Trane Centrifugal Water Chillers CVGF User Manual 2

Centrifugal Water Chillers

Model CVGF

Water-Cooled Hermetic Centrifugal

Refrigeration Capacities from

400 to 1000 Tons (1400〜3510 kW)

50 and 60 Hz

October 2008

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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. Trane continues to deliver its reliability and energy ﬁ tness commitment

on its newest line of gear-drive centrifugal water chillers, the Model CVGF. The major advantages of

the Model CVGF are:

• High reliability

• Low sound levels

• Compact size

• High efﬁ ciency at a competitive market price

• Designed to use environmentally responsible HFC-134a refrigerant

The Model CVGF chiller is ideal for ofﬁ ce, hospital, school, hotel, retail store and industrial

buildings. TheTrane 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 ﬁ rst cost,

low operating cost, or other criteria important for a particular selection. Centrifugal Water Chiller

computer selection program is certiﬁ ed in accordance with ARI Standard 550/590. Trane Sales

Engineers are available to assist in selecting the optimum machine to satisfy the particular project

requirements.

Turn to the Model CVGF for energy efﬁ ciency provided by the two stage, gear drive centrifugal

water chillers with economizers. The Trane Model CVGF is your choice for energy ﬁ t operation year

after year.

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Contents

Introduction

Features and Beneﬁ ts

Application Considerations

General Data

Jobsite Connections

Controls

Physical Dimensions

Mechanical Speciﬁ cations

Conversion Table

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Features and Beneﬁ ts

Standard CVGF Features

The following features are provided as standard with all Trane Model CVGFchillers:

• Hermetic two-stage centrifugal compressor-motor assembly with integral lubrication system

and economizer cycle

• Evaporator and condenser assembly

• Prewired instrument and control panel

• Oil charge

• Integral oil heaters

• Isolation pads

• Wiring and oil system interconnection to main control panel

• Advance motor protection

• Two-stage gear drive with economized cycle for high efﬁ ciency and high reliability

• Liquid cooled hermetic induction motor; the motor operates at lower temperatures for longer

motor life

Optional Features

Applications

Patents

• Unit and remote wye-delta mounted starters

• Unit mounted, ﬂ oor mounted, and wall mounted solid state starters.

• Across-the-line, Primary Reactor, and Auto Transformer Remote mounted starter for medium/

high voltage

• Marine waterboxes for evaporator and condenser

• Factory-applied thermal insulation

• One-inch deﬂ ection spring isolators for vibration-sensitive installations

• Refrigerant available from a local distributor

• Building automation systems (BAS) Interface

• Factory testing

• Comfort cooling

• Industrial process cooling

• Polygon drive for refrigeration compressor impellers

• Centrifugal compressor sump demister

• Internal oil ﬁ lter

• Thermosiphonic oil cooler

• Compressor height and alignment adjustment

• Oil return using hot gas for motive force

• Centrifugal impeller assembly

• Internal oil ﬁ lter

Oriﬁ ce System

• Simpliﬁ ed oriﬁ ce system with improved part load performance down to 20 percent part load

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Advanced Heat Transfer Surfaces

• Evaporator and condenser tubes use the latest heat transfer surfaces

• Less refrigerant needed due to advanced patented evaporator design

Compact Size

• Designed with the retroﬁ t and replacement market in mind

• The 400 to 500 NTON sizes can ﬁ t through most double-width doors

• Small footprint of the CVGF chiller saves valuable equipment room space

Simple Installation

• Simpliﬁ ed piping; the only water piping required is for the evaporator and condenser

• Simple power connection

• Unit mounted starter eliminates additional jobsite labor requirements

Environmental Features and Beneﬁ ts

Improved Efﬁ ciency:

• High Efﬁ ciency: 0.55 kW/Ton at ARI conditions

• Motor cooling vented to economizer cycle, efﬁ ciency advantage

• HFC-134 optimized inlet guide vanes and impellers for improved cycle efﬁ ciency using

computational ﬂ uid dynamics

Features and Beneﬁ ts

Reduced Emissions:

• Over 30 percent joint reduction in compressor/motor assembly compared to previous designs

• Patented integral heaters imbedded into the compressor casting, no seals no leaks

• Beaded ﬂ at gasket technology instead of O-rings, lower susceptibility to developing leaks

• Minimal NPT pipe threads on chiller system, SAE O-ring boss ﬁ tting, lowerleak potential

• Oil sump internal to compressor/motor assembly with internal pump/motor; eliminates vent and

drain lines, leak prevention

• Patented internal oil ﬁ lter prevents leaks and contamination from pipes; ﬁ lter is isolated and easily

replaced

• 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 Beneﬁ ts

• Patented polygon attachment instead of a keyed shaft, self-balancing

• Easy to replace motor terminals

• Motor/stator assembly is easily removed; speed assembly can be removed independent of the

high-speed assembly

• Rolling element bearings

• Hydrodynamic bearings

• Advanced evaporator design: no eliminator necessary with an advanced suction bafﬂ e design

• All metric fasteners

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Features and Beneﬁ ts

Tracer AdaptiView

Control Operator Interface

Tracer AdaptiViewTM control is the unit-mounted operator interface with a touch sensitive 12/1"

display. The display presents information through an intuitive navigation system. Alternate

languages are also available for the control panel display.

Tracer AdaptiView

devices on the chiller’s communications link. Tracer AdaptiView

control receives information from and communicates information to the other

control performs the Leaving

Chilled Water Temperature and Limit Control algorithms.

• Data graphs

• Mode overrides

• Status (all subsystems) with animated graphics

• Auto/Stop commands

• 50 diagnostics

• ASHRAE chiller log

• Setpoint adjustment (daily user points)

Tracer AdaptiView

control can be connected to the service tool using a standard USB type cable.

The connections is located on the side of the control panel, along with a power outlet for a laptop

PC power supply.

a At-a-glance status

On highly-readable color display showing key operating parameters of major chiller components

b Intuitive navigation

Helps operators access data and alarms for quick and accurate response and resolution

c Reports

Summarize data for clear understanding and interpretation

d Graphs

Visualize trend data for troubleshooting and ﬁ ne-tuning

e Adaptive control

Algorithms built into Tracer AdaptiviewTM pre-empt chiller disruptions during rapidly changing conditions

f Open protocol ﬂ exibility

Bacnet, Lontalk, and Modbus with no gateways

g Adjustable viewing angle

For all operators in close quarters via ergonomic arm

h Water-resistant

To cleaning overspray; weather-resistant for outdoor mounting with optional cover

i Security levels

Limit access to designated, qualiﬁ ed staff members

j 24 selectable languages

Convert the Tracer Adaptiview deployment including simpliﬁ ed chinese, traditional chinese, japanese, korean, thai, etc.

user-centered design for global

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Tracer TU Interface

Features and Beneﬁ ts

The Tracer chiller controller adds a level of sophistication better served by a PC application to improve

service technician effectiveness and minimize chiller downtime. Tracer AdaptiView™ control is intended

to serve only typical daily tasks. The portable PC-based service-tool software, Tracer TU™,

supports service and maintenance tasks.

Tracer TU serves as a common interface to all Trane 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 sensor veriﬁ cation. Only the defective device is

replaced. Tracer TU can communicate with individual devices or groups of devices.

All chiller status, machine conﬁ guration settings, customizable limits, and up to 100 active or

historic diagnostics are displayed through the service-tool software interface.

LEDs and their respective Tracer TU indicators visually conﬁ rm the availability of each connected

sensor, relay, and actuator.

Tracer TU is designed to run on a customer’s laptop, connected to the AdaptiView control panel

with a USB cable.

Hardware requirements for Tracer TU:

• CD-ROM

• 1 GB RAM

• 1024 x 768 resolution

• Ethernet 10/100 Lan card

• Windows® XP Pro or Vista

• Pentium IV or higher processor

• An available USB port (USB 2.0)

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Features and Beneﬁ ts

Tracer AdaptiViewTM Controller

Today's centrifugal chillers offer predictive controls that anticipate and compensate for load

changes. Other control strategies made possible with the Tracer AdaptiView

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 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 ﬁ ltering 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

controls are:

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

The controller allows the CenTravac chiller to restart during the postlube process. 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.

Building Automation and Chiller Plant Control

Trane Tracer SummitTM building automation systems

include pre-engineered and ﬂ exible control for

chiller plants. 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.

The main functions are:

• Chiller sequencing: equalizes the number of

running hours of the chillers. Different control

strategies are available depending on the

conﬁ guration of the installation.

• Control of the auxiliaries: includes input/output

modules to control the operation of the various

auxiliary equipments (water pumps, valves,

cooling towers, etc.)

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Features and Beneﬁ ts

• Time of day scheduling: allows the end user to deﬁ ne the occupancy period, i.e. time of the

day, holiday periods and exception schedules.

• Optimization of the start/stop time of the installation: based on the programmed schedule

of occupancy and on the historical temperature records, Tracer Summit

start/stop time of the installation to get the best compromise between energy savings and

comfort of the occupants.

• Soft loading:

satisfy a large chilled-water-loop pull down, thus preventing an overshoot of the actual capacity

required. Unnecessary starts are avoided and the peak current demand is lowered.

Communication capabilities: local, through a PC workstation keyboard Tracer SummitTM

•

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.

• 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 soft loading function minimizes the number of chillers that are operated to

calculates the optimal

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 efﬁ ciency of the subsystem.

Integrated Comfort™ System (ICS)

The onboard Tracer chiller controller is designed to be able to communicate with a wide 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 beneﬁ ts do not stop at the chiller plant. At Trane, 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 efﬁ ciency.

The building owner’s challenge is to tie components and applications expertise into a single

reliable system that provides maximum comfort, control and efﬁ ciency. Trane’s Integrated-Comfort

™ Systems (ICS) are a concept that combines system components, controls and engineering

applications expertise into a single, logical and efﬁ cient 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 veriﬁ cation.

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+ 19 hidden pages

Trane Centrifugal Water Chillers CVGF User Manual 2

Specifications and Main Features

Frequently Asked Questions

User Manual