TRANE CVHE CenTraVac Water-Cooled Chillers Installation Guide
- June 13, 2024
- Trane
Table of Contents
Installation Instructions
CenTraVac™ Water-cooled Chillers
Hot Gas Bypass Field Installation
CVHE CenTraVac Water-Cooled Chillers
Model Numbers: CVHE, CVHF, CVHG
This document applies to service offering applications only.
SAFETY WARNING
Only qualified personnel should install and service the equipment. The
installation, starting up, and servicing of heating, ventilating, and air-
conditioning equipment can be hazardous and requires specific knowledge and
training.
Improperly installed, adjusted or altered equipment by an unqualified person
could result in death or serious injury.
When working on the equipment, observe all precautions in the literature and
on the tags, stickers, and labels that are attached to the equipment.
Introduction
Read this manual thoroughly before operating or servicing this unit.
Warnings, Cautions, and Notices
Safety advisories appear throughout this manual as required.
Your personal safety and the proper operation of this machine depend upon the
strict observance of these precautions.
The three types of advisories are defined as follows:
WARNING
Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, could
result in minor or moderate injury. It couldalso be used to alert against
unsafe practices.
NOTICE
Indicates a situation that could result in equipment or property-damage only
accidents.
Important Environmental Concerns
Scientific research has shown that certain man-made chemicals can affect the
earth’s naturally occurring stratospheric ozone layer when released to the
atmosphere. In particular, several of the identified chemicals that may affect
the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon
(CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs).
Not all refrigerants containing these compounds have the same potential impact
to the environment. Trane advocates the responsible handling of all
refrigerants.
Important Responsible Refrigerant Practices
Trane believes that responsible refrigerant practices are important to the
environment, our customers, and the air conditioning industry. All technicians
who handle refrigerants must be certified according to local rules. For the
USA, the Federal Clean Air Act (Section 608) sets forth the requirements for
handling, reclaiming, recovering and recycling of certain refrigerants and the
equipment that is used in these service procedures. In addition, some states
or municipalities may have additional requirements that must also be adhered
to for responsible management of refrigerants. Know the applicable laws and
follow them.
WARNING
Proper Field Wiring and Grounding Required!
Failure to follow code could result in death or serious injury. All field
wiring MUST be performed by qualified personnel. Improperly installed and
grounded field wiring poses FIRE and ELECTROCUTION hazards. To avoid these
hazards, you MUST follow requirements for field wiring installation and
grounding as described in NEC and your local/state/national electrical codes.
WARNING
Personal Protective Equipment (PPE) Required!
Failure to wear proper PPE for the job being undertaken could result in death
or serious injury. Technicians, in order to protect themselves from potential
electrical, mechanical, and chemical hazards, MUST follow precautions in this
manual and on the tags, stickers, and labels, as well as the instructions
below:
- Before installing/servicing this unit, technicians MUST put on all PPE required for the work being undertaken (Examples; cut resistant gloves/sleeves, butyl gloves, safety glasses, hard hat/bump cap, fall protection, electrical PPE and arc flash clothing). ALWAYS refer to appropriate Safety Data Sheets (SDS) and OSHA guidelines for proper PPE.
- When working with or around hazardous chemicals, ALWAYS refer to the appropriate SDS and OSHA/GHS (Global Harmonized System of Classification and Labeling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection and handling instructions.
- If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other country-specific requirements for arc flash protection, PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASH CLOTHING. ENSURE ELECTRICAL METERS AND EQUIPMENT ARE PROPERLY RATED FOR INTENDED VOLTAGE.
WARNING
Follow EHS Policies!
Failure to follow instructions below could result in death or serious injury.
- All Trane personnel must follow the company’s Environmental, Health and Safety (EHS) policies when performing work such as hot work, electrical, fall protection, lockout/tagout, refrigerant handling, etc. Where local regulations are more stringent than these policies, those regulations supersede these policies.
- Non-Trane personnel should always follow local regulations.
Copyright
This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part without written permission. Trane reserves the right to revise this publication at any time, and to make changes to its content without obligation to notify any person of such revision or change.
Trademarks
All trademarks referenced in this document are the trademarks of their respective owners.
Revision History
Document updated to reflect Service Offering number.
General Information
The following instructions show the hot gas bypass installation on CVHE, CVHF,
or CVHG CenTraVac™ chillers. When the hot gas bypass option is ordered through
Trane Parts for field installation, the following is shipped in this kit: a
hot gas bypass valve with actuator, piping, pipe flanges, flange gaskets, and
hardware to attach the flanges to the valve. A temperature sensor (4R16), bulb
well, hot gas bypass actuator control relays (1A12) and hot gas bypass valve
closed inputs (1A4) will also be included if not already on the unit.
Notes:
- New O-rings also need to be ordered for the suction elbow.
- Conduit and additional wiring need to be provided locally.
Installation
WARNING
Hazardous Voltage w/Capacitors!
Failure to disconnect power and discharge capacitors before servicing could
result in death or serious injury.
Disconnect all electric power, including remote disconnects and discharge all
motor start/run capacitors before servicing. Follow proper lockout/tagout
procedures to ensure the power cannot be inadvertently energized. For variable
frequency drives or other energy storing components provided by Trane or
others, refer to the appropriate manufacturer’s literature for allowable
waiting periods for discharge of capacitors. Verify with a CAT III or IV
voltmeter rated per NFPA 70E that all capacitors have discharged.
WARNING
Refrigerant May Be Under Positive Pressure!
Failure to follow instructions below could result in an explosion which could
result in death or serious injury or equipment damage.
System contains refrigerant and may be under positive pressure; system may
also contain oil. Recover refrigerant to relieve pressure before opening the
system. See unit nameplate for refrigerant type. Do not use non-approved
refrigerants, refrigerant substitutes, or non-approved refrigerant additives.
CAUTION
Refrigerant at Freezing Temperature!
Direct contact with liquid refrigerant could result in minor or moderate
injury.
Avoid contact with skin. If working with refrigerant is necessary, you MUST
wear all Personal Protective Equipment (PPE) including eye protection, safety
gloves, long sleeves, and pants. In case of contact, treat the injury similar
to frostbite. Slowly warm the affected area with lukewarm water and seek
immediate medical attention.
-
Stop the chiller and properly remove the refrigerant or nitrogen holding charge. Refer to CTV-SVX05*-EN (Installation, Operation, and Maintenance: Refrigerant Handling Guidelines).
Notes:
• For stick welding, use AWS E7016 or E7018 stick electrodes.
• For MIG or TIG welding, use AWS ER70S-6 filler metal. -
Remove insulation from the suction elbow around the area where the hot gas bypass connection will be made.
-
Weld the straight pipe (Figure 1, Item 1) to one of the provided pipe flanges (Figure 1, Item 2) for the suction elbow connection.
-
Weld the appropriate angled pipe (Figure 1, Item 3) to the other pipe flange (Figure 1, Item 4) for the condenser connection.
-
Allow welds to cool, and then bolt the flange assemblies, with gaskets (Figure 1, Item 5), to the hot gas bypass valve (Figure 1, Item 6).
-
Locate the hot gas bypass assembly on the condenser and suction elbow where it will be installed and fit the down pipe to the condenser (Figure 1, Item 7).
-
Weld the down pipe to the flange pipe assembly.
-
Mark the suction elbow (Figure 1, Item 8) and condenser (Figure 1, Item 9) for cutting.
-
Prior to cutting, remove the suction elbow (Figure 2, Item 1) from the unit in order to avoid contamination of the unit with excess metal shavings.
-
Where marked in Step 8, cut a hole in the suction elbow using a hand plasma cutter with the appropriate plasma cutting tip for the metal thickness.
-
Replace the suction elbow removed in Step 9. Use new O-rings (Figure 2, Item 2) when replacing.
-
Where marked in Step 8, cut a hole in the condenser using a hole saw to avoid hot slag from falling on tubes.
-
Use a magnet to clean the inside of the shell of all metal shavings.
-
Locate the hot gas bypass assembly on unit and weld piping to suction elbow (Figure 3, Item 1) and condenser (Figure 3, Item 2).
-
If not already on unit, install the (1A12) I/O module (Figure 4, Item 1) to the control panel with the provided hardware.
-
Wire the valve to the I/O module in accordance with the provided schematic on the last page.
-
If not already on unit, install the hot gas bypass valve closed input (1A4) (Figure 4, Item 2) with the provided hardware.
Note: The added modules need to be bound to the controller with Tracer™ TU or TechView™ and the HGBP option needs to be enabled in the menu. -
If not already on unit, install the bulb well and discharge gas temperature sensor (4R16) (Figure 5, Item 1). The coupling is located on the front side of the condenser compressor discharge connection (Figure 5, Item 2).
-
Replace insulation on the suction elbow.
-
Paint as required.
Trane – by Trane Technologies (NYSE: TT), a global climate innovator – creates
comfortable, energy efficient indoor environments for commercial and
residential applications. For more information, please visit
trane.com or
tranetechnologies.com.
Trane has a policy of continuous product and product data improvement and
reserves the right to change design and specifications without notice. We are
committed to using environmentally conscious print practices.
SO-SVN007A-EN 31 Aug 2023
Supersedes PART-SVN218C-EN (Aug 2021)
©2023 Trane
August 2023
SO-SVN007A-EN
References
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