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Trane HORIZON ABDA User Manual

Trane HORIZON ABDA
92 pages
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Controls
Single and Two-Stage Steam and
Two-Stage Direct-Fired
Absorption Chiller
With Microprocessor Control Panel
Unit Models
ABDA, ABTF, ABSD
ABS-CTR-3B
HORIZON
®
April 2004
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Trane HORIZON ABDA Specifications

General IconGeneral
BrandTrane
ModelHORIZON ABDA
CategoryChiller
LanguageEnglish

Summary

Controls

HORIZON® Absorption Chiller With Microprocessor Control Panel

Details the HORIZON® absorption chiller with microprocessor control panel.

Introduction and Manual Layout

Manual Layout

Outlines the major sections and their content within the manual.

Absorption Cycle

Explains the basics of the solution cycle and refrigerant/lithium bromide flow.

Absorption Cycle Details

Condensate Heat Exchanger ABTF

Describes the function of the condensate heat exchanger for ABTF models.

Hot Water Heating ABDA

Explains heating with cooling using a heat exchanger for ABDA models.

Machine Solution Cycle

Single-stage Absorption Refrigeration Cycle

Illustrates the single-stage absorption refrigeration cycle.

Sequence of Operation Overview

Operational Diagnostics During Machine Startup

Details diagnostics and external device feedback during the machine start sequence.

ABDA Burner Sequence

Describes the burner start sequence for ABDA models, including flame safeguard control.

Sequence of Operation Events

Sequence of Events from a Stop or Auto condition through Start

Details events from stop/auto to start, including pump operation and diagnostics.

Sequence of Operation Details

Sequence of Events: From Running through Dilution Cycle

Describes events from running state through the dilution cycle.

Sequence of Operation Time Line

Startup/Shutdown

Covers startup pre-heat and shutdown dilution cycle procedures.

Shutdown Dilution Cycle

Explains the purpose and process of the dilution cycle for crystallization prevention.

Sequence of Operation Modes

Normal Stop

Details the normal stop sequence, including burner firing rate and pump operation.

Panic Stop

Describes the panic stop procedure and its consequences for chiller operation.

Control Panel Identification

Control Panel Location and Internal Hardware

Explains the location and internal hardware components of the chiller control panel.

Component Description

Details the two sections of the main control panel: control side and power side.

Panel Layout and Modules

Panel Layout Legend

Lists and describes the components within the control panel layout.

1U1 - Starter Module

Describes the starter module's function for pump operation and AFD interface.

Control Modules

Figure 5. Location of microprocessor control modules

Illustrates the placement of microprocessor control modules within the main and burner control panels.

Signal Block Diagram and Module Descriptions

Signal Block Diagram

Illustrates the interrelationship of interprocessor communications (IPC) link.

1U1 Starter Module

Controls pump operation and interfaces with AFDs for solution flow.

Module Descriptions

1U4 Purge Module

Manages purge system logic, monitors sensor, and initiates pumpout cycles.

1U6 Local Clear Language Display (LCLD, or Operator Interface)

Used to communicate with the chiller module for parameters and data monitoring.

Power Termination and Protection

Main Power Termination Point

The connection point in the power section for customer three phase power.

Circuit Breakers and Fuses

Identifies circuit breakers and fuses providing branch circuit protection.

Using the Control Panel

Display

Illustrates the operator interface with its display, LED, and keypad for chiller information.

Operator Interface (LCLD) Operation

Describes the operator interface keypad layout and its three key fields.

Control Panel Menus and Keypad

Menus

Details access to status, machine data, setup, service, and diagnostics.

Alarm LED.

Explains the function of the single red LED for diagnostics and manual service functions.

Operator Interface Navigation

Using Group Menus

Guides on selecting group keys for reports and accessing menu items.

To Create the Custom Report:

Provides steps to create a custom report by selecting desired menu items.

Operator Interface Reports

Report Menus

Lists the four preformatted report menus: CUSTOM, CHILLER, CYCLE, and PUMP/PURGE.

Custom Report

Explains how to create and customize reports by selecting up to twenty items.

Chiller Operation Modes

Typical "Chiller Operation Mode Displays"

Lists machine conditions and their corresponding displayed messages during operation.

Display Navigation and Setpoints

3. Active Priority Setpoint-Heat or Cool Priority Setpoint Source Setpoint

Identifies active priority and its source for heating/cooling.

4. Chilled Water Setpoint or Evaporator Leaving Water Temperature

Describes the source for chilled water setpoint or evaporator leaving water temperature.

Cycle Report Navigation

Cycle Report

Explains how to navigate through the Cycle Report menu.

2. Solution Temperature Leaving HTG

Displays the solution temperature leaving the High Temperature Generator.

Purge/Pump Report Details

1. Pump or Purge Hours, Starts and Amps

Provides information on pump or purge hours, starts, and amps.

2. Purge Operating Mode:

Details the purge operating modes: Stop, On, and Service Pumpout.

Purge/Pump Report Data

Purge Setpoints

Describes the set points used by the purge module, including operating modes.

Inputs

Lists inputs for the purge module, such as condenser saturation temperature.

Settings Menu Navigation

Operator Settings

Allows operator to select from four menu groups for settings and parameters.

Purge Mode

Explains how to set the purge operating mode (Stop, ON, Service Pumpout).

Operator and Hot Water Settings

13. Heat/Cool Priority Setpoint Source

Defines the priority setpoint source for auxiliary heating.

14. Hot Water Reset Type

Specifies the type of hot water reset to be used.

Operator Settings Configuration

Chilled Water Setpoints and Purge Control

Covers chilled water setpoints and purge control settings.

Purge Operating Mode: (Mode)

Allows adjustment of the purge operating mode.

Service Settings Overview

Service Settings: Basic Setups:

Contains basic setups and feature enables for chiller controls.

Keypad/Display Lockout

Enables or disables keypad and display lockout features.

Service Settings Configuration

Service Settings: BASIC SETUPS

Provides access to basic setups and feature enables within service settings.

Optional Series Printer Displays (if installed)

Details printer setup options when a series printer is installed.

Service Settings Groups

FIELD STARTUP Group

Password protected group for chiller field commissioning.

Machine Configuration Group

Password protected group for programming unit control module.

Module Settings

5. ICS Address

Sets the ICS address for Trane BAS systems.

7. Cooling Delta Temperature Setpoint

Sets the difference between entering and leaving chilled water temps.

Evaporator and Concentration Control

Evaporator Leaving Water Control

Controls evaporator leaving water temperature.

Concentration Control

Adjusts energy input for optimum solution cycle efficiency.

Solution Flow Control

Figure 7 - Selectable LTSP range - solution flow automatic speed drive control

Illustrates the selectable LTSP range for solution flow speed control.

26. Solution Pump AFD Minimum Frequency Setpoint

Sets the UCP2 minimum flow output signal in hertz for the LTSP.

Energy Input and Heating Settings

In-Direct Fired Energy Input Adaptive Mode

Manages energy input for adaptive modes.

Optional Direct-Fired Heating Mode Settings

Settings for direct-fired heating mode, including delta temperature setpoint.

Purge Control and Flow Settings

Purge Control

Manages purge system operation, including pumpout rate and setpoints.

Optional Flow Display Settings (Option)

Configures flow display settings for pressure drop curves.

Energy Coefficients

55. Load Coefficients (ABDA)

Top level menu for ABDA energy linearization settings.

60. Adaptive Energy Linearization Coefficient Upload Menu

Uploads adaptive energy linearization coefficients.

Energy Input Coefficient Configurations

Figure 9 - Linear coefficients

Illustrates linear coefficients used with modulating head burners.

Figure 10 - Butterfly valve coefficients

Illustrates butterfly valve coefficients for fixed head burners.

Service Settings Field Startup Overview

2. Keypad or Display lock feature: [d/e]

Enables or disables the keypad and display lock feature.

3. Menu settings password feature: [d/e]

Enables or disables the menu settings password feature.

Service Settings Continuation

1. Machine Configuration Group Heading

Header for the machine configuration group settings.

3. Unit Types

Specifies the possible unit types for the chiller.

Sales Order Specified Features

17. Line Voltage Sensing Option

Option for line voltage sensing if transformers and fuses are present.

19. External Chilled Water Setpoint Option

Allows external analog signal to adjust chilled water setpoint remotely.

Machine Configuration Options

27. Tracer Option

Option for Tracer module communication.

28. TCI Option

Option for TCI module communication.

Service Tests Overview

1. Service Tools Group Password Request

Requests password to access the service tools group.

3. Chilled Water Pump: (Status)

Displays the status of the chilled water pump (Auto or On).

Service Tests - Pump and Energy Control

16.1. LTSP Solution Pump AFD Speed Command.

Sets the LTSP solution pump AFD speed command.

17. Energy Input control (Auto, Manual or Slave)

Sets the energy input control mode.

Service Tests - Water Flow and Pump Status

Differential Water Pressure Sensing Options (if installed)

Configures differential water pressure sensing options.

Hot Water Pump: auto/on

Sets the hot water pump control mode to auto or on.

Diagnostics Menu Structure

New Diagnostic Display sequence.

Describes the display sequence when a new diagnostic is detected.

Header Screen:

Displays the header screen for active and historic diagnostics.

Diagnostics Menu Operations

5. Clearing Active Diagnostics

Provides steps to clear active diagnostics and reset the system.

6. Clearing informational warnings (IFW)

Explains how to clear informational warnings.

Diagnostics Display Flow

Header Screens

Describes the header screens within the diagnostics menu.

New Diagnostic One Time Display

Displays a one-time screen for new diagnostic information.

Sensors and Controls Locations

ABDA Control Locations

Details the locations of electrical components and controls for ABDA models.

Figure 12. Location of electrical components

Diagram showing the location of electrical components on the machine.

Machine Sensor Locations

Figure 12. Machine Sensor Locations (Continued)

Continues the illustration of machine sensor locations.

Figure 13. Sensor locations of the absorption fluid cycle – see table 7

Diagram showing sensor locations within the absorption fluid cycle.

Sensor Function Table

Sensor

Identifies sensors, their primary function, and module connection.

ABTF Control Locations Diagram

Figure 14. Machine sensor locations

Illustrates the locations of machine sensors for ABTF models.

Machine Sensor Locations Continued

ABTF Absorption Fluid Cycle Sensor Locations

1 Evaporator Entering Water Temperature - 4RT6

Identifies the evaporator entering water temperature sensor and its reference.

Sensor Functionality Table

Sensor

Lists sensors, their primary function, module, and operating range.

ABTF Absorption Fluid Cycle Sensing Points

Table 3. Sensing points for single stage Horizon Chiller

Lists sensing points for the single stage Horizon Chiller.

Machine Control Strategy

Simplified Diagram of Leaving Water Temperature Control and Concentration Control

Diagram showing LWT and concentration control inputs to the microprocessor.

1. Leaving Water Temperature (LWT)

Explains LWT control via refrigerant vapor pressure and absorber spray concentration.

Horizon's Adaptive Cycle Management

Cycle Management

Illustrates generator temp, interstage pressure, and low refrigerant temp limits.

Management Functions

Lists functions for adaptive cycle management and their purposes.

Leaving Chilled Water Temperature Control

Figure 16. Temperature control monitoring flow results

Diagram illustrating temperature control monitoring flow results.

Low Leaving Water Temperature Cutout (LCWTC)

Control Band

Defines the control band around the setpoint where temperature functions are active.

Figure 17

Illustrates leaving water temperature setpoint and LCWTC setpoint range.

Concentration Control Logic

Concentration Control Block Diagram

Diagram showing concentration control logic and inputs.

4. When no limit conditions take precedence

Explains how mixed concentration is controlled relative to crystallization line.

LTHX Margin vs Capacity Control Signal

Figure 18

Illustrates LTHX margin versus capacity control signal.

Control System PID Control

Figure 19. Simplified diagram of leaving water temperature control and concentration control

Simplified diagram of LWT and concentration control using PID.

Figure 20. Identifies the PID functions.

Diagram identifying Proportional, Integral, and Derivative functions.

Control System Limits Overview

Figure 21

Identifies limit conditions that can override LWT and concentration control.

Crystallization Sensing Detection and Recovery (SDR)

Figure 22. Solution flows

Illustrates solution flows, sensing, and detection of reverse flow.

Electrical Block Diagram

Diagram showing electrical connections for SDR system.

SDR System Response and Reset

C) RECOVERY SEQUENCE

Describes the recovery sequence performed by the SDR system.

Reset, Stop, or Panic stop during SDR cycle

Explains actions for Reset, Stop, or Panic stop during an SDR cycle.

SDR Occurrence Illustration

Figure 23

Illustrates a typical SDR trip temperature and recovery.

Soft Loading Time Control

Figure 24

Illustrates soft loading time duration and setpoint changes.

Absorber Entering and Low Condensing Temperature Limit

Figure 25

Graph showing low tower limit based on saturated condensing temperature.

Temperature Cutouts and Limits

Low Chilled Water Temperature Cutout (LCWTC)

Shuts down the machine when leaving water temp reaches cutout setpoint.

Figure 26. Example illustrating leaving water temperature setpoint and LCWTC setpoint range

Illustrates leaving water temperature setpoint and LCWTC range.

Low Refrigerant Temperature Cutout (LRTC) and Limit

Figure 27. Refrigerant limiting function operation

Illustrates refrigerant limiting function operation and setpoints.

Differential to Start/Stop Logic

Filtered Setpoint Feature

Figure 29. Three examples of setpoint changes with and without the filter feature

Compares setpoint changes with and without the filtered setpoint feature.

Leaving Water Temperature Control Setpoints

Table 9. Maximum differential start and stop settings for leaving water temperature setpoints

Identifies max differential settings for LWT setpoints without violating other limits.

Figure 30. Leaving water temperature control settings

Composite graph of all settings regarding leaving water temperature control.

Inter-Stage Pressure Limit

Low Interstage Pressure Limit

Monitors inter-stage pressure for increase to avoid startup diagnostic issues.

Figure 31. Example illustrating the microprocessor response to a pressure increase approaching cutout

Illustrates microprocessor response to increasing interstage pressure.

Generator Solution Temperature Limit

Figure 32

Graph showing generator solution temperature limits and loading regions.

High Exhaust Gas Temperature Limit and Cutout

High Exhaust Gas Temperature Limit

Limits burner fire rate or turns off burner to reduce generator temperature.

Figure 33. Exhaust stack limit during automatic operation

Graph showing exhaust stack limit during automatic operation.

High Exhaust Gas Temperature Cutout - HEGTC

Figure 34. HTC control module

Diagram of the HTC control module and its connections.

Typical HTC Circuit Diagram

Figure 35. The following diagram indicates a typical HTC circuit

Diagram illustrating a typical HTC circuit.

Adaptive Steam Control

% Energy input Auto Command verses Energy Valve Position

Relates energy input commands to energy valve position.

Generator Entering Hot Water Limit Control

Figure 36. Loading region and temperature limits

Graph showing loading regions and temperature limits for hot water generators.

Purge System Operation

Figure 37. Horizon Purifier Purge

Diagram of the Horizon Purifier Purge system.

Purge Theory and Operation

Explains how the purge system removes air and non-condensables.

Purge Setpoints and Inputs

Purge Setpoints

Describes the set points used by the purge module, including operating modes.

Maximum Pumpout Rate

Sets the maximum allowable pumpout rate per 24 hours.

Purge System Outputs and Modes

Liquid Level Sensor

Indicates the presence of high liquid refrigerant in the primary purge tank.

Service Pumpout Setpoint

Sets the pumpout rate timer and allows manual pumpout entry.

Purge System Status

Ready to Pumpout

Indicates purge system is running, pumpout disabled.

Service Pumpout

Initiates pumpout sequence for mechanical repairs, regardless of chiller state.

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