Trane CVGF User's Manual
Contents
1. Max Flow Ips gpm 63 995 71 1120 79 1248 87 1385 97 1536 108 1706 127 2009 142 2251 158 2497 175 2777 Standard Efficiency Shells 1 00 inch 25 4 mm Int Enhanced Cu Tube Condenser Nominal Shell 500 500 500 700 700 700 1000 1000 1000 1000 Bundle Size Small Medium Large Small Medium Large Small Medium Large Extra Large Number of Passes 2 2 2 2 2 2 2 2 2 2 Min Flow Ips gpm 31 499 35 557 38 606 43 682 48 764 53 838 58 925 64 1020 75 1172 83 1307 Max Flow Ips gpm 115 1831 129 2041 140 2221 158 2501 177 2801 194 3071 214 3391 236 3741 276 4372 302 4792 Evaporator Nominal Shell 500 500 500 700 700 700 1000 1000 1000 1000 Bundle Size Small Medium Large Small Medium Large Small Medium Large Extra Large Number of Passes 2 2 2 2 2 2 2 2 2 2 Min Flow lps gom 28 447 31 496 35 550 39 625 45 706 49 784 49 781 57 896 63 1003 70 1115 Max Flow Ips gpm 103 1638 115 1818 127 2018 145 2293 163 2589 181 2874 181 2864 207 3287 232 3678 258 4090 Evaporator Nominal Shell 500 500 500 700 700 700 1000 1000 1000 1000 Bundle Size Small Medium Large Small Medium Large Small Medium Large Extra Large Number of Passes 3 3 3 3 3 3 3 3 3 3 Min Flow Ips gom _19 298 21 330 23 367 26 417 30 471 33 523 33 521 38 598 42 669 47 744 Max Flow lps gom 69 1092 76 1212 85 1346 96 1522. Centrifugal Water Chillers Model CVGF Water Cooled Hermetic Centrifugal Refrigeration Capacities From 400 to 1000 Tons 1400 kW 3510 kW 50 and 60 Hz September 2004 CTV PRC001 GB TRANE Introduction Introducing Trane s Model CVGF Centrifugal Water Chiller Introduction The basic gear driven centrifugal water chiller design was introduced in 1976 and has been proven in thousands of installations The Trane Company continues to deliver its reliability and energy fitness commitment on its newest line of gear drive centrifugal water chillers the Model CVGF The major advantages of the Model CVGF are e High reliability e Low sound levels e Compact size e High efficiency at a competitive market price e Designed to use environmentally responsible HFC 134a refrigerant The Model CVGF chiller is ideal for office hospital school hotel retail store and industrial buildings The Trane centrifugal chiller line offers hundreds of individual evaporator condenser compressor combination selections permitting precise tailoring of the machine capacity to system requirements Machine selections can be computer optimized to provide low first cost low operating cost or other criteria important for a particular selection Centrifugal Water Chiller computer selection program is certified in accordance with ARI standard 550 590 Trane Sales Engineers are available to assist in selecting the optimum
3. TE28 0 711 mm W 19 mm Internally Enhanced TE28 0 028 W 0 75 Internally Enhanced Evap Cond Working Pressure bar 10 psi 150 Evap Cond Water Connection Victaulic Connection Flanged Adaptor English Unit Flanged Adaptor SI Unit Agency Approvals Chiller UL CUL Listed ASME CE Approval PED European Code Motor Volt Hz 380 400 415 3300 6600 Volts 50 Hz 380 460 575 3300 4160 Volts 60 Hz Starter Unit Mounted Remote Mounted Wye Delta Solid State Inside the Delta Wye Delta Solid State Inside the Delta Across the line Primary Reactor Auto Transformer Medium Voltage 3300 4160 6600 Starter Types Full Voltage X Line Primary Reactor Auto Transformer Table GD 2 Weight Without Starter With Starter Shell Size Operating Shipping Operating Shipping Model Compressor Evaporator Condenser Ibs kgs Ibs kgs Ibs kgs Ibs kgs CVGF 400 500 500 500 22391 10157 19656 8916 23336 10585 20601 9345 CVGF 500 700 700 29438 13353 25593 11609 30383 13782 26538 12038 CVGF 650 700 700 30889 14011 27044 12267 31765 14409 27920 12665 CVGF 800 1000 1000 41646 18891 35627 16160 42522 19288 36503 16558 CVGF 1000 1000 1000 42462 19261 36443 16531 43407 19689 37388 16959 Note Values represent estimate maximum unit weights including shells with TECU tubes max bundles 2 pass evaporator and condenser 150 psig non marine waterboxes and compressors with the largest low vo
4. Water Treatment The use of untreated or improperly treated water in a chiller may result in scaling erosion corrosion algae or slime It is recommended that the services of a qualified water treatment specialist be used to determine what treatment if any is advisable The Trane Company assumes no responsibility for the results of untreated or improperly treated water CTV PRC001 GB General Data Table GD 1 Model CVGF Description Model CVGF Nominal Cooling Capacity NTON 400 500 500 650 800 1000 Heat Exchanger Size Evaporator EVSZ 500 500 700 700 1000 1000 Condenser CDSZ 500 500 700 700 1000 1000 Heat Exchanger Bundles Evaporator EVBS A Small A Small A Small A Small A Small A Small B Medium B Medium B Medium B Medium B Medium B Medium C Large C Large C Large C Large C Large C Large D Extra Large D Extra Large Condenser CDBS A Small A Small A Small A Small A Small A Small B Medium B Medium B Medium B Medium B Medium B Medium C Large C Large C Large C Large C Large C Large D Extra Large D Extra Large Heat Exchanger Tube Evaporator EVTM IE25 0 635 mm W 25 4 mm Internally Enhanced IE25 0 025 W 1 00 Internally Enhanced TE25 0 635 mm W19 mm Internally Enhanced TE25 0 025 W 0 75 Internally Enhanced Condenser CDTM IE28 0 711 mm W 25 4 mm Internally Enhanced IE28 0 028 W 1 00 Internally Enhanced
5. eThe radial velocity component V which is directly proportional to the refrigerant gas flow Q e The tangential velocity component V which is a function of both impeller diameter D and the rotational speed rpm Two Stage Compressors Surge Less and Later To produce the same head as a single stage compressor two stage machines use two small diameter impellers Component V is the same as on each stage though V is the same as ona single stage compressor This results in a better balance of forces at low loads and produces a machine with a wider unloading capability In Trane centrifugal chillers gas prerotation vanes ahead of the compression stage improve impeller aerodynamic efficiency resulting in smoother unloading and reducing power consumption The curves show that two stage compressors surge less and later than single stage machines Intersection point B when the load line meets the surge area corresponds to a higher part load for the single stage compressor than would be the case with a two stage compressor Two stage machines therefore have a wider range of applications CTV PRCO01 GB Features and Benefits The length of the resultant vector V is proportional to the kinetic energy available for conversion to static pressure in the volute Consequently for a given compressor V is fixed and V varies with the cooling load With the chiller unloading the pressure differential between evaporato
6. 22 87 276 10 87 10 bar 150 psig NMAR 3 530 20 87 530 20 87 Condenser Water Box Length SI English Length No mm in Shell Pressure Evap Passes Supply Return 500 10 bar 150 psig NMAR 2 483 19 02 200 7 87 10 bar 150 psig NMAR 2 438 17 24 222 8 74 700 10 bar 150 psig NMAR 2 581 22 87 213 8 39 10 bar 150 psig NMAR 2 524 20 63 235 9 25 1000 10 bar 150 psig NMAR 2 654 25 75 232 9 13 10 bar 150 psig NMAR 2 632 24 88 276 10 87 19 TRANE The Trane CVGF packaged centrifugal water chillers using HFC 134a refrigerant consist of a hermetic two stage gear drive centrifugal compressor evaporator condenser interstage economizer unit mounted microprocessor based control panel and compressor motor starter The chiller is completely factory assembled Compressor Two stage centrifugal compressor with high strength aluminum alloy fully shrouded impellers The impellers are tested at 25 percent over design operating speed The rotating assembly is dynamically balanced for vibration of less than 5 1 mm s 0 2 ips peak velocities at nominal operating speeds The control system affords 100 20 percent capacity modulation by electrically actuated guide vanes upstream of each impeller Drive Train The drive train consists of helical bull and pinion gears Gear tooth surfaces are case hardened and precision ground The one piece impeller shaft is supported by hydrodynamic thrust and radi
7. 6 8 1 4 6 6 1 4 650 700 4235 mm 1850 mm 4083 mm 2270 mm 2083 mm 2076 mm 13 10 3 4 3 11 13 4 3 4 7 5 38 6 10 6 9 3 4 800 1000 1000 4235 mm 1219 mm 4083 mm 2521 mm 2305 mm 2257 mm 13 10 3 4 4 13 4 3 4 8 3 1 4 7 6 3 4 7 47h CL1 at either end of machine and is required for tube pull clearance CL2 is always at the opposite end of machine from CL1 and is for water box plus clearance Recommended clearance D1 for machine with unit mounted starter is 914 mm 36 Recommended clearance D2 for machine without unit mounted starter is 1219 mm 38 Unit length is not included for the waterbox See page 19 for waterbox dimension 18 CTV PRC001 GB CTV PRCO01 GB Physical Dimensions TRANE Model CVGF Water Connection Pipe Size Shell Size 500 700 1000 Water Passes Metric Pipe Size mm DN Evaporator 2 Pass DN 200 8 DN 250 10 DN 300 12 3 Pass DN 200 8 DN 200 8 DN 250 10 Condenser 2 Pass DN 250 10 DN 300 12 DN 350 14 Evaporator Water Box Length SI English Length No mm in Shell Pressure Evap Passes Supply Return 500 10 bar 150 psig NMAR 2 371 14 61 156 6 14 10 bar 150 psig NMAR 3 371 14 61 371 14 61 700 10 bar 150 psig NMAR 2 489 19 25 235 9 25 10 bar 150 psig NMAR 3 438 17 24 438 17 24 1000 10 bar 150 psig NMAR 2 581
8. GPM litres second Vs 0 06308 0 00075 ft F hr BTU 0 132 m K kM Velocrty 0 00025 ft F hr BTU 0 044 m K kW Feet per minute ft m meters per second m s 0 00508 Feet per second ft s meters per second m s 0 3048 Temperature Centigrade C Versus Fahrenheit F Note The center columns of numbers referred to as BASE TEMP is the temperature in either degrees Fahrenheit F or Centigrade C whichever is desired to convert into the other If degrees Centrigrade is given read degrees Fahrenheit to the right If degrees Fahrenheit is given read degrees Centigrade to the left w www A NBQAOS iia wt oe Sa NwWWAD oowoo gt gt gt NN NNNN NW FO BOXSN WANDS AGLAN SOorFrn SOO NN WWWWW WWW NNOWKR TID 1 NO DBMRYO WAHRBNSO AMANO Bite pi ti ROD Kowo OD 3 3 3 3 2 2 Boose BBNO OOR PNNOW ANNDOD N 000000 NNMOWO BOTAN NOWOR N N ONN amp WN Ow tH WOM WaONA INY eh oan ig olo Lolo TA TR VOLOM o npo N 1 1 1 1 k NNNNN NNNNN PANNO WATIOID Nvwow OROD gt te tee 2324NN IDDNN LOO OM NNO WORDD ODON DDAN WWNN gt BOWAON N oof WOWONN erry t e ete FOR INTERPOLATION IN THE ABOVE be USE BASE TEMPERATURE F or C 1 3 4 5 6 7 8 9 10 DEGREES CENTIGRADE 0 56 i 1 67 2 22 2 78 3 33 3 89 4 44 5 00 5 56 DEGREES FAHRENHEIT 1 8 3 6 5 4 7 2 9 0 10 8 12 6 14 4 16 2 18 0 CTV PRCO01 GB 23 S TRANE www trane com For more inform
9. and terminates chiller operation when the temperature is excessive The controller monitors each of the three winding temperature sensors any time the controller is powered up and displays each of the temperatures at the service menu Immediately prior to start and while running the controller will generate a latching diagnostic if the winding temperature exceeds 265 5 F 129 4 2 8 C Surge Detection Protection Surge detection is based on current fluctuations in one of three phases The default detection criterion is two occurrences of RMS current change of 30 percent within 0 8 seconds in 60 10 percent seconds With the Tracer chiller controller the detection criterion is adjustable Overvoltage and Undervoltage Protection The unit will be shut down with an automatic reset if the line voltage is below or above 10 percent of nominal Must trip 15 percent of nominal Time to trip minimum of 1 minute 10 seconds and maximum of 5 minutes 20 seconds Overvoltage and undervoltage protection can be disabled using TechView Power Factor and kW Measurement Three phase measurement of kW and unadjusted power factor yields higher accuracy during power imbalance conditions than with CH530 Short Cycling Protection Short cycling protection is based on a start to start time This method uses a straight start to start timer to determine when to allow the next start A Restart Inhibit Start to StartTime set
10. e All metric fasteners CTV PRC001 GB Microprocessor Controls with CH530 DynaView Operator Interface DynaView is the unit mounted control panel and also serves as the main processor and operator interface It has a touch sensitive overlay on a 1 4 VGA display DynaView presents information through an intuitive tabbed navigation system Alternate languages can be downloaded to the control panel which can hold English plus two other languages at one time Features and Benefits S TRANE DynaView receives information from and communicates information to the other devices on the chiller s communications link DynaView performs the Leaving Chilled Water Temperature and Limit Control algorithms arbitrating capacity against any operating limit against which the chiller may find itself working e Auto Stop commands e Status all subsystems e Setpoint adjustment daily user points 10 active diagnostics e Mode overrides e ASHRAE chiller log CTV PRCO01 GB DynaView can be connected to the service tool using a standard 9 pin male 9 pin female RS 232 serial cable The serial connection is located at the bottom of the DynaView panel behind a sliding door Touch sensitive screen provides information and navigation at the same time Change setpoints and settings with touch screen commands Displays chiller status and operating points Touch for more information If diagnostic exists an ala
11. machine to satisfy the particular project requirements Turn to the Model CVGF for energy efficiency provided by the two stage gear drive centrifugal water chillers with economizers The Trane Model CVGF is your choice for energy fit operation year after year 2004 American Standard Inc All rights reserved CTV PRC001 GB CTV PRCO01 GB Contents Introduction Features and Benefits Application Considerations General Data Jobsite Connections Controls Physical Dimensions Mechanical Specifications Conversion Table 10 12 13 17 19 23 TRANE Standard CVGF Features The following features are provided as standard with all Trane Model CVGF chillers e Hermetic two stage centrifugal compressor motor assembly with integral lubrication system and economizer cycle e Evaporator and condenser assembly e Prewired instrument and control panel e Oil charge e Integral oil heaters e Isolation pads e Wiring and oil system interconnection to main control panel e Advance motor protection e Two stage gear drive with economized cycle for high efficiency and high reliability e Liquid cooled hermetic induction motor the motor operates at lower temperatures for longer motor life Optional Features e Unit and remote wye delta mounted starters e Unit mounted floor mounted and wall mounted solid state starters e Across the line Primary Reactor and Auto Transformer Remote mounted starter for medium hig
12. respond faster and maintain stable leaving water temperatures Soft Loading The chiller controller uses soft loading except during manual operation Large adjustments due to load or setpoint changes are made gradually preventing the compressor from cycling unnecessarily It does this by internally filtering the setpoints to avoid reaching the differential to stop or the current limit Soft loading applies to the leaving chilled water temperature and current limit setpoints Multi Objective Limit Arbitration There are many objectives that the controller must meet but it cannot satisfy more than one objective at a time Typically the controller s primary objective is to maintain the evaporator leaving water temperature Whenever the controller senses that it can no longer meet its primary objective without triggering a protective shutdown it focuses on the most critical secondary objective When the secondary objective is no longer critical the controller reverts to its primary objective Fast Restart While the inlet guide vanes are closing the controller will allow the centrifugal chiller to restart and going to a postlube operational mode If the chiller shuts down on a nonlatching diagnostic the diagnostic has 30 60 seconds to clear itself and initiate a fast restart This includes momentary power losses CTV PRCO01 GB TRANE Features and Benefits e Time of day scheduling allows the end user to def
13. saves unit set up information during power loss without the need for batteries Password protection is provided to secure the operator interface PC based service tool software displays the last 60 active or 60 historic diagnostics indicating the time date of occurrence and system parameters at the time of the diagnostic The service tool provides advanced troubleshooting and access to sophisticated configuration settings not needed during operation of the chiller Any PC that meets the installation requirements may be loaded with the service tool software via download from www trane com Unit mounted display is capable of displaying chiller parameters in IP or SI units and language in English and any 2 downloadable and or locally translated languages Compressor Motor Starter Unit mounted starters can either be a star delta or solid state in NEMA1 type enclosure wired to compressor motor up to 952 RLA at 380 480 volts star delta 900 RLA at 481 600 Volts star delta and 1472 RLA at 380 600 volts solid state Remote mounted starters can either be star delta or solid state for low voltage Across the line primary reactor or auto transformer for medium and high voltage All in a NEMA 1 type enclosure up to 1402 RLA at 380 600 volts star delta 1472 RLA at 380 600 volts solid state and 360 RLA at 3300 6600 volts x line primary reactor and auto transformer 21 TRANE Unit mounted or remote mounted s
14. screws ensure that the appropriate mounting hardware is available TechView can communicate with individual devices or groups of devices Features and Benefits TechView All chiller status machine configuration settings customizable limits and up to 60 active or historic diagnostics are displayed through the service tool software interface Any PC that meets the system requirements may download the service interface software and DynaView updates from Trane s Web site at www trane com TechView is designed to run ona customer s laptop which connects to DynaView with a serial cable DynaView s serial port is located behind a sliding door on the bottom of the DynaView enclosure It uses a standard 9 pin male and 9 pin female RS 232 cable Hardware requirements for TechView e Pentium Il Ill or higher processor e 128 MB RAM 1024 x 768 resolution e CD ROM e 56K modem e 9 pin RS232 serial connection e Windows 95 98 2000 CTV PRC001 GB Feedforward Adaptive Control The Tracer chiller controller allows the system designer to explore energy saving strategies and allows the centrifugal chiller to be used in ways that were never thought possible Feedforward Adaptive Control Feedforward is an open loop predictive control strategy designed to anticipate and compensate for load changes It uses evaporator entering water temperature as an indication of load change This allows the controller to
15. 9 109 1726 121 1916 120 1909 138 2191 15 2452 172 2726 12 CTV PRC001 GB CTV PRCO01 GB Jobsite Connections TRANE Supply and Motor Lead Wiring and Connections Copper conductors only should be connected to the compressor motor due to the possibility of galvanic corrosion as a result of moisture if aluminum conductors are used Copper conductors are recommended for supply leads in the starter panel Suggested starter panel line and load side lug sizes when lugs are provided are noted in the starter submittals These submitted lug sizes should be carefully reviewed for compatibility with conductor sizes specified by the electrical engineer or contractor If they are not compatible the electrical engineer or contractor should specify the required lug sizes for the particular application Ground lugs are provided in the motor terminal box and starter panel The motor terminals are supplied with connection pads which will accommodate bus bars or standard terminal lugs crimp type recommended Terminal lugs are field supplied These connection pads provide additional surface area to minimize improper electrical connections Also a s inch bolt is provided on all connection pads for mounting the lugs Figure J 1 illustrates the connection between the motor connection pads and the terminal lugs Figure J 1 Electric Connections Terminal Lugs Field Supplied S Connection Pad Mo
16. al bearings 20 Mechanical Specifications Motor The motor is a hermetic liquid refrigerant cooled two pole low slip squirrel cage induction motor A radial hydrodynamic bearing and duplex angular contact ball bearings support the rotor assembly Winding embedded sensors provide positive thermal protection Lubrication System The lubrication system consists of an internal oil sump with heaters positive displacement oil pump brazed plate condenser cooled oil cooler and oil distillation return line Economizer Orifice The economizer consists of a carbon steel shell with internal components designed to prevent liquid carryover to the compressor Liquid refrigerant is admitted through a single calibrated orifice no moving parts which maintains a pressure differential between condenser and economizer Evaporator The evaporator is designed tested and stamped in accordance with ASME Boiler and Pressure Vessel Code or PED European Code for refrigerant side working pressure of 15 2 bars 220 psig It consists of a carbon steel shell with steel tube sheets welded to each end Intermediate tube support sheets positioned along the shell axis prevent relative tube motion Individually replaceable externally finned and internally grooved 19 mm 4 in and 25 4 mm 1 0 in nominal diameter seamless copper tubes are mechanically expanded into tube sheets Two or three pass water boxes rated at 10 5 bar 150 ps
17. ation contact your local district office or e mail us at comfort trane com ISO 9001 Quality System Certified avr La Crosse C Business Unit Literature Order Number CTV PRC001 GB File Number PL RF CTV 000 PRC001 0904 Supersedes CTV PRCO01 GB 103 Literature Stocking Location Europe Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice Only qualified technicians should perform the installation and servicing of equipment referred to in this publication American Standard Europe BVBA Registered Office 1789 Chauss e de Wavre 1160 Brussels Belgium
18. e low oil temperature setpoint the compressor is shut down ona latching diagnostic and cannot be started The diagnostic is reported at the user interface The oil heaters are energized in an attempt to raise the oil temperature above the low oil temperature setpoint High oil temperature protection is used to avoid overheating the oil and the bearings Low Differential Oil Pressure Protection Oil pressure is indicative of oil flow and active oil pump operation A significant drop in oil pressure indicates a failure of the oil pump oil leakage or other blockage in the oil circuit The differential pressure during oil pump compressor prelube mode should not fall below 12 psid A failure on this parameter generates a shutdown diagnostic When the compressor is running a diagnostic is issued when the differential pressure is lost Phase Unbalance Protection Phase unbalance protection is based on an average of the three phase current inputs The ultimate phase unbalance trip point is 30 percent In addition the RLA of the motor is derated by resetting the active current limit setpoint based on the current unbalance The RLA derate protection can be disabled in the field startup menu The following derates apply when the phase unbalance limit is enabled 10 unbalance 100 RLA derate 15 unbalance 90 RLA derate 20 unbalance 85 RLA derate 25 unbalance 80 RLA derate 30 unbalance Shutdown Phase Loss Pr
19. efine an exact voltage sag or voltage level at which a particular motor will no longer consume power but we are able to make some general statements concerning MPL protection The chiller will remain running under the following conditions e Line voltage sag of 1 5 line cycles or less for any voltage magnitude sag e Control voltage sags of less than 3 line cycles for any magnitude sag Control voltage sags of 40 percent or less for any amount of time e Second order or lower harmonic content on the line CTV PRCO01 GB Controls TRANE The chiller may shut down under the following conditions e Line voltage sags of 1 5 or more line cycles for voltage dips of 30 percent or more e Control voltage sags of 3 or more line cycles for voltage dips of 40 percent or more e Third order or higher harmonic content on the line Current Overload Protection The control panel will monitor the current drawn by each line of the motor and shut the chiller off when the highest of the three line currents exceeds the trip curve A manual reset diagnostic describing the failure will be displayed The current overload protection does not prohibit the chiller from reaching its full load amperage The chiller protects itself from damage due to current overload during starting and running modes but is allowed to reach full load amps High Motor Winding Temperature Protection This function monitors the motor temperature
20. h voltage e Marine waterboxes for evaporator and condenser e Factory applied thermal insulation e One inch deflection spring isolators for vibration sensitive installations e Refrigerant available from a local distributor e Building automation systems BAS Interface e Factory testing Features and Benefits Applications e Comfort cooling e Industrial process cooling Patents e Polygon drive for refrigeration compressor impellers e Centrifugal compressor sump demister e Internal oil filter e Thermosiphonic oil cooler e Compressor height and alignment adjustment e Oil return using hot gas for motive force e Centrifugal impeller assembly e Internal oil filter Orifice System e Simplified orifice system with improved part load performance down to 20 percent part load Advanced Heat Transfer Surfaces e Evaporator and condenser tubes use the latest heat transfer surfaces e Less refrigerant needed due to advanced patented evaporator design Compact Size e Designed with the retrofit and replacement market in mind e The 400 to 500 NTON sizes can fit through most double width doors e Small footprint of the CVGF chiller saves valuable equipment room space Simple Installation e Simplified piping the only water piping required is for the evaporator and condenser e Simple power connection e Unit mounted starter eliminates additional jobsite labor requirements Environmental Features and Benefits I
21. i is standard Grooved pipe stubs for Victaulic couplings are standard flanged connections are optionally available The waterside is hydrostatically tested at 1 5 times maximum working pressure Liquid refrigerant is admitted to the evaporator through a single calibrated orifice no moving parts which maintains a pressure differential between the economizer and the evaporator Condenser The condenser is designed tested and stamped in accordance with the ASME Boiler and Pressure Vessel Code or PED European Code for a refrigerant side working pressure of 15 2 bars 220 psig It consists of a carbon steel shell with steel tube sheets welded to each end Individually replaceable externally finned and internally grooved 19 mm 3 4 in and 25 4 mm 1 0 in nominal diameter seamless copper tubes are mechanically expanded into the tube sheets CTV PRC001 GB Welded steel two pass water boxes are bolted to the tube sheets Water connections are steel pipe stubs grooved for Victaulic couplings flanged connections are optionally available Maximum waterside working pressure of 10 5 bars 150 psi is standard The waterside is hydrostatically tested at 1 5 times maximum working pressure Unit Control Panel The Tracer CH 530 is a microprocessor based chiller controller that provides complete stand alone system control for water cooled centrifugals It is a factory mounted packaged and tested on the CVGF unit All control
22. ide range of building automation systems To take full advantage of the capabilities of the chiller incorporate your chiller into a Tracer Summit building automation system But the benefits do not stop at the chiller plant AtTrane we realize that all energy used in your cooling system is important That is why we worked closely with other equipment manufacturers to predict the energy required by the entire system We used this information to create patented control logic for optimizing the HVAC system efficiency The building owner s challenge is to tie components and applications expertise into a single reliable system that provides maximum comfort control and efficiency Trane s Integrated Comfort systems ICS are a concept that combines system components controls and engineering applications expertise into a single logical and efficient system These advanced controls are fully commissioned and available on every piece of Trane equipment from the largest chiller to the smallest VAV box As a manufacturer only Trane offers this universe of equipment controls and factory installation and verification CTV PRC001 GB Two Stage Compressor Widens the Application Range Why Centrifugal Compressors Surge Centrifugal compressors produce their pressure differential head by converting the kinetic energy of the gas leaving the impeller into static pressure The velocity of this gas is the result of two components
23. ine the occupancy period i e time of the day holiday periods and exception schedules Building Automation and Chiller Plant Control For a preprogrammable and flexible building automation and chiller plant control Trane has developed the Tracer Summit It can control the operation of the complete installation chillers pumps cooling towers isolating valves air handlers and terminal units Trane can undertake full responsibility for an optimized automation and energy management for the entire chiller plant e Optimization of the start stop time of the installation based on the programmed schedule of occupancy and on the historical record of the behavior of the temperatures calculates the optimal time of start and stop of the installation to get the best compromise between energy savings and comfort of the occupants e Soft loading the soft loading function minimizes the number of chillers that are operated to satisfy the building morning pull down thus preventing an overshoot of the actual capacity required Unnecessary starts are avoided and the peak current demand is lowered The main functions are e Chiller sequencing equalizes the number of running hours of the chillers Different control strategies are available depending on the configuration of the installation e Control of the auxiliaries includes input output modules to control the operation of the various auxiliary equipments water pumps valve
24. isable and modulate the hot water control mode Occasionally centrifugal chillers are used to provide heating as a primary mission In this case the external controller or operator would select a hot water temperature setpoint and the chiller capacity would be modulated to maintain the setpoint Heating is the primary mission and cooling is a waste product or a secondary mission This technique provides application flexibility especially in multiple chiller plants in conjunction with undersized heating plants The chiller needs only one condenser for hot water control whereas Heat Recovery uses a secondary condenser Refrigerant Monitor The Extended Operation package allows for a refrigerant monitor to send a 4 20 mA signal to the DynaView display It can be calibrated to correspond to either 0 100 ppm or 0 1 000 ppm concentration levels The concentration level is displayed at DynaView but the chiller will not take any action based on the input from the refrigerant monitor Alternatively a refrigerant monitor can be connected to Tracer Summit which has the ability to increase ventilation in the equipment room in response to high refrigerant concentrations 15 TRANE Tracer Chiller Controller The chiller controller uses proportional integral derivative PID control for all limits there is no dead band This removes oscillation above and below setpoints and extends the capabilities of the chiller S
25. ltage motors for each family CTV PRCO01 GB 1 1 TRANE General Data Table GD 3 Evaporator and Condenser Flow rates Minimum and Maximum liters per second gallons per minute High Efficiency Shells 0 75 inch 19 mm Int Enhanced Cu Tube Condenser Nominal Shell 500 500 500 700 700 700 1000 1000 1000 1000 Bundle Size Small Medium Large Small Medium Large Small Medium Large Extra Large Number of Passes 2 2 2 2 2 2 2 2 2 2 Min Flow lps gom 31 487 34 542 37 586 42 668 47 744 52 816 59 938 67 1056 74 1176 77 1213 Max Flow Ips gpm 113 1786 125 1987 136 2148 155 2450 172 2727 189 2993 217 3441 244 3874 272 4311 280 4447 Evaporator Nominal Shell 500 500 500 700 700 700 1000 1000 1000 1000 Bundle Size Small Medium Large Small Medium Large Small Medium Large Extra Large Number of Passes 2 2 2 2 2 2 2 2 2 2 Min Flow lps g om 26 407 29 458 32 511 36 566 40 628 44 698 52 822 58 921 64 1021 72 1136 Max Flow lps gpm 94 1493 106 1680 118 1873 131 2077 145 2304 161 2559 190 3013 213 3377 236 3745 263 4165 Evaporator Nominal Shell 500 500 500 700 700 700 1000 1000 1000 1000 Bundle Size Small Medium Large Small Medium Large Small Medium Large Extra Large Number of Passes 3 3 3 3 3 3 3 3 3 3 Min Flow Ips gpm 17 271 19 305 21 340 24 378 26 419 29 465 35 548 39 614 43 681 48 757
26. mproved Efficiency e High Efficiency 0 55 kW Ton at ARI conditions e Motor cooling vented to economizer cycle efficiency advantage e HFC 134 optimized inlet guide vanes and impellers for improved cycle efficiency using computational fluid dynamics Reduced Emissions e Over 30 percent joint reduction in compressor motor assembly compared to previous designs e Patented integral heaters imbedded into the compressor casting no seals no leaks e Beaded flat gasket technology instead of O rings lower susceptibility to developing leaks e Minimal NPT pipe threads on chiller system SAE O ring boss fitting lower leak potential e Oil sump internal to compressor motor assembly with internal pump motor eliminates vent and drain lines leak prevention e Patented internal oil filter prevents leaks and contamination from pipes filter is isolated and easily replaced e Advanced evaporator design minimizes the refrigerant charge a reduced charge reduces the exposure to the environment in the event of a catastrophic charge loss Additional Features and Benefits e Patented polygon attachment instead of a keyed shaft self balancing e Easy to replace motor terminals e Motor stator assembly is easily removed speed assembly can be removed independent of the high speed assembly e Rolling element bearings e Hydrodynamic bearings e Advanced evaporator design no eliminator necessary with an advanced suction baffle design
27. o mode of operation the chiller will be inhibited from running by a nonlatching diagnostic 16 Controls Evaporator Limit Protection Evaporator Limit is a control algorithm that prevents the chiller tripping on its low refrigerant temperature cutout The machine may run up to the limit but not trip Under these conditions the intended chilled water setpoint may not be met but the chiller will do as much as it can The chiller will deliver as much cold water as possible even under adverse conditions Low Evaporator Water Temperature Low evaporator water temperature protection also known as Freeze Stat protection avoids water freezing in the evaporator by immediately shutting down the chiller and attempting to operate the chilled water pump This protection is somewhat redundant with the Evaporator Limit protection and prevents freezing in the event of extreme errors in the evaporator refrigerant temperature sensor The cutout setting should be based on the percentage of antifreeze used in the customer s water loop The chiller s operation and maintenance documentation provides the necessary information for percent antifreeze and suggests leaving water temperature cutout settings for a given chilled water temperature setpoint Oil Temperature Protection Low oil temperature when the oil pump and or compressor are running may be an indication of refrigerant diluting the oil If the oil temperature is at or below th
28. ome of the standard protection features of the chiller controller are described in this section There are additional protection features not listed here High Condenser Pressure Protection The chiller controller s condenser limit keeps the condenser pressure under a specified maximum pressure The chiller runs all the way up to 100 percent of the setpoint before reducing capacity using its adaptive control mode Starter Contactor Failure Protection The chiller will protect itself from a starter failure that prevents the compressor motor from disconnecting from the line to the limits of its capabilities The controller starts and stops the chiller through the starter If the starter malfunctions and does not disconnect the compressor motor from the line when requested the controller will recognize the fault and attempt to protect the chiller by operating the evaporator and condenser water pumps and attempting to unload the compressor Loss of Water Flow Protection The chiller controller has an input that will accept a contact closure from a proof of flow device such as a flow switch or pressure switch Customer wiring diagrams also suggest that the flow switch be wired in series with the cooling water condenser water pump starter s auxiliary contacts When this input does not prove flow within a fixed time during the transition from Stop to Auto modes of the chiller or if the flow is lost while the chiller is in the Aut
29. ondenser water temperature may cause an increase in system power consumption In many applications Trane centrifugal chillers can start and operate without control of the condenser water temperature However for optimum system power consumption and for any applications with multiple chillers control of the condenser water circuit is recommended Integrated control of the chillers pumps and towers is easily accomplished with Trane s CH530 and or Tracer system Chillers are designed to ARI conditions of 29 4 C 85 F but Trane centrifugal chillers can operate to a five psig pressure differential between the condenser and evaporator at any steady state load without oil loss oil return motor cooling refrigerant hang up problems And this differential can equate to safe minimum entering condenser water temperatures at or below 12 8 C 55 F dependent on a variety of factors such as load leaving evaporator temperature and component combinations Start up below this differential is possible as well especially with CH530 soft start features Water Pumps Avoid specifying or using 3600 rpm condenser and chilled water pumps Such pumps may operate with objectionable noises and vibrations In addition a low frequency beat may occur due to the slight difference in operating rom between water pumps and centrifugal motors Where noise and vibration free operation are important The Trane Company encourages the use of 1750 r
30. otection The controller will shut down the chiller if any of the three phase currents feeding the motor drop below 10 percent RLA The shutdown will result in a latching phase loss diagnostic The time to trip is 1 second at minimum 3 seconds maximum Phase Reversal Rotation Protection The controller detects reverse phase rotation and provides a latching diagnostic when it is detected The time to trip is 0 7 seconds Phase rotation protection can be disabled in TechView CTV PRC001 GB Momentary Power Loss and Distribution Fault Protection Three phase momentary power loss MPL detection gives the chiller improved performance through many different power anomalies MPLs of 2 5 cycles or longer will be detected and cause the unit to shut down The unit will be disconnected from the line within 6 line cycles of detection If enabled MPL protection will be active any time the compressor is running MPL is not active on reduced voltage starters from the initial start signal through transition The MPL diagnostic is an automatic reset diagnostic MPL protection can be disabled in TechView An MPL has occurred when the motor no longer consumes power An MPL may be caused by any drop or sag in the voltage that results in a change in the direction of power flow Different operating conditions motor loads motor size inlet guide vane IGV position etc may result in different levels at which this may occur It is difficult to d
31. owatts e Power factor uncorrected Chilled Water Reset Chilled water reset reduces energy consumption during periods of the year when heating loads are high and cooling loads are reduced It is based on return chilled water temperature Resetting the chilled water temperature reduces the amount of work that the compressor must do by increasing the evaporator refrigerant pressure This increased evaporator pressure reduces the pressure differential the compressor must generate while in the heat recovery mode Chilled water reset is also used in combination with the hot water control By resetting the chilled water temperature upward the compressor can generate a higher condenser pressure resulting in higher leaving hot water temperatures CTV PRC001 GB Extended Operation Package Select the extended operation package for chillers that require external hot water control and or base loading capabilities This package also includes a 4 20 mA or 0 10 Vdc analog input for a refrigerant monitor e External base loading control input e External base loading setpoint e External hot water control input e Refrigerant monitor input Base Loading Control This feature allows an external controller to directly modulate the capacity of the chiller It is typically used in applications where virtually infinite sources of evaporator load and condenser capacity are available and it is desirable to control the loading of the chiller T
32. pm pumps Water Flow Today s technology challenges ARI s traditional design of three gpm per ton through the condenser Reduced condenser flows are a simple and effective way to reduce both first and operating costs for the entire chiller plant This design strategy will require more effort from the chiller But pump and tower savings will typically offset any penalty This is especially true when the plant is partially loaded or condenser relief is available In new systems the benefits can include dramatic savings with e Size and cost for condenser lines and valves e Size and cost of the cooling tower e Size and cost of the water pumps e Pump energy 30 to 35 reduction eTower fan energy 30 to 35 reduction Replacement chiller plants can reap even greater benefits from low flow condensers Because the water lines and tower are already in place reduced flows would offer a tremendous energy advantage Theoretically a 2 GPM ton design applied to a system that originally used 3 GPM ton would offer a 70 reduction in pump energy At the same time the original tower would require a nozzle change but would then be able to produce about two degrees colder condenser water than before These two benefits would again typically offset any extra effort required by the chiller Contact your local Trane Sales Office for information regarding optimum condenser water temperatures and flow rates for a specific application
33. point is used to set the desired start to start time There is no free start on a power up at DynaView The real time clock is used to determine when the next start will be allowed based on the previous start When the start is inhibited by the restart inhibit function the time remaining is displayed along with the restart inhibit mode 17 TRANE Physical Dimensions Figure PD 1 Model CVGF Cooling Only With Unit Mounted Starter f AA 914 mm 36 RECOMMENDED CLEARANCE i 4 HEIGHT WIDTH Figure PD 2 Model CVGF Cooling Only Without Unit Mounted Starter for Remote Mounted Starter HA Al 914 mm 36 RECOMMENDED CLEARANCE HEIGHT WIDTH i 457 mm 18 RECOMMENDED CLEARANCE E LL wm CL1 CL2 LENGTH lt CL1 CL2 D1 Dimensions SI Units English Units Clearance Unit Dimensions Unit Dimensions Tube Pull With Unit Mounted Starters Without Unit Mounted Starters Comp Shell Size CL1 CL2 Length Height Width Width 400 500 500 4235 mm 1118 mm 4083 mm 2094 mm 1984 mm 1929 mm 13 10 3 4 3 8 13 4 3 4 6 10 6 6 1 6 3 16 500 700 4235 mm 1850 mm 4083 mm 2200 mm 2038 mm 1988 mm 13 10 3 4 3 11 13 4 3 4 7 25
34. r and condenser decreases The compressor matches the new load and the lower head by closing the inlet guide vanes This reduces the gas flow it draws in and modifies its direction Component Vr decreases accordingly the vector diagram shifts and at some point the balance of forces breaks down As pressurized gas rushes backwards through the impeller the pressure in the gas passages falls allowing the compressor to restore the balance of forces If the process repeats itself the compressor is said to surge al eee NO _ Oi ve 5 gt Typical single stage compressor performance curve ge o ZnO aon aaa o l i 1 1 D a Typical two stage compressor performance curve 1 V f Q 2 V f D RPM 3 V Resultant RPM 4 5 D 6 Q 1 Load Line 2 Surge Line 3 A 4 B 5 40 6 90 Vanes 7 100 8 Compressor Head 9 Refrigerant Gas Flow 1 Load Line 2 Surge Line 3 A 4 B 5 20 6 90 7 80 8 70 Vanes 9 100 10 Compressor Head 11 Refrigerant Gas Flow TRANE 10 Application Considerations Condenser Water Limitations Temperature Trane centrifugal chillers start and operate over a range of load conditions with controlled water temperatures Reducing the condenser water temperature is an effective method of lowering the chiller power input However the effect of lowering the c
35. rm indicator will appear Press for detail Auto Stop Contrast Control Extensive diagnostics customized to the chillar type installed centrifugal helical rotary or absorption TRANE Serviceability Previous Trane chiller controllers included a user interface that presented all chiller data necessary for both daily tasks and service or maintenance tasks The amount of information presented ona limited display made a number of tasks difficult A service technician s ability to assess and resolve chiller problems was hampered by the limited presentation of multiple pieces of chiller information The Tracer chiller controller adds a level of sophistication better served by a PC application that improves service technician effectiveness and minimizes chiller downtime The Tracer chiller controller provides a user interface and main processor DynaView that is intended to serve only typical daily tasks The portable PC based service tool software TechView supports service and maintenance tasks The Tracer chiller controller will be gradually applied to all Trane chillers TechView will then serve as a common interface to allTrane chillers and will customize itself based on the properties of the chiller with which it is communicating Thus the service technician learns only one service interface The panel bus is easy to troubleshoot using LED verification of sensors Only the defective device is replaced Captive
36. s cooling towers etc TRANE Features and Benefits e Communication capabilities several communication levels are provided local through a PC workstation keyboard Summit can be programmed to send messages to local or remote workstations and or a pager in the following cases Analog parameter exceeding a programmed value Maintenance warning Component failure alarm Critical alarm messages In this latter case the message is displayed until the operator acknowledges the receipt of the information From the remote station it is also possible to access and modify the chiller plant s control parameters e Remote communication through a modem As an option a modem can be connected to communicate the plant operation parameters through voice grade phone lines The remote terminal is a PC workstation equipped with a modem and software to display the remote plant parameters Chiller Tower Optimization Tracer Summit chiller tower optimization extends Adaptive Control to the rest of the chiller plant Chiller tower optimization is a unique control algorithm for managing the chiller and cooling tower subsystem It considers the chiller load and real time ambient conditions then optimizes the tower setpoint temperature to maximize the efficiency of the subsystem Integrated Comfort System ICS The onboard Tracer chiller controller is designed to be able to communicate with a w
37. s necessary for the safe and reliable operation of the chiller are provided including oil management interface to the starter and three phase motor overload protection It also includes comprehensive status and diagnostic monitoring controls A control power transformer included in the starter panel powers the control system The microprocessor controller is compatible with reduced voltage or full voltage electro mechanical starters and solid state starter Starter for Europe with the CE mark is available CTV PRCO01 GB Mechanical Specifications TRANE The microcomputer control system processes the leaving evaporator fluid temperature sensor signal to satisfy the system requirements across the entire load range The controller will load and unload the chiller via control of the stepper motor actuator which drives the inlet guide vanes open and closed The load range can be limited either by a control limit function such as motor current low evaporator temperature or high condenser pressure limit or by an inlet guide vane limit whichever comes first It will also control the evaporator and condenser pumps to insure proper chiller operation Status and 10 active diagnostics are communicated to the operator via display with a tabbed navigation system Setpoints are entered through the touch sensitive screen Countdown timer displays remaining time s during wait states and time out periods Nonvolatile memory
38. tarters for Europe CE mark will be star delta solid state across the line primary reactor and auto transformer only in a IP 20 enclosure A steel panel door with optional mechanical interlock disconnects the system when the door is opened required for CE listing The panel also contains three phase current transformer for overload protection and an oil pump starter with overloads The starter is factory mounted and wired to the compressor motor and the control panel The CVGF chiller starter assembly is factory tested Optional remote mounted electromechanical starters are available 22 Mechanical Specifications Isolation Pads Molded neoprene isolation pads are supplied with each chiller for placement under all support points Spring isolators are optionally available Refrigerant and Oil Charge A full charge of oil is supplied with each unit The oil ships in the unit s sump and the refrigerant ships directly to the jobsite from refrigerant suppliers Painting All painted CVGF surfaces are coated with two coats of air dry beige primer finisher prior to shipment Insulation The chiller can be ordered with or without factory applied insulation Factory supplied insulation is applied to all low temperature surfaces including the evaporator water boxes and suction elbow Insulation material is 19 mm 3 4 in Armaflex II or equal thermal conductivity 0 04 W m C 0 3 Btu in h ft2 F The oil s
39. tor Terminal 3 8 Bolt Stud Shipment and Assembly All style hermetic centrifugal units ship as a factory assembled factory tested package ready to rig into place on factory supplied isolation pads 13 TRANE Standard Features Field Connection The field connected elements are involved in physically turning the chiller on or off This involves ensuring that the chiller is not in an emergency or external stop condition starting the pumps and verifying that flow has been established The optional factory supplied flow switch or a customer supplied differential pressure switch can be used to prove flow Heat Exchanger Control Fundamental internal variables that are necessary to control the chiller are gathered and acted upon by the heat exchanger control function 14 Controls Motor Control and Compressor Protection This includes all functions that start run and stop the motor The starter module provides the interface and control of Y delta across the line primary reactor autotransformer and solid state starters The motor control also provides protection to both the motor and the compressor Phase Voltage Sensors 3 phase Includes factory installed potential transformers in the starter for monitoring and displaying phase voltage and provides over undervoltage protection DynaView TechView and Tracer Summit display the following e Compressor phase voltage a b b c c a e Kil
40. ump is insulated with 9 5 mm s in and 13 mm 1 in insulation respectively Rigging Evaporator and condenser tube sheets provide rigging support points A rigging diagram is affixed to the chiller Quality The La Crosse chiller manufacturing facility is ISO 9001 CTV PRC001 GB TRANE Conversion Table To Convert From To Mulgpiy By To Convert From To Multiply By Length Energy and Power and Capacity Feet ft meters m 0 30481 British Thermal Units BTUH KilowattlkW 0 000293 Inches In millimeters mm 25 4 British Thermal Units BTU KCalorie Kcal 0 252 Arca Tons refrig effect Kilowatt refrig effect 3 516 Square Feet ft square meters m 0 093 Tons refrig effect Kilocalories per hour Kcal hr 3024 Square Inches In square millimeters mm 645 2 Horsepower Kilowatt kW 0 7457 Volume Pressure Cubic Feet ft Cubic meters m 0 0283 Feet of water ftH O Pascals PA 2990 Cubic Inches In Cubic mm mm 16387 Inches of water inH O Pascals PA 249 Gallons gal litres I 3 785 Pounds per square inch PSI Pascals PA 689 Gallons gal cubic meters m 0 003785 PSI Bar or KG CM 6 895 x 10 Flow Weight Cubic feet min cfm cubic meters second m s 0 000472 Ounches oz Kilograms kg 0 02835 Cubic Feet min cfm cubic meters hr m hr 1 69884 Pounds Ibs Kilograms Kg 0 4536 Gallons minute GPM cubic meters hr m hr 0 2271 Fouling factors for heat exchanges Gallons minute
41. wo examples are industrial process applications and cogeneration plants Industrial process applications might use this feature to impose a specific load on the facility s electrical system Cogeneration plants might use this feature to balance the system s heating cooling and electrical generation All chiller safeties and Adaptive Control functions are in full effect when Base Loading is enabled If the chiller approaches full current the evaporator temperature drops too low or the CTV PRCO01 GB Controls TRANE condenser pressure rises too high the controller s Adaptive Control logic limits the loading of the chiller to prevent the chiller from shutting down on a Safety limit These limits may prevent the chiller from reaching the load requested by the Base Loading signal An alternative and less radical approach to Base Loading indirectly controls chiller capacity Artificially load the chiller by setting the chilled water setpoint lower than it is capable of achieving Then modify the chiller s load by adjusting the current limit setpoint This approach provides greater safety and control stability because it leaves the chilled water temperature control logic in effect The chilled water temperature control responds more quickly to dramatic system changes and limits chiller loading prior to reaching an Adaptive Control limit Hot Water Control This feature allows an external controller to enable d
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