Trane CVGF-SVU02B-E4 User manual

Operation

Maintenance Manual

Gear-Driven Centrifugal

Water-Cooled Liquid

Chillers with CH530

Controls

CVGF-SVU02B-E4

X39640691020

Unit Model

CVGF 400-1000 Ton Units

(50 and 60 Hz)

CVGF-SVU02B-E4

Warnings and

Cautions

Warnings and Cautions

Notice that warnings and

cautions appear at appropriate

intervals throughout this

manual. Warnings are provided

to alert installing contractors to

potential hazards that could

result in personal injury or

death, while cautions are

designed to alert personnel to

conditions that could result in

equipment damage.

Your personal safety and the

proper operation of this machine

depend upon the strict

observance of these precautions.

NOTICE: Warnings and Cautions appear at appropriate sections throughout this manual.

Read these carefully.

WARNING – Indicates a potentially hazardous situation which, if not avoided, could result

in death or serious injury.

CAUTION – Indicates a potentially hazardous situation which, if not avoided, may result in

minor or moderate injury. It may also be used to alert against unsafe practices.

CAUTION – Indicates a situation that may result in equipment or property-damage-only

accidents.

CVGF-SVU02B-E4 3

Contents

Warnings and Cautions

General Information

Unit Control Panel (UCP)

Base Loading Control Algorithm

Control System Components

Machine Protection and Adaptive

Unit Startup

Unit Shutdown

Periodic Maintenance

CVGF-SVU02B-E4

Model Number

Refer to the Installation Manual.

Product Description Block

A typical Product Description

Block is shown in the Installation

Manual.

Unit Nameplate

The unit nameplate is located on

the left side of the unit control

panel.

Note: Trane starters are

identified by a separate model

number found on the starter.

Literature History

CVGF-SVU02A-E4

(November 2002)

This is a new manual.

About this manual

Operation and maintenance

information for models CVGF

are covered in this manual. This

includes both 50 and 60 Hz.

CVGF centrifugal chillers

equipped with the Tracer CH530

Chiller Controller system.

Carefully review this information

and follow the instructions given

to successfully operate and

maintain a CVGF unit.

If mechanical problems do

occur, contact a qualified service

organization to ensure proper

diagnosis and repair of the unit.

General

Information

CVGF-SVU02B-E4 5

Commonly Used

Abbreviations

For convenience, a number of

abbreviations are used

throughout this manual. These

are listed alphabetically below,

along with a translation of each:

ASME = American Society of

Mechanical Engineers

ASHRAE = American Society of

Heating, Refrigerating and Air

Conditioning Engineers

BAS = Building Automation

System

CDBS = Condenser Bundle Size

CDSZ = Condenser Shell Size

CH530 = Tracer CH530 Controller.

CWR = Chilled Water Reset

CWR’ = Chilled Water Reset

Prime

DTFL = Design Delta-T at Full

Load (for example, the

difference between entering and

leaving chilled water

temperatures)

DV = DynaView™Clear Language

Display, also know as the Main

Processor (MP)

ELWT = Evaporator Leaving

Water Temperature

ENT = Entering Chilled Water

Temperature

EXOP = Extended Operation

GBAS = Generic Building

Automation Interface

GPM = Gallons-per-minute

HLUV = High Lift Unloading

Valve.

Hp = Horsepower

HVAC = Heating, Ventilating, and

Air Conditioning

IE = Internally-Enhanced Tubes

IPC = Interprocessor

Communication

LCD = Liquid Crystal Display

LED = Light Emitting Diode

General

Information

LLID = Low Level Intelligent

Device (Sensor, Pressure

Transducer, or Input/output UCP

module)

MAR = Machine Shutdown Auto

Restart (Non-Latching where

chiller will restart when

condition corrects itself.)

MMR = Machine Shutdown

Manual Restart (Latching where

chiller must be manually reset.)

MP = Main Processor

PFCC = Power Factor Correction

Capacitor

PID = Proportional Integral

Derivative

PSID = Pounds-per-Square-Inch

(differential pressure)

PSIG = Pounds-per-Square-Inch

(gauge pressure)

ODT = Outdoor Temperature

OPST = Operating Status

Control

RLA = Rated Load Amps

RTD = Resistive Temperature

Device Tracer CH530= Controls

Platform used on this Chiller

TRMM = Tracer

Communications

UCP = Unit Control Panel

CVGF-SVU02B-E4

Figure 2. Component location for typical CVGF unit (back view)

Motor

Unit nameplate

Relief valves

Oil cooler

Economizer

Condenser

Two-Stage Compressor

Unit-Mounted Starter (Optional)

Relief Valves

Unit Nameplate

Control Panel CH530

Oil Pump

Evaporator

General

Information

Figure 1. General CVGF unit component

CVGF-SVU02B-E4 7

Cooling Cycle

The refrigeration cycle of the

CVGF chiller can be described

using the pressure-enthalpy

diagram shown in Figure 3. Key

state points are indicated and

will be referred to in the

following discussion. A

schematic of the system

showing refrigerant flow is given

in Figure 4.

Evaporator - A liquid vapor

refrigerant mixture enters the

evaporator at state point 1.

Liquid refrigerant is vaporized to

state point 2 as it absorbs heat

from the system cooling load.

The vaporized refrigerant flows

into the compressor first stage.

Compressor first stage -

Refrigerant vapor is drawn from

the evaporator into the first

stage compressor. The first stage

impeller accelerates the vapor

increasing its temperature and

pressure to state point 3.

General

Information

Figure 3. P-H chart

RE1

Evaporator

Economizer

Condenser 4

Compressor

2nd stage

Compressor

1st stage

CVGF-SVU02B-E4

Compressor second stage -

Refrigerant vapor leaving the

first stage compressor is mixed

with cooler refrigerant vapor

from the economizer. This

mixing lowers the enthalpy of

the vapor entering the second

stage. The second stage

impeller accelerates the vapor,

further increasing its

temperature and pressure to

state point 4.

Condenser - Refrigerant vapor

enters the condenser where the

system cooling load and heat of

compression are rejected to the

condenser water circuit. This

heat rejection cools and

condenses the refrigerant vapor

to a liquid at state point 5.

Economizer and refrigerant

orifice system - Liquid

refrigerant leaving the

condenser at state point 5 flows

through the first orifice and

enters the economizer to flash a

small amount of refrigerant at

an intermediate pressure

labeled P1. Flashing some liquid

refrigerant cools the remaining

liquid to state point 8.

Another benefit of flashing

refrigerant is to increase the

total evaporator Refrigeration

Effect from RE’ to RE. The

economizer provides around 4

percent energy savings

compared to chillers with no

economizer.

To complete the operating cycle,

liquid refrigerant leaving the

economizer at state point 8

flows through a second orifice.

Here refrigerant pressure and

temperature are reduced to

evaporator conditions at state

point 1.

An innovative design feature of

the CVGF chiller is maximizing

the evaporator heat transfer

performance while minimizing

refrigerant charge requirements.

This is accomplished by the

Trane-patented falling film

evaporator design. The amount

of refrigerant charge required in

CVGF is less than that in

comparably sized chillers of

flooded evaporator design.

General

Information

CVGF-SVU02B-E4 9

General

Information

Figure 4. Refrigerant flow diagram

Starter

Condenser

Motor

Economizer Oil sump

Pump

Fixed

orifice

Distributor

Evaporator

Fixed

orifice

Strainer

Fixed

orifice

Condenser

sump

Internal filter

Compressor

Inlet

vanes

High lift

unloading

valve

(HLUV)

Gears

Bearings

Oil cooler

Refrigerant Flow

CVGF-SVU02B-E4

Compressor Description

The CVGF compressor consists

of three distinct sections: the

two-stage centrifugal

compressor, the motor, and the

gear box with integral oil sump.

See Figure 5.

Compressor

The centrifugal compressor is

two-stage 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/sec (0.2 ips peak

velocities) at nominal operating

speeds. The control system

affords 20 to 100 percent

capacity modulation by

electrically actuated guide vanes

upstream of each impeller.

General

Information

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