Horizon Single-Stage Steam or Hot Water Absorption Chiller...

Operation/Maintenance

Horizon™

Single-Stage Steam or

Hot Water Absorption Chiller

ABS-M-10A

Unit Model: ABSD

X39640542-02

©American Standard Inc. 2001 ABS-M-10A

GeneralInformation

How to Use This Manual

ContentsThis manual describes the operation andmaintenance requirements for the TraneHorizon Single-Stage Steam or HotWater Absorption Chiller. Theinstructions are intended to provide themachine operator with sufficient detailedinformation to safely operate the chillerThis manual has been developed andapproved within a quality systemcertified as conforming to ISO 9001.

Contents

3ABS-M-10A

Owner

General InformationMechanical Specification, Component Identification,Unit Nameplate Location and Description,Model Number Description

Sequence of OperationMachine Solution Cycle, Control Panel and Unit Controls,Machine Sequence of Operation, Machine ControlStrategies, Purge System Operation

Operator GuideOperator Display Reports, Settings, Test and Diagnostics,Adjustable Frequency Drive Display Menu

MaintenanceDaily, Seasonal, Purge, Inspection Items, Evap., Abs. andCondenser Care, AFD’s, Pumps, Filter Replacement

Troubleshooting/Diagnostics

Troubleshooting/DiagnosticsControl Panel Diagnostics, AFD Diagnostics, Pumps

Troubleshooting Checklist

Unit Wiring DiagramsElectrical Connections, Field Wiring, Electrical Data,Unit Wiring Diagrams

2

13

29

42

58

59

60

ABS-M-10A4

Machine Description

The following chapter contains machineidentification of major components andwarning and caution label locations. Theitems identified are referencedthroughout this manual in eachapplicable section.

Figure 1 illustrates the majorcomponents of a typical ABSDAbsorption Chiller.

Figure 2 identifies control panel labels,tags and warning or cautions thatpertain to unit identification, installationand operation.

GeneralInformation

Mechanical Specifications

GeneralThe Trane Horizon™ Model ABSD chilleris a complete single effect steam or hotwater fired absorption chiller packagebuilt in an ISO 9001 environment. Chillerconsists of generator/condenser section,evaporator/absorber section, controls,pumps, heat exchanger, and energycontrol valve. All Horizon chillers are ofhermetic design, factory assembled andleak tested prior to shipment. Horizonchillers can be separated and shippeddisassembled for rigging purposes.Horizon chiller controls are factorymounted and wired including microelectronic control panel, sensors andpurge system, energy valve can befactory mounted and wired as an optionon steam fired units. Horizon chillers arepainted prior to shipping with two coatsof a water base air dry primer. Standardmethod of shipment is by truck fromthe USA.

Generator/Condenser-Evaporator/AbsorberThe shell material is carbon steel.Standard generator tube material iscupro-nickel, evaporator is copper,absorber is cupro-nickel and condenseris copper. Tubes are mechanically rolledinto the tube sheets and are replaceablefrom either end. Condenser, evaporatorand absorber tube supports are fixed.Generator consists of fixed and floatingtube supports to allow for even tubeexpansion. Solution spray systems arereplaceable from end of unit withoutsacrificing the hermetic integrity of theunit.

Generator/Condenser-Evaporator/AbsorberDesign working pressure for the waterboxes is 150 psig (10.5 kg/cm2). All tubebundles are tested at 150 percent ofdesign working pressure. All waterboxes have gasketed removable coversfor access. Optional Marine type waterboxes can be provided on the condenserand absorber section. Water connectionsare provided with either victaulic orraised-face flanged connections.

Heat ExchangersA brazed plate solution heat exchangeris provided to reduce energy use andimprove unit performance. Heatexchanger surfaces are 300 seriesstainless steel.

PumpsSolution and refrigerant are circulated bymeans of 3 hermetic, single stagecentrifugal pumps. The pump impeller iscast iron with a steel shaft supported by2 tapered carbon bearings. The bearingsare lubricated and the motor is cooled bythe fluid that is pumped. An adjustablefrequency drive is provided on thegenerator pump and absorber pump toprovide solution control.

Automatic Purge SystemThe purge system utilizes an eductor formoving non-condensables to thecondenser, Purifier™ purge to collect thenon-condensables in an external storagetank, and vacuum pump for removal ofthe non-condensables. The purgeoperates automatically to remove non-condensables from the unit duringperiods of chiller operation andshutdown. Logging of purge informationis provided via the unit control panel.

GeneratorThe shell is carbon steel. Tube sheets aresteel and standard generator tubes areconstructed of cupro-nickel. Thegenerator has fixed and floating tubesupports to allow for even tubeexpansion. The steam side of thegenerator is designed and stamped for50-PSI ASME construction. Generator/condenser includes rupture disk, whichis sized to meet ANSI/ASHRAE B 15.

Lithium Bromide FilterThe filter system consists of the filterassembly and the associated piping andfilter isolation valves needed foroperation and maintenance. The mainfilter body is stainless steel with areplaceable element. The filter isolationvalves allow service of the filterassembly without disturbing operationof the rest of the machine.

5ABS-M-10A

Component Identification and LocationA typical Horizon ABSD steam machine is illustrated in Figure 1. Major components are identified in a front, back, right-end, andleft-end view. Figure 2 illustrates the machine labels location.

Figure 1 – Typical 500 Two-Stage Steam Machine

GeneralInformation

[47 mm]

ABS-M-10A6

GeneralInformation

Figure 1 (Continued) – Typical 500 Two-Stage Steam Machine

7ABS-M-10A

GeneralInformation

Legend1. C.E. Compliance Label2. ETL Listing Label3. Nameplate Label4. Customer Notes5. Nameplate (Horizon)6. Voltage Warning Label7. Field Wiring Connection Diagram8. Flat 9 x 12 Plastic Bag *9. Operation and Maintenance Manual

10. Installation Manual11. Poly Clear Envelope12. Plastic SH Antistatic Foam13. Lift/Move/Level Label14. Inspect/Damage Label15. Customer ID Tag16. Customer Marked Package Tag17. AFD Drive Manuals

*Contains installation and operation/maintenance, AFD drive manuals andincludes as-built schematic wiringdiagram prints (laminated).

Note: UCP panel “keys” ship in anenvelope taped behind the controlpanel.

Figure 2 – Machine Labels Location

Machine Panel LabelingThe unit control panel ships with thelabeling indicated in Figure 2. Thevarious labels are identified as well asthe ship with literature pieces.

ABS-M-10A8

GeneralInformation

Trane Horizon Absorption SeriesSingle-Stage Absorption Liquid Chiller

Catalog Model Number ABSD800

Service Model Number ABSD080GF0KXXXXXANXXAVAMBEEBGAHDCAXXXXAXAXXXX0

Sales Order Number Unit Serial NumberAXB123 L00D12345M

Maximum Inlet Steam Pressure: 14PSIG

Electrical CharacteristicsRated Voltage: 460 Volt 60 HZ 3 PHVoltage Utilization Range: 414-506 VACRated Current: 39.0 AmpsMinimum Circuit Ampacity: 47.0 AmpsMax Overcurrent Protective Device: 50.0 AmpsPurge Compressor RLA: 4.8 AmpsControl Circuit: 115 VAC 2000VA

Motors KW FLAPurge Pump: .19 4.4Refrigerant Pump: 3.7 2.0Absorber Solution Pump: 5.6 15.0Low Temp Solution Pump: 3.7 12.0

Service LiteratureInstallation Manual ABS-IN-10AOper/Maint. Manual ABS-M-10A

Manufactured Under the Following U.S. Patents: 4223539, Other Patents Pending

This advanced model ABSD HORIZON Single-Stage Absorption Unitwas developed with the assistance of the Gas Research Institute.

Product Description:

MODL ABSD DSEQ FO NTON 800VOLT 460 BURN NSEL BOPA NSELFTAA NSEL SMHC NSEL ENSR STMENPR 50 PVCN STD PURG AUTOLGTM SB04 HGTM NSEL CDTM SB09EVTM ES12 ABTM SB00 GNWA GN02CAWA CA17 EVWA EV01 CAWC REREEVWC LEFR CAFT WTR EVFT WTREVLV BF03 EVIN FACT EVPN SSTLUPNT SFPT WCNM SNMP SPKG DAUELPP SELP PPCO NFDS LCLD CLDOWVUO YES OPTM YES AFDS YES

NameplateNameplateThe ABSD unit nameplate is located onthe chiller control panel. The nameplateillustrated is an ABSD 800 ton, Single -Stage Steam Absorption.

Note: For temperature, pressure drops,and water flow data see the orderwrite-up.

The Unit Nameplate contains veryimportant service information such asthe unit serial number, sales ordernumber and the service model number.Always have this information readilyavailable when requesting service.

9ABS-M-10A

GeneralInformation

Service Model Number

Single Stage Absorption

Standard Options Only

Service Modeldigit / variable Description Selection

1 - 4 Absorption Unit ModelABSD Single Stage Absorption

5 - 7 Unit Nominal Tonnage050 500 Nominal Tons060 600 Nominal Tons070 700 Nominal Tons080 800 Nominal Tons097 975 Nominal Tons110 1100 Nominal Tons122 1225 Nominal Tons135 1350 Nominal Tons

8 Unit VoltageA 190 Volt - 50 HZB 200 Volt - 60 HZC 220 Volt - 50 HZD 230 Volt - 60 HZE 380 Volt - 50 HZF 415 Volt - 50 HZG 460 Volt - 60 HZH 575 Volt - 60 HZ

9 Unit Energy SourceJ Steam Energy SourceG Hot Water Energy Source

10 Design Sequence

11 Design Sequence

12 Generator Waterbox Design PressureK Steam - 50 PSIG ASME RequiredM Hot Water - 150 PSIG ASME RequiredN Hot Water - 400 PSIG ASME RequiredE Pressure Vessel Construction

Standard construction (includes ASME generator)

13 X Not Applicable

14 X Not Applicable

15 X Not Applicable

16 X Not Applicable

17 X Not Applicable

18 - 19 Low-Temperature Generator TubesAN .028 Wall 90-10 CUNI Smooth SurfaceAP .035 Wall 90-10 CUNI Smooth SurfaceAR .049 Wall 90-10 CUNI Smooth SurfaceBD .028 wall 409 SST Smooth Surface

20 X Not Applicable

21 X Not Applicable

ABS-M-10A10

GeneralInformation


22 - 23 Condenser TubesAV .028 Wall Copper Smooth SurfaceAW .035 Wall Copper Smooth SurfaceAN .028 Wall 90-10 CUNI Smooth SurfaceAP .035 Wall 90-10 CUNI Smooth SurfaceAR .049 Wall 90-10 CUNI Smooth SurfaceBF .028w 316L SST Smooth Surface

24 - 25 Evaporator TubesAM .025 Wall Copper Enhanced SurfaceAL .025 Wall 90-10 CUNI Enhanced SurfaceAE .035 Wall 90-10 CUNI Enhanced Surface

26 - 27 Absorber TubesBE .022 Wall 95-5 CUNI Smooth SurfaceAK .028 Wall 95-5 CUNI Smooth SurfaceAL .035 Wall 95-5 CUNI Smooth SurfaceAM .049 Wall 95-5 CUNI Smooth SurfaceAN .028 Wall 90-10 CUNI Smooth SurfaceAP .035 Wall 90-10 CUNI Smooth SurfaceAR .049 Wall 90-10 CUNI Smooth SurfaceBF .028 Wall 316L SST Smooth SurfaceAV .028 Wall Copper Smooth Surface

28 Pressure Vessel Construction

E Standard construction (ASME Generator)

29 Generator Water Box ArrangementB 1-Pass Non-Marine RF FlangeC 2-Pass Non-Marine RF Flange

30 Condenser & Absorber Water Box ArrangementG 150 PSI Marine VictaulicH 150 PSI Marine RF FlangeJ 150 PSI Non-Marine VictaulicK 150 PSI Non-Marine RF Flange

31 Evaporator Water Box ArrangementC 1-Pass 150 PSI Non-Marine VictaulicD 1-Pass 150 PSI Non-Marine RF FlangeA 2-Pass 150 PSI Non-Marine VictaulicB 2-Pass 150 PSI Non-Marine RF Flange

32 Unit Energy ValveG 2-Way 3" 150# Wafer BtrflyH 2-Way 4" 150# Wafer BtrflyJ 2-Way 6" 150# Wafer BtrflyK 2-Way 8" 150# Wafer BtrflyL 3-Way 3" 150# Flanged tee Wafer BtrflyM 3-Way 4" 150# Flanged tee Wafer BtrflyN 3-Way 6" 150# Flanged tee Wafer BtrflyP 3-Way 3" 300# Flanged tee Wafer BtrflyR 3-Way 4" 300# Flanged tee Wafer BtrflyT 3-Way 6" 300# Flanged tee Wafer BtrflyU 2-Way 3" 150# Flanged BtrflyV 2-Way 4" 150# Flanged BtrflyW 2-Way 6" 150# Flanged BtrflyY 2-Way 8" 150# Flanged BtrflyA 2-Way 2" 150# Wafer V-Ball

11ABS-M-10A

GeneralInformation


B 2-Way 3" 150# Wafer V-BallC 2-Way 4" 150# Wafer V-BallD 2-Way 2" 300# Wafer V-BallE 2-Way 3" 300# Wafer V-BallF 2-Way 4" 300# Wafer V-BallZ 2-Way 2" 150# Flanged V-Ball1 2-Way 3" 150# Flanged V-Ball2 2-Way 4" 150# Flanged V-Ball

33 Electrical Protection PackageD Standard Electrical Package

34 Control Panel Power ConnectionA Circuit BreakerB Fused Disconnect SwitchC Non-Fused Disconnect SwitchD Terminal Block

35 Local Clear Language DisplayA Clear Language Display - Complex CharacterB Clear Language Display - Suitable for Outdoor Use

36 X Not Applicable

37 Tracer Interface Control ModuleA Tracer 100 Interface Module (com3)B Tracer Summit Interface Module (com4)

38 Printer Interface Control ModuleA Printer Interface Module

39 Ambient Chilled Water ResetA Ambient Chilled Water Reset

40 Under/over Phase Voltage ProtectionA Under/over Voltage Protection

41 Chiller/tower Water Flow DisplayA Differential Water Pressure Transducers

42 Options Control ModuleA Options Module

43 X Not Applicable

44 Unit InsulationC Cold Unit Insulation Only

45 Lithium Bromide FilterA Lithium Bromide Filter

46 Unit Special FeaturesX Not ApplicableS Special

47 X Not Applicable

48 Purge System1 Automatic Purge System2 Manual Purge System

49 Adjustable frequency drive1 Frequency drive

ABS-M-10A12

GeneralInformation

WARNING

Warnings and cautions appear atappropriate intervals throughout thismanual. Warnings are provided to alertinstalling contractors to potential hazardsthat could result in personal injury ordeath. Cautions are used to alertpersonnel to conditions that may resultin minor or moderate injury orequipment damage.

IMPORTANTOperation without proper water pumpand flow sensing interlocking will voidunit warranty.

Note: This machine uses lithiumbromide inhibited with lithiummolybdate and lithium hydroxide.Lithium bromide that contains otherinhibitors cannot be used in thisequipment.

To avoid risk of injury never climb over amachine or step on components. Alwaysuse a platform, ladder or similar.

To avoid risk of injury always use a craneor hoist to lift or move machinecomponents.

Lift locations are marked.

Safety Precautions

HAZARDOUS VOLTAGE!

DO NOT USE WATER ON A MOTOR ORELECTRICAL FIRE. USE CO2 (CARBONDIOXIDE) OR ANSAL (DRY CHEMICAL)(CLASS ABC OR BC).

USE OF WATER ON AN ELECTRICALFIRE MAY RESULT IN SERIOUSPERSONAL INJURY OR DEATHCAUSED BY ELECTRICAL SHOCK.

HAZARDOUS VOLTAGE!

DISCONNECT ALL ELECTRIC POWERINCLUDING REMOTE DISCONNECTSBEFORE SERVICING.

FAILURE TO DISCONNECT POWERBEFORE SERVICING CAN CAUSESEVERE PERSONAL INJURY OR DEATH.

LITHIUM BROMIDE!

LITHIUM BROMIDE IS NORMALLYNONTOXIC; HOWEVER, OTHERCHEMICALS MIXED WITH THESOLUTION CAN CAUSE IRRITATIONAND ADDITIVE VAPORS CAN CAUSENAUSEA. ALWAYS PROVIDEVENTILATION TO REMOVEACCUMULATED VAPORS.

IN CASE OF ACCIDENTAL CONTACTWITH THE SOLUTION, WASH THEAFFECTED AREA WITH WATERIMMEDIATELY.

ELECTRICAL COMPONENTS!

KEEP PAINT AWAY FROM ALLELECTRICAL COMPONENTS ANDNEVER PAINT WHILE THE MACHINE ISENERGIZED.

FUMES MAY BE PRESENT CAUSINGEXPLOSIVE CONDITIONS.

SOLUTION VAPOR AND CONDENSATEPIPES!

SOLUTION VAPOR AND CONDENSATEPIPES CONNECTED TO THEGENERATOR SECTIONS OF THEMACHINE HAVE SURFACETEMPERATURES AS HIGH AS 300°F.

AVOID CONTACT WITH THESE AREASWHILE THE MACHINE IS IN SERVICE TOPREVENT PERSONAL INJURY IN THEFORM OF SEVERE BURNS.

WARNING

WARNING

CAUTION CAUTION

CAUTION

CAUTION

13ABS-M-10A

Machine Solution Cycle

The machine solution cycle is discussed in this section. Refer to the cooling cycleschematic, Figure 3, during the cycle explanation and reference Table 1.

Figure 3 – Single-Stage Absorption Refrigeration Cycle

Table 1 – Machine Cooling Cycle (Ref. Figure 3) (Typical Temperatures)

Concentration Temperature TemperaturePoint LiBr Solution or Refrigerant Water % (°F) (°C)

1 Absorber Dilute Solution 60.8 107 422 Absorber Dilute Solution Entering the LTG 60.8 185 853 Solution Leaving the LTG 64.4 216 1024 Solution Entering ABS Sump/Spray Pump 64.4 129 545 ABS Spray Solution (Mixed w/abs dilute) 63.1 121 496 LTG Refrigerant Vapor NA 208 987 Condensed Refrigerant NA 110 438 Evaporator Pump Refrigerant NA 41 59 System Chilled Water/Entering NA 54 12

10 System Chilled Water/Leaving NA 44 711 Absorber Cooling Water NA 85 2912 Absorber Leaving/Condenser Entering Cooling Water NA 94 3413 Condenser Leaving Cooling Water NA 101.6 38.614a Steam Entering Unit @12 psig @ Sea Level NA 244 11814b Hot Water Entering Unit @270°F (option) NA 270 13215a Condensate Leaving Generator NA 244 11815b Hot Water Leaving Generator (option) NA 222 106

1

9

7

13

5

11

3

8

2

14

6

12

4

10

15

Sequence ofOperation

To understand the Horizon chilleroperation, a thorough understanding ofthe various aspects of the machine arerequired. This section of the manual,therefore, explains the lithium bromidecycle, the controls utilized to control thelithium bromide cycle, and the sequenceof operation of the cycle and associatedcontrols.

ABS-M-10A14


Refrigerant Cycle(Ref. Figure 3)

Refrigeration CycleThis is an example of typical machineoperation at a standard rating pointcondition (i.e., 85°F/29°C tower, 44°F/6.7°C leaving chilled water) at full load.Dilute solution has a relatively highrefrigerant content and low lithiumbromide content. An intermediatesolution is a mixture of dilute andconcentrated solutions. A concentratedsolution is one with a relatively lowrefrigerant content and high lithiumbromide content.

GeneratorDilute solution (1) is pumped into thegenerator (2) where it is boiled by thesteam or hot water in the tube bundle,creating refrigerant vapor. Therefrigerant vapor is drawn to thecondenser (6). The now concentratedsolution flows by gravity through thesolution heat exchanger (3) to theabsorber (4) spray system where it ismixed with dilute solution (1) from theabsorber and sprayed on the absorbertubes (5).

CondenserRefrigerant vapor (produced by the lowtemperature generator) enters thecondenser (6) to be reduced in pressure/temperature via expansion device fordelivery to the evaporator. The heat ofcondensation is rejected to the coolingwater inside the tube bundle (12-13).

EvaporatorSystem water runs through the tubebundle (9-10) where its heat istransferred to the sprayed refrigerantwater (8) causing the refrigerant tovaporize/boil. The refrigerant vapor isdrawn to the slightly lower pressure inthe absorber.

AbsorberRefrigerant vapor is absorbed by thelithium bromide solution (dilute) to becirculated and cycled again. The solutionis pumped through the solution heatexchanger to the generator. AbsorberHeat (acquired in the evaporator) isrejected via the cooling water inside thetube bundle (11-12).

Absorption ProcessSolution (concentrated) enters the spraysystem from the generator and entersthe spray system wetting the tubes andproviding a liquid surface for therefrigerant vapor from the evaporator toabsorb into the lithium bromide solution.The solution temperature/concentrationsprayed in the absorber controls theabsorber pressure thereby controllingthe evaporator refrigerant temperature.

Solution Heat ExchangerSolution flows through the heatexchanger being preheated reducing theheat energy required to induce boilingwithin the generator and to decreasingthe temperature of the solution beingreturned to the absorber, thusdecreasing the load on the coolingtower.

15ABS-M-10A


Control Panel Location andInternal Hardware

Component DescriptionThe main control panel (Figure 4) hastwo sections. The left side (control side)includes clear language display(mounted through door), chiller, circuit,purge, stepper, and optionalcommunications modules, a terminalblock, and a 115 Vac-control voltage to24 Vac transformer. The right side(power side) consists of a main linevoltage terminal block or disconnectservice for line power connections, linevoltage to control voltage transformer,relays, transformers, starter module andpurge module. Line voltage is restrictedto the right-hand side.

Voltages in Panels

Voltages present within the unit control panel include:• Three phase line voltage (power side only)• 115 Vac control circuits• 24 Vac module power supply

Low voltage, low power (30 Vdc or less – Class II) circuit connection points are locatedon the left side of modules. High voltage, high power (greater than 30 Vdc – Class I)circuit connection points are located on the right side of modules. All 115 Vac circuitsare Class 1.

The stepper drive uses less than 30 Vdc however, the output signals are Class 1 due toits output current (amps).

Class 1 and Class 2 wiring must not be routed together without shielding.

Figure 4 – Machine Control Panel

The components within the controlpanel are illustrated in Figure 5. Modulesare stacked and located top, bottom ormiddle configuration.

Control Side Power Side

Figure 5 – Panel Layout

Panel Layout Legend

1U1 - Starter Module1U2 - Circuit Module1U3 - Chiller Module1U4 - Purge Module1U5 - Stepper Module1U7 - Options Module*1U8 - Tracer Communication Module*1T1-2-3 - Phase Current Transformer1T4 - Line Voltage Transformer1T5 - Control Voltage Transformer1T6-7-8 - Under-Over Phase Voltage Transformers*L1-2-3 - Main Power Entrance

1TB2 - Pump Motor Terminal Block1TB3 - UCP2 Control Panel Mounted Terminal Strip1S1 - Line Voltage Fused Disconnect Switch*1K1 - Refrigerant Pump Abnormal Relay1K6 - Purge Relay1K11 - Refrigerant Pump Contactor1U11 - Refrigerant Pump Overload1F1, F2 - Line Voltage Transformer Fuses1F3 - Phase Voltage Transformer Fuse*1F4, F5, F6 - Refrigerant Pump and Absorber

Solution Pump Motor Fuses1F7, F8, F9 - Low Temp Solution Pump Motor Fuses*Optional

ABS-M-10A16


Signal Block DiagramThe following signal block diagramillustrates the interrelationship of theinterprocessor communications (IPC) linkthat allows the various modulemicroprocessors to communicate. Allcontrol modules are mounted in thechiller control panel. The option andcommunication modules are presentonly when specified. The Trane TracerAutomation System providescommunications outside the unit controlpanel.

The Chiller Module (1U3) serves as themaster control. This module isresponsible for implementing thealgorithms that control chiller operation.It manages the functions of machinesafety, operating limits, chilled watertemperature control by monitoring unitmounted sensors and information fromother modules on the interprocessorcommunications (IPC) link.

The chiller module initiates and controlsall data communications. Internal controlalgorithms and external input data areused to produce chilled watertemperature while maintaining safereliable chiller operation. The input/output ports on the chiller modulemonitor and control-chilled water andcooling water pump operation. Theevaporator and condenser water pumpsare electrically controlled and interlockedto the unit control panel. Thisinterlocking arrangement providesprotection from improper system waterpump control or loss of flow conditions,which can damage the machine.

This module communicates through theinterprocessor communicationsconnection to other modules such as:the stepper drive module to control theenergy input, the starter module to start/stop the solution pumps and controlsolution flow, and to the operatorinterface to display machine statusinformation to the operator.

Setpoint Communication and StorageThe machine setup information selectedat the operator interface is stored in thechiller modules non-volatile memorythat is retained when the panel is notpowered. The chiller module isresponsible for verifying that the setupmemory is not corrupted, and forsubstituting default settings if the storedsettings become corrupted.

1U1 Starter ModuleThe starter module controls externalwater pump operation and provides aninterface to an adjustable frequencyvariable speed drive for solution pumpcontrol.

1U2-Circuit ModuleThe circuit module is located in the lowerportion of the control section beneaththe starter module. The main purpose ofthe circuit module is that of an input/output (I/O) expander for the chillermodule. The circuit module providesinput data from unit temperaturesensors, unit pressure and switch inputs,and makes this information available byway of an interprocessorcommunication link. This moduleprovides output contact closures forcontrol of the purge and lithium bromideconcentration sensing, detection, andrecovery control.

1U4 Purge ModuleThe purge module provides automaticpurge pumpout logic. A sensor locatedon the purge condensing unit suctionline is monitored to determine whenpumpout is required. An output thenturns on the pumpout cycle. Thepumpout period duration is monitoredand stored for analysis.

1U5 Stepper ModuleStepper module 1U5 collects input fromunit sensors and binary input devices.The stepper output is used for control ofthe energy valve.

1U6 Local Clear Language Display(LCLD, or Operator Interface) (std)The LCLD is located on the control sidedoor. The module connecting wiring isaccessible on the door backside. Thismodule accepts operator keypad inputand communicates with the othercontrol elements within the controlpanel. See operator interface forcomplete details.

1U7 Options Module (optional)Present only when optional features arespecified that required additional inputor outputs (I/O).

1U8 Tracer CommunicationsInterface Module (optional)Required for Tracer communications.

Unit Control Panel with Modules

Figure 6

17ABS-M-10A


Terminal BlocksTerminal blocks are used for variousconnection points within the controlpanel as identified below.• 1TB1 Main terminal block (standard).• 1TB2 Pump Motor Terminal Block –

Line voltage distribution point for thethree phase motors.

• 1TB3 Control Panel Mounted TerminalStrip-Provides termination points forinternal wiring, and for field wiringinterface points. See the electricalconnection’s points on the typical unitschematics.

Main Power Termination PointThe connection point in the powersection used for customer three phasepower.• 1TB1 Main terminal block (standard).• 1S1 Line voltage non-fused disconnect

switch-optional.• Circuit breaker, or shunt trip circuit

breaker - optional.

Circuit Breakers and FusesCircuit breakers and fuses that providethe branch circuit protection.• 1CB2 Line voltage transformer circuit

breaker.• Circuit breaker provides branch circuit

protection to 1T5 primary winding.• 1F1, 1F2 Line voltage transformer

fuses.• 1F3 Phase voltage transformer fuse.• 1F4 ,1F5, 1F6 Refrigerant and absorber

solution pump motor fuses.• 1F7, 1F8, 1F9 Low temperature solution

pump motor fuses.

RelaysThe following relays are used to isolate115 volt signals from low voltagemodule input signals.• 1K1 - Refrigerant pump abnormal relay• 1K6 - Vacuum pump relay

TransformersTransformers are used to reduce voltageto required levels. Some are used todistribute power and others for moduleinput signals. The various transformersare identified below.

1T1, 1T2, 1T3 Phase CurrentTransformersCurrent transformers are used to sensethe total 3 phase line current draw. Theoutput of each current transformer isinput to the 1U1 starter module. Currenttransformers are polarity sensitive.Typically there is a marking ”dot” on oneside and the secondary wires are blackand white. The installation of thetransformers must be with the markingsall facing the same direction regardingthe current flow through the primarywiring. The current transformer outputsare input to the starter module anddisplayed at the LCLD with in the Purge/Pump Report.

1T4 Line Voltage TransformerTransformer that steps down line voltageto 115 Vac control powered circuits.

1T5 - Control Voltage TransformerTransformer that steps down the 115 Vaccontrol voltage to 24 Vac power.

1T6, 1T7, 1T8 Under-Over Phase VoltageTransformer (Optional)Voltage potential transformers providean isolated secondary voltage that is aproportional representation of theprimary voltage. Each line voltage of thethree phase supply to the unit controlpanel is sensed. Each potentialtransformer’s low voltage output is inputto the 1U5 starter module.

Control System Features and Functions

• Operator interface with a 40 character,2-line display and a 16 key keypad.

• The microprocessor automaticallydilutes the lithium bromide solution,before shutting down the machine.

• Chilled water pump control outputcontacts.

• Absorber/Condenser pump controloutput contacts.

• Automatic and manual control ofsolution and refrigerant pumps.

• Adjustable frequency drive for solutionflow control of the low temp solutionpump and absorber spray pump.

• Automatic and manual purge systemincorporating the Trane PurifierPurge™.

• Dilution control Refrigerant DumpValve provides refrigerant where it’sneeded to properly reduce solutionconcentration during a dilution cycle orloss of power.

• If an extended loss of power occurredwhile running, a dilution cycle will beinitiated when the power is restored.This dilution cycle will attempt toreduce the solution concentration toprevent crystallization.

Additional System Protection:• Under/over voltage detection (optional)• Chilled water flow confirmation input• Condenser water flow confirmation

input• Emergency stop shutdown input

ABS-M-10A18

Control Locations

Machine controls are factory mounted and wired. External controls are connected with field wiring, and are controlled by thechiller or used by the chiller system.

Figure 7 – Machine Sensor Locations


19ABS-M-10A


Table 2

ABS-M-10A20


Machine Control

This section identifies sequence ofoperation and control strategy, machinecontrol panel details and specificmachine mounted controls.

The illustration represents time andevent proceeding from left to right. Theoperator interface displays, time and theevents in the sequence that they occur.Follow the sequence to understandwhen external and internal controldevices are used. The time line providesinformation that may not be obviouswhen watching the display. Additionally,this information can be used for troubleshooting purposes.

The sequence of operation illustratestime and events that occur at initialpower-up, during start-up when auto isselected, auto off cycle operation, ormanual stop operation. The time line 1and 2 (page 21) and time line 3 (top halfof page 22) pictorially illustrates theevents that occur during normaloperation.

Machine Start-upDuring the machine start sequence thechiller relies on external devices toprovide correct feedback specifically, thechilled water pump starter and flowswitch confirmation, condenser waterpump starter and flow switchconfirmation. During machine start-up,the appropriate message will bedisplayed that confirm the sequencesoccurred.

The Unit Control Panel (UCP) waits up tofour minutes and fifteen seconds forproof of chilled water flow after a waterpump start command output is given.

Failure to receive chilled water flowwithin the allotted time confirmationresults in a message stating“Diagnostics -auto.” This is a Machineshutdown Auto Restart (MAR)-diagnostic where the chiller will startonce the chilled water flow switch logicis satisfied.

Failure to receive condenser water flowwithin the time periods’ results in anMachine shutdown Manual Restart(MMR)- diagnostic where the chillermust be reset before continuedoperation is allowed.

Dilution CycleA 3 to 15 minute dilution cycle isperformed on all shutdown modes withone exception. The exception is a “PanicStop” that consists of an operatordepressing the stop key twice (orcontinuously) within a 5-second period.This will execute a pump stop commandand all pumps will stop without thenormal dilution cycle. A restart can beinitiated at anytime by pressing the autokey. A dilution cycle may be entered bypressing the stop key. If “Stop” isselected, the events following a stopcommand is pictorially illustrated on thebottom half of page 22.

Sequence of Operation Time LineReferenced Notes

1) See “Operator Guide” for a listing ofvalid modes that may occur during“Unit is Running.”

2) Upon power up, refrigerant dilutionvalve 1 (4B6) remains off for thirtyseconds.

3) When a “need to cool” exists, anincomplete dilution cycle can beexited by pressing the Auto key. Thechiller will continue with a new start-up sequence.

4) The “Auto, waiting for a need to cool”can be exited by pressing Stop.

5) Power loss at this point will result in adilution cycle upon re-establishingpower, if there is no need to cool.

6) Power loss at this point will result inthe remainder of a dilution cycle beingcompleted upon re-establishingpower.

7) Chilled water pump will be stoppedafter the dilution cycle is completedfor all MAR and MMR except in thecase of chilled water pump flowoverdue where the chilled waterpump signal remains on.

8) Panic stop; operator presses the stopkey twice within 5 seconds. This statemay be exited by pressing either thestop or auto key.

21ABS-M-10A


Stop Auto Starting Absorber/Condenser Pumps

Wait for Chilled WaterFlow, If flow notestablished in less than4 min and 15 sec. thenissue: Chilled Wtr Flownot Est. MARVariable 6 sec to 4 min,15 sec

Figure 8 – Sequence of Events from a Stop or Auto condition through Start

Standard ModeDisplay:

Wait for aCall forCooling(See Note 4)

Wait for Cond. WaterFlows, if flow notestablished in lessthan 4 min. and 15sec. then issue: Cond.Wtr Flow not Est.MMR

VariableVariable 6 sec. to4 min. 15 sec.

TimeLine 1START

Go toTimeLine 2(Below)

TimeLine 1a

Events:

Chilled Water Pump Off

Cond. Water Pump Off

Solution Pumps Off

ABS and RFGT Pumps Off

Energy Valve Closed

All other Diagnostics areactive

RDV1 Closed

AUTO Selected

Chilled Water PumpStarted

Chilled WaterFlowEstablished Differential to Start

is Reached (CoolingRequired)Condenser Water PumpStarted

Low Temp Solution PumpStarted (AFD at Min. Speed)

Hot Water MachinesHot Water Pump On

Point of Re-Entry if the OperatorHits AUTO from Dilution Cycle

orReset from Diagnostic Auto

orWaiting for Differential to Start(System in AUTO Mode)

Indicates Time Line (1,2 or 3) LocationStandardModeDisplay:

Start FillingGenerator

Start - Preheating Solution Unit is RunningSee Note 1 and 5)(See Note 5)

30Seconds

Waiting to EstablishConcentration of 54%LiBr - Var. Basedon Concentration

Hold for 3 min.to StabilizeSystem

Time Line 2

Events:Command Energy Valve40% of allowable rangeand begin Pre-Heat withAbsorber and RefrigerantPumps Off

RefrigerantPump StartedAbsorberPump Started

Modulate Low Temp SolutionPumps AFD to satisfy LWT

Modulate energy Valve to SatisfyLTHX Crystallization Margin

Go to TimeLine 3(Next Page)

ABS-M-10A22


Figure 8 (Continued) – Sequence of Events: From Running through Dilution Cycle

23ABS-M-10A


Machine Control Strategy

The objective of the unit control systemis to reliably achieve and maintainleaving chilled water setpoint. The unitcontrol panel (UCP) monitors chilledwater temperature and its relation to thepanel set point, and adjusts the amountof solution supplied to the generator,and the energy applied as needed.Adjusting the solution flow maintainsthe leaving water temperature. Adjustingthe energy input maintains solutionconcentration. These two adjustmentsare the two primary control algorithmsemployed in the UCP. ReferenceFigure 9.

1. Leaving Water Temperature (LWT)The unit control panel compares leavingchilled water temperature to the leavingwater set point and adjusts therefrigerant vapor pressure in theevaporator to achieve control. Therefrigerant vapor pressure is determinedby the absorber spray concentration. Theabsorber spray concentration is changedby adjusting the generator solution flowwith the adjustable frequency drive(AFD) control of the absorber spray andlow temperature solution pumps.

Figure 9 – Simplified Diagram of LWT Control and Concentration Control

Absorber spray solution concentrationdetermines the absorber vapor pressurethat controls the refrigerant vaporpressure and temperature. The refrig.spray temperature then controls the LWTto the leaving water temperaturesetpoint.

2. Concentration ControlSolution concentration control adjuststhe generator energy input to holdsolution concentration to optimumefficiency. The strong solutionconcentration is typically maintained15°F [-9.4°C] from theoreticalcrystallization point. This is called thelow temperature heat exchanger (LTHX)temperature margin. As strong solutionconcentration is varied by LWT solutionflow control, the theoreticalcrystallization temperature is changed.The control system adjusts the energyinput to maintain the LTHX temperaturemargin throughout the load range. Thesimplified control illustration belowillustrates the two control inputs andindicates that these inputs must passthrough the “limit control” before thesignals are output the solution pumpAFD and/or energy input control.

Along with the microprocessor control ofLWT and concentration control as statedpreviously, the microprocessor monitorsoperating conditions that could altermachine operation. If such a condition isdetected the limit control system willoverride LWT and concentration controlrequests. The override limit occurs whena control output (from LWT orconcentration control) request is greaterthan allowed by the particular limitschedule. The limit control modifiesmachine control to continue operation.

When a limit or safety takes prioritycontrol, the clear language display willso indicate the active limit mode. A limitmode does not necessarily mean that aproblem exists. In many cases this limitis a normal function such as soft loadduring start-up.

ABS-M-10A24


The microprocessor will shutdown thechiller if a safety set point is violated.

Figure 10 illustrates the limits that canoverride LWT and concentration control.The primary control signal can bemodified by any limit.

Soft LoadingSoft loading is accomplished via afiltered setpoint change function in that itaffects the speed that the machine loadsor unloads when given a new setpointtarget. This occurs at start-up andwhenever the chilled water setpoint ischanged. On start-up, this allows themachine to warm-up gradually, andallows for the tower water to warm-up.Soft loading is also active when a chilledwater setpoint change is received. The

Figure 10 – Limit Conditions that could Override LWT and Concentration Control

new setpoint will be reached as the newtarget setpoint at the end of the set softloading time period. The soft loadingtime period is factory set to 15 minutesand can be set from 1 to 100 by the start-up personnel.

Low Condensing Temperature LimitLow temperature may limit solution flowto prevent salt carryover and/orcrystallization. The factory default settingis designed to provide reliable chilleroperation with low tower temperatures.To do this the solution flow may need tobe limited at condensing temperaturesbelow design. The further below designand the higher the load will increase thelikelihood of this limit mode becomingactive.

Low Refrigerant Temperature Limit andCutoutThis limit prevents the machine fromdriving down the refrigerant temperaturebelow safe and reliable temperatures. Ifan unsafe level is approached the controlstrategy will first limit loading, then entera hold where continued loading is notallowed. If the refrigerant temperaturecontinues to fall, the unit will unload inan attempt to keep the chiller on lineavoiding a low temperature trip. If therefrigerant temperature continues todecrease and the cutout is reached thenan MMR will occur requiring manualreset. For example, with a typical lowrefrigerant temperature setpoint of 36°F[2.2°C] the following will be active points;limit loading will begin with a decreasingrefrigerant temperature reaching 38.5°F[3.6°C], hold loading will occur @ 38°F[3.3°C], and unload will occur at 37.5°F[3.1°C]. Cutout will occur @ 36°F [2.2°C]resulting in a machine shutdown manualreset- MMR- diagnostic. The factorydefault setting is 36°F [2.2°C] and can beadjusted, if required by Trane servicepersonnel.

Low Chilled Water Temperature LimitLow chilled water temperature limitoperates similarly to the low refrigeranttemperature limit previously discussed.For example, with a typical low chilledwater temperature setpoint of 38°F[3.3°C], limited loading begins @ 40.5°F[4.7°C], hold loading @ 40°F [4.4°C],unload at 39.5°F [4.2°C], and trip @ 38°F[3.3°C] resulting in a machine shutdownmanual reset- MMR- diagnostic. Thefactory default setting is 38°F [3.3°C] andcan be adjusted, if required by Traneservice personnel. The minimumdifference between these limits is 2°F or1°C.

25ABS-M-10A


Sensing Detection and Recovery (SDR)Solution flow sensing provides the inputinformation for proper solution flowdetection. This is a back up systemproviding a second line of defense ifconcentration control fails to maintainthe set margin of degrees away from thecrystallization point. If an incorrect flowpattern is detected the control systementers a recovery mode of operation thatcycles the solution pumps andrefrigerant dump valve to dilute thestrong solution, reestablishing thecorrect flow pattern. The control systemwill, on the first and second occurrence,increase the set concentration margin by5°F [-15°C] in an attempt to prevent areoccurrence, and an informationalwarning message will be displayed onthe clear language display. Upon thethird occurrence a machine shutdownmanual reset (MMR) diagnostic will beset and require manual reset aftercorrective action is established.

Steam Input Flow ControlSteady steam input flow is important tomaintain stable concentration control.The control rate at which steam entersthe unit is a function of: A) supplypressure, B) saturation pressure in thegenerator, and, C) the steam valveposition. With steady steam supplypressure the flow can be controlled quitewell with the valve position alone.However, in cases where building steamsupply pressure variations do occur

various flow rates would occur. Thecontrol system would sense this via theabsorption fluid pressures andtemperature, and then makeadjustments as necessary. Today’sSteam Input Flow Control incorporatedin our ABSD and ABTF chillers utilizessteam pressure transducers to measurethe pressures to the valve and at themachine. This information is thenutilized to calculate steam flow todetermine the proper valve positionduring these undesired pressurechanges. The energy valve has a steppercontrol motor with 16,300 steps ofresolution providing very precise valveposition control. The flow controlalgorithm and the finite control of thestepper motor provide the best possiblesteam input control.

Adjustable Frequency Drive (AFD)The low temperature solution pump andabsorber spray pump flow rate arecontrolled by adjusting the operationalspeed of the pumps. This is done by theAFD’s. The main unit control paneloutputs an analog signal to the AFD’sthat drive the solution pumps at thedesired speed to provide the correctamount of solution flow for the machineload condition. This section discussesthe AFD.

AFD Description:An adjustable frequency AC drive is adevice for controlling the speed of an ACmotor by changing the frequency of thepower supplied to the motor. Theadjustable frequency drive is a solid-state power conversion unit that receives3 phase, 60 Hz input power, converts it toDC power, filters it, and then inverts it toprovide motor power that is modulatedto the frequency desired. The AC drivealso regulates the output voltage inproportion to the frequency to provide anominally constant ratio of voltage tofrequency as required by thecharacteristics of the AC motor.

AFD Operation within the AbsorptionSystemThe output from the AFD's providespower for the Absorber (4B2) and LowTemp Solution (4B3) pumps.

Operating FrequencyFigure 11 illustrates the solution range offrequencies used for typical pump motorcontrol, 25 Hz minimum to 54 Hzmaximum. The minimum andmaximum stop values, used in thisexample, are the frequency utilizedrange. The end points will change bymachine size and are factory selected.The end stop locations, indicated inFigure 11, illustrate the differencebetween available and actualfrequencies that could be used during afactory calibration of the controls.

See operator guide for AFD Keypadillustration and flow chart of menu item.

Figure 11 – Pump Motor Supply Frequency

ABS-M-10A26


Purge System Operation

The machine is factory leak checked tohigh standards. Hermetic integrity is thefocus of this design since stability of theunit vacuum is required to maintainchiller efficiency and reliability.Consistent maintenance practice willensure that the factory establishedhermetic integrity is maintained. Non-condensables that accumulate in themachine must be removed by purging.

Absorber Removal of Non-CondensablesAbsorber removal of non-condensablesfrom the absorber/evaporator shell isaccomplished via the pickup tubes andthe eductor. Depending on the chillerconfiguration, the purge pickup tubeswill be through a collection chamber ordrop down tubes. Refer to Figures 12and 13 to see the differences.

The eductor uses the solution beingpumped by the Low TemperatureSolution Pump (LTSP) to remove thenon-condensables from the chamberand pickup tubes. The discharge of theeductor is to the suction side of the LTSPwhere the non-condensable aretransported to the Low TemperatureGenerator (LTG). The dilute solutionpumped through the LTSP carries thenon-condensable to the LTG section. Inthe LTG the non-condensable arereleased from solution and migrate tothe lower pressure of the condenser.From the condenser, the Purifier Purgeremoves the non-condensable bycreating even a lower pressure in thepurge tank. Any non-condensable fromthe high temperature generator arepassed to the condenser through a ventline. The Purifier Purge pumpout cycleinitiates and terminates per the suctiontemperature of the compressor. Thelower temperature creates a lowerpressure to draw non-condensablesfrom the condenser into the purgecollection tank.

Figure 13 – Eductor Position

Timed PumpoutThe purge system will initiate a “timedpumpout” cycle periodically, asdetermined by the timed pumpoutsettings within the Service Settings fieldstart-up menu. This pumpout will pumpout of the absorber via the lowermotorized valve. Usage depends onmachine characteristics and loadconditions.

Automatic Purifier™ Purge OperationAutomatic purge operation occurs withthe absorption machine “on”. Thenormal mode of operation is with thepurge set to “On” on the control panelclear language display. With “On” purgeoperation, the purge condensing unitoperates during chiller operation, andvacuum pump runs continuously. Thecondensing unit draws non-condensables out of the condenser to anon-condensable collection tank.The purge senses when the collectiontank contains non-condensables viasuction temperature and executes thepumpout cycle as necessary. A pumpoutvalve opens to allow the vacuum pumpto expel the collection tank of non-condensables. Pumpout time ismonitored and stored for analysis.

If the purge suction temperature dropsbelow the 30°F [-1.1°C] inhibit level, thepurge system will go into a “standby”mode.

Automatic operation of the purgesystem when the chiller is in the offposition is slightly different. Only thevacuum pump operates and themotorized valve(s) open and close basedon the purge pumpout time andduration interval defined in the FieldStart-up menu.

Figure 12 – Purge tubes and collectionchamber (early design)

Figure 13 – Purge drop tubes (used on laterchillers)

27ABS-M-10A


Purge Operation Modes

Within Operator settings, purge operation can be selected as: Off, On, or Service/Pumpout.

Table 3 identifies the modes and the status of the major components in each mode.

Table 3 – Modes and Status of Major Components in Each Mode

Purge Operating Mode Chiller Operating Mode Condensing Unit Vacuum Pump Pumpout Valve (s)Off On/Off Off Off Closed/OffOn On On On Pumpout By TemperatureOn On On On Pumpout by timed interval

(absorber valve, if installedOn Off Off On Pumpout by timed interval

(condenser tank valve only)Service Pumpout NA On On Open/On

Note: Normally, purge should be in the “on” mode position.

Purge Components

Purifier Purge OperationThe purifier purge is active when thepurge-condensing unit is powered. Theevaporator coil of the condensing unit isused to condense refrigerant vapor inthe purge collection tank. This results ina slightly lower pressure in the purgecollection tank thus, drawing refrigerantvapor and non-condensables into thepurge collection tank. Refrigerant vaporand non-condensables enter the purgetank through a pickup line connected atthe bottom of the purge tank.

Once inside the tank, the refrigerantvapor condenses on the purge tank coiland falls to the bottom of the tank,leaving non-condensables toaccumulate. Liquid refrigerant returns tothe condenser through the return line.The pickup and return lines haveisolation valves that can be closed whentank service is required.

Figure 15 – Purifier Purge Components

ABS-M-10A28


Purifier Purge Operating Cycle

Figure 16 illustrates the cycle of theactive purge.

As non-condensables accumulate in thepurge tank (1) the available condensingsurface in the tank becomes limited, andthe condensing unit compressor suctiontemperature (2) will begin to fall. Whenthe condensing unit compressor suctiontemperature drops to the pumpouttemperature, a sensor signals the purgemodule and a pumpout cycle begins.Non-condensables in the purge tank arethen evacuated with a vacuum pump. Asthe non-condensables are removed fromthe purge tank, the condensing unitcompressor suction temperatureincreases. This condensing temperatureis again sensed at the purge module thatwill terminate the pumpout cycle whenthis temperature rises sufficiently. Thepumpout suction temperature varies inrelationship to the units condensingtemperature. This allows purgeoperation with condensing temperaturesfrom 50°F to 180°F [10°C to 82°C].

Figure 16 – Purifier Purge Refrigerant Circuit

29ABS-M-10A

OperatorGuide

Using the Control Panel

This section provides detail of theoperator interface display, operation,keypad key functions, display groupmenus-report and settings, and how touse these functions.

Operator Interface (Local ClearLanguage Display – LCLD)The operator interface (LCLD) provides amethod to communicate with the chiller.The operator selects information to bedisplayed from eight group keys thathave predetermined menus. All operatorselections and monitored informationare entered and/or displayed from thisdevice. The operator interface obtainsthe selected setup values and data fromthe interprocessor communications (IPC)link. The settings and temperatures willnot be displayed until they have beenread by way of the IPC. Displayed items,such as temperature, will be updatedevery two seconds. Service modemenus provide machine setup, servicetests, and manual control operation.

DisplayFigure 17 illustrates the operatorinterface that features a two-line, forty-character display, an alarm indicator(LED), and a keypad for the selection ofspecific formatted chiller informationmenus. The display has backlighting forlegibility in low light conditions. Thisbacklight is also used to maintain theoperating temperature of the display.During low ambient temperature periodsthe backlight will illuminate. This is doneby the control module controlling thebacklight current, based on theequipment room ambient temperature.

MenusThe display includes all operation status,reports, settings, service, and diagnosticmessages. Details of these menus arediscussed later in this section

Alarm LED

1) The single red LED located to the rightof the display will BLINK whenever amachine manual reset (MMR)diagnostic exists and manual machinereset is required to restore operation.

2) The alarm LED will illuminatecontinuously when a service test itemis placed into manual mode operation.The LED serves as a reminder thatsomething remains in manual mode.

Normal machine operation does notrequire manual mode operation of anyservice tests (password protected) items.

Operator Interface (LCLD)Operation

KeypadFigure 17 illustrates the operatorinterface keypad. The keypad is a sealedmembrane type with 16 keys arranged 4by 4. The keys are separated into threefields:

1) Report keys are located across the toprow and are used for viewing ofpreformatted information menus.

2) The second row of keys are setting’sgroup menus.

3) Functional keys are located across thebottom two rows and are used toinput changes.

The functional keys are discussed nextsince the operation determines how theuser communicates with the report andsetting’s menus.

Figure 17– Operator Interface

Functional KeysThe Next and Previous keys cause thedisplay to step through the variousmenus within a group. The report groupwill sequence around to the top orbottom of the group when the end orbeginning is reached, respectively. The(+) and (-) keys cause the setting beingdisplayed to increase or decrease,respectively. If the (+) or (-) key is helddown for more than 1/2 second it willincrement or decrement the settingcontinuously at 10 counts per second,until the key is released. (Settings do notwrap around when the end of range isreached.) Once the (+) or (-) key has beenpressed to select a particular setting, theEnter key or Cancel key must be pressed.(The Next or Previous keys will notadvance until Enter or Cancel ispressed.) A Setting is not changed untilthe Enter key is pressed. The Cancel keyis pressed if a changed setting shouldnot be saved. When the Enter key ispressed the display will blank outmomentarily to indicate to the operatorthat the keystroke was recognized.

ABS-M-10A30

If the boundaries of a specific selectionare exceeded the operator interface willdisplay out of range and will not allowthat selection to be entered.

When Auto is pressed the chiller willenter an auto mode of operation. WhenStop is pressed the chiller will stop,entering the “Unit is Preparing toShutdown” mode.

During the five-second period a messageindicating the optional emergency stopcommand will be displayed. The Stopkey is located in the lower right handcorner.

IMPORTANTIf the Stop key is pressed a second timewithin five seconds an immediate “PanicStop” will be executed, overriding thenormal “Unit is Preparing to Shutdown”mode.

To restart the dilution cycle, press Stopkey. To reenter auto mode press Auto. Ifthe leaving water temperature does notexceed the differential, to start thedilution cycle is entered for the durationof the timer, and “Auto waiting need tocool” will be displayed along withdilution cycle time remaining. If theleaving water temperature is greaterthan differential to start, then the restartauto sequence will occur.

When the Auto or Stop key is pressedthe display will go to the first display ofthe Chiller Report indicating the currentoperating mode.

Using Group Menus

1. Select one of the group keys labeledChiller, Cycle, or Purge-Pump sincethese groups contain preformattedreport menus. This will bring up therespective header display. PressingCustom Report will bring up itsheader display however; there maynot be any items within this group atthis time. Pressing Operator Settings,Service Settings, Service Tests, orDiagnostics will bring up its headerdisplay. See the operator interfaceoverview for a listing of displayheaders and the menu items.

2. Press the Next key to advance, orpress the Previous key to backup,while scrolling through the displayswithin each group menu. (To quicklygo to the last menu item press thePrevious key at the display header.)

To Create the Custom Report:

1. Go to one of the Report Groups(Chiller, Cycle, Pump/Purge) and selectthe desired menu item to add to theCustom Report.

2. Press the (+) key. The item is nowentered into the Custom Reportgroup.

3. To add another repeat step 1 and 2.

4. Up to twenty items can be enteredinto the Custom Report group. Whenthere are twenty items in the report nomore can be added until one isremoved.

5. To remove an item from the CustomReport, press the (-) key, while it isdisplayed.

To Change Settings

1. Press the appropriate settings groupkey.

2. Press the Next key at the headerdisplay.

3. Enter password if required.

4. Use the Next/Previous key to bring upthe item to be changed.

5. When the item to be changed is on thedisplay press the (+)(-) to bring up thenew value.

6. Press Enter to enter the new value.Press Cancel to keep the previousvalue.

To Reset the Chiller

1. Press the Diagnostics group key.

2. The Diagnostics display header will beshown. Press the Next key.

3. Enter password if required.

4. View all active diagnostics displayed.Investigate and correct the problemthat caused the shut down, beforeproceeding to restart the chiller.

5. To reset the chiller press Next until thediagnostics clearing display stating“Press (Enter) to clear all diagnosticsand reset system” is displayed. PressEnter. When the diagnostic is clearedthe chiller will return to theoperational mode that wasinterrupted by the diagnostic. Thechiller must not be reset until thediagnostic condition is addressed, andcorrected. If required, contact the localTrane service agency for assistance.

6. Chiller may restart if in “auto” anddifferential to start is satisfied. Pressstop to prevent starting, if desired.

To Change Setpoint

1. Press Operator Settings key.

2. Using the Next key, advance to “FrontPanel Chilled Wtr Setpt.”

3. Using the +/- keys, change the setpointas desired. Press Enter.

PurgingThe purge operation mode is normallyset to “on“ mode.

While in on, purging will occur duringmachine auto and stop modes ofoperation. To check or set to on:

1. Press Operator Settings key.

2. Press Next to advance to “PurgeOperating Mode” display.

3. Use +/- keys to toggle between modes.Select On. Press Enter.

For manual on purging see maintenancesection.

Operator Interface (LCLD)Overview

The following is a listing of preformattedmenu information contained in theoperator interface, including options.

Menu items are listed in sequence and incolumns under each group key.

OperatorGuide

31ABS-M-10A

OperatorGuide

Figure 18 – Custom Report, Chiller Report, Cycle Report

ABS-M-10A32

OperatorGuide

Figure 19 – Purge/ Pump Report

33ABS-M-10A

OperatorGuide

Figure 20 – Operator Settings

ABS-M-10A34

OperatorGuide

Figure 21 – Service Settings

35ABS-M-10A

OperatorGuide

Figure 22 – Service Tests

ABS-M-10A36

OperatorGuide

Figure 23 – Diagnostics

37ABS-M-10A

OperatorGuide

Operator Interface Detail

This section provides detailed menuinformation.

Report MenusThe Report Keys (top row) allow theoperator to access four report groupsthat are labeled CUSTOM, CHILLER,CYCLE, and PUMP/PURGE. TheCUSTOM report is formatted by themachine operator. The report groups(CHILLER, CYCLE, and PURGE/PUMP)have preformatted menus.

When a report group key is pressed themenu header is displayed. The headerdisplay indicates the title of the reportgroup and a brief summary of thereports contained in the group. Thisenables a user to quickly review eachreport header to determine if the desiredinformation is in the group. The headeralso serves as the top of the reportindicator.

CustomReport

ChillerReport

CycleReport

Pump/PurgeReport

Custom ReportThe Custom Report contains informationselected by the operator. The customreport section allows the user to selectand display up to twenty items of theirchoice selected from the CHILLER,CYCLE, and/or PUMP/PURGE reportgroups. The Custom report is the onlyreport where the displayed informationis selected by the user.

The custom report can easily beprogrammed by the following sequence:

Menu Items can be duplicated in thecustom report by pressing the (+) key,when the desired report is beingdisplayed from one of the other reportmenus. The custom report group cancontain up to twenty entries. Attemptingto enter another report when the usercustom report is full results in the displayindicating “User Report -> Full.” Tochange or remove reports in the customreport group, simply press the (-) keywhile it is being displayed and the reportitem is removed.

The custom report sequence starts withthe following header display:

If no entries are selected and the nextkey is pressed the following is displayed:

User Defined Report

Press (Next) (Previous) to Continue

No Items are Selected for Custom Report

See Operators Manual to Select Entries

If entries exist they will be displayed inthe order that they were selected fromthe other report groups.

The Chiller Report, Cycle Report, andPump/Purge Report groups containpreformatted information that cannot bechanged.

CustomReport

ChillerReport

CycleReport

Pump/PurgeReport

Chiller ReportThe Chiller Report contains unitoperating condition information. Status,water temperature, and setpoints.

Chiller Operating Mode: Two lines ofdisplay indicate the Chiller OperatingMode depending upon machine status,various chiller operation modes that canbe displayed is illustrated in the columnto the right. In the case of timingfunctions, line 2 indicates the associatedtimer information. Timer functions aredisplayed and inform the operator ofexpected delays within the sequence ofoperation.

Operating Mode Line 1 and Line 2(Two Lines Describing Operating Conditions)

Press (Next) or (Previous) to Continue

CustomReport

ChillerReport

CycleReport

Pump/PurgeReport

Cycle ReportThe CYCLE REPORT is used to displaymachine temperatures and pressures.

CustomReport

ChillerReport

CycleReport

Pump/PurgeReport

Purge/Pump ReportThe PUMP/PURGE REPORT is used todisplay run time information regardingpumps in the machine.

ABS-M-10A38

OperatorGuide

Table 4 – Chiller Operation Mode Displays

Machine Condition Displayed Message (First Line/Second Line)Reset ResettingStop Local Stop: Cannot be overridden by any External or Remote DeviceRemote Stop Remote Display Stop: Chiller may be set to Auto by any Ext or Rmt DeviceExternal Unit Stop Remote Run Inhibit from External SourceUnit Remote Stop Remote Run Inhibit from TracerStart InitializingStart Starting is Inhibited by Staggered Start

Time Remaining: Min/SecStart StartingStart Starting

Waiting for Chilled Water FlowAuto Waiting for Tracer Communications to Establish Operating StatusAuto Auto

Waiting for a Need to CoolStart Starting

Absorber/Condenser Water FlowStart Starting Solution PumpsStart Starting - Pre-heating Solution

Spray Pumps OffStart Starting - Pre-heating Solution

Spray Pumps OnRun: Normal Cooling Only Unit is CoolingRun: Low Cooling Unit is Running:Water Temp Limit Low Absorber/Cds Temp LimitRun: Evap Limit Unit Is Running

Low Evap Rfgt Temp LimitRun: Crystallization Sensing Solution Recovery Pump OffDetection and Recovery Time Remaining Min/SecRun: Crystallization Sensing Solution Recovery Pump OnDetection and Recovery Time Remaining Min/SecDilution Cycle Dilution Cycle Remaining:

Min/SecWaiting for a Need to Cool

Dilution Cycle Dilution Cycle Remaining:Min/SecDiagnostic Shutdown Auto

Dilution Cycle Dilution Cycle Remaining:Min/SecDiagnostic Shutdown Stop

Dilution Cycle Dilution Cycle Remaining:Min/SecLocal Stop

Dilution Cycle Dilution Cycle Remaining:Min/SecRemote Stop

Dilution Cycle Dilution Cycle Remaining:Min/SecRemove Run Inhibit from Ext Source

Dilution Cycle Dilution Cycle Remaining:Min/SecRemote Run Inhibit from Tracer

Stop: Transitioning to Stop Transitioning to StopPanic Shutdown Panic Shutdown Seq. Complete

Press Auto/Stop to ContinueDiagnostic Shutdown Diagnostic Shutdown StopStop ModeDiagnostic Shutdown Diagnostic Shutdown AutoAuto from Auto Mode

39ABS-M-10A

OperatorGuide

Operator SettingsThe Settings keys (second row) allowthe operator to select from four menugroups. Entering a group allows theoperator to select any items containedwithin the group. A setting’s group startsat a header display when the selectedsetting’s key is pressed.

Operator Level PasswordThe operator settings, service settings(basic setup), and diagnostics groupmenu items can be secured by anoperator level password.

This feature is predetermined and set atthe factory. If operator password isdesired contact your local Trane servicecompany. On all machines, this feature isselected within a higher level securityaccessible within the service levelpassword field start-up group.

When this feature is enabled, the displayfollowing the header will state either“Settings in this menu are LOCKED orUNLOCKED.” If LOCKED, the second linewill state “Enter password to unlock.”Operator level password is(-+-+-+ & Enter). An incorrect passwordwill result in the message “accessdenied.” If UNLOCKED, the second linewill state “Press (Enter) to lock.”Pressing ENTER will lock all the settingswithin the three groups (operatorsettings, service settings (basic setup),and diagnostic groups). When locked,menu items can be viewed, however, thesecond line of the displays will notindicate “Press +/- to change setting”and any attempt to change a setting willcause the second line to momentarilyindicate “setting is locked.” To UNLOCK,sequence back to the screen that statesenter password to unlock the threegroups (operator settings, servicesettings (basic setup), and thediagnostics groups).

When “Service Settings, Field Start-up”selection of this feature is disabled theprevious operator password displaysand indications of locked or unlocked isbypassed and is not shown.

OperatorSettings

ServiceSettings

ServiceTests Diagnostics

The Service Settings menu has threesubmenus within it. The first is non-password protected and consists of allthe settings, feature enables, setpointsetc. While they are seldom changed by auser, changes in them do not seriouslyeffect the protection or reliability of thechiller.

The other submenus (field start-up andmachine configuration) are protected,each with a separate service levelpassword. These are for changingparameters and settings regarding fieldcommissioning and fundamentalprotection and control of the chillersubsystems (Field Start-up) or forprogramming of the unit control module(UCM) as to how the specific chiller wasbuilt in the Factory (MachineConfiguration).

Once properly set, these menus shouldnever be changed again without specificknowledge of the effects of the changes.In rare instances, certain field problemsmay be corrected by making changes inthese protected menus but certainaspects of chiller reliability may becompromised. The main reason theseare accessible at all is for fieldcommissioning and to allow for theprogramming of service replacementmodules.

OperatorSettings

ServiceSettings


OperatorSettings

ServiceSettings


Service TestsThe Service Test menu provides accessto screens used to change from “Auto”mode to Manual mode. Manual modecontrol overrides specific auto controlfunctions. Tests and status screensprovide a means to check the operationof some output and input devices.

Anytime a manual mode is selected thealarm light will remain on.

OperatorSettings

ServiceSettings


Diagnostics MenuThe Diagnostics Menu contains bothactive and historical information. Themenu also contains the facility to clearactive diagnostics, historic diagnostics,and purge diagnostics as individualgroups. To clearly enunciate theoccurrence of a diagnostic, the displaywill automatically go to this menu anddisplay certain messages as explainedbelow.

New Diagnostic Display SequenceWhen a new diagnostic is sensed by thesystem, the display will reset to thediagnostic menu. A “one-time” screenwill be displayed to inform the user thata new diagnostic has been detected.

This “one-time” screen will varydepending on the type of diagnosticdetected. The two major categories ofdiagnostics are those which areinformational warning only (IFW), andthose which have resulted in machineshutdown; machine shutdown manualreset required (MMR) and machineshutdown auto reset (MAR).

Settings Menus Normal machine operation does notrequire the use of any service test items;therefore they remain within apassword-protected (+ + - - + +) menu.Manual operation of these items willeffect chiller operation and will causeunreliable operation, if left in manualmode. It is therefore recommended thatonly qualified personnel use servicetests.

ABS-M-10A40

Adjustable Frequency Drive (AFD)KeypadFigure 24 illustrates the AFD keypad.Machine operation does not requireusing this keypad. The AFD will normallyoperate in “auto” mode. Only in the caseof abnormal condition for reset, or byservice personnel, will this keypadrequire usage.

Figure 24 – AFD Keypad Overview (Model JVOP-130P Illustrated)

The AFD is factory programmed for usein this application. Do not attempt toreprogram any parameter as this mayjeopardize machine operation andreliability.

OperatorGuide

CAUTION

41ABS-M-10A

Figure 25 – LED Description

OperatorGuide

Pressing the “DSPL” key advances theDigital Operator through the Menusillustrated in Figure 25.

ABS-M-10A42

Maintenance

Maintenance

This section contains maintenanceinformation for the Steam or Hot WaterAbsorption Chiller.

Daily MaintenanceTo ensure reliable, safe and efficientoperation the following items should bechecked daily as routine maintenance.This will avoid unnoticed problems thatcould lead to down time, and providesdaily data that can highlight trends,locating potential problems before theyoccur:

1. Record and review operating data.Use the operating log found on thenext page and log the pointssuggested.

Familiarization with the daily logtemperatures and other items allowsthe operator to identify when achange occurs, possibly indicating anabnormal condition. Review the dailyoperating history with the servicepersonnel as necessary or at the nextinspection. (Verify temperatures andpressure gauges for operation.)

2. Make sure the machine is operatingproperly. Cycle the machine on andoff periodically to make sure it startsand stops properly. This allows safetydevices to sequence through a start-up to confirm operation.

3. Check the cooling tower for correctwater treatment, machine inlettemperature and flow, and checksystem chilled water (EvaporatorCircuit). Check water flow pressuredrop daily. Clean strainers yearly.

The owner should engage theservices of a qualified water treatmentspecialist to obtain the treatmentneeded to control tube fouling andmaintain machine efficiency.Untreated or improperly treated waterwill reduce machine efficiency, andmay require extensive tube cleaningor possible tube replacement, if thechemical balance of the water is notcontrolled.

Always allow the chiller to complete adilution cycle before disconnecting thechiller power source.

CAUTION

43ABS-M-10A

Maintenance

Figure 26

Horizon – Absorption Operating Log

Job Name _____________________________________________ Serial Number ____________________________________________

Machine Model Number _________________________________ Date - Month: ________________ Week: ______________________

Sunday Monday Tuesday Wednesday Thursday Friday SaturdayItem AM PM AM PM AM PM AM PM AM PM AM PM AM PM

Evaporator IN

Pressure OUT

Absorber/Cond IN

Pressure OUT

Accumulated Run Time

Solution Cycle Data Items

S.D.R. Temp.

Solution Leaving LTG

Saturated Condenser Rfgt. Temp.

Absorber Entering Concentration

LiBr Crystallization Margin

Solution Temp. Entering Absorber

Absorber Spray Temp.

Solution Temp. Leaving Absorber

Solution Temp. Entering LTG

Saturated Evaporator Rfgt. Temp.

Evaporator Leaving Water Temp.

Evaporator Entering Water Temp.

Absorber Entering Water Temp.

Absorber Leaving Water Temp.

Condenser Leaving Water Temp.

Steam: Supply Pressure

Steam: Generator Pressure

Solution Pump AFD Auto Speed

Energy Input Command

Purge Status

“ “ Suction Temperature

“ “ Pump Out Rate

“ “ Pump Out Time

“ “ Time Since Pump Out Time Reset

“ “ Chiller Average Run Time

ABS-M-10A44

Maintenance

Seasonal Maintenance

Cooling Season Preliminary RemindersThe following items should be checkedbefore seasonal start-up. Contact youlocal Trane service representative toperform the service.

1. Check unit vacuum. Check the actualunit internal vacuum to determine ifpurging is required, before the unitcan be safely started after extendedshutdown. See unit vacuum checkout.The maximum internal pressure isdependent on the machinetemperature. If purging is requiredfollow purging instructions (Purgesection).

2. Determine the purge pump condition.Run the pump and verifyperformance. Check the ultimatepressure performance and change oil/repair pump if required.

3. Prepare machine for cooling. Fillcondenser, vent air from thecondenser water boxes. Venting willremove air from within the piping andavoid nuisance trips of the condenserflow switch input.

4. Check all piping connections forpossible water leakage. Checkabsorber, condenser, evaporatorwater piping. Assure that any offseason work and reassembly iscomplete.

5. Check pressure drop across the chillerevaporator and condenser sections.Compare to unit design conditions.

6. Visually inspect electrical system. Lookfor signs of any alterations performedsince the last operational season, andverify wiring is intact. Clean AFD’s ofdust and grime.

7. Confirm the chilled/hot water pump,cooling water pump and coolingtower is interlocked. Check the fieldproof of operation interlocking wiringfor the chilled/water flow, and forcondenser water flow.

8. Determine electrical condition ofpump motor contactors.

9. Test run the unit. Check machinecontrol sequence.

10. Replace bromide filter.

11. Purge the machine of non-condensibles. Check purge rate afterthe machine is started. Keep machineenergy rate reduced until purge ratediminishes during unit operation

12. Log unit-operating data. Checktemperatures and pressuresthroughout the fluid cycle. Check thatLTSP, ASP, and RP Amp draw andvoltages are normal and notexcessive.

13. Water treatment It is recommendedthat all tubes be tested periodicallyby a qualified nondestructive tubetesting service. This testing willconfirm tube condition and identifypotential problems.

Extended Shutdown

Drain water circuits (Evap, Cond/Abs)completely, and blow out all water fromtubes and water boxes.

Main power must remain applied to theunit to allow automatic purging.

45ABS-M-10A

Maintenance

Chart 1 – Shutdown Machine Vacuum ChartSeasonal Start-Up UnitVacuum Check

Start-up after extended shutdownshould not be attempted until the unitvacuum is measured and compared withChart 1. Any combination of temperatureand pressure that falls on or below theline of Chart 1 indicates a safe condition.The unit purging is required before start-up if the measured vacuum is above theacceptable limit.

Check unit internal vacuum at theabsorber service valve located on theside of the absorber shell. This valve isabove the liquid level in the chiller.

20[-6.7]

30[-1.1]

40[4.4]

50[10]

60[15.6]

70[21.1]

80[26.7]

90[32.2]

100[37.8]

120[49.9]

140[60]

Machine Temperature °F [°C]

ABS-M-10A46

Maintenance

Purging During Extended UnitShutdownDuring periods of extended shut down,when chiller will not be operated, theoperator can open an additional handvalve to provide a path for non-condensables between the evaporator/absorber section and the generator/condenser section. Reclose this manualvalve before the chiller is placed intooperation.

Purifier Purge Service PumpoutOperationServicing may require continuouspumping out of non-condensables. Inthis case, “service pumpout” mode canbe used.

To enter Service pumpout mode select“Service Pumpout - ON” at the purgescreen within the Operators Settingsgroup. The condensing unit, vacuumpump, and valve all turn “on.” Servicepumpout will run continuously untilmanually selected to another mode. Nominutes will accumulate on thepumpout timer in the service pumpoutmode.

Aux. Absorber Pumpout -ManualThe absorber is automatically depletedof non-condensables during chilleroperation by the eductor operation, andthe absorber motorized valve. If manualpumpout is desired, this can beaccomplished by way of the manualhand valve and the temporaryconnection of an auxiliary vacuumpump. Manual purging the absorbermust only be performed during machineoperation when the dilute solution levelis below the top of the absorber.

Purge as a Maintenance ToolPurge activity indicates non-condensables within the chiller.Excessive purging activity may indicatean air leak or unusual inhibitorconsumption. An inhibitor analysis maybe required. The 24 hour fault timermonitors the total pumpout time withinany 24 hour period, and if it exceeds thepreset timer setting a fault signal isgenerated to alert the operator thatpurge activity is excessive. The operatorinterface provides access to this data inthe pump/purge report group.

Note: The pumpout time onlyaccumulates the minutes of pumpoutactivity of the automatic pumpoutoperation. It does not accumulate thetime of pumpout for service pumpoutoperation or timed pumpout operation.

47ABS-M-10A

Maintenance

Machine Checkout

GeneralTo assure machine reliability, safety, andefficiency, routine maintenance of thechiller/control system is required.

During servicing, always operate thechiller from the unit local control panel.Always allow the chiller to complete adilution cycle before disconnectingpower. See sequence of operation fordilution cycle details located in thecontrols section.

Always turn electrical power supply(s)off before undertaking any maintenancethat does not require machineoperation.

Machine inspections should beperformed periodically. Some inspectionis recommended every 3 months,whereas others are at 6 and/or 12months.

Inspection FrequencyRecommendationsTable 5 illustrates machine relatedinspection items and the appropriatefrequency. Performing the maintenanceat the intervals suggested will providethe basis for machine reliability.

When appropriate, contact your localTrane service representative and followcomponent manufacturerrecommendations in all cases, and checklocal codes for any additional regulationsthat may be required.

Table 5 – Machine Inspection Recommendations

Machine Inspection Items MonthsFor the following Machine Items, refer to the applicable section in this Manualand/or contact a Trane service technician. 3 6 121) Analyze unit solution to determine inhibitor consumption X2) Check unit control panel Sequence of operation X

Check all wire terminal connections for tightnessCheck AFD’s for cleanliness. Follow the corrective action in Table 12. XAlways keep cover(s) closed on control panel and connection boxes.

3) Check unit safeties setting and function – Contact a Trane service technician. X4) Check purge system: X• Checking belt tension and condition. X• Check purge pump - ultimate pressure. X• Replacement or overhaul purge pump – Contact a Trane service technician. 3 yr• Check for leaks, purge valves – Contact a Trane service technician. X• Clean condensing unit coil – Contact a Trane service technician. X X• Check condition of purge vacuum pump oil – Contact a Trane service technician. X X X5) Check volts and amps of solution pumps and refrigerant pump. X6) Clean tubes. X• Brush tubes. X• Check water quality analysis of evaporator water and cooling water. X*• Eddy current tube inspection should be conducted every third year of operation. 3 yr7) Solution Pumps: Verify amps, Listen to operation. X

*Or as directed.

Service Frequency RecommendationsThese recommendations may varywhen unusual machine room conditionsexist. Lithium bromide analysis isrecommended yearly. The purpose is todetermine solution inhibitor levels andreplace as needed to control solutionquality.

System Chilled Water (Evaporator)Circuit and Water TreatmentIt is recommended that the ownerengage the services of a qualified watertreatment specialist to make tests andrecommend the treatment necessary tocontrol any contaminating material fromthe water.

THE TRANE COMPANY ASSUMES NORESPONSIBILITY FOR EQUIPMENTFAILURE RESULTING FROMUNTREATED OR IMPROPERLYTREATED WATER.

It is further recommended that all tubesbe tested periodically by a qualifiednondestructive tube testing service. Thistesting will confirm tube condition andidentify potential problems.

Check water flow pressure drop daily.Clean strainers yearly.

The system water circuit is a closedcircuit and normally will not accumulatean appreciable amount of sludge orscale. However, if cleaning should berequired, use the same method outlinedfor the cooling water circuit.

Condenser and AbsorberTube Care

Internal fouling of the condenser andabsorber tubes will seriously reducetheir ability to transfer heat to the coolingwater.

The resulting higher temperature andpressure have several undesirableeffects.

1. The refrigerant condensing capabilityof the condenser is reduced.

2. The absorber saturation pressure isincreased because the solution is notcooled.

3. The higher condenser saturationtemperature may cause the formationof hydrogen gas, which must bepurged from the absorber.

NOTE: To insure reliable and efficientmachine operation, the cooling watermust be properly treated. The TraneCompany assumes no responsibility forequipment failure resulting fromuntreated or improperly treated water.

CAUTION

ABS-M-10A48

Maintenance

Cleaning the Tower WaterCircuit

Check water flow pressure drop daily.Clean strainers yearly or as conditionsrequire.

Water available for cooling frequentlycontains minerals that will precipitate outon the walls of the tower water circuit inthe form of a carbonate scale. Coolingtowers collect foreign material that willdeposit in the tubes and limit machineefficiency. At a minimum, condenser andabsorber tubes should be brushed aftereach cooling season.

To insure maximum efficiency, thecooling water circuit must be kept free ofboth sludge and scale. Even a very thincoating of scale will greatly decrease theheat transfer capacity of the absorberand condenser bundles. The condensertubes should be inspected once a year todetermine if mechanical cleaning isrequired and if the water treatment iseffective.

Two methods for cleaning the tubes are:1. Mechanical2. Chemical

The mechanical method is used toremove sludge and loose material fromthe tubes. Access to the tubes isobtained by removing the absorber andcondenser water headers. To loosen thematerial, work a nylon or brass bristlebrush through the tubes (a brass brushis recommended). After the material hasbeen loosened, flush the tubes with clearwater.

Scale deposits are best removed bychemical means. The tower water circuitis constructed of copper, steel and cupro-nickel.

Figure 27 illustrates a typical chemical-cleaning hookup. The cleaning hookup ismade to pipe fittings installed in theabsorber supply and condenser returnpiping.

Figure 27 – Tube Cleaning Arrangement

All materials used in the externalcirculation system, quantity of solution,duration of cleaning period and anyrequired safety precautions should beapproved by the company furnishing thematerials or performing the cleaning.Table 6 lists the liquid volume (in gallons/liters) of the tubes and water boxes.

Table 6 – Tube and Water Box Liquid Volumes (Gallons)

Tube and Water Box Volumes(US Gallons/Liter)

Unit Size Evap. Abs./Cds.500 164 / 622 328 / 1241600 189 / 717 375 / 1419700 244 / 923 435 / 1648800 273 / 1032 481 / 1820975 300 / 1137 570 / 2158

1100 325 / 1231 612 / 23171225 350 / 1325 654 / 24761350 375 / 1419 696 / 2635

Water Box Cover BoltingRequirements(Refer to Table 7)

To insure gasket sealing, the boltingprocedure of covers must be as follows:• Use anti-seize compound on all bolts

before installing water box covers.• Insert and snug up the first 6 to 10 bolts

towards the centerline of each cover.Insure the cover is flat against themating surface and the bolts are justmore than finger tight.

• Tighten bolts starting from the center attop and bottom of each cover andworking outwards to the corners.

Table 7 – Bolt Torque Requirements

Bolt Size Torque(Inch) (Ft. Lbs.) N-M

1/4 7 9.55/16 15 20.03/8 40 54.07/16 52 70.01/2 100 135.05/8 160 216.03/4 295 400.07/8 410 555.01 550 745.0

Note: General bolt torque’s requirements for grade 5 zinc-plated course threaded bolts are listed above.

49ABS-M-10A

Cooling Tower TemperatureControl

Control

1. Cooling tower water temperaturesmust be maintained at or above 65 Ffor reliable operation. Control panellogic circuits allow start-up attemperatures well below the designselection temperature and will protectagainst unsafe conditions.

2. To avoid oscillatory effects of towerwater fluctuations being influenced onthe leaving chilled water temperatureentering tower water temperaturecontrol should be kept constant.

Any time tower entering temperature isat or below design, the potential for“Low cooling entering watertemperature limit” exists. Depending onthe chiller load, the actual temperature ofthe water will determine the likelihood tosee this limit actively limiting machinecapacity. The further away from designthat the water temperature deviates themore limiting potential exists. Thiscontrol system logic feature is built in toassure continued machine operation andmachine reliability, and to control thepotential for salt carryover and/orcrystallization.

Figure 28 – Typical Machine Piping and Instrumentation

Maintenance

The maximum rate of tower temperaturechange must be kept to a minimum.Inherent problems with larger towerwater fluctuations are:• First, the potential to drop the leaving

water temperature to the chillersdifferential to stop setpoint.

• Second, cause a crystallizationdetection and recovery cycle to beentered (typically lasts approximately11 minutes after which the chiller willrestart and proceed to reestablishchilled water temperature control).

• Inefficient operation because unable tomaintain margin.

A cooling tower bypass or variablespeed fan is recommended for stablecontrol of the chilled water circuit.

See Figure 28.

ABS-M-10A50

Maintenance

Tube Support LocationsTable 8 identifies the location of the internal tube supports.

Table 8

LH TubeUnit sheetSize Bundle to 1st 1st - 2nd 2nd - 3rd 3rd - 4th 4th - 5th 5th - 6th 6th - 7th 7th - 8th 8th - 9th 9th - 10th 10th - 11th 11th - 12th 12th - 13th 13th - 14th

500 abs 42 7/8 42 7/8 42 7/8 42 7/8 naevap 42 7/8 42 7/8 42 7/8 42 7/8 naCond 42 7/8 42 7/8 42 7/8 42 7/8 nagen 21 3/8 21 3/8 21 3/8 21 3/8 21 3/8 21 3/8 21 3/8 21 3/8 na

600 abs 40 5/8 40 5/8 40 5/8 40 5/8 40 5/8 naevap 40 5/8 40 5/8 40 5/8 40 5/8 40 5/8 naCond 40 5/8 40 5/8 40 5/8 40 5/8 40 5/8 nagen 20 3/8 20 3/8 20 3/8 20 3/8 20 3/8 20 3/8 20 3/8 20 3/8 20 3/8 20 3/8 na

700 abs 39 ¼ 39 ¼ 39 ¼ 39 ¼ 39 ¼ 39 ¼ Naevap 39 ¼ 39 ¼ 39 ¼ 39 ¼ 39 ¼ 39 ¼ NaCond 39 ¼ 39 ¼ 39 ¼ 39 ¼ 39 ¼ 39 ¼ Nagen 19 5/8 19 5/8 19 5/8 19 5/8 19 5/8 19 5/8 19 5/8 19 5/8 19 5/8 19 5/8 19 5/8 19 5/8 na

800 abs 38 ¼ 38 ¼ 38 ¼ 38 ¼ 38 ¼ 38 ¼ 38 ¼ naevap 38 ¼ 38 ¼ 38 ¼ 38 ¼ 38 ¼ 38 ¼ 38 ¼ naCond 38 ¼ 38 ¼ 38 ¼ 38 ¼ 38 ¼ 38 ¼ 38 ¼ nagen 19 1/8 19 1/8 19 1/8 19 1/8 19 1/8 19 1/8 19 1/8 19 1/8 19 1/8 19 1/8 19 1/8 19 1/8 19 1/8 19 1/8

975 abs 35 3/8 35 3/8 35 3/8 35 3/8 35 3/8 35 3/8evap 46 38 44 ½ 38 46 naCond 52 7/8 53 53 52 7/8 nagen 23 3/8 26 ½ 26 ½ 26 ½ 26 ½ 26 ½ 26 ½ 23 3/8 na

1100 abs 35 ¼ 35 ¼ 35 ¼ 24 ½ 35 ¼ 35 ¼ 35 ¼ naevap 47 3/8 47 ¼ 47 ¼ 47 ¼ 47 3/8 naCond 47 1/8 47 47 47 47 1/8 nagen 23 5/8 23 ½ 23 ½ 23 ½ 23 ½ 23 ½ 23 ½ 23 ½ 23 ½ 23 5/8

1225 abs 35 35 24 7/8 35 35 24 7/8 35 35 naevap 47 5/8 47 ¼ 47 ¼ 35 ¼ 35 ¼ 47 5/8 naCond 43 1/8 43 1/8 43 1/8 43 1/8 43 1/8 43 1/8 nagen 21 9/16 21 9/16 21 9/16 21 9/16 21 9/16 21 9/16 21 9/16 21 9/16 21 9/16 21 9/16 21 9/16 21 9/16

1350 abs 35 3/8 35 ½ 35 ½ 35 ½ 35 ½ 35 ½ 35 ½ 35 3/8 naevap 47 5/8 47 ¼ 47 ¼ 47 ¼ 47 ¼ 47 5/8 naCond 47 3/8 47 47 47 47 47 5/8 nagen 23 ¾ 23 5/8 23 ½ 23 ½ 23 ½ 23 ½ 23 ½ 23 ½ 23 ½ 23 ½ 23 5/8 23 ¾

Table of Tube support locations. Column 1 indicates (inches) from left hand tube sheet to the 1st tube support, column 2 indicates inches between 1st and 2nd supports,column 3 indicates inches between 2nd to 3rd support, etc.

51ABS-M-10A

Purge Vacuum Pump and MotorAssembly

Drive Belt Checkout and Adjustment

Do not touch the belt while it is rotating.

Serious personal injury can result fromcontact with rotating parts. Turn powerOFF before servicing belt.

Belt tension maintenance is important.Too tight or loose adjustment can causedamage to the shaft bearings. Too loosean adjustment allows the belt to slipand shorten the lifetime of the belt.

1. Check pulley alignment and V-belttension. The belt should depressabout 1/2 to 3/4" [13 to 19 mm] underlight hand pressure applied tomidway between the pulleys. Beltadjustments are made by looseningthe motor hold-down bolts and slidingthe motor toward or away from thevacuum pump as required.

2. Adjust the tension of the belt onceagain a week after unit operation tocompensate for stretch due to break-in.

3. The adjustment of the belt tensionshould be made by parallel shifting ofthe motor. Tighten adjusting nuts orbolts securely after adjustments.

4. If required, clean the purge drive beltswith an approved belt cleaner.

Periodic CheckingCheck the following points periodically.

1. Check if bolts and nuts are tight.

2. Check to see if the gas ballast valveand solenoid valve is operable.

3. Check for leakage of oil from the shaftseal or pump casing.

4. Replace vacuum pump oil periodicallyto maintain pump performance.Check the oil turbidity through the oillevel window.

Oil ReplacementReplace oil when the ultimate pressureof the pump itself is unsatisfactory or theoil becomes too dirty. Although the oilbecomes somewhat dirty duringoperation, the pump can be operatedproviding an adequate suction vacuumis obtained. Milky oil indicates highmoisture content. Excessive pumpingand/or purging when noncondensablesare not present will cause water vapor tobe drawn from the chiller whichcondenses into the oil. Limit the use ofservice pumpout and verify correctballast settings, and verify timedpumpout settings.

Oil ReplacementReplace the oil using the followingprocedures:

1. Warm the oil by operating the pumpfor approximately fifteen minutes withthe intake closed. Stop the purgeoperation from operator setting groupmenu. Open the drain oil cock anddrain, almost all the oil. Most of the oilwill drain out freely.

Do not touch the belt while it is rotating.

Serious personal injury can result fromcontact with rotating parts. Turn powerOFF before servicing belt.

The small residue remaining in thepump can be forced out by turning thepump pulley by hand, with the exhaustport closed and the intake open. The oilwill spurt out suddenly and should bedeflected into the drain pan. Avoidextensive operation with the exhaustport sealed; excessive internal pressuremay loosen the shaft seal.

Use extreme care. The oil will be hotand can cause severe burns.

Oil Filling

2. After removing all oil, close the drainand pour three or four ounces of cleanDuo-seal oil into the intake port. Openthe exhaust port and run the pump fora short period to completely circulatethe new oil. Drain the oil and force outthe residue as above. Repeat flushingwith new Duo-seal oil until flushingremains clean and free of color andforeign matter. One or two flushingsnormally cleans accumulated residueand protects the pump.

Operate the pump and check theultimate vacuum achievable.

3. Repeat steps 1 - 2 several times if thepump does not perform.

4. Replace the dust cap. Start the purgepump with the manual hand valveclosed and allow it to operate onehour to warm the oil. Recheck the oillevel with the oil at operatingtemperature.

Recommended OilWelch Duo Seal Oil, Oil-1

Once a YearLubricate the purge pump motor with agood grade of machine oil.

Maintenance

Periodic Purge Maintenance

The following information describes themaintenance requirements of the purgesystem. To assure efficient and reliablemachine operation, perform allinspections and procedures at theprescribed intervals. Keep a record of allinspection results to establish properservice intervals and document changesthat occur in purge activity that couldreflect on chiller performance.

Purifier PurgeThe following sections describe therequired periodic maintenance:

WeeklyCheck the vacuum pump oil quality.

Semi-AnnuallyInspect the air-cooled condensing unitcoil and clean as needed. Clean the coilfrom the fan side using compressed airor coil cleaner. A fouled coil will reducepurge efficiency and capacity.

CAUTION

WARNING

WARNING

WARNING

ABS-M-10A52

Solution Maintenance

To maintain machine efficiency, thelithium bromide solution must beanalyzed periodically to determine if theinhibitor levels are within acceptablelimits. A laboratory test is required todetermine the inhibitor level (and otheradditive levels), and any necessaryadjustments. To maintain the correctlevels, additive and inhibitor must beadded periodically to the lithiumbromide solution. It is recommendedthat the solution be analyzed once a yearif the machine is used for comfortcooling and twice a year if it is incontinuous or critical. (Monitor the lapsetime meter and provide this informationwhen lithium bromide analysis isperformed). Contact your local TraneService Agency for qualified lab testing.

Air leaks will accelerate inhibitordepletion resulting in excessivehydrogen production. Since absorptionmachines are unable to cool effectivelywhen excessive hydrogen is formed,machine operation under theseconditions is not recommended until theleak is eliminated.

Note: This machine uses lithiumbromide inhibited with lithiummolybdate and lithium hydroxide.Lithium bromide that contains otherinhibitors cannot be used in thisequipment.

Solution Filter

Rinsing the FilterAs the filter is used to remove solidsfrom the lithium bromide solution, someinhibited solution (lithium molybdate inthe lithium bromide) will be collectedwith the solids. Periodically this inhibitedsolution must be returned to the solutionfor proper filter operation and before anytime the filter is cleaned. Introducingrefrigerant water to dilute the brinesolution will return the lithium molybdateinhibited solution but not remove thefiltered out solids and particles. Also, thiswill allow for easier filter elementcleanup or changeout since the servicerwill be dealing with primarily refrigerantwater versus a stronger lithium bromideconcentration.

The filter assembly should not be usedfor continuous operation. It should beperiodically valved into operation asneeded for cleanup purposes only. If thefilter has been in operation for more thanone month, the following proceduremust be completed to insure properoperation and solution maintenance.

ProcedureBefore opening the filter to clean orexchange elements, the following shouldbe completed:

1. Close the inlet feed valve (LTSP onHorizon) stopping the flow of LithiumBromide to the filter.

2. Open the refrigerant pump dischargeservice valve and the service valvefrom step 1. The purpose is to providerefrigerant flow through the filterassembly.

3. Operate the refrigerant pump forapproximately 5 minutes. Do notexceed 10 minutes as this may causeexcessive lost of refrigerant water. Therefrigerant flow will be through thefilter and returning to the brine side ofthe chiller. Operation of the pump fortoo long a period could deplete allrefrigerant water. Continue procedureuntil the entire filter canister feels cold.

4. Close the refrigerant pump dischargevalve and the filter assembly servicevalve.

5. Change or clean filter elements asneeded. Refer to Cleaning the Filter.

Maintenance

53ABS-M-10A

Maintenance

LITHIUM BROMIDE!

LITHIUM BROMIDE IS NORMALLYNONTOXIC; HOWEVER, OTHERCHEMICALS MIXED WITH THESOLUTION CAN CAUSE IRRITATIONAND ADDITIVE VAPORS CAN CAUSENAUSEA. ALWAYS PROVIDEVENTILATION TO REMOVEACCUMULATED VAPORS.

In case of accidental contact with thesolution, wash the affected area withwater immediately.

Precaution: Make certain thatappropriate application equipment islocked and tagged-out safely, asapplicable. This should include, but notlimited to, pumps, motors and otherdevices that may affect solution flow orpressure.

CAUTION

1. Close the filter system isolationvalves. This isolates the filter systemfrom the unit. Servicing the filter willnot affect unit operation.

2. Remove the pipe plug from theservice valve located immediatelynext to the filter. Open the valve tobreak the vacuum in the filter system.A container may be necessary tocatch solution draining from thevalve.

3. Open the filter assembly by looseningthe filter assembly bolt located in thecenter of the filter head. The filtermay be drained prior to disassemblyvia the drain bolt located on thebottom of the filter tank.

4. Remove the filter tank from the filterhead.

5. Clean the filter tank and the reusablefilter element. The element is mosteffectively cleaned by backwashingwith a high-pressure spray device.

6. Place the clean element in the filtertank.

7. Reassemble the filter, making surethat the o-rings are properly seated. Athin layer of silicone grease applied tothe o-rings assures a leaktight seal.

8. Tighten the filter assembly bolt. Thisshould be torqued to 50-55 ft-lbs.

9. Use the service valve locatedimmediately next to the filter toevacuate the filter system. Afterevacuation, close and plug the valve.

10. Open the filter system isolationvalves.

Cleaning the FilterPeriodic cleaning of the filter isnecessary. Experience has shown a newfilter, versus a full or plugged filter, willhave negligible differential pressurebetween the inlet and outlet; thereforeother means of determining flow can beused, for example, a sight glass, flowmeters, etc. The particle size rating forthe cleanable filter is approximately 150micron. The disposable filter is rated atapproximately 30 microns. While theseshould not be considered absolutevalues, they do provide a range ofcleanliness that the solution can attain.These ratings are based on nominal flowand will vary as flow rates vary.

To clean the filter, follow the givenprocedure.

Precaution: As will all chemicals, avoidgetting the solution ON YOU or IN YOU.Do not eat or drink while handling theLithium Bromide solution. Thetechnician should use personalprotective handling equipment. Thisshould include, but not limited to, glovesfor hand protection, splash goggles orsafety glasses, and an apron orequivalent for body protection.

ABS-M-10A54

Pump MaintenanceThe solution pump should bedisassembled and inspected at routineintervals. The need to inspect/or servicethe pumps are expected to be veryinfrequent. The expected intervalbetween start-up and the first partsreplacement is approximately 50,000hours of normal operation. Thisassumes proper solution analysis andmaintenance is performed. Highamounts of suspended solids mayreduce the design life. Parts should bereplaced as determined by a qualifiedTrane Service Engineer.

Since the interval between inspectionand repair is quite long it is logical toreplace the wearing components to a likenew condition anytime that the pumpsare opened. Therefore pump partsshould be ordered and on hand any timethe pumps are opened. Table 9 indicatesitems that should be inspected and theaction to be taken, whenever the pumpsare opened. For cutaway view of pumpsee Figure 29.

Pump Operational Care andMaintenance

OperationFirst time operation — on initialoperation or after installation oroverhaul, make the following checksbefore putting the unit back intooperation. Be sure pump is completelyfilled with liquid. Run unit for only a fewseconds to make sure it operatessmoothly. There should be no unusualvibration, grinding, or scrapping noises.

Do not run this unit dry. Evenmomentary operation without pumpand motor casing filled with liquid willdamage bearings.

If pump trips on overload currentperform the following checks:

a. Note discharge pressure with thepump running.

b. Stop motor, but do not close or adjustvalves.

c. Disconnect all power.

d. Reverse any two line leads at motorstarter to reverse direction of rotation.

e. Start motor and note dischargepressure. The direction of rotation thatprovides the higher dischargepressure is the correct rotation.

Maintenance

Table 9 – Pump Inspection Items

Item Inspection Action ReplaceImpeller Balance Remove Material to Balance If RequiredWearing Rings Clearance .006/.009” Nominal Replace if 2 times nominal

[.15/.23 mm] NominalBearings Axial Wear 3/16” [4.8 mm] Max. Allowed XRotor/Journal Scoring Visual Check If Scored Replace with

new motorRotor/Stator Liners Wear/Scrapping Adjust/Repair/Replace If Cannot RepairCirculation Passages Clean Check/Clean N/A(Clean)Motor Lead Insulation Abrasion Shrink-wrap/Tape If RequiredMotor Windings Megohm Dry Out in Oven If RequiredCheck All Parts Check for Cracks/Wear Repair or Replace N/A

Certain procedures common torefrigeration system service may exposeoperating and/or servicing personnel toliquid and/or vaporous refrigerant. Toavoid injury or death due to skinexposure or inhalation of refrigerant,closely follow all safety proceduresdescribed in the material safety datasheet, and to all labels on refrigerantcontainers.

Only certified service personnel shouldservice the refrigerant system. To avoidinjury or death due to electrical shock,never open access panels to inspect orservice the unit without first opening alldisconnect switches.

Use caution when working on certainareas of this unit. Surface temperaturesmay exceed 150°F [65.1°C] on thecondensing unit. Contact with bare skincould result in burns and injuries.

WARNING

CAUTION

55ABS-M-10A

Maintenance

Solution Pumps

This section provides detail of the threepumps located on the machine. Also,this section includes motor and pumpconstruction and pump motor coolingand lubrication.

PumpsThere are three individual pumpsoperating within the absorption cycle.Refer to the absorption cycle fluidschematic, Figure 3, which illustrates thefluids and piping arrangementsassociated with each pump.• The low temperature solution pump

(LTSP) supplies dilute lithium bromidesolution from the absorber through theheat exchanger then to the lowtemperature generator forconcentration.

• The absorber spray pump (ASP)supplies intermediate solution, whichis a mixture of dilute and concentratedto the absorber sprays.

• The refrigerant pump (RP) suppliesrefrigerant to the evaporator sprays.

The (LTSP) and (ASP) operate at variablespeeds. A solid-state adjustablefrequency drive (AFD) controls motorspeed in response to an analog signalprovided by the unit control module. TheAFD also serves as the start/stop andovercurrent device for the associatedpump motors.

The refrigerant pump (RP) operates atconstant speed controlled by motorstarter contactors. The refrigerant pumpcircuit has an individual current overloadprotection device, and each pump has awinding temperature thermostat.

Motor/Pump ConstructionThe pump is a single stage, hermeticallysealed, centrifugal pump designed forAbsorption application. The pump/motorconsists of two sections: the motor statorshell, and the pump casing. The motorand impeller can be removed from thepump casing without disturbing suctionand discharge piping by first separatingthe two sections, then removing themotor rotor and impeller with the motorstator shell as an assembly. The rotor issupported with two self-centeringbearings that are internally tapered tomate with complimentary shapedjournals on motor shaft. A coil springholds the bearings in firm contact withthe journals and compensatesautomatically for wear.

Pump Motor Cooling and LubricationPart of the pumped liquid flows from thecasing volute through a spacingbetween the wearing ring housing andthe attached bearing cap in the wearingring housing assembly through thebearing cap flange to the cavity betweenthe welded stator liner and rotor liner.The liquid returns to the pump suctionthrough the hollow shaft. The liquidcools and lubricates the bearings, andcarries away heat generated by themotor rotor and stator.

ABS-M-10A56

Maintenance

Figure 29 – Typical Pump Assembly and Recirculation Liquid Flow

57ABS-M-10A

AFD Maintenance

Periodically, inspect the AFD asdescribed in Table 10, to preventaccidents and to ensure highperformance reliability.

Maintenance

Table 10 – AFD Component Check and Corrective Action

External Terminals, Connectors,Mounting Screws, etc. Loose screws or connectors Securely tighten.Heat Sink Build-up of dust and dirt Blow with dry, compressed air

[39.2x104 to 58.8x104 Pa (4 to 6kgcm2) pressure]

Printed Circuit Board (PCB) Accumulation of conductive dust or oil Blow with dry, compressed air[39.2x104 to 58.8x104 Pa (4 to 6kgcm2) pressure]. If dust and oilcannot be removed, replace theboard.

Cooling Fan For abnormal noise and vibration Replace the cooling fan.Cooling Fan Debris on fan blades. Blow off and wipe, if necessary.Power Components Accumulation of dust and dirt Blow with dry, compressed air

[39.2x104 to 58.8x104 Pa (4 to 6kgcm2) pressure].

Smoothing Capacitor Discoloration or odor Replace the capacitor or the AFD.

To prevent electrical shock, disconnectall power before servicing the inverterand then wait at least five minutes afterthe power supply is disconnected and allLED’s are extinguished.

WARNING

ABS-M-10A58

Troubleshooting/Diagnostics

General Information

The following section contains generaltrouble shooting information. When anabnormal machine condition exists, theunit control panel clear language display(CLD) will indicate the condition and abrief message. Always determine thecause and perform corrective actionbefore you restore full machineoperation.

Review the indicated message andproceed to the appropriate sectiondefined below.

Control Panel OperatorInterface (Clear LanguageDisplay) Diagnostics

There are three types of diagnosticsscreens. They are:

“Informational Warning Only” (IFW)diagnostics that do not shutdown thechiller.

“Machine Shutdown Automatic Reset”(MAR); This diagnostic turns the MARalarm relay ON, however the machinewill automatically reset and allow restartwhen the condition corrects itself.

“Machine Shutdown Reset Required”(MMR); This diagnostic turns the MMRalarm relay “ON”. The alarm relay turns“OFF” when the diagnostic is manuallyreset.

The second line of the diagnostictypically identifies additional informationintended to assist the operator to defineand correct problems. Contact the localTrane Service Representative forassistance when necessary.

The reason for all diagnostic must bedetermined and corrected. Do not resetand restart the chiller as this can cause arepeat failure.

After corrective action, the chiller can bereset and/or restarted. In the case of“Unit Shutdown - Reset Required”diagnostic types, the chiller will have tobe manually reset through theDiagnostics group menu.

Note: For more information and anoverview of the various types of screenssee “Operators Guide: Using the controlpanel” (where diagnostics group menuof the clear language display (CLD) isexplained.

Adjustable Frequency Drive –AFD

AFD Self DiagnosticsThe AFD controls frequency driveoperation. In the case of an AFDabnormal fault conditions, the Chillerclear language display will indicateabsorber spray pump, or low tempgenerator pump “Drive Fault.” The AFDdisplay will indicate the current faultcondition. If a fault condition occurs, usethe reference instruction manual and/orcall [ ] the local Trane Service agency

to discuss the fault and determine thecause.

59ABS-M-10A

Pump Troubles andCorrections

In the event that trouble occurs refer tothe Troubleshooting Table 11 for a listingof the more common pump troubles andprobable causes

If the pump has stopped for unknownreasons, the motor may be grounded tofull line voltage. Disconnect primarypower before proceeding.

TroubleshootingChecklist

Probable Causes

1. Motor Incorrectly Wired. Refer to unitwiring diagram and motor wiringdiagram on inside of motor terminalbox cover.

2. Incorrect Motor Voltage. Voltage atmotor terminals must be within 10%of motor nameplate voltage. Checkvoltage at load-side terminals onmotor overload.

3. Fuses Blown. Replace using correctfuse size. See panel nameplate.

4. Thermal Overload Protection Open.With power removed, remove thewires from K1 and K2 and check forcontinuity from K1 and K2 of themotor. If circuit is open, allow motor tocool and check continuity again. If stillopen, call service to check motor.

5. No Current In One Line To Motor.Check voltage on all lines. Voltagesmust be within 10% of nameplatevoltage and (current) not more than20% unbalanced.

6. Motor Winding Grounded To MotorFrame. REMOVE ALL POWER.Contact you local Trane servicerepresentative.

7. Motor Windings Open. REMOVE ALLPOWER. With motor leadsdisconnected, check each motorwinding resistances. Values should bewithin 10%.

8. Foreign Object in Motor or Pump.REMOVE ALL POWER. Reconnectmotor leads with any two leadsinterchanged: try starting the motor inreverse direction. If pump runs,reconnect to original connection anddetermine if pump now runs. Thisprocedure will sometimes remove asmall obstruction blocking the unit.

9. Pump Not Running. Check powersupply to assure power is at line sideof motor starter.

10. Impeller Clogged. Inspect impellerand remove obstructions.

11. Pump Not Completely Primed.Completely fill pump and suctionline, and purge unit.

12. Air Leaks In Suction Piping. Inspectsuction piping, gaskets, and fittings.Repair or replace as necessary.

13. Air Or Gases In Liquid. Purge unit,repair system to exclude non-condensables.

14. Motor Overheating. Investigate andeliminate cause of overheating.

15. System Temperature Higher ThanDesign Temperature. Check andcorrect temperature. Check machinecycle temperatures.

16. Wrong Direction Of Rotation. Reversedirection of rotation.

17. Obstruction In Piping System. Inspectpiping, remove obstruction.

18. Mechanical Defects. Check for wornwearing rings, damaged impeller,worn or seized bearings, or damagedsprings.

19. Speed Too Low. Check power supplyand control, or excess mechanical orhydraulic loads.

20. Speed Too High. Check power supplyand control, or loss of mechanical orhydraulic loads.

21. Foreign Material In Close RunningFits Of Unit. Disassemble and cleanthoroughly.

22. No Fluid Flowing Through Motor.Fluid must circulate through wearingring-housing spacing and holes inwear ring (208) and back throughhollow shaft (229) to the pumpsuction.

23. Noise Caused By Other Equipment.Investigate and correct.

24. Loose Parts. Inspect pump. Tighten,repair, and replace as necessary.

25. Magnetic Hum Due To ElectricalInput. Check for high or unbalancedvoltage or broken line. Voltage mustbe within 10% of motor nameplatevoltage and (current) not more than20% unbalanced.

26. Mechanical Unbalance. Check with avibration meter or by pIacing handon unit. Dismantle and correctbalance.

27. External Loading On Pump. Check forexternal mechanical stress on pumpfrom suction and discharge piping.Adjust or add support if necessary.

28. Bearing or Spring Damaged CausingBinding. Remove, disassemble, andinspect parts.

29. Condensate Due To Change InTemperature. When subjected tochanges in temperature, liquidcondenses on the encapsulatedstator windings and must bepermitted to drain out of thecondensate drain holes provided inthe stator housing.

30. Hole In Stator Can. If liquid drainingfrom pump is pumpage rather thancondensate, there may be a hole inthe stator can. Disassemble andinspect.

Table 11 – Troubleshooting Chart

Trouble Probable Cause (Item Number)Pump will not start 1 2 3 4 5 6 7 8Pump will not deliver liquid 9 10 11 12 13 14 15 17Pump loses prime after starting 10 11 12 13 14 15 17Capacity too low 10 11 12 13 14 15 16 17 18 19Discharge pressure too low 10 11 12 13 14 15 16 17 18 19Pump motor overload 1 2 5 8 10 15 16 18 20, 21Motor overheats 1 8 15 16 17 18 19 20 21 22Noisy installation 11 12 13 14 15 17 18 20 23 24 25 26 27 28Excessive vibration 24, 26, 28Excessive maintenance 2 10 11 12 13 14 15 16 17 18 20 21 22 24 26 27 28Leakage from motor frame 29 30

CAUTION

ABS-M-10A60

Unit WiringDiagrams

External Electrical Connections

The electrical wiring in this section isintended to show the relationshipbetween externally connected devicesthat are needed by the control panel tosequence the machine.

If there is a machine diagnostic conditionoccurring the main control panel clearlanguage display will provide amessage, and basic troubleshooting canbe performed. The local Trane serviceagency can provide qualified personnelfor assistance to test appropriate pointswithin the electrical system; field wiringto the machine, or machine wiring.

RequiredInputs and outputs that must beprovided are identified as Required.Required wiring is used to providereliable machine operation. Failure toprovide this wiring may cause machinefailure.

Acronyms1. Binary Output (contact closure) (BO)2. Binary Input (BI)3. Analog Input (4-20mA or 2-10Vdc) (AI)4. Analog Output (AO)

ExternalThe electrical connections between themachine and external devices that arenot machine mounted are illustrated inFigure 30.

The chiller control system must be fieldwired to the items identified asREQUIRED. Other items are identified asrecommended or optional.

61ABS-M-10A

Unit WiringDiagrams

Required Wiring includes:Chilled water pump control (start/stop) 1U3-J12-1-2 BOChilled water pump flow switch 1TB3-9-10 BICondenser water flow control (Start and stop) 1U3-J14-1-2 BOCondenser water flow switch. 1TB3-11-12 BIEnergy Valve 1U5-J8-1-4 BOSteam transducer 1U3-J9-1-10 AI

OptionalOptional use inputs and outputs are identified Optional. These connection points arenot required because the condition of use does not effect machine reliability oroperation. Note: 1U7, 1U8, 1U9 and 1U10 are optional modules that are providedwhen specified on the sales order.

Optional Status Wiring (Std):Limit Warning status 1U3-J20-1-2 BOAlarm, Manual Reset required status (MMR) 1U3-J18-1-3 BOAlarm, Auto Restart status (MMR) 1U3-J22-1-2 BOAlarm, Purge Status 1U4-J16-1-3 BO

Output SignalHot water pump flow control (start/stop) 1U3-J10-1-2 BO

Optional Input Signals (Std):External auto start/stop N.C. (local auto mode req.) 1U3-J5-1-2 BIEmergency Stop N.C. (Manual reset req.) 1U3-J5-3-4 BIOutdoor air temperature sensor for CWR 1U3-J5-5-6

External Chiller Capacity Limit Enable (Jumper(1U3-J7 1 to 2)Closed = Enable) BI

External Chiller Capacity Limit Analog Input 1U3-J711 (-) to 12 (+) AI

Optional Modules not Provided UnlessSpecified on the Sales Order1U7 – Options Module1U8 – Tracer Communications Module

Options Module required for the following:

Optional Status:Maximum Capacity status 1U7-J14-1-2 BO

Optional Control:Tracer controlled relay 1U7-J18-1-3 BOTower Temp Low Relay 1U7-J20-1-2 BO

Optional Inputs:Tracer temperature sensor 1U7-J7-7-8External Chiller water setpoint isolated 2-10 Vdcor 4-20mA 1U7-J9-4-5 AI

Optional OutputSteam or Hot Water Valve Energy ValveMonitor Output 1U7-J7-1-2 AO

Optional modules for communicationsoutside of main unit control panel.

1U8 Tracer Communications moduleRequired for Comm. with Tracer 1U8-J3-1-2

ABS-M-10A62

Unit WiringDiagrams

Figure 30 – Field Wiring Connection Diagram – Detail of Control Panel Connection Points

63ABS-M-10A

Unit WiringDiagrams

ABS-M-10A64

Unit WiringDiagrams

Figure 31 – Field Wiring Connection Diagram – Detail of Control Panel Connection Points

65ABS-M-10A

Unit WiringDiagrams

ABS-M-10A66

Unit WiringDiagrams

The chiller control panel requires proofof water flow for both evaporator(chilled) and absorber/condensercircuits. A flow switch and motor starterauxiliary contact connections satisfy thisrequirement. This input must be hardwired to the chiller control system. Theflow switch must be set to open whenflow drops to 70% or below of designevaporator flow.

The control panel is designed with acontact closure used for control of thewater pump operation. The evaporatorand condenser water pumps areelectrically interlocked and sequencedby the control panel. Proof of bothchilled and condenser water flow mustbe provided to the control panel. Underno conditions can chiller operation beterminated by stopping chilled waterflow. Under no situation can condenserwater flow exist without chilled waterflow.

The above interlocking arrangementassures proper sequence of operation,and helps provide protection againstmechanical failure from improperoperation.

Required Absorber/Condenser WaterFlow ControlThe chiller requires start and stop controlof the abs/cds water flow. The condenserpump motor starter and water flowcontrol signal must be hard wired inseries with the chiller panel outputcontacts provided. Condenser water flowmust start and stop as determined by thecontrol panel. Failure to stop flow risksevaporator freeze-up.

CAUTION

CAUTION

Damage caused by operation withoutproper water pump and flow sensinginterlocking is not warranteed.

Required Chilled Water Flow ControlThe chiller requires start and stop controlof the chilled water flow. The chillercontrols also provide a chilled waterpump off delay feature. Under noconditions can chiller operation beterminated by stopping chilled waterflow. For remote start/stop control,always use the auto/start/stop input ofthe chiller and allow chilled water flow tocontinue up to thirty minutes aftertermination of the machine dilution cycle.

Table and FiguresTables 12 and 13 provide electrical databy voltage and unit size.

Table 14 identifies electrical devices andtheir description.

Figures 32 to 35 illustrate typical machinewiring and field connected wiring. Theseschematics are typical, therefore, refer tothe schematic diagrams supplied withthe particular chiller control panel thatreflect the actual wiring “as built.”

Figures 36 to 40 illustrate connectionpoints of unit and control panel wiring.

67ABS-M-10A

Table 12 – ABSD 500-1350 Ton – 50 Hertz Electrical Data

4B1 Refrigerant 4B2 Absorber Spray 4B3 Lt Solution Total Motor Control Minimum MaximumUnit Pump Motor Pump Motor Pump Motor Rating Circuit Circuit FuseSize Voltage FLA HP KW FLA HP KW FLA HP KW FLA HP KW Amps Ampacity Size

190 12.0 3.0 2.3 25.0 5.0 3.7 25.0 5.0 3.7 62.0 13.0 9.7 10.5 79 80500 220 10.4 3.0 2.3 21.0 5.0 3.7 21.0 5.0 3.7 52.4 13.0 9.7 9.1 67 70

380 6.0 3.0 2.3 12.0 5.0 3.7 12.0 5.0 3.7 30.0 13.0 9.7 5.3 38 40415 5.5 3.0 2.3 11.0 5.0 3.7 11.0 5.0 3.7 27.5 13.0 9.7 4.8 35 35190 12.0 3.0 2.3 25.0 5.0 3.7 25.0 5.0 3.7 62.0 13.0 9.7 10.5 79 80

600 220 10.4 3.0 2.3 21.0 5.0 3.7 21.0 5.0 3.7 52.4 13.0 9.7 9.1 67 70380 6.0 3.0 2.3 12.0 5.0 3.7 12.0 5.0 3.7 30.0 13.0 9.7 5.3 38 40415 5.5 3.0 2.3 11.0 5.0 3.7 11.0 5.0 3.7 27.5 13.0 9.7 4.8 35 35190 12.0 3.0 2.3 30.0 7.5 5.6 25.0 5.0 3.7 67.0 15.5 11.6 10.5 85 90

700 220 10.4 3.0 2.3 26.0 7.5 5.6 21.0 5.0 3.7 57.4 15.5 11.6 9.1 73 80380 6.0 3.0 2.3 15.0 7.5 5.6 12.0 5.0 3.7 33.0 15.5 11.6 5.3 42 45415 5.5 3.0 2.3 14.0 7.5 5.6 11.0 5.0 3.7 30.5 15.5 11.6 4.8 39 40190 12.0 3.0 2.3 30.0 7.5 5.6 25.0 5.0 3.7 67.0 15.5 11.6 10.5 85 90

800 220 10.4 3.0 2.3 26.0 7.5 5.6 21.0 5.0 3.7 57.4 15.5 11.6 9.1 73 80380 6.0 3.0 2.3 15.0 7.5 5.6 12.0 5.0 3.7 33.0 15.5 11.6 5.3 42 45415 5.5 3.0 2.3 14.0 7.5 5.6 11.0 5.0 3.7 30.5 15.5 11.6 4.8 39 40190 25.0 5.0 3.7 25.0 5.0 3.7 30.0 7.5 5.6 80.0 17.5 13.0 10.5 98 100

975 220 21.0 5.0 3.7 21.0 5.0 3.7 26.0 7.5 5.6 68.0 17.5 13.0 9.1 84 90380 12.0 5.0 3.7 12.0 5.0 3.7 15.0 7.5 5.6 39.0 17.5 13.0 5.3 48 50415 11.0 5.0 3.7 11.0 5.0 3.7 14.0 7.5 5.6 36.0 17.5 13.0 4.8 44 45190 25.0 5.0 3.7 30.0 7.5 5.6 30.0 7.5 5.6 85.0 20.0 14.9 10.5 103 110

1100 220 21.0 5.0 3.7 26.0 7.5 5.6 26.0 7.5 5.6 73.0 20.0 14.9 9.1 89 90380 12.0 5.0 3.7 15.0 7.5 5.6 15.0 7.5 5.6 42.0 20.0 14.9 5.3 51 60415 11.0 5.0 3.7 14.0 7.5 5.6 14.0 7.5 5.6 39.0 20.0 14.9 4.8 47 50190 25.0 5.0 3.7 30.0 7.5 5.6 30.0 7.5 5.6 85.0 20.0 14.9 10.5 103 110

1225 220 21.0 5.0 3.7 26.0 7.5 5.6 26.0 7.5 5.6 73.0 20.0 14.9 9.1 89 90380 12.0 5.0 3.7 15.0 7.5 5.6 15.0 7.5 5.6 42.0 20.0 14.9 5.3 51 60415 11.0 5.0 3.7 14.0 7.5 5.6 14.0 7.5 5.6 39.0 20.0 14.9 4.8 47 50190 25.0 5.0 3.7 30.0 7.5 5.6 30.0 7.5 5.6 85.0 20.0 14.9 10.5 103 110

1350 220 21.0 5.0 3.7 26.0 7.5 5.6 26.0 7.5 5.6 73.0 20.0 14.9 9.1 89 90380 12.0 5.0 3.7 15.0 7.5 5.6 15.0 7.5 5.6 42.0 20.0 14.9 5.3 51 60415 11.0 5.0 3.7 14.0 7.5 5.6 14.0 7.5 5.6 39.0 20.0 14.9 4.8 47 50

Unit WiringDiagrams

ABS-M-10A68

Table 13 – ABSD 500-1350 Ton – 60 Hertz Electrical Data

4B1 Refrigerant 4B2 Absorber Spray 4B3 Lt Solution Total Motor Control Minimum MaximumUnit Pump Motor Pump Motor Pump Motor Rating Circuit Circuit FuseSize Voltage FLA HP KW FLA HP KW FLA HP KW FLA HP KW Amps Ampacity Size

200 13.0 3.0 2.3 28.0 5.0 3.7 28.0 5.0 3.7 69.0 13.0 9.7 10.0 86 90500 230 12.0 3.0 2.3 24.0 5.0 3.7 24.0 5.0 3.7 60.0 13.0 9.7 8.7 75 80

460 6.0 3.0 2.3 12.0 5.0 3.7 12.0 5.0 3.7 30.0 13.0 9.7 4.4 37 40575 5.0 3.0 2.3 10.0 5.0 3.7 10.0 5.0 3.7 25.0 13.0 9.7 3.5 31 35200 13.0 3.0 2.3 28.0 5.0 3.7 28.0 5.0 3.7 69.0 13.0 9.7 10.0 86 90

600 230 12.0 3.0 2.3 24.0 5.0 3.7 24.0 5.0 3.7 60.0 13.0 9.7 8.7 75 80460 6.0 3.0 2.3 12.0 5.0 3.7 12.0 5.0 3.7 30.0 13.0 9.7 4.4 37 40575 5.0 3.0 2.3 10.0 5.0 3.7 10.0 5.0 3.7 25.0 13.0 9.7 3.5 31 35200 28.0 5.0 3.7 34.0 7.5 5.6 28.0 5.0 3.7 90.0 17.5 13.0 10.0 109 110

700 230 24.0 5.0 3.7 30.0 7.5 5.6 24.0 5.0 3.7 78.0 17.5 13.0 8.7 94 100460 12.0 5.0 3.7 15.0 7.5 5.6 12.0 5.0 3.7 39.0 17.5 13.0 4.4 47 50575 10.0 5.0 3.7 12.0 7.5 5.6 10.0 5.0 3.7 32.0 17.5 13.0 3.5 39 40200 28.0 5.0 3.7 34.0 7.5 5.6 28.0 5.0 3.7 90.0 17.5 13.0 10.0 109 110

800 230 24.0 5.0 3.7 30.0 7.5 5.6 24.0 5.0 3.7 78.0 17.5 13.0 8.7 94 100460 12.0 5.0 3.7 15.0 7.5 5.6 12.0 5.0 3.7 39.0 17.5 13.0 4.4 47 50575 10.0 5.0 3.7 12.0 7.5 5.6 10.0 5.0 3.7 32.0 17.5 13.0 3.5 39 40200 28.0 5.0 3.7 28.0 5.0 3.7 34.0 7.5 5.6 90.0 17.5 13.0 10.0 109 110

975 230 24.0 5.0 3.7 24.0 5.0 3.7 30.0 7.5 5.6 78.0 17.5 13.0 8.7 94 100460 12.0 5.0 3.7 12.0 5.0 3.7 15.0 7.5 5.6 39.0 17.5 13.0 4.4 47 50575 10.0 5.0 3.7 10.0 5.0 3.7 12.0 7.5 5.6 32.0 17.5 13.0 3.5 39 40200 28.0 5.0 3.7 34.0 7.5 5.6 34.0 7.5 5.6 96.0 20.0 14.9 10.0 115 125

1100 230 24.0 5.0 3.7 30.0 7.5 5.6 30.0 7.5 5.6 84.0 20.0 14.9 8.7 100 110460 12.0 5.0 3.7 15.0 7.5 5.6 15.0 7.5 5.6 42.0 20.0 14.9 4.4 50 60575 10.0 5.0 3.7 12.0 7.5 5.6 12.0 7.5 5.6 34.0 20.0 14.9 3.5 41 45200 28.0 5.0 3.7 34.0 7.5 5.6 34.0 7.5 5.6 96.0 20.0 14.9 10.0 115 125

1225 230 24.0 5.0 3.7 30.0 7.5 5.6 30.0 7.5 5.6 84.0 20.0 14.9 8.7 100 110460 12.0 5.0 3.7 15.0 7.5 5.6 15.0 7.5 5.6 42.0 20.0 14.9 4.4 50 60575 10.0 5.0 3.7 12.0 7.5 5.6 12.0 7.5 5.6 34.0 20.0 14.9 3.5 41 45200 28.0 5.0 3.7 34.0 7.5 5.6 34.0 7.5 5.6 96.0 20.0 14.9 10.0 115 125

1350 230 24.0 5.0 3.7 30.0 7.5 5.6 30.0 7.5 5.6 84.0 20.0 14.9 8.7 100 110460 12.0 5.0 3.7 15.0 7.5 5.6 15.0 7.5 5.6 42.0 20.0 14.9 4.4 50 60575 10.0 5.0 3.7 12.0 7.5 5.6 12.0 7.5 5.6 34.0 20.0 14.9 3.5 41 45

Unit WiringDiagrams

69ABS-M-10A

Unit WiringDiagrams

SEE NOTE 6

SEE NOTE 6

OPTIONAL

OPTIONAL

OPTIONAL

H1 AND H3

H1 AND H4

H1 AND H5

H1 AND H2

H1 AND H3

H1 AND H2

H1 AND H3

CONNECTIONS

H1 AND H2

LINE VOLTAGE

190V

200V

220V

230V

380V

415V

460V

575V

TABLE "A"

SEE NOTE 6

LINE VOLTAGE

6

9

11

7

8

3

4

5

1

2

OPTIONAL1CB1, 1S1 OR 1TB1

SEE NOTE 5

31

19

21

SEE NOTE 5

1TB2

SEE NOTE 6

SEE NOTE 6

24

30

25

26

27

28

29

12

18

20

22

23

13

14

15

17

16

10

41

42

36

37

38

39

40

32

33

34

35

1TB3-5

42C

115 VAC

LINE VOLTAGE

5

3

1

37A

4

X2

T1

L1

1T4 H1

6

24VAC

2

X1

7T2

L2

H2

GRN

8

460V-60HZ CONNECTION SHOWN

CONNECTIONS

REFER TO TABLE "A"FOR OTHER LINE VOLTAGE

42B

42A

LINE 791TB3-6

1K11-32,33,3421

1K1

24

49A1K11

A1 A2

1B

1TB3-1

102A

101A

4A

3

2

B

AP2A

41A

34A

35A

41B

20A

1CB2

INTER-PROCESSORCOMMUNICATION

1U1 STARTER CONTROL MODULE

24 VAC

J2

LINE 77WIRE 41D

41D

3

1

2

P10

48A

PHASE A CURRENT

PHASE B CURRENT

PHASE C CURRENT

PUMP START RELAYREFRIGERANT

J10

1T5

4B3

4B2

4B1 1U11-81

T2

T1

T3

T3

T2

6

4

2

BLK

RED

YEL

9A

7A

8A

T3

T1

T1

T2

RED

YEL

BLK 6B

4B

5B

L3

L2

L1

1K11 1U11

+3

6

5

4 -

1

2

+

-

J1

1F22B 35A

1F11B 34A

WHT

WHT

BLK

BLK

WHT

BLK

P5A

P5B

P5C

135A

134A

133A

132A

131A

130A1

4

6

5

2

3

J5

1T1

1T2

1T3

BLK

RED

YEL

3D

2D

1D

BLK

RED

YEL

3C

2C

1C

1F7

1F8

1F9

1F6

1F4

1F5

101B

102B

P2B1U2 J2-4LINE 72

LINE 731U2 J2-3

P1A

LINE 721U2 J1A-1

LINE 731U2 J1A-2

199B

198B

1U3 J1-3 BOT

1U3 J1-4 BOT

P1B

LINE 92

LINE 93

199A

198A

1U4 J2-4LINE 142

WIRE 101D1U4 J2-3LINE 143

WIRE 102D

S1 (1)

4U2

4S2

SPLICE

BLK BLK

SPLICE

52A

4S3

SPLICE

BLK

SPLICE

51A,B

BLK

44A,B

45AS2 (3)

SC (11)

S2 (3)

SC (11)

S1 (1)

4U1

42C

43A

3

P6J6

DRIVE FAULT

1

51A

50A

44A

3

2

P12

2

1

SOLUTION PUMPLOW TEMPERATURE

SOLUTION PUMP

SPEED SIGNAL

DRIVER FAULT

SOLUTION PUMPLOW TEMPERATURE

PUMP START RELAYABSORBER SOLUTION

J12

START RELAY

51B

44B

BLK

T1

YEL

RED

YEL

BLK

18A

17A

16A

11A

12A

RED 10A

BLK

YEL

RED

YEL

RED

BLK

15A

14A

13A

5A

6A

L3

T2

T1

T3

L2

L1

L3

L1

L2

4A

4U1

T3

T2

4U2

P1C

121A

120A(19) MB

(20) MC

4U1

139A

138A

139B

138B

P7B

P7C

139A,B

136A

137A

138A,B5

6

4

3

J7

4U2

4U1

(20) MC

(13) FV

(17) FC

(19) MB

(17) FC

(13) FV

5A,B

6A,B

4A,B

ADJUSTABLE FREQUENCY DRIVE



ABSORBER SOLUTION PUMP

L1

YELRED

1A1B

2A2B

BLK

3A

L3L2

1S1

L1

RED YEL BLK

L2 L3

1C1D

2C2D

1A 2A

3C3D

3A

1U5 J2-4WIRE 101G

LINE 170 LINE 1711U5 J2-3

WIRE 102G

PHASE A-B VOLTS

PHASE B-C VOLTS

PHASE C-A VOLTS

BLK

BLK

BLK

BLK

4

P3C1T735C

36A

126A

127A

5

6

P3B1T634B

35B

124A

125A

3

J3

,B,C

,B,C

BLK

BLK

P3D1T8

34C

36B

129A

128A7

8

3B 36A,B1F3

Figure 32 – ABSD Horizon Single-Stage Steam or Hot Water Absorption with Adjustable Frequency Drives

– Main Power Connection, Starter Control Module and Pump Motors

ABS-M-10A70

Unit WiringDiagrams

Table 14

71ABS-M-10A

Unit WiringDiagrams

Figure 33 – ABSD Horizon Single-Stage Steam or Hot Water Absorption with Adjustable Frequency Drives – Circuit and Chiller Control(See Notes Page 70)

SEE NOTE 5

P2B 101F OR 101

102F OR 102

71

STEAM CONDENSATETEMPERATURE LEAVING

GENERATORLOW TEMPERATURE

P1C

(STEAM UNITS)

SEE NOTE 5

81

198G OR 198

199G OR 199

88

87

89

84

85

86

82

83

78

79

80

76

77

73

75

74

72

91

SEE NOTE 6

SEE NOTE 6

123

120

122

121

117

118

119

116

115

92

103

112

113

114

110

111

109

106

108

107

105

104

101

102

100

98

99

97

95

96

94

93

90

126

124

125

(HOT WATER UNITS)

HOT WATER TEMPERATURELEAVING LOW

TEMPERATURE GENERATOR

1K1-20,7467A66ABLK

SPLICE 9695 A1 A2

4S1 1U11 1K1

LINE 9

102B

1U1 J2-4101BP2B

LINE 10

BLK41F

SPLICE

1U1 J2-3

P1A1U1 J1-1LINE 6

199B

198B

PUMP ABNORMALREFRIGERANT

P1C

14

LINE 7

11

1K1

144A

143A

1U1 J1-2

P1B1U1 J1-3

1U1 J1-4

LINE 6

LINE 7

199A

198A

1TB3-6

LINE 1201TB3-7

42E

42F

LINE 51TB3-5

L2

4B6

L1

4A

J2

41D

LINE 18WIRE 41D

65A

41E

41F

1TB3-2

1

2

J18

3

24 VAC

2

1B

A

P18

3B


J1A

1

TEMPERATUREAND RECOVERY

SENSING DETECTION

P3A

2

7

8

1

J3

5

6

4RT1

BLK

WHT

2

1U2 CIRCUIT CONTROL MODULE

REFRIGERANT DUMPVALVE RELAY

24 VAC

4A

J2

3B

6K3-123

6K2-100,119

6K4

6K2

6K2

6K3

MAXIMUM MODULE CONTACT RATINGS:

115 VAC 15A

2.88A INDUCTIVE, 1/3 HP

CUSTOMER PROVIDED DEVICES AND WIRING

1TB3-7

1TB3-11

42M

1TB3-10

LINE 791TB3-6

6S6

6S5

41K

6K3

6K2

6K7

6K6

6K5

3

J18

2

1

P18

1

J16

3

J14

2

J12

2

1

P16

P14

P12

1

2

B

A

42L

87A

86A

1TB3-12

1TB3-9

1TB3-3

1

J28

1

J26

OPTO INPUT2

P28

P26

J22

2

J20

2

1

2

1

P22

P20

LINE 1491TB3-81TB3-4

LINE 148

42MOPTO INPUT

2

1

2

1 +J1 TOP

-

3

EVAPORATOR LEAVINGWATER TEMPERATURE

WATER TEMPERATURE

WATER TEMPERATUREEVAPORATOR ENTERING

ABSORBER LEAVING

CONDENSER LEAVINGWATER TEMPERATURE

UNIT EMERGENCY STOP

MUST BE JUMPEREDUNIT EXTERNAL AUTO STOP

IF NOT USED

P5B

W1

P5A

3

J5

1

2

P3D

P3C

7

8

4

5

6

P3A

P3B

J3

1

3

2

J1 BOTTOM

+

-4


3

4-

+1

2 -

+

6S1

6S2

4RT9

4RT8

4RT7

4RT6

BLK

WHT

BLK

WHT

BLK

WHT

BLK

WHT

WATER TEMPERATUREABSORBER ENTERING

MUST BE JUMPEREDIF NOT USED

P7D

8

J7

7

6

4

5

4RT10

BLK

WHT

W2

WATER FLOW SWITCHCONDENSER-ABSORBER

CHILLED WATERFLOW SWITCH

RUNNING

STATUS RELAYLIMIT WARNING

STATUS RELAY

MACHINE AUTOMATICRESET ALARM

STATUS RELAY

MACHINE MANUAL

STATUS RELAYRESET ALARM

WATER PUMP RELAY

SOLUTION PUMP

CONDENSER-ABSORBER

PUMP RELAYCHILLED WATER

1U3 CHILLER CONTROL MODULE

1U4 J2-2LINE 144

1U4 J2-1LINE 145

102E

P2A 101E1U4 J1-1LINE 142

1U4 J1-2LINE 143

199D

198D P1A

TEMPERATURE SENSORPROVIDED BY TRANE

FIELD INSTALLED

OUTDOOR AIRP5C

5RT1

6K1

J10

2

1

P10

HOT WATER TEMPERATUREENTERING LOW


P5C J5

5

6 (HOT WATER UNITS ONLY)

4RT22WHT

BLK

HOT WATER PUMP

(HOT WATER UNITS ONLY)RELAY

P3D4RT23

WHT

BLK

42F

LINE 1171TB3-3

LINE 771TB3-2

PRESSURE TRANSDUCER

PRESSURE TRANSDUCER

SUPPLY STEAM

LOW TEMPERATUREGENERATOR STEAM

10

7

9

8

P9B

4

6

5

3

2

P9A J9

1

(STEAM UNITS ONLY)

(STEAM UNITS ONLY)

4R3

+DIF

+5 VDC

-DIF

4R2

GND

+DIF -DIF

+5 VDC

BLK

GRN

SHIELD

WHT

GRN

RED

SHIELD

BLK

WHT

RED

GND

ABS-M-10A72

Unit WiringDiagrams

SEE NOTE 6

ENERGY VALVESTEPPER

SEE NOTE 5

STEAM OR HOT WATER

144

145

141

142

143

150

151

147

148

149

146

153

154

152

156

157

155

159

163

160

161

162

158

169

166

167

168

165

171

170

164

175

172

173

174

181

178

179

180

176

177

185

186

187

182

183

184

191

192

193

189

190

197

198

199

194

195

196

200

201

188

1U3 J2-2LINE 90

1U3 J2-1LINE 91

P2A

102E

101E

199D

198D P1A

LINE 911U3 J1-2 BOT

LINE 901U3 J1-1 BOT

21

42N4TB4-3

BLK

YEL 42P

42R

WHT

SPLICE

SPLICE

A2

YEL

SPLICE

42AM

42S

42T

42AN

BLK

BLK94B

LINE 1171TB3-3

BLK96B

98A

SPLICE

SPLICE

A1

BLK

SPLICE

4TB4-1

1K6

4TB4-2

11

41U

14

4B9

4L18

4B10

1K6

4L20

4L19

42N,T,AM,AN

LINE 1201TB3-7

1TB3-8

6DS1

PURGE ALARM

MAXIMUM MODULE CONTACT RATINGS:CUSTOMER PROVIDED DEVICES AND WIRING

2.88A INDUCTIVE, 1/3 HP

115 VAC 15A

LINE 6

1T5-8

1T5-3

LINE 6

41T

95A

41L

94A

P2B4

1

2

3

P6

P8

2

2

1

102D

101D

96A

41M

41N

97A

41V

99A

P10

P12

2

1

1

P14

2

1

2

1

24 VAC

J6

J8

RELAY

1U4 PURGE CONTROL MODULE

TANK VALVE RELAY

PURGE PUMPOUT

J10

J12

J14

ABSORBER

PUMP RELAY

COMPRESSOR RELAYPURGE REFRIGERANT

PURGE VACUUM

VALVE RELAY

J2

B

A

B

A

+

-

J1

+

-

1

3

4

2

J3

3

BLK

RED

4JB3

P3B

6

5RED

BLK

P3C

4

4RT11

4S16 RED

BLK

BLK

RED

LIQUID LEVEL SENSOR

PURGE REFRIGERANTCOMPRESSOR SUCTION

TEMPERATURE


P16

2

3

1

J16

ALARM RELAY

1TB3-4

41L,M,N,U,V

101G

102G

P2B

1T5-7

LINE 61T5-4A

J2

B 3

4

24 VAC

B

A 2

1

LINE 6

198E

199E

P1B

J1+

-2

1198E

199E

P1A

+

-

J5

3

1

4

WHT

BLK

P5A

4

2

3

7

5

6

J7

8

5

6

WHT

WHT

BLK

WHT

BLK

WHT

BLK

BLK

P7B

P5C

P5D

P5B

4RT12

4RT14

4RT13

4RT15

4RT16

J9

J11

3

4

3

4

WHT

BLK

BLK

WHT P11B

P9B4RT18

4RT19

INTER-PROCESSOR

SATURATED CONDENSERREFRIGERANT TEMPERATURE

SOLUTION TEMPERATURE

LEAVING LOWSOLUTION TEMPERATURE


TEMPERATURE GENERATORENTERING LOW

ENTERING ABSORBERSOLUTION TEMPERATURE

SOLUTION TEMPERATURELEAVING ABSORBER

COMMUNICATION

SPRAY TEMPERATURE

SATURATED EVAPORATORREFRIGERANT TEMPERATURE

ABSORBER

1U5 STEPPER CONTROL MODULE

102H

101HP2A

101H

102H

P2

24 VAC

CHASSIS GROUND

GRN

J2

B

A

1

2

198F

199F

P1B

J1

-

+

2

1

199F

198F P1


1U6 LOCAL CLEAR LANGUAGE DISPLAY PANEL

3

1

5

4

P8

115A WHT

114A YEL

111A BLK

113A RED

4B11

J8

2

3

4

1

(See Notes Page 70)

Figure 34 - ABSD Horizon Single-Stage Steam or Hot Water Absorption – Purge and Stepper Control Modules and Local Clear Language Display Panel

73ABS-M-10A

Unit WiringDiagrams

Figure 35 – ABSD Horizon Single-Stage Steam or Hot Water Absorption – Options Control Module and/or Communication Control Modules(See Notes Page 70)

ABS-M-10A74

Figure 36 – Connections: Main Unit Control Panel (Left Side)

Unit WiringDiagrams

6

75ABS-M-10A

Unit WiringDiagrams

Figure 37 – Connections: Unit Control Panel (Right Side)

ABS-M-10A76

Unit WiringDiagrams

Figure 38 – Connections: Unit Control Panel

77ABS-M-10A

Unit WiringDiagrams

Figure 39 – Connection Diagram – Unit Mounted Controls

ABS-M-10A78

Unit WiringDiagrams

Figure 40 – Connection Diagram – Unit Mounted Controls

79ABS-M-10A

Unit WiringDiagrams

SensorsThe table below Indicates unit sensors, primary function control or monitor,connection points, and the normal operation temperature range.

Control sensor abnormal will cause a diagnostic shutdown. Monitor sensor abnormalwill generate an informational warning message only, allowing chiller operation tocontinue.

Table 15

Sensor Application Sensor Primary Function Module1 Evap. Entering Water Temp LCWT Control Chiller2 Evap. Leaving Water Temp LCWT Control Chiller3 Absorber Ent. Water Temp ELWT-Fdfwd & Low Tower Limit Chiller4 Absorber Leaving Water Temp Monitor Chiller5 Cond Leaving Water Temp Monitor Chiller6 Solution Temp Leaving LTG Concentration Calc (LTG) Stepper7 Saturated Evap. Rfgt Temp Evap Limit Stepper8 Saturated Cond. Rfgt Temp Concentration Calc (LTG) Stepper9 Diff Evap Wtr Pressure (Optional) Monitor TBD

10 Diff Tower Wtr Pressure (Optional) Monitor TBD1112131415 Solution Temp Entering Absorber Control T-Margin Stepper16 Solution Temp Leaving Absorber Monitor Stepper17 Solution Temp entering LTG Monitor Stepper18 Absorber Spray Temp Monitor Stepper1920 SDR Temperature SDR Logic Circuit21* Supply Steam Pressure (4R2) Control Chiller22* High Temperature Steam Pressure (4R3) Control Chiller23 Entering Steam Temperature or Hot Water Entering Monitor Circuit24 Steam Condensate Leaving CHX Or Hot Water Leaving Monitor Circuit

The Trane Company

An American Standard Company

www.trane.com

For more information contactyour local district office ore-mail us at [email protected]

Since The Trane Company has a policy of continuous product and product data improvement, it reserves theright to change design and specifications without notice. The installation and servicing of the equipmentreferred to in this booklet should be done by qualified, experienced technicians.

Literature Order Number

File Number

Supersedes

Stocking Location

ABS-M-10A

SV-RF-ABS-ABSD-M-10A-0401

Supersedes ABS-M-10-0500

La Crosse

Horizon Single-Stage Steam or Hot Water Absorption Chiller...

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