 0.005” above the diffuser plate surface. See 4. Install the cover with the new O-ring and tighten the
Figure 24. Insert the key and install the impeller. See retaining bolts to 150 ft.-lbs. torque.
Figure 25.

FIGURE 24 - Aligning Second Stage Impeller with Diffuser FIGURE 25 - Impeller Key and Impeller
Surface

8.3-7
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 rO ' T T F ir^ T T IA r

FIGURE 26 - Second Stage Suction Cover Being Installed FIGURE 27 - Second Stage Suction Cover In Place

12. Measure the impeller nose runout by mounting a dial indi­ d. Tighten the bolts to 24 ft.-lbs. torque and then recheck
cator as shown in Figure 28. Rotate the impeller by hand and the clearance. Readjust the clearance as necessary to
observe the dial indicator. The nose runout tolerance is achieve the proper clearance. If the clearane is too tight,
0.003” maximum. If the runout exceeds 0.003” , inspect the the seal m ay be lig h tly sanded to achieve proper
shims for burrs or debris between the shims. Recheck the clearance.
runout. Replace the impeller if the runout is still excessive. e. Bend the tabwashers to secure the bolts.
Refer to Figure 29. 14. Install the second stage vane shroud. See Figure 31.
13. Install the second stage impeller nose seal. Refer to Figure a. Thoroughly clean the shroud and all mating surfaces.
29. b. This component may be lifted using a nylon sling or
a. Thoroughly clean the seal and examine the labyrinth cable through the center of the shroud. Lift the shoud up
grooves for excessive wear. and on to the guide rods.
b. Install the seal with the TOP properly positioned. Lightly c. Install the shroud with the TOP correctly positioned.
tighten the 3/8” -16x1” bolts with tabwashers. d. Tighten the 1/4” -20x3/4” flathead screws to 6 ft.-lbs.
c. Set the seal clearance according to Table 1. Refer to torque. The heads of these screws must not protrude
Figure 30. into the diffuser passage. Also, note that these inlet
vanes are fixed and are not adjustable.

F IG U R E 2 8 - M e a s u rin g S e c o n d S ta g e Im p e lle r N o s e R u n o u t

8.3-8
 C O N FID E N TIA L^ HERMETIC CENTRAVAC SERVICE GUIDE
U se ResGiluted HCTV-SG-2
Vv-rr P m ir 'V H ^ rlo r* FEBRUARY 1982

NOTE: THE FOLLOWING PROCEDURE IS FOR CVHE

15. Install the first stage diffuser plate. Refer to Figure 32. 089 THROUGH 125 UNITS ONLY.
a. Thoroughly clean the plate and all mating surfaces.
b. Use a rope or nylon sling to lift the plate and use guide Refer to Figure 62, Detail a, Page 8.3-17 of this Section.
rods to move the vane plate into place with the TOP a. Install the spacer ring. (CVHE 089 and 090 units only).
properly positioned. See Figure 33. b. Install the spacer sleeve (CVHE 089 through 125).
c. Use the first stage impeller to correctly position the dif­ c. Install the spacer interstage seal.
fuser plate. See Figures 34 and 35. Use feeler gauges to d. Install the shims and second stage impeller.
center the diffuser plate with respect to the impeller. e. Install the spring washer, lockwasher, and locknut.
Obtain the same clearance all the way around the Tighten the locknut until solid metal-to-metal contact is
impeller. achieved and so that a lockwasher tab aligns with the
d. With the plate in the proper position, tighten the socket slot in the locknut.
head capscrews to 24 ft.-lbs. torque. f. Proceed with Step 22, Page 8.3-12.

F IG U R E 32 - S e c o n d S ta g e D iffu s e r P la te In s ta lla tio n F IG U R E 33 - S e c o n d S ta g e D iffu s e r Plate in P o sitio n

8.3-9
HERM ETIC CENTRAVAC SERVICE GUIDE C O T T F IT V ^ T T ! A l

HC TV-SG -2 U s e He:.- i'5d

FIGURE 34 - Centering the Diffuser Plate FIGURE 35 - Centering the Diffuser Plate

16. Install the impeller spacer. b. Install the seal with the TOP correctly positioned. Lightly
a. Thoroughly clean the spacer. tighten the bolts with tabwashers. Refer to Figure 38.
b. Lubricate the spacer with Lubriplate or an equivalent c. Set the seal clearance at between 0.018" minimum and
lubricant. 0.024” maximum radial clearance. See Figure 39.
c. Install the spacer with the pull-off holes facing away d. Tighten the bolts to 24 ft.-lbs. torque and recheck the
from the motor. See Figure 36. seal clearance. Readjust the clearance as necessary. If
17. Install the first stage shaft seal. Refer to Figure 37. a new seal is being used and the clearance is too tight,
a. Thorougly clean the seal and all mating surfaces. Exam­ the seal may be lightly sanded with sandpaper to
ine the labyrinth grooves for excessive wear. If the seal achieve the proper clearance.
was found to be outside of the specifications given in e. Bend the tabwashers to secure the retaining bolts.
Table 1 during disassembly, replace the seal.

F IG U R E 3 6 - Im p e lle r S p a c e r R e ta il S h o w in g P u ll-O ff H o les

8.3-10
 confidential ^
HERMETIC CENTRAVAC SERVICE GUIDE
Use R estricted HCTV-SG-2
Court Order FEBRUARY 1982

FIGURE 38 - First Stage Seal Installation FIGURE 39 - Measuring First Stage Seal Clearance

18. Install the first stage impeller. Refer to Figure 40. c. Add shims as necessary to align the inner discharge
a. Thoroughly clean the impeller and compressor shaft. In­ surface of the impeller with the first stage diffuser plate
spect the im p e lle r fo r wear, cracks, warpage and surface. The surfaces must be level with one another or
scratches on the seal surface. If there are scratches at most, the impeller surface may be no more than
deeper than 1/16” present, replacement of the impeller 0.005” above the diffuser plate surface. Refer to Figures
is recommended. Use dye penetrant as described in 41 and 42.
Step 3. 19. Install the spacer.
b. Lubricate the impeller bore or the shaft with Lubriplate or
an equivalent lubricant. Insert the key and install the 20. Install the spring washer.
impeller.

8.3-11
 C 0 rc F I!^ T
J 7 IA i;_

HERMETIC CENTRAVAC SERVICE GUIDE Uso R e s t r i c t e d .

HCTV-SG-2 hy Coart Urdey
FEBRUARY 1982
21. Install the lockwasher and locknut. Refer to Figure 43. during disassembly, with the scribe marks on the mating
a. Tighten the locknut to achieve solid metal-to-metal con­ surfaces. This will insure proper alignment when the
tact and so that a lockwasher tab aligns with the slot in compressor is completely reassembled,
the locknut. See Figure 44 which shows the locknut d. Tighten the retaining bolts to 150 ft.-lbs. torque.
being loosened. 23. Measure the first stage impeller nose runout. Refer to
b. Bend over the lockwasher tab into the locknut slot. Figure 47.
22. Install the first stage suction cover. Refer to Figure 45. a. Mount the dial indicator on a solid surface.
a. Thoroughly clean the suction cover and mating sur­ b. Rotate the impeller by hand and observe the dial indi­
faces. Also clean the O-ring grooves. cator. The runout must not exceed 0.003” . If the runout
b. Lubricate the new O-ring with Lubriplate or an equiv­ exceeds the tolerance, inspect the shims behind the im­
alent lubricant and install in the suction cover. peller for burrs or debris between the shims. Recheck
c. Using the tool illustrated in Figure 46 and guide rods, the runout. If the runout is still not within tolerance, it is
move the suction cover into position. Align the scribe recommended that the impeller be replaced.
marks on the outside of the cover which were made

FIGURE 42 - Aligning Impeller Discharge with Diffuser Plate FIGURE 43 - Lockwasher and Locknut

F IG U R E 4 4 - A lig n in g L o c k n u t S lo t w ith L o c k w a s h e r T ab F IG U R E 4 5 - S u c tio n C o v e r Ins ta llatio n

8.3-12
 CONF J D I2 P
HERMETIC CENTRAVAC SERVICE GUIDE
U se J t e s u i ^ t e $_ HCTV-SG-2
J jy C o u rt p r ( i, t j £ FEBRUARY 1982

FIGURE 46 - Suction Cover Lifting Attachment FIGURE 47 - Measuring Impeller Nose Runout

24. Install the first stage impeller nose seal. tighten the bolts with tabwashers. See Figure 48.
a. Thoroughly clean the seal and all mating surfaces. Ex­ c. Set the seal clearance according to the specifications
amine the labyrinth grooves for excessive wear. If the given in Table 1.
seal did not meet specifications when disassembled d. Tighten the 3/8” -16x1” bolts to 24 ft.-lbs. torque.
(See Table 1) it is recommended that the seal be e. Recheck the seal clearance and readjust as necessary.
replaced. f. Bend the tabwashers to secure the bolts.
b. Install the seal with theT O P correctly positioned. Lightly

FIGURE 48 - Tightening First Stage Impeller Nose Seal Retaining FIGURE 49 - Measuring First Stage Impeller Nose Seal Clearance
Bolts

8.3-13
HERMETIC CENTRAVAC SERVICE GUIDE CONFIDENT IAE_
HCTV-SG-2 Use Restricted
FEBRUARY 1982 b.v Court Order
25. Install the first stage inlet vanes. assembly and then slide the assembly into the suc­
a. Thoroughly clean the inlet vane assembly. Inspect the tion cover. This procedure requires two men.
inlet vane assembly components for excessive wear or c. Position the inlet vane assembly so that when inserted
damage. If it is necessary to replace any of the com ­ into the suction cover the tang operator connects with
ponents, refer to Section 8.5 of this service guide. the proper drive vane. Refer to Figure 51.
b. Insert the assembly into the suction cover. This may be d. Secure the assem bly with three 5/16 ” -18x3/8” set
accom plished using fixture sim ilar to that shown in screws. See Figure 50.
Figure 50, or it may be done using the following alter­ 26. Insert the tang operator assembly. Refer to Figure 52.
nate procedure. a. Clean the assembly thoroughly.
1. Slide one end of a 5 foot section of heavy duty pipe b. Lubricate the new O-ring with Lubriplate or an equiv­
between the vane blades at the top of the vane alent lubricant.
housing. c. Engage the tang with the vane assembly in the suction
2. Position a chain or sling around the pipe as close to cover.
the housing as possible. d. Secure with three 5/16"-18x1 ” capscrews. Tighten to 14
3. The pipe is used as a fulcrum to lift the weight of the ft.-lbs. torque. See Figure 53.
e. Check for smooth and free inlet vane movement.

FIGURE 50 - First Stage Inlet Vane Assembly Installation

F IG U R E 5 2 - T a n g O p e ra to r A s s e m b ly

8.3-14
 CONFIDENTIAL HERMETIC CENTRAVAC SERVICE GUIDE
Use Restricted HCTV-SG-2
FEBRUARY 1982
by Court Order
27. Install the suction elbow. Refer to Figure 54. 29. Reattach the control panel support bracket. See Figure 55.
a. Remove the protective covers which were installed 30. Reconnect the suction cover drain line. Refer to Figure 56.
during disassembly. 31. Reinstall and reconnect the economizer. See Figure 57.
b. Thoroughly clean the suction elbow and all mating sur­ Clean all mating surfaces prior to reassembly. Use new
faces. Pay particular attention to all gasket surfaces and gaskets.
O-ring grooves. 32. Reconnect the inlet vane actuator and linkages. Move the
c. Lubricate the new O-ring with Lubriplate or an equiv­ linkages by hand to assure proper operation.
alent lubricant and then insert in the O-ring groove. 33. After the compressor is completely reassembled, the Cen-
d. The suction cover may be lifted using a nylong sling as TraVac must be restarted as if it were the initial startup of a
shown in Figure 54. Set the suction elbow in place and new machine. This includes pressure testing the chiller,
tighten the retaining bolts to 150 ft.-lbs. torque. evacuation, and charging and all other procedures included
28. Reconnect the oil sump vent line. Use a sweat coupling to in an initial startup. Refer to Section 4.0 for details.
silver solder the line together.

FIGURE 54 - Suction Elbow Installation FIGURE 55 - Control Panel Support Bracket

FIGURE 56 - Suction Cover Drain Line FIGURE 57 - Installing the Economizer

8.3-15
 COT^TDEITTIAS
HERMETIC CENTRAVAC SERVICE GUIDE Use stric te d
HCTV-SG-2 hv Court Qr&ey
FEBRUARY 1982

RGURE 58 - Inlet Vane Actuator Linkage Assembly

FIGURE 61 - Attaching Lever Assembly to Inlet Vane Actuator

Motor
8.3-16
 'CONFIDENT I AT HERMETIC CENTRAVAC SERVICE GUIDE
Use R e s tric te d HCTV-SG-2
bv Court Order. FEBRUARY 1982

LOCKNUT
LOCKWASHER
SPACERS SPRINGWASHER
DETAIL A - CVHE 089 THROUGH 125 UNITS ONLY

TANG
OPERATOR
'ASSEMBLY
-HEX HEAD
kS—CAPSCREW

SETSCREW

THIRD STAGE
DIFFUSER PLATE

H P Y H P A H O foxrrn si* *? »ss* fw inn tt* cr

nCA n t n u , scb(« must not ppctbu* into oiffuse*

CAPSCREW '
CD v in e s t
with lever in th e closed
THIRD
. ’ ” .
STAGE POSITION AXIAL E
take up
f Ti 5 T E N SET SCREW . USING PILOT
m
no p la t

SUCT WON COVERU M0Lf ” aveB *s ALEVER

D'A THRU CUID4t. SH
0,ILL
AFT.
INSERT ROl l PIN ( it e m 2751 t REMOVE
SET SCREW
--H *J " ]'P K ■ » i(t FUN-0U1 00T'

F IG U R E 62 - C u ta w a y V ie w , M o d e l C V H E C o m p re s s o r FWB LLW

8.3-17
 'CCTTFIDSUTIAr
Use R estricted

LITERATURE FILE NO. HCTV-SG-2

C O M PR ES SO R M O TO R
R E M O VA L SECTION
AN D R EP LA C E M E N T 8.4
FEBRUARY 1982
Motor Rem oval
This section describes the procedure for removal and replace­
1. Disassemble the compressor. Refer to Section 8 . 2 o f this
ment of the Model CVHE CenTraVac motor. The procedure ap­
Service Guide for the procedure.
plies to all motors regardless of the compressor size.
2. Disconnect the oil supply and return lines at the thrust end of
WARNING: Before working on thla equipment always discon­ the motor. Also disconnect the internal oil supply line to the
nect all electrical power. Failure to do so may result In serious compressor shaft end roller bearing. Refer to Figures 1 ,2 ,3
personal Injury or death due to electric shock. _____ and 4. The internal line may be disconnected by unsweating
the coupling as shown in Figure 4.

FIGURE 1 - Removing Paint From Oil Drain Line FIGURE 2 - Cutting the Drain Line

F IG U R E 3 - C u ttin g an O il S u p p ly Line F IG U R E 4 - U n sw e a tin g th e In tern al O il S u p p ly L in e

'TH E TRANE COMPANY 1982

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A.

8.4-1
 TTOiTPXDTCTTTXATT
HERMETIC CENTRAVAC SERVICE GUIDE U 0 3 iu ; 3 "0 ^
HCTV-SG-2 by Ccurt Order
FEBRUARY 1982
3. Disconnect the refrigerant supply and drain lines from the 6 . Attach lifting slings to the motor. See Figure 8 .
motor. The flanges are simply unbolted from the motor. See 7. Remove the bolts which secure the back bracket as shown in
Figures 5, 6 and 7. Figure 7.
4. If equipped, remove the factory mounted motor starter from 8 . Loosen and remove two of the bolts which secure the motor
the motor terminal casting. Remove and mark all motor to the third stage volute casing. Insert two guide pins in place
power leads and interconnecting wiring of the factory moun­ of the bolts.
ted starter. If a remote starter is used, mark and disconnect 9. Remove the remaining bolts and withdraw the motor straight
the motor power leads and remove the conduit box. out until the shaft clears the volute casing. Refer to Figures 8
5. Mark and remove the m otor winding temperature sensor and 9.
leads.

FIGURE 5 - Motor Cooling Refrigerant Supply and Drain Lines FIGURE 6 - Refrigerant Supply Flange

F IG U R E 7 - R e frig e ra n t D rain F la n g e an d B a c k B ra c k e t F IG U R E 8 - L iftin g th e M o to r C le a r o f th e C o m p re s s o r

8.4-2
 'COITFIDEITTIAE HERMETIC CENTRAVAC SERVICE GUIDE
Use lie s w icted HCTV-SG-2
fry Court. Order FEBRUARY 1982

FIGURE 9 - Removing Motor

If the motor is to be reused, or if a replacement motor will be in­ during storage and/or transit. A megger test or stator megger
stalled, adhere to the following guidelines:1 resistance measurement made with a Megohm Insulation
tester should be taken between the motor winding and the
1. Motor Storage - If the original motor is to be reused or if a new
motor housing. A 500 volt DC megohm insulation tester is
motor has been received as a replacement, it must be stored
recommended for this test. The insulation resistance reading
in a clean, dry location, protected from dirt and temperatures
of the winding should be above the minimum value shown on
below 40 F. It must also be protected from extreme variations
the curve in Figure 10. The motor winding insulation mea­
of temperature and humidity. During storage, the winding
surements are to be taken at or corrected to 6 8 F.
must be protected so as to keep the temperature of the motor
above the dewpoint of the surrounding air. The oil lubricated After testing, discharge the motor winding by touching the
roller bearings are run-in tested at the factory with a rust pre­ motor terminal studs with a ground wire connected to the
ventive oil which protects the bearing and bearing structure motor housing.
from corrosion. (New motors only). Bearing oil is drained
before shipment. To protect the bearing and bearing struc­ If the insulation resistance reading is less than the minimum,
ture from corrosion during storage (all motors), one pint of the motor must be dried out prior to installation into the Cen-
rust preventive oil, such as Texaco Preservative Oil No. 30, TraVac chiller.
or equivalent should be added every 90 days to each bearing 4. Drying of Wet Motor Winding - The motor winding may be
while rotating the shaft by hand. For storage beyond 12 dried out by applying a single phase voltage of approxi­
months, contact the factory for special instructions concern­ mately 5% of the motor nameplate voltage. For six terminal
ing special precautions required. design low voltage motors, the motor is connected per the
2. Mechanical Inspection - Visually inspect the motor exterior nameplate for across-the-line starting. The single phase
for rust. If external rust is present, remove the shaft exten­ voltage is then to be applied to terminals T 1 and T2. For three
sion bearing bracket (refer to Section 8.5 for procedure) to terminal high voltage motors, apply the single voltage be­
inspect the motor interior for rust. All rust, particularly of tween T 1 and T2. The time element required to dry out a
motor interior and motor shaft extension/bearing bracket, winding cannot be predicted. Dry-out time is dependent
must be removed prior to installation. Also, rotate the shaft upon the size of the motor and the amount of moisture the
by hand to verify free rotation while adding oil to each bearing winding has absorbed. Generally, the drying out process is
oil inlet. The bearings are designed for pressure lubrication, to be continued until the insulation resistance ground readi­
therefore it is imperative that the oil pressure system be con­ ngs become fairly constant. It must be remembered that suc­
nected to the motor and proper bearing oil pressure estab­ cessive insulation resistance readings must be made at the
lished before the motor is started. same temperature since considerable numerical reading
3. Electrical Test - Megger test the motor winding insulation to variations will be obtained when such readings are taken at
ensure that the motor winding has not absorbed moisture different temperatures.

8.4-3
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

Use^jTestrictefl
Py Court ni-rfrr

LU
X
z
LU
X
X
<
LL

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LU
LU
X
O
UJ
O
Z

X
3
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X
LU
X

L— «'

10 20 30 ' 40 ' 50” 60

INSULATION RESISTANCE IN MEGOHMS

FIGURE 10 - Temperature Vs. Insulation Resistance

tings with threaded connections.

CAUTION:DonotHighPotentialTestRepeatedHighPoten­ 3. Install the motor on the third stage volute using the reverse
tialtests drasticallyreducemotorlife.All motors are High Po­ procedure of disassembly. Connect only the bearing oil
tential testedat thefactoryat twicethe ratedvoltageplus supply lines at this time.
1000volts. PerNEUAMG1. ________________________ 4. Measure the oil flow rate through the motor bearings. This is
accomplished as follows:
CAUTION:Donotapptyanyvoltagetothemotorwhileit Is a. Remove the oil from the sump and recharge the sump
underavacuum.If themotorIsundervacuum,DONOT: with the proper amount of new oil which will not be mixed
1. Highpotential test with refrigerant. Energize the oil sump heater to bring
2. Idagger test(Insulationresistancetest) the oil temperature up to 120 F.
3. A pplysinglephasevoltageto themotor windingfor b. Once the oil is properly heated the oil pump is energized
drying the w in d o w by setting the purge system switch to the MANUAL posi­
4. Applythreephaselinevoltage tion. This energizes the purge unit as well as the oil
pump. The purge unit requires a 2 GPM water flow rate
Ifanyoftheseoperationsare donewhilethe motorisunder with a 2 foot pressure drop. Also, the supply water tem­
vacuum,seriousdamagetothemotormayresult________ perature must be 80 F or less.
c. The oil pressure regulating valve must be set to main­
Motor Installation tain a constant 15 psig oil pressure.
1. Measure the motor winding insulation resistance according d. The quantity of oil leaving the motor bearings should be
to the preceeding procedures. measured for a period of one minute. The approximate
2. If the motor is to be replaced with a new motor, rem oveallthe oil flow rate from each bearing should be 1.0 to 3.0 pints
lubrication supply and drain line fittings from the old motor per minute. (Sight glasses are provided in each return
and install them on the new motor. Use Teflon tape on all fit­ line for visually checking the oil flow of a running chiller).

8.4-4
 HERMETIC CENTRAVAC SERVICE GUIDE
Use -Rustrictea HCTV-SG-Z
tv C o u r i_ i!E & £ £ FEBRUARY 1982

The amount of oil flow to each bearing is determined by an particular size orifice for the proper oil flow rate through the
orifice which is part of the oil inlet fitting on the compressor bearing. Refer to Table 1 which lists the appropriate orifice
motor. for each bearing.

There are four basic bearings which are used with the CVHE 5. After the oil flow rates through the motor bearings have been
compressor motor. On the compressor end (opposite the ter­ determined to be acceptable, the oil drain lines may be
minal end) there are two different size bearings which may reconnected. Use slip couplings and silver solder to join the
be used, depending upon the motor. A bearing with an inside lines back together.
diameter of 5.1 inches may be used or a bearing with an 6 . Reconnect the motor cooling refrigerant supply and drain
inside diameter of 5.9 inches may be used. Again, the size lines at the motor.
bearing is dependent upon the motor specifications. At the 7. Reassemble the compressor according to the procedures
terminal end (thrust end) there are also two different size given in Section 8.3 of this Service Guide.
bearings which may be used, depending upon the motor 8 . R econnect the m otor w inding therm ostat tem perature
specifications. At this end a 2 inch inside diameter bearing or sensor leads.
a 3 inch inside diameter bearing may be used, depending 9. Reconnect the motor power supply when ready and restart
upon the particular motor. Each of these bearings requires a the chiller according to the procedure given in Section 4.0,
“ Start-Up” .

TABLE 1 - Bearing Orifice Requirements

BEARING ORIFICE
5.1" I.D. (TERMINAL END) 0.067”
5.9" I D. (TERMINAL END) 0.082”
2.0" I.D. (THRUST END) 0.0935”
3.0" I.D. (THRUST END) 0.116"

FWB/LLW

8.4-5
 LITERATURE FILE NO. HCTV-SG-2
M O D EL CVH E C E N TR A V A C
C O M P R ES S O R M O TO R SECTION
D IS A S S EM B LY
AN D R EA S S EM B LY
8.5
FEBRUARY 1982
This section describes the disassembly and reassembly of the the motor must be disassembled first if the entire motor is to be
Model CVHE CenTraVac compressor motor. Before the com­ disassembled. The thrust bearing assembly can be replaced
plete motor is disassembled it is necessary to disassemble the from the opposite drive end of the motor without affecting the
compressor. Refer to Section 8.2 compressor.

NOTE: Figures 91 and 92, found on pages 25 and 26, are cut­ NOTE: The motor bearings and rotor can be changed without re­
away and exploded views of the motor. Refer to these during moving the entire motor. The following section describes motor
disassembly and reassembly of the motor. disassembly with the motor mounted on the chiller.

NOTE: The following instructions identify motor orientation for WARNING: Before workingonIftte oranyelectricalequip­
the procedures. DRIVE END refers to the shaft extension end or ment,alwaysdisconnect*11electricalpower.Failuretodoso
compressor end of the motor. OPPOSITE DRIVE refers to the rrmyraaultinaerlouepenonallnjuryordeatttcauaadbyahc-
electrical terminal end of the motor. The compressor drive end of trteahockorbecomlwantanghdbtrotatingaqulpmmt.
D IS A S S E M B LY _________________________________________
1 . Disconnect the drive end motor bearing supply line. Unsweat centerline and then insert two guide rods approximately
the line near the volute casting as shown in Figure 1 . 1 2 inches long.

2. Using large snap ring pliers, remove the bearing snap ring b. Remove the remaining bearing bracket bolts.
shown in Figure 2.
c. Insert four 6 inch bolts into the jack-out bolt holes in the
3. Remove all bolts securing the inner seal and back bearing bearing bracket.
race retaining ring. See Figures 3 and 4. Remove the re­
d. Tighten the bolts evenly to push the bearing bracket
taining ring by carefully sliding it off the shaft.
squarely away from the motor until the bearing and
4. Remove the drive end motor bearing bracket. The entire spacer are past the pressed-on area of the shaft. See
drive end bearing will also be removed. The procedure is as Figure 6 . The bearing bracket can rest on the guide
follows (Refer to Figure 5): rods. Remove the bearing and spacer assembly. Refer
a. Remove two bolts 180 degrees apart on the horizontal to Figure 7.

FIGURE 1 — Unsweating the Internal Oil Supply Line FIGURE 2 — Snap Ring

CTHE TRANE COMPANY 1962

COUFir" ;; t ijt r,
COMMERCIAL AIR CONDITIONING DIVISION Use Heatriotdj
LA CROSSE, WISCONSIN 54601 8.5-1
PRINTED IN U S A
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

FIGURE 4 — Drive End Bearing Race Retaining Ring

FIGURE 5 — Drive End Bearing Bracket FIGURE 6 — Drive End Bearing and Spacer

FIGURE 7 — Drive End Bearing and Spacer

8.5-2
 HERMETIC CENTRAVAC SERVICE GUIDE
TAL HCTV-SG-2
Ugs T '' FEBRUARY 1982
by Coui l ,
e. Attach an overhead lifting rig to the bearing bracket. g. Remove the outer bearing race by carefully prying it
Attach with a clevis pin to the bracket and remove slowly from the bearing bracket. This is not a pressed fit, how­
from the shaft. Remove the O-ring and bearing cap. ever, care must be taken so as not to damage the race.
Figure 8 illustrates the lifting support and the motor side Replace the bearing if the race is damaged. Figures 9
of the bracket with bearing cap removed. The rotor will and 1 0 illustrate the bearing parts.
rest on the stator.
h. Remove the inner bearing cap and gasket from the
f. Protect the rotor shaft to prevent damage while the shaft.
bearing bracket is removed.

FIGURE 8 — Drive End Inner Bearing Cap FIGURE 9 — Assembled Drive End Bearing

8.5-3
HERMETIC CENTRAVAC SERVICE GUIDE Use Restricted
HCTV-SG-2
fry r .n u r t O r d e r
FEBRUARY 1982
5. Using a tubing cutter, cut the oil supply and drain lines on the 9. Remove the opposite drive end bearing bracket. Refer to
opposite drive end of the motor. Before cutting the lines, Figures 15, 16, 17 and the following procedure:
sand all paint from the area where the cut is to be made. This a. Remove two bolts, 180 degrees apart on the horizontal
will allow brazing the lines together during reassembly. Be centerline and insert two guide rods approximately 6
sure to sand the paint off before making the cut to prevent the inches long.
entry of dust into the oil lines. Cover the open pipe ends to
prevent the entry of dirt, debris and moisture. Refer to Figure b. Remove the remaining bearing bracket bolts.
11 . c. Insert three bolts in the jack-out holes to pull the bearing
6 . Remove the bearing cover with the sight glass. See Figure bracket evenly away from the motor.
12.
d. Move the bracket out far enough so that a clevis can be
7. Release the bearing cap by removing the outer diameter attached. Support and remove the bracket from the
bolts. See Figure 13. motor.
8 . Remove the bearing race retaining ring bolts (inner di­
ameter) and remove the retaining ring. Refer to Figure 14.

FIGURE 11 — Removing Paint from Oil Supply Line at Opposite

Drive End Bearing

8.5-4
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-S6-2
FEBRUARY 1982

RGURE 15 — Bearing Bracket FIGURE 16 — Bearing Bracket Removal

FIGURE 17 — Bearing Bracket

1 0. Remove the thrust bearing shaft locknut. See Figures 18 and CAUTION: (1} Do not put the straight state of the puller
19. Bend the lockwasher tab back, then loosen the locknut jaws against the bearing-this wMscore the motor shaft.
with a spanner and unscrew from the shaft. The threads are Do not attampt to pull toe thrust bearing assembly
right-hand. from the abaft by puMIng on the roPera, roller cege as­
11. Remove the spacer — this is not a keyed or press fit. See sembly, ortho tapered OUp. This vrMresult k> beating or
Figure 18, page 8.5-6.
theft damage. (3) Examine the puller carefully during re­
moval to Insure that the puUer te lined up squarely with
1 2. Remove the front end thrust bearing using a puller. The fol­ toe motor shaft Failure to do so may reeutt In b^ury to
lowing combination of tools may be used for pulling the thrust personnel ontf damage to the puller, bearing or ahaft. (4)
bearing: Always urn shaftprotector Insert on the end of the puller
Owatonna Tool Company, Inc. as a bearing surface to avoid damage to the motor shaft.
Model PP30 manual bearing pull (PPH30 Hydraulic) (5) Never attempt to heat the bearings while Installed on
Model AP13 jaws the motor abaft at an aid to removal. Machine damage
Model KSP150 shaft protector adaptor m a y r e s u l t . __________ _______ _________
Attach the puller with bevelled edge of the jaws against the
backside of the inner thrust bearing cone. See Figures 20 ,2 1
and 2 2 .

8.5-5
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

FIGURE 18 — Thrust Bearing Locknut FIGURE 19 — Use of Spanner Wrench

8.5-6
 CONFIDENTTAII HERMETIC CENTRAVAC SERVICE GUIDE
Use Hea-uricted HCTV-SG-2
by Court Q r ( i e r FEBRUARY 1982
13. Insure that the puller assembly is lined up squardTy orTthe 14. Remove the inner bearing cap and gasket from the motor
motor shaft while removing the bearings. This should be shaft. Notice the position of the oil drain hole at the bottom of
checked several times. Cover the puller shaft with rags to the bearing cap. See Figures 24 and 25.
prevent bearing damage when the bearing cones pull free of
the motor shaft. Continue pulling the bearing off the shaft 15. Use the following procedure and Figure 26 to remove the
until the outer bearing assembly is free. The bearing will rotor assembly.
“ pop” off the shaft. Place the bearing and roller assembly on a. Protect the rotor shaft while removing the assembly.
the protected portion of the puller shaft. See Figure 23. Con­ Cover the shaft with brass pipe or other suitable material
tinue pulling the inner bearing and roller assembly off the to prevent damage during removal.
shaft. It will also "pop" off the shaft when free. Remove the
b. Place a sling around the pipe as near to the rotor as pos­
puller from the shaft.
sible. See Figure 26.
CAUTION: WHEN THE INNER BEARING MID ROLLER c. Raise the chain hoist to support the full weight of the
\ASSEMBLY PULL FREE FROM THE SHAFT, THE PULLER rotor and withdraw the rotor from the stator. Withdraw
\WILL FALL HAVE PERSONNEL READY TO SUPPORT THE the rotor from the drive end of the motor.
PULLER AND BEARINGS TO AVOID DAMAGE TO THE
SHAFT AND BEARINGS. CAUTION: USE EXTREME CARE WHEN REMOVING
THE ROTOR TO NOT STRIKE OR DAMAGE THE
MOTOR WINDINGS IN ANY WAY.

FIGURE 23 — Pulling BEARING Assembly FIGURE 24 — Inner Bearing Cap

F IG U R E 2 5 — R e m o v in g B e a rin g C ap F IG U R E 2 6 — R e m o v in g R o to r

8.5-7
HERMETIC CENTRAVAC SERVICE GUIDE a O U F IB E H T IA r
HCTV-SG-2 Uk d Be ji;rioted
FEBRUARY 1982
by Court Orde^

MAIN TERMINAL BOARD DISASSEMBLY

This portion describes the disassembly of the main terminal NOTE: If the chiller is equipped with a factory mounted start­
board. Refer to Figure 27 which is a cutaway view of the terminal er, remove the starter. This must be accomplished before
board when disassembling. work may proceed.

1. Disconnect all electrical power to the unit before proceeding. 3. Disconnect the power leads at the motor terminals.
Verify that there is no power applied by checking with a
voltmeter. NOTE: It is necessary to completely remove the conduit box
or the factory mounted starter, depending upon the chiller.
WARNING: BEFORE WORKING ON THIS OR ANY ELEC- Also, mark the motor power leads to insure that the motor is
TRiCAL EQUIPMENT, A LW A YS D IS C O N N EC T ALL ELEC­ wired properly upon reassembly.
TRICAL POWER. FAILURE TO DO SO MAY RESULT IN
4. Loosen and remove all hex head brass jam nuts and spring
SERIOUS PERSONAL INJURY OR DEATH FROM ELEC-
TRIC SHOCK. washers from the terminals. See Figures 28, 29 and 30.

5. Loosen the terminals from the terminal board either by hand

2. Remove all refrigerant from the chiller and then evacuate the
or by using a wood mallet to tap the terminals and break the
chiller to 5mm Hg. Then, pressurize the chiller to 0 psig using
O-ring seal. See Figure 31.
dry nitrogen.
6 . Loosen and remove all terminal board bolts. Refer to Figure
WMMNGL* USE ONLY DRY NITROGEN TO PRESSURIZE
32.
THE CULLER. TH E U K O F O X Y G E N O ff ACETYLENE
MAY CAUSE A t t B U i r O M j O S W N RESULTING IN
7. Remove the terminal board and gasket by slipping it over the
studs.

FIGURE 27 — Main Terminal Board Assembly

8.5-8
 'CONFIDENTIAL' HERMETIC CENTRAVAC SERVICE GUIDE
Use R e s t r i c t e d HCTV-SG-2
FEBRUARY 1982

BMaHllhfcl

FIGURE 28 — Terminal Board FIGURE 29 — Terminal Stud

F IG U R E 32 — R e m o v in g T e rm in a l B o ard R e tain in g B o lts

8.S-9
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 COTTT’I'DEHTIAL’
FEBRUARY 1982 Use Res ^ ioted
fry Court Ux^der
Terminal Stud Removal “ RTD Terminal Board Reassembly
With the entire terminal board removed from the chiller, loosen 1. Feed the motor RTD lead wires through the hole in the motor
and remove the brass bolts securing the motor leads to the termi­ barrel.
nal. See Figures 33 and 34.
2 . Slip the motor temperature detector terminal board O-rings
NOTE:Although all terminals and motor leads are marked, it is over the RTD lead wires.
recommended that they be marked again.
3. Attach the RTD leads to the temperature detector terminals
R.T.D. (Resistive Temperature Detector) Terminal Board by pressing the stab-on connectors on wires leads on to the
Disassembly terminals. See Figure 39.
1. Remove the screws securing the conduit box cover. See
Figure 35. NOTE:All RTD lead wires are marked to coincide with em­
bossed numbers on terminal. Number 4 is common.
2. Disconnect the RTD leads from the stab-on connector.
4. Place O-ring in groove on temperature detector terminal
3. Remove the screws securing the conduit box and remove board. Lightly lubricate the O-ring with Lubriplate or equiv­
box. See Figure 36. alent. See Figure 39.

4. Remove the four screws securing the temperature detector 5. Secure the motor temperature detector board to the motor
terminal block. Refer to Figures 37 and 38. barrel with screws and lockwashers. See Figure 37.

5. Disconnect the motor RTD leads by removing the stab-on 6 . Install the conduit box with screws and lockwashers. See
connections and remove th terminal O-ring. See Figure 39. Figure 36.

NOTE:Motor-side RTD leads are marked to coincide with the 7. Reconnect the external RTD leads and conduit.
embossed numbers on the terminal. Number 4 terminal is
common. 8 . Install the conduit box cover.

NOTE: The stator assembly of the compressor cannot be re­

moved and no attempt should be made to do so. The stator is
welded in place, making field removal inadvisable.

FIGURE 33 — Removing Motor Leads from Terminal Stud FIGURE 34 — Motor Lead and Terminal Stud

8.5-10
 ’C01TFIDMTIAL' HERMETIC C8IT1UVAC SERVICE GUIDE
Use E o s t"io te d HC1V-SG-2

FIGURE 36 — Removing Conduit Box Retaining Screws FIGURE 37 — Removing Temperature Detector Terminal Block
Retaining Screws

[TEMPERATURE DETECTOR LEADl

FIGURE 38 — Terminal Block FIGURE 39 — Terminal Block

5-11
HERMETIC CENTRAVAC SERVICE GUIDE C O t f P ID M T IA r
HCTV-SG-2 Use R e s tric te d
FEBRUARY 1982
by Court Oi^der
Main Terminal and Terminal Board Assembly
1. Attach motor leads to terminal studs. If terminal studs are to b. Install spring washers and brass jam nuts over studs.
be reused, each stud has a number on it to coincide with the Seat the studs in slot on inside of terminal board to pre­
motor lead. If replacement terminal studs are used, number vent stud rotation, and hand tighten the jam nuts. See
them appropriately. Motor leads also have an embossed Figures 43 and 44.
number to coincide with the terminals. See Figure 40. Use
brass bolts to attach motor leads to terminal studs. Figure 41 c. Position the terminal board gasket — do not lubricate
illustrates terminal stud components. Tighten to 10 ft.-lbs. this gasket, the terminal board or the motor casting.
THE GASKET AND SEALING SURFACES SHOULD
2. Insert new o-rings over terminal studs and lightly lubricate BE CLEAN AND DRY.
with Lubriplate.
d. Position the terminal board and gasket using the termi­
3. Install the terminal board and a new gasket. nal board bolts. Tighten the terminal board bolts to ap­
proximately 25 ft.-lbs. torque or until gasket begins to
a. Insert the motor terminals through the holes in the termi­
extrude. See Figure 45.
nal board. The terminal board holes are labelled to coin­
cide with embossed numbers on the terminal studs and e. Tighten the brass jam nuts on terminals until the spring
motor leads. See Figure 42. washers are completely compressed. See Figure 46.

FIGURE 40 — Motor Lead with Number FIGURE 41 — Motor Terminal Stud

8.5-12
 HERMETIC CENTRAVAC SERVICE GUIDE
CONFIDENT IAT,' HCTV-SG-2
FEBRUARY 1982
U oG JrCGo t, r’ j G

by Coui11, Order
MOTOR ASSEM BLY
1. Rig and position the rotor in the stator. Use the protective pipe to balance the rotor as it is
moved into the stator. The ends of the laminated steel
a. Take appropriate precautions to protect the rotor shaft
rotor core must be aligned with the ends of the lami­
during insertion into the stator. Use a length of brass
nated steel stator core. See Figures 48,49 and 50.
pipe or similar to cover the rotor shaft.

b. Put a sling around the pipe near the rotor and lift into
e. Lower the rotor assembly to rest on the stator core.
position.
2. Install the opposite drive end inner bearing cap and new
c. Carefully move the rotor into position in the stator. See
gasket on the shaft. Thoroughly clean the seal. See Figures
Figure 47. 51 ,5 2 , 53 and 54. Inspect the seal grooves for scratches or
damage, replace if necessary. (Install seal with oil drain at
CAUTION: USEEXTREMECARENOTTOSTRIKE bottom. Make sure drain is clear.)
THESTATORWINDINGSWITHTHEROTOR.

F IG U R E 4 6 — T ig h te n in g J a m N u ts o n T e rm in a l S tu d s

8.5-13
 C O N F ID E N T IA T
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
Use HeCoi'ioted
FEBRUARY 1982 by Cornet Order

FIGURE 47 — Installing Rotor FIGURE 48 — Rotor Laminations

FIGURE 49 — Stator Core

F IG U R E 51 — O p p o s ite D riv e E n d In n e r B e a rin g C ap F IG U R E 5 2 — S e a l G ro o v e s o f B e a rin g C a p

8.5-14
 HERMETIC CENTRAVAC SERVICE GUIDE
CONFIDENTIAX HCTV-SG-2

FIGURE 53 — Oil Drain Hole FIGURE 54 — Opposite Drive End Bearing Cap

3. Install the thrust bearing assembly. See Figure 55.

NOTE: The thrust bearing assembly is a matched set. Do

not mix parts with another thrust bearing assembly. All
mating bearing parts have a serial number inscribed on
them to identify the assembly. (See Figures 58 and 59). The
thrust bearing can be installed on the shaft in either direc­
tion, but it must be assembled properly. For example: one
roller assembly will have a matching letter scribed after the
serial number. This is to indicate that the bearing must be
installed with the lettered roller on the lettered side of the ta­
pered cup. It is recommended that the lettered components
face outward from the motor to avoid confusion.

a. Examine the shaft for scratches or burrs and remove

with a fine tooth file. See Figures 56 and 57.

NOTE: This is extremely important on the shaft O.D.

where the thrust bearing cones are installed. If a
scratch is present on the shaft O.D. carefully file it out.
Polish it out with crocus cloth and check for high spots
with a micrometer. All scratches must be removed or
thrust bearing assembly will be extremely difficult.

b. Thoroughly clean the bearing components and shaft

using Virginia 10 or an equivalent solvent. Do not use
solvent which may leave residue. Remove all oil and de­
bris. Heat the inner bearing assembly to approximately
250-275 F.

Cross-Section

8.5-15
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

FIGURE 56 — Examining Shaft for Scratches and Burrs FIGURE 57 — Filing Scratch Out of Shaft

FIGURE 58 — Bearing Component Serial Numbers FIGURE 59 — Bearing Components

w A m m ao; u s e w e l d e r s g l o v e s t o p r o t e c t CAUTION. BEARING ROLLER MSTAUARON MUST

T M HAROS AM D PREVENT PERSONAL INJURY. BE ACCOMPLISHED QUICKLY BUT CAREFULLY
MEAT THE REAMERS DRY, USW G A PORTABLE WHILE BEARING IS HOT TO PROPERLY POSITION
OWEN OR INDUCTION HEATER. DO NOT M EAT THE THE BEARING BEFORE THE BEAMNQ COOLS AND
BEARIRQSBt OR-USE A SURFACE THERMOMETER SEIZES ONTO THE SHAFT. IF THE BEARING IS NOT
TO MEASURE THE TEMPERATURE. DONOTEXCEED PROPERLY POSITIONED, PULL IT OFF THE SHAFT
AND START OVER.___________________________
c. Install the inner bearing assembly onto the shaft against d. After the bearing cools try to insert a 0.002 inch or 0.003
the shaft shoulder. Hold in place for approximately 30 inch feeler gauge between the bearing and shaft shoul­
seconds. See Figure 60. der. Figure 61 illustrates this procedure. If a 0.003 inch
feeler gauge will fit, the bearing is not properly posi­
tioned. Pull it off, and start over.

C 0 ” r T " - ' Tr" t

8.5-16
Use II i. L '
 HERMETIC CENTRAVAC SERVICE GUIDE
rr I AX HCTV-SG-2
Use Ao; t eA FEBRUARY 1982
t)vC_pu
Allow the shaft and inner bearing cone to cool for aneast 4. W hile the assembly is still warm, use a machined piece of
15 minutes before the outer bearing cone is installed. pipe (see enclosed figures) to tap the outer bearing cone
onto the shaft. See Figures 6 6 . Figure 67 provides dimen­
f. Install the spacer on the shaft. This is not a shrink fit and
sions and construction of the pipe. If this is not done, exces­
does not require heating. The spacer may be installed in
sive end float and resultant machine vibration will occur.
either direction. See Figures 62 and 63.
5. Insert a stiff wire into one of the oil inlet holes of the tapered
g. Install the tapered cup. Double check for proper match
cup and while observing through another oil inlet hole with a
marks with the outer bearing cone. See Figure 64.
light, try to turn the inner spacer. See Figure 6 8 . If the spacer
h. Heat (as before) and install the outer bearing cone. rotates, the motor shaft will have too much end float and will
Insert the bearing cone squarely on the shaft to prevent vibrate. Using the machined pipe and hammer, tap the outer
binding and seizure on the shaft. One person must hold bearing and move it farther onto the shaft to take up the end
and rotate the cup while another positions the hot bear­ float. Recheck the spacer for movement as previously de­
ing cone on the shaft. Push the roller assembly firmly scribed while the bearing is cooling.
against the cup until it cools while rotating the double
cup. See Figure 65.

F IG U R E 6 2 — In s ta llin g B e a rin g C o n e S p a c e r F IG U R E 6 3 — C o n e S p a c e r In s ta lle d

8.5-17
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

FIGURE 64 — Outer Bearing Cone Assembly FIGURE 65 — Installing Outer Bearing Cone

Co n f id e n t ia l

Use Restricted
by Court

CVHE-020-030 -THIS SURFACE MACHINE

PERPENDICULAR TO
LENGTH OF PIPE
1/4-INCH STEEL PLATE, 2 INCH
WELD TO PIPE ------» .D. NOMINAL

6-8 INCHES -
MATERIAL: NOMINAL 2 INCH I.D. STEEL PIPE, APPROX. 6-8 INCHES LONG.
■THIS SURFACE MACHINE
CVHE-050-125 PERPENDICULAR TO
LENGTH OF PIPE.

'/4 INCH STEEL PLATE, 4 INCH

WELD TO PIPE — i NOMINAL

-6-8 INCHES-

MATERIAL: NOMINAL 4 INCH I.D. STEEL PIPE, APPROX. 6-8 INCHES LONG
FIGURE 67 — Machined Pipe Dimensions

8.5-18
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

t0 W T- O T ’ , T l “ a

U se
u j .; d e r.
co ue :

FIGURE 68 — Checking for Cone Spacer Rotation

6 . Install the spacer, lockwasher and locknut on the shaft. See compressor oil to ease bearing bracket insertion on the
Figure 69. The lockwasher has a tab that fits into the keyway bearing. See Figure 73.
on the motor shaft. Tighten the locknut until firm metal-to- c. Hoist the bearing bracket into position.
metal contact is made. Line up one tab of the lockwasher
with a slot in the locknut and bend tab over to secure. See d. Install two guide rods on the motor barrel to line up the
Figure 70. bearing bracket.

7. Install two 6 inch or 8 inch guide rods through gasket into two e. Insert the bearing cap guide rods into proper holes in the
random holes in the inner bearing cap. See Figure 71. The bearing bracket and slide the bracket into position.
guide rods sen/e to align the bearing cap with the bearing Again verify the bearing cap is positioned w/oil drain
bracket. Be sure the small oil drain hole in the seal and hole down.
gasket are on the bottom. See Figure 72.
f. Remove the lifting clevis and push the bracket firmly
8. Install the opposite drive end bearing bracket. Use the fol­ against the motor barrel. Bolt in position. See Figures 74
lowing procedure. and 75.

a. T horough ly clean the bearing bracket and o-ring g. Loosely bolt the inner bearing seal to the bearing brack­
groove. et. Do not tighten at this tim e. Use the bolts with the tab-
ramp washers. Use guide rods to line up the seal and
b. Lubricate the new o-ring with Lubriplate or equivalent inner bearing cap. See Figure 76. Remove when fin­
and install on the bearing bracket. Lubricate the outside
ished. The drive end bearing bracket must be in place
of the bearing cup with the proper Trane recommended
before the seal bolts are tightened.

F IG U R E 6 9 — In s ta llin g S p a c e r, L o c k w a s h e r a n d L o c k n u t F IG U R E 7 0 — L o c k w a s h e r D e tail

8.5-19
FIGURE 71 — Inner Bearing Cap FIGURE 72 — Inner Bearing Cap Installation

F IG U R E 7 5 — B e a rin g B ra c k e t in P o s itio n F IG U R E 7 6 — B o lt a n d T a b -R a m p W a s h e r

8.5-20
 CONFIDENTIAL HERMETIC CENTRAVAC SERVICE GUIDE
Use R estricted HCTV-SG-2
by Court Order FEBRUARY 1982

9. Place the inner bearing cap over the drive end of the motor c. Insert two guide rods, 180 degrees apart on the horizon­
shaft. Use the following procedure. See Figure 77. tal centerline, into the motor barrel to align the bearing
bracket. See Figure 78.
a. Clean the drive end seal thoroughly. Replace if worn
excessively. d. Attach a hoist to bearing bracket with a clevis and lift into
position. Align the seal rods and bearing bracket, verify
b. Install two 6 inch or 8 inch guide rods in any two holes in
the seal oil drain is on the bottom and move into position.
seal.
See Figure 79.
c. Install gasket on seal and position on shaft.
e. Remove the clevis and install the bearing bracket bolts
10. Install the drive end bearing bracket. with tab-ramp washers. Tighten the bolts.

a. Clean the bracket thoroughly, especially the o-ring f. Insert two bolts into the inner seal to hold in place and
groove. then remove the guide rods. This allows clearance for
bearing installation.
b. Lubricate the new o-ring with Lubriplate or equivalent.
Install on bearing bracket. See-Figure 77.

FIGURE 77 — Drive End Bearing Bracket and Gasket FIGURE 78 — Motor Barrel with Guide Rods

F IG U R E 7 9 — B e a rin g B ra c k e t In P lace

8.5-21
HERMETIC CENTRAVAC SERVICE GUIDE COTlTi^TTAE
HCTV-SG-2 Use Iwv.3■... io'cecl
FEBRUARY 1982
11. Install the roller bearing on the shaft. p y Co U i i G rdei^ Install the outer race in the bearing bracket. Clean thor­
a. Thoroughly clean all oil and dirt off the bearing. oughly and lubricate with WF - 6 8 oil. It may be neces­
sary to lift the shaft to insert the race in the bearinc
b. Heat the bearing dry — do not use oil — to approxi­ bracket. It may also be necessary to lightly tap the rac.
mately 250-275 F. into position. See Figures 83 and 84.
CAUTION: EXAMINETHEDRIVEENDROLLER
B£AmNQ.THEtNNERRAC£EDQEMTHTHELMGE f. Install the outer race retaining ring. Use bolts with tab-
RADIUSMACHINEDONITMUSTFACETOWARDS ramp washers. See Figure 85.
THESHAFTSHOULDER.SMALLCHAMFEREDEDGE
MUSTFACETOWARDSTHEOUTSIDEOFTHE NOTE: These bolts also secure the inner bearing cap
MOTOR.SEEFIGURE80._______________________ seal. Install two guide rods in the seal to aid in centering
the inner seal and tighten the bolts. Remove the guide
c. Insert the hot bearing onto the shaft with the more roun­
rods and insert and tighten the remaining bolts to 24 ft.-
ded bearing towards the motor as described in the CAU­
Ibs. torque. Lightly oil both bearings. Rotate the shaft
TION above. See Figure 81. Insert the bearing squarely
by hand. If the shaft does not rotate smoothly it may be
on the shaft to avoid binding and seizure on the shaft.
necessary to readjust the drive end inner seal. Install
Push the bearing against the motor shaft shoulder and
the remaining bolts to secure the opposite drive end
hold in this position for approximately 30 seconds until
inner bearing cap. Center the seal and check to see
the bearing cools and binds to the shaft.
that the shaft rotates freely. Readjust the seal location if
d. Slide the drive end bearing spacer against the bearing necessary. Secure the opposite drive end outer bear­
and lock into place with large snap ring. See Figure 82. ing race retaining ring. Bolt into position using bolts
NOTE: This spacer does not require heating to install with tab-ramp washers.
on shaft.
 HERMETIC CENTRAVAC SERVICE GUIDE
C O N F ID E N T IA L ' HCTV-SG-2
U se K t b .,i i c t e d FEBRUARY 1982

FIGURE 84 — Outer Race Installed FIGURE 85 — Outer Race Retaining Ring

12. Check the motor shaft end float. e. Slowly tighten the bar and rock the shaft to take up end
float in the opposite direction to that previously indi­
a. Mount a dial indicator with the dial stem on the shaft cated. Read the dial indicator to determine the total end
shoulder to read the shaft end float. See Figure 8 6 .
float. Total end float is 0.007 inch maximum, 0.002 inch
b. Mount a 1 inch x 1 inch steel bar and 1 inch diameter minimum.
ball bearing on opposite drive end of motor as shown in
f. If the end float is excessive, remove the thrust locknut,
Figures 87 and 8 8 to push the motor shaft towards the lockwasher, and spacer. Tap the outer bearing towards
compressor end. Rock the shaft back and forth to load
the inner cone. Reinstall locknut, lockwasher, and spac­
the roller bearing while tightening the steel bar. Tighten er. Recheck the end float. Use the machined pipe as
the bar only enough to take up all the end play. Zero the
previously used to tap the outer bearing towards the
dial indicator. Figure 89 provides dimensions for fabri­
inner cone. Recheck the end float.
cating the bar.
13. Reconnect the oil supply lines on the back end bearing
c. Remove the steel bar and ball bearing from the opposite
bracket.
drive end of the motor.
14. Install the front end cover plate with a new o-ring. Lubricate
d. Using long threaded rods inserted in the bearing bracket
the o-ring with Lubriplate or equivalent.
to attach the steel bar and ball bearing to the drive end of
the motor. See Figure 90. 15. Reconnect the oil supply and drain lines on the front end of
the motor.

8.5-23
HERMETIC CENTRAVAC SERVICE GUIDE COT*, IT)t T- AL
HCTV-SG-2 Z'JO ‘V i c t a a .
FEBRUARY 1982 f c y C o u r t 0 rd e ^

FOR CVHE FOR CVHE

020 AND 315 050-125

LOCATION APPROXIMATE -
DRILL HOLE AT JOBSITE
1 " * 1 ” STEEL BAR FOR EXACT LOCATION

FIGURE 89 — Bar Stock Dimensions

FIGURE 88 — Loaded Motor Shaft

8.5-24
 (

c" a
■k: cn O
Ct O
S2}

8.5-25
O M he)
C <!-= H
>-i 07 t j
c+ ■' £rf
r- ^ -4
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HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

w
to
 LITERATURE FILE NO. HCTV-SG-2

O IL P R ES S U R E SECTION
R E G U L A TO R R EPAIR
8.6
FEBRUARY 1982

This Section describes the oil pressure regulating valve including sure regulator will be apart for an extended length of time. If
replacement of the adjusting stem, adjusting stem O-ring, cage the unit will be open to the atmosphere for any length o f time,
and cage gasket, spring, and the piston. it is recommended that the refrigerant be removed. Refer to

WARNING:Beforeproceedingwiththisprocedure- discon­ Section 6.17 for refrigerant removal procedures.

nectdielectrics!powertotheohlltertoutalsoset thechiller 3. Loosen the cage from the regulator body and remove all in­

OFF-AUTO-ONswitchtotheOFFposition.Also,setthepurge ternal components from the regulator. See Figures 1 and 2 .

unitswitchtotheOFFposition.ThisIstopreventtheoilpump
andoilsumpheaterfrombecomingenergizedwhileworkis
Inprogress. Failuretodosomayresult Inhot oil being
sprayedfromtheoil sumpcausingburnsandseriousper­
sonalInjury.
1. Drain the oil from the sump. If the evaporator pressure gauge
indicates a positive pressure, connect a drain line to the oil
sump charging valve. Open the valve and drain the oil into a
clean container.

If the evaporator pressure gauge indicates less than 0 psi,

pressurize the chiller using dry nitrogen to 1 to 2 psig. This
will force the oil from the sump through the sump charging
valve and drain line.

WARNING:Onlyuse drynitrogenforpressurizingthe
chiller.TheuseofoxygenoracetylenemayresultInavl-
olentexplosioncausingseriouspersonalInjuryordeath.
2. If necessary, operate the purge unit to remove enough dry
nitrogen so that the chiller is at 0 psig. It will not be necessary
to remove the refrigerant from the chiller unless the oil pres­

'CGTTI,'T?~'T"T M;
Use
la y C u u x h v i 'C tu i

FIGURE 1 - Oil Pressure Reguletlng Valve Detail

°THE TRANE COMPANY 1982
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601
PRINTED IN U S A. 8.6-1
HERMETIC CENTRAVAC SERVICE GUIDE Co n f i d e n t t a e
HCTV-SG-2
FEBRUARY 1982
Use R e stricte d
by Court Order
4. The piston, spring and cage-to-housing gasket can now be NOTE: Lubricate the new adjusting stem O-ring with com­
removed and replaced. See Figure 3. pressor oil before positioning on the adjusting stem or in­
5. Loosen and remove the locking nut that secures the adjust­ sertion into the cage.
ing stem to the cage. See Figure 7.
6 . Screw the adjusting stem into and through the cage to 8 . Pressure test all regulator connections.
remove the adjusting stem or adjusting stem O-ring. The ad­ 9. Refill the oil sump with the oil that was drained or use new oil
justing stem cannot be backed out from the cage. Refer to of the proper type. Use a hand pump to pump the oil into the
Figures 4 and 5. sump.
10. To adjust the oil pressure it is necessary to operate the oil
7. Replace defective parts and then reassemble the regulator
in reverse order of disassembly. Thoroughly clean all parts pump. This is accomplished by setting the purge compressor
switch the the MANUAL position. Just prior to doing this it is
before reassembly.
necessary to start the auxiliary water supply flowing through
the purge condenser coil. W ater flow through the purge con­
densing coil is necessary to prevent loss of refrigerant from
the chiller. When the purge switch is placed in MANUAL the
oil pump will also run in conjunction with the purge com­
pressor. Turn the adjusting stem of the oil pressure regu­
lating valve until a net oil pressure of 15 psig is achieved. See
Figure 6 .
11. Secure the adjusting stem to prevent it from moving by tight­
ening the locking nut. Refer to Figure 7.
12. The chiller is now ready to operate in the normal manner.

FIGURE 3 - Piston, Spring and Cage to Housing Gasket

FIGURE 4 - Cage and Adjusting Stem

FIGURE 6 - Turning Adjusting Stem to Set Oil Pressure

FIGURE 5 - Adjusting Stem

8.6-2
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982

CONFIDENTIAE
Use Hoc..dieted
b£jC o u.x‘ ~G Uruer

FIGURE 7 - Tightening the Locknut

PRINTED BY PRODUCTION SERVICES - LA CROSSE FWB DJL

8.6-3
 LITERATURE FILE NO. HCTV-SG-2

ECONOM IZER REM OVAL

SECTION
8.7
FEBRUARY 1982

This section describes the removal and replacement of the econ­ using dry nitrogen. Read the pressure on the evaporator
omizer assembly on the Model CVHE CenTraVac chiller. Re­ pressure gauge.
moval of the economizer is necessary if the compressor must be
overhauled or if the gaskets in the economizer piping must be WARNING: Use only dry nitrogen to pressurise die
changed. Use the following procedure. chiller. The use of oxygen or acetylene may result in a vl-
olent explosion causing seriouspersonal Injury or death.
WARNING:Beforeworkingonthisor anyelectrical equip­
ment alwaysdisconnect themainelectricalpowerdiscon­ 3. Loosen the bolts on the condenser liquid line flange. This is
nect switch. FailuretodosomayresultinseriousInjuryor located at the bottom of the condenser. See Figure 1. D o not
deathcausedbyelectricshock. ________ rem ove the bolts at this time.
1. Shut the machine off and open the main power disconnect 4. Loosen the bolts on the evaporator liquid line flange. This
switch. connection is near the bottom of the evaporator. See Figure
2. Remove the refrigerant from the machine. Evacuate the re­ 2. Do not remove the bolts at this time.
frigerant vapors and then pressurize the machine to 0 psig

FIGURE 1 - Condenser Liquid Line Flange FIGURE 2 - Evaporator Liquid Line Flange

CONFIDENTIAL’
Use Restricted.
Court urday
®THE TRANE COMPANY 1982
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A. 8.7-1
 'C ” r -^
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2 \J U c i'i
FEBRUARY 1982 C o u ii Oroei

5. Support the weight of the economizer with a floor jack. Place 8 . Carefully remove the economizer vent pipe flange bolts to
the floor jack under the economizer sump as shown in Figure loosen the economizer. W hen the bolts are free, back the
3. The economizer may also be supported by wrapping a economizer away from the chiller. If a floor jack is being
sling or chain, supported by an overhead lift or A-frame, used, the economizer will tend to rotate off the jack towards
around the economizer. Either method requires a lifting ca­ the compressor. Be prepared to offset the rotation.
pacity of 3000 lbs. 9. Move the economizer away from the chiller and set on the
6 . Loosen the economizer vent pipe bolts which secure the floor until ready for reassembly. Cover all openings to pre­
vent pipe flanges to the compressor interstage castings. Do vent entry of foreign objects into the economizer when it is
not remove the bolts. separated from the machine.
7. Remove the bolts from the condenser and evaporator liquid
lines. Adjust the floor jack or overhead lift as necessary to Reassemble the chiller in reverse order using new gaskets. Be
support the weight of the economizer. sure to clean all flanges before reassembly and tighten bolts only
enough so that the gasket just begins to extrude from between
the flanges.

FIGURE 3 - Removing the Economizer

PRINTED BY PRODUCTION SERVICES - LA CROSSE 8.7-2 FWB /SPS

 LITERATURE FILE NO. HCTV-SG-2

S P EC IFIC ATIO N S
SECTION
9.0
FEBRUARY 1982

TABLE 1 - Unit Weights, Refrigerant Charges, Oil Charges, Water Volume

SHELL AND WATER
REFRIGERANT OIL SHIPPING OPERATING BOX VOLUME
CHARGE (LBS.) CHARGE WEIGHT WEIGHT EVAP. CONDENS
MODEL COMPRESSOR EVAP. CONDENSER R-11 (GAL) (LBS.) (LBS.) (GAL) (GAL)
CVHE 020 2C 2C 340 7 8,796 9,696 31 33
CVHE 020 2D 2D 450 7 9,611 10,611 39 41
CVHE 032 2C 2C 560 7 10,991 12,491 47 54
CVHE 032 2D 2D 750 7 11,915 13,915 60 68
CVHE 050 2C 2C 760 7 14,309 16,509 76 87
CVHE 050 2D 2D 1,000 7 15,767 18,667 97 109
CVHE 080 2C 2C 1,000 7 20,605 24,305 123 144
CVHE 080 2D 2D 1,320 7 23,164 27,664 156 179
CVHE 125 3D 2D 2,360 7 30,351 37,351 231 278
CVHE 125 2D 2D 2,390 7 30,351 37,351 253 278

TABLE 2 - Compressor Component Weights

COMPRESSOR WEIGHT COTTFIUFNTTAX'
MODEL COMPONENT NAME (IBS.)
Use R e s .;*• - ;'-
CVHE 020 Volute 800 by Court ivcier
First Stage Suction Cover 715
Second Stage Suction Cover 820
Third Stage Suction Cover 768
Total Compressor Weight 5,200
CVHE 032 Volute 793
First Stage Suction Cover 1,008
Second Stage Suction Cover 719
Third Stage Suction Cover 742
Total Compressor Weight 5,680
CVHE 050 Volute 910
First Stage Suction Cover 1,050
Second Stage Suction Cover 875
Third Stage Suction Cover 775
Total Compressor Weight 6,400
CVHE 080 Volute 1,110
First Stage Suction Cover 1,145
Second Stage Suction Cover 1,132
Third Stage Suction Cover 880
Total Compressor Weight 8,000
CVHE 125 Volute 1,608
First Stage Suction Cover 1,285
Second Stage Suction Cover 1,257
Third Stage Suction Cover 1,200
Total Compressor Weight 10,500

®THE TRANE COMPANY 1962

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A. 9.0-1
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982 CONFITiEITTIAE
Use He... r i o t e d
Coux o Oi‘der

TABLE 3 - Compressor Motor Electrical Data

NO M M AL VOLTAGE 206 44Q 460 ■; 4 57S to o 2300 .4000:. 4160
uw r AVAILABLE VOLTAGE
COMPRESSOR M O TO R MOTOR UTILIZATION
DESIGNATION DESIGNATOR RATING (Kw) RANGE 167/229 187/229 414/506 414/506 414/506 $40/660 64W660 2180/2840 2160/2840 3744/4576 3744/4576
Rated Load Amps 314 302 142 136 130 107 103
A 96
Locked Rotor Amps 2154 2240 995 1040 1085 763 796
Rated Load Amps 342 329 155 148 142 117 112
B 105
Locked Rotor Amps 2154 2240 995 1040 1085 763 796
Rated Load Amps 379 364 172 164 157 131 126
C 118
Locked Rotor Amps 2154 2240 995 1040 1085 763 796
CVHE Rated Load Amps 419 403 190 182 174 146 140
D 131
013*020 Locked Rotor Amps 2154 2240 995 1040 1085 763 796
Rated Load Amps 464 446 210 201 193 159 152
E 142
Locked Rotor Amps 2862 2976 1239 1295 1351 958 1000
Rated Load Amps 503 484 228 218 209 173 166
F 155
Locked Rotor Amps 2862 2976 1239 1295 1351 958 1000
Rated Load Amps 553 532 251 240 230 192 184
G 172
Locked Rotor Amps 2862 2976 1239 1295 1351 958 1000
Rated Load Amps 464 446 203 196 188 159 152
E 142
Locked Rotor Amps 3014 3135 1349 1410 1471 1045 1090
Rated Load Amps 501 482 224 214 205 173 166
F 155
Locked Rotor Amps 3014 3135 1349 1410 1471 1045 1090
Rated Load Amps 551 530 248 237 227 192 184
G 172
Locked Rotor Amps 3014 3135 1349 1410 1471 1045 1090
CVHE Rated Load Amps 604 581 272 260 249 206 197
H 184
022-032 Locked Rotor Amps 4003 4163 1679 1755 1831 1272 1327
Rated Load Amps 662 637 299 286 274 228 218
J 204
Locked Rotor Amps 4003 4163 1679 1755 1831 1272 1327
Rated Load Amps 744 715 337 322 309 257 246
K 230
Locked Rotor Amps 4003 4163 1679 1755 1831 1272 1327
Rated Load Amps 820 788 373 357 342 286 274
L 256
Locked Rotor Amps 3880 4035 1720 1798 1876 1261 1316
Rated Load Amps 654 629 295 282 270 225 216
J 204
Locked Rotor Amps 4610 4794 1971 2060 2150 1466 1530
Rated Load Amps 732 704 333 318 305 254 243 63.9 61.2 36.7 35.3
K 230
Locked Rotor Amps 4610 4794 1971 2060 2150 1466 1530 347 362 201 209
Rated Load Amps 815 784 370 354 340 283 271 71.1 68.1 40.9 393
L 256
Locked Rotor Amps 4610 4794 1971 2060 2150 1466 1530 347 362 201 209
CVHE Rated Load Amps 916 881 415 397 380 316 303 79.2 75.9 45.6 43.8
M 284
035-050 Locked Rotor Amps 4495 4675 2023 2115 2207 1550 1617 376 392 217 226
Rated Load Amps 1037 997 469 449 430 359 344 90.1 86.3 51.8 49.8
N 323
Locked Rotor Amps 4495 4675 2023 2115 2207 1550 1617 408 426 237 246
Rated Load Amps 525 502 481 402 385 99.4 95.3 57.2 55.0
P 361
Locked Rotor Amps 2023 2115 2207 1550 1617 485 506 281 292
Rated Load Amps 580 555 532 445 426 111.8 107.1 64.3 61.8
R 403
Locked Rotor Amps 2541 2657 2773 1954 2039 542 565 314 326

9.0-2
 HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
COTTFIDMTIAL FEBRUARY 1982
Use Kes i.rioted.
byCourt Or&ex
TABLE 3 - Compressor Motor Electrical Data (Continued)
N O M IN A L V O L T A G E 200 208 440 4 60 4 60 575 600 2300 24Q0 400 0 4160

U N IT A V A IL A B L E V O LTA G E
COM PRESSOR M O TO R M O TO R U T IL IZ A T IO N
D E S IG N A T IO N D E S IG N A T O R R A T IN G (K w ) RANGE 187/229 187/229 414/506 414/508 414/506 540/880 540/680 2180/2640 2160/2840 3744/4676 3744/4576
Rated Load Amps 1018 979 462 442 424 359 344 89.8 86.1 51.7 49.7
N 323
Locked Rotor Amps 5649 5875 2541 2657 2773 1550 1617 449 468 260 270
Rated Load Amps 515 493 472 402 385 994 95.3 57.2 55.0
P 361
Locked Rotor Amps 2541 2657 2773 1550 1617 485 506 281 292
Rated Load Amps 580 555 532 445 426 111.8 107.1 64.3 61.8
R 403
Locked Rotor Amps 2541 2657 2773 1954 2039 542 565 314 326
CVHE Rated Load Amps 667 635 609 508 487 128.3 123.0 73 8 71.0
T 453
055-080 Locked Rotor Amps 3326 3477 3528 2580 2692 601 627 348 362
Rated Load Amps 752 719 689 576 552 145.0 139.0 83.7 80 5
U 513
Locked Rotor Amps 3326 3477 3528 2580 2692 601 627 348 362
Rated Load Amps 859 822 788 658 631 164 9 158.0 95.2 91 5
V 586
Locked Rotor Amps 3694 3862 4030 2816 2938 701 731 406 422
Rated Load Amps 952 911 873 727 697 182.6 175.0 105 0 1 0 1 .0
w 653
Locked Rotor Amps 4916 5139 5362 3616 3773 821 857 476 495
Rated Load Amps 749 716 686 574 550 , 143 5 138.0 82 8 79.6
u 513
Locked Rotor Amps 4448 4650 4852 3528 3681 766 797 442 460
Rated Load Amps 854 017 783 655 628 164.3 158 0 94 6 91.0
V 586
Locked Rotor Amps 4440 4650 4052 3528 3681 766 797 442 460
CVHE Rated Load Amps 952 91 1 373 727 697 182 6 175 0 105 0 101.0

089-125 Locked Rotor Amps 4916 5139 5362 3616 3773 821 857 476 495
Rated Load Amps 1080 1033 990 830 795 210 201 121 116
X 742
Locked Rotor Amps 5618 5073 6128 4534 4731 849 886 491 511
Rated Load Amps 1242 1188 1139 951 911 240 230 138 133
Y 853
Locked Rotor Amps 6554 6852 7150 5062 5282 1141 1191 661 687
Rated Load Amps 1393 1332 1277 1063 1019 269 258 155 149
2 954
Locked Rotor Amps 7714 8065 8416 5668 5914 1141 1191 661 687

TABLE 4 - Model CVHE Normal Operating Conditions

Evaporator Pressure 12 To 18 Inches Vacuum
Condenser Pressure 2 To 13 PSI
Purge Drum Pressure 0 To 22 PSI
Oil Pressure Gauge 3 To 9 PSI
Reading
Net Oil Pressure 12 To 15 PSI
Oil Sump Temperature, 110 F To 135 F
Chiller Operating
Oil Sump Temperature, 130 F To 135 F
Chiller Not Operating
Oil Level Solid Level Between Sight
Glasses With Chiller
Operating
Compressor Current Draw 20% To 100% Of Chiller RLA
Line Voltage Design Voltage ±10%

PRINTED BY PRODUCTION SERVICES — LA CROSSE FWB SAG

9.0 -3
 LITERATURE FILE NO. HCTV-SG-2

M ODEL CVHE SECTION

TO O L REQUIREM ENTS
9.1
FEBRUARY 1982
This section contains information concerning tool requirements RIGGING EQUIPMENT
for disassembly and reassembly of the compressor and motor
components of the Model CVHE CenTraVac chiller. The tool lists The tools listed as follows are required for lifting and rigging the
compressor and motor assemblies of CVHE chillers. The size
are divided into the following categories:
and rating of the equipment must be adequate to insure proper
1. Basic Hand Tools handling of the components.
2. Rigging Equipment
T o ;T rT T -:-7 T A r WARNING: Always use property sized equipment, In good
3. Special Tools
working order, to avoid accidents in handling heavy equip­
BASIC HAND TOOLS ment. Failure to do so could cause serious personal Injury or

3/8 inch drive socket set

£JLCyurt_ Order death.________________________________________________

1 /2 inch drive socket set For the weight of specific key components of the CVHE Cen-
Electric impact wrench, 1/2 inch drive TraVac chiller refer to Section 9.0.
1 /2 inch impact sockets
A-frame (adjustable) or other suitable overhead lifting fixture
Allen wrench set
I-beam trolley
Pliers Chain hoist
Brass hammer
Clevis (various)
Hacksaw
Nylon sling or wire rope slings
Crescent wrench
Ratchet lever hoist (come-along)
Small pry bar
Lifting chains (various)
Torque wrench, 0 to 300 inch-pounds
Torque wrench, 0 to 150 foot-pounds SPECIAL TOOLS
Set of feeler gauges A. Impeller Puller
Various screwdrivers, straight and Phillips Qty. 1, Plate per Figure 1. The plate should be manufactured
Open and box end combination wrenches, locally.
3/8 inch through 1-1/2 inches Qty. 3, All thread rod, No. 10-32 UNC x 22 inches long
Tap and die set, 1/4 inch through 3/4 inch NC Qty. 3, All thread rod, 5/16 inch x 18 UNC x 30 inches long
Files, round and flat Qty. 1, Forcing screw, OTC 927-2
Teflon sealing tape Qty. 1, Forcing nut, OTC 927-3
Tubing cutter, 1/8 inch through 5/8 inch Qty. 1, Forcing washer, OTC 927-4
Tube cutter, 1/2 inch through 3 inch
Roll of sandpaper Purchase from: Owatonna Tool Company
Power Team Division
Presto-Lite torch assembly
Owatonna, MN 55060
Oxy-Acetylene torch assembly
Gasket scraper
Parts cleaning solvent (Virginia 10 or equivalent)
Rags
Duct tape
Snap ring pliers
Tube flaring set
Wire brush, hand and for electric drill
3/8 inch electric drill and bits
Silver brazing alloys
Copper to copper, BCUP-5, Sil-Fos
Copper or brass to steel, Bag-1, Easy Flo 45
Brazing flux
Nitrogen and regulator assembly
Dial indicator with magnetic base
6 inch spanner wrench

•THE TRANE COMPANY 1962

COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE, WISCONSIN 54601
PRINTED IN U S A.

9.1-1
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
FEBRUARY 1982
B. Roller Bearing Heater (Induction) D. Bearing puller (manual)
Qty. 1, Reco Model SC Bearing Heater, with three cross bars, Qty. 1, Pulling attachment OTC AP5 (Figure 2), 0.50 inch to
110 volts, maximum amperage -1 7 amps. For bearings to 10 5.25 inches spread for 2 inch bearing
inches O.D. x 4-3/8 inches wide. Qty. 1 , Pulling attachment OTC AP 8 , 0.62 inch to 8.0 inches
Cross bars: spread for 3 inch bearing
3/4 inch x 3/4 inch x 9-1/4 inches Qty. 1 , Adapter, 1-14/.62-18 OTC TA21P
1-1/4 inch x 1-1/4 inch x 9-1/4 inches Qty. 1 , Protector kit, OTC KSP150
2 inches x 2 inches x 9-1/4 inches COTCFXBEETIAE Qty. 1 , Push-puller, OTC PP30, (Figure 3)

Manufactured by:
Use . .. .,-icted All items may be purchased from Owatonna Tool Company
Reed Electric Sales and Supply, Inc. by Cour l _QrcLer
2539 N.W. Vaughn Street
P.O. Box 10303
Portland, Oregon 97210

C. Tempilstik, temperature indicating crayon, 250F

Purchase from:
Big Three Industries, Inc.
Tempil-Div.
2901 Hamilton Blvd.
South Plainfield, NJ 07080

Use of Tempilstik: suitable for both rough and smooth sur­

faces and for determining all temperatures. Comes in an ad­
justable metal holder.

Stroke workpiece with the proper Tempilstik from time to time 7-16.25
during heating. Below its temperature rating, the Tempilstik
leaves a dry, chalky mark. When its rating is reached, the
Tempilstik leaves a liquid smear.

A lte rn a tive m ethod: Can be used for determ ining te m ­ FIGURE 3 - Bearing Push-Puller
peratures below 700 F and when heating rapidly to higher
E. Bearing puller (hydraulic)* - A hydraulically operated bearing
temperatures.
puller assembly is also available from Owatonna Tool Com­
Mark the workpiece with the appropriate Tempilstik before pany. The following items are required for a hydraulic puller
heating begins. When its stated temperature is reached, the assembly. Some of the items below are also required as part
mark liquefies. of the manual puller assembly.

NOTE: Disregard color changes. Temperature signal is the

Qty. 1 , Pulling attachment, OTC AP5
melting of Tempilstik - not a color change.
Qty. 1 , Pulling attachment, OTC AP 8
Maximum range: 2500 F Qty. 1, Adapter, OTC TA 21P
Accuracy: ±1.0% Qty. 1 , Protector kit, OTC KSP 150
Qty. 1 , Push-puller, hydraulic, OTC PPH 30

All items may be purchased from Owatonna Tool Company

F. Items required to run compressor motor (less impellers) for vi­

bration analysis.

Qty. 1 , Spacer (large), Figure 4

Qty. 1 , Spacer (small), Figure 5
Qty. 3, Half keys, 0.25 inch x 0.50 inch x 3.5 inches LG
keystock
Qty. 1 , Half key, 0.25 inch x 0.50 inch x 0.75 inch LG keystock

NOTE: Half keys can be made from standard square 0.50

inch keystock material, locally purchased.

G. Motor bearing end float adjusting tool - this tool may be locally
F IG U R E 2 - B earin g Puller fabricated. Refer to Figures 6 and 7.

9.1-2
 nmraT-n.
C O N F I D E lA T j HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
use 1; - luted FEBRUARY 1982

H. End float measurement tool (all sizes) - the following items are I. Model CVHE volute and casing lifting tool - the lifting tool (Part
required to measure motor end float. number TOL-89) is designed for handling the suction covers,
interstage casings, and discharge volutes for CVHE 020
Qty. 1, Bar stock (Figure 8 ) through 125 compressors. This tool is available for purchase
Qty. 1, Steel ball (1 inch diameter), purchase locally
as indicated in the RSP price sheets.

5.125 O.D. X 1.5 LG x .500 WALL

FIGURE 4 - Spacer For CVHE 050-125

UNLESS OTHERWISE SPECIFIED

TOLERANCES ARE AS FOLLOWS:
.X = ± .050
.XX = ± .015
XXX = ± .005

- 2 x8 .201
.250 - 20 UNC - 2B

3.00 O.D. x 1.5 LG x .500 WALL

F IG U R E 5 - S p acer For C V H E 0 2 0 and 030

9.1-3
HERMETIC CENTRAVAC SERVICE GUIDE
HCTV-SG-2
C0r,‘r 7'HT7'7'rxAl?
FEBRUARY 1982 ' .■c bed
b ,/ U - i l

THIS SURFACE MACHINE

PERPENDICULAR TO
LENGTH OF PIPE

T2" I D.
1/41STEEL PLATE NOMINAL
WELD TO PIPE
±
MATERIAL: 2” I D. STEEL PIPE, 6”-8” LONG

FIGURE 6 - Bearing End Float Adjusting Tool (CVHE 020-030)

FOR CVHE 020 AND 315 FOR CVHE 050-125

EXACT LOCATION

F IG U R E 8 - T o o l F o r E n d F lo a t M e a s u re m e n t

FWB ■LLW

9 .1 -4
 LITERATURE FILE NO. HCTV-SG-2

R EC O M M EN D ED SECTION
S ER VIC E B U LLE TIN S
10.0
FEBRRUARY 1982
This Section provides a list of suggested Service Bulletins for further reference. Refer to the Trane Service Literature Price and
Descriptive Catalog for ordering information.

SERVICE BULLETIN
EOTTFTBEITTIAE
NUMBER AND DATE DESCRIPTION
Use !•: i o t ed
CTV-SB-4A, July 1981 Service Bulletin describes service
~by C ourt Order
policies for CenTraVac starters. 3
pages.

CTV-SB-4B, July 1981 S e rvice Bulletin lists Cutler

Hammer service representatives. 5
pages.

CTV-SB-4C, July 1981 Service Bulletin lists General Elec­

tric service re p re se n ta tive s. 10
pages.

CTV-SB-4D, July 1981 Sen/ice Bulletin lists Furnas Ser­

vice representatives. 4 pages.

CTV-SB-4E, July 1981 Service Bulletin lists Westinghouse

service representatives. 10 pages.

CTV-SB-23, July 1981 Service Bulletin describes replace­

ment purge relief valve and purge
relief valve repair kit. 1 page.

CTV-SB-27, July 1981 Service Bulletin provides recom­

mendations for painting factory in­
sulated chillers. 1 page.

CTV-SB-28, July 1981 Service Bulletin describes proper

flow switch installation. 2 pages.

CTV-SB-32, July 1981 Service Bulletin provides insulation

resistance test curve for megging
motors. 2 pages.

CTV-SB-33, July 1981 Service Bulletin gives procedure for

obtaining true meg-ohm readings. 1
page.

CTV-SB-35, July 1981 Service Bulletin gives acceptable

meg-ohm readings and recommen­
dations. 1 page.

CTV-SB-38, July 1981 Service Bulletin describes theory

and operation of motors and start­
ers. 25 pages.

CTV-SB-42, July 1981 Service Bulletin provides log sheet

for evacuation. 2 pages.

CTV-SB-48, July 1981 S ervice B ulletin d e scrib e s open

rotor test procedure. 1 page.
®THE TRANE COMPANY 1982
COMMERCIAL AIR CONDITIONING DIVISION
LA CROSSE. WISCONSIN 54601
PRINTED IN U S A. FWP .SPS