Trane Centrifugal Water Chillers CVGF User Manual
Centrifugal
Water Chillers
Model CVGF
Water-Cooled Hermetic Centrifugal
Refrigeration Capacities From
400 to 1000 Tons (1400 kW-3510 kW)
50 and 60 Hz
CTV-PRC001-GBSeptember 2004
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:
• High reliability
• Low sound levels
• Compact size
• High efficiency at a competitive
market price
• 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 evaporatorcondenser-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 Engineer s are
available to assist in selecting the
optimum 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.
CTV-PRC001-GB© 2004 American Standard Inc. All rights reserved.
Contents
Introduction
Features and Benefits
Application Considerations
General Data
Jobsite Connections
Controls
Physical Dimensions
Mechanical Specifications
Conversion Table
2
4
9
10
12
13
17
19
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Features and
Benefits
Standard CVGF Features
The following features are provided as
standard with all Trane Model CVGF
chillers:
• 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 efficiency
and high reliability
• Liquid cooled hermetic induction
motor; the motor operates at lower
temperatures for longer motor life
Optional Features
• Unit and remote wye-delta mounted
starters
• Unit mounted, floor 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 deflection spring isolators
for vibration-sensitive installations
• Refrigerant available from a local
distributor
• Building automation systems (BAS)
Interface
• Factory testing
Applications
• Comfort cooling
• Industrial process cooling
Patents
• Polygon drive for refrigeration
compressor impellers
• Centrifugal compressor sump
demister
• Internal oil filter
• Thermosiphonic oil cooler
• Compressor height and alignment
adjustment
• Oil return using hot gas for motive
force
• Centrifugal impeller assembly
• Internal oil filter
Orifice System
• Simplified orifice system with
improved part load performance
down to 20 percent part load
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 retrofit and
replacement market in mind
• The 400 to 500 NTON sizes can fit
through most double-width doors
• Small footprint of the CVGF chiller
saves valuable equipment room
space
Simple Installation
• Simplified 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
Benefits
Improved Efficiency:
• High Efficiency: 0.55 kW/Ton at ARI
conditions
• Motor cooling vented to economizer
cycle, efficiency advantage
• HFC-134 optimized inlet guide vanes
and impellers for improved cycle
efficiency using computational fluid
dynamics
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 flat gasket technology instead
of O-rings, lower susceptibility to
developing leaks
• Minimal NPT pipe threads on chiller
system, SAE O-ring boss fitting, lower
leak potential
• Oil sump internal to compressor/
motor assembly with internal pump/
motor; eliminates vent and drain
lines, leak prevention
• Patented internal oil filter prevents
leaks and contamination from pipes;
filter 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
Benefits
• 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 highspeed assembly
• Rolling element bearings
• Hydrodynamic bearings
• Advanced evaporator design:
no eliminator necessary with an
advanced suction baffle design
• All metric fasteners
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Features and
Benefits
Microprocessor Controls with
CH530
DynaView Operator Interface
™
DynaView
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.
is the unit-mounted control
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.
• Auto/Stop commands
• Status (all subsystems)
• Setpoint adjustment
(daily user points)
• 10 active diagnostics
• Mode overrides
• ASHRAE chiller log
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
lf diagnostic exists, an alarm indicator will
appear. Press for detail.
Auto / Stop
Contrast Control
Extensive diagnostics customized to the
chillar type installed-centrifugal, helical
rotary, or absorption
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Features and
Benefits
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
on a 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 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 verification of sensors. Only
the defective device is replaced.
Captive screws ensure that the
appropriate mounting hardware is
available. TechView can communicate
with individual devices or groups of
devices.
Te c h V i e w
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 on a
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:
• Pentium II, III, or higher processor
• 128 MB RAM
• 1024 x 768 resolution
• CD-ROM
• 56K modem
• 9-pin RS232 serial connection
®
• Windows
95, 98, 2000
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Features and
Benefits
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 enteringwater 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 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.
Building Automation and
Chiller Plant Control
For a preprogrammable and flexible
building automation and chiller plant
control, Trane has developed the Tracer
Summit
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
• Control of the auxiliaries: includes
™
. It can control the operation
number of running hours of the
chillers. Different control strategies are
available depending on the
configuration of the installation.
input/output modules to control the
operation of the various auxiliary
equipments (water pumps, valves,
cooling towers, etc.)
• Time of day scheduling: allows the
end user to define 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 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.
• 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.
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Features and
Benefits
• 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.
• 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
optimization extends Adaptive Control
to the rest of the chiller plant. Chillertower 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.
™
chiller-tower
™
Integrated Comfort
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 benefits 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 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
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.
™
systems (ICS) are a concept
System (ICS)
8
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