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
© 2005 American Standard Inc. All rights reserved.
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
2
4
22
44
47
62
73
76
77

CVGF-SVU02B-E4
4
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
6
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
P
Pc
P1
Pe
5
8
1
RE
RE1
Evaporator
Economizer
Condenser 4
Compressor
2nd stage
3
Compressor
1st stage
2
H

CVGF-SVU02B-E4
8
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
S
F
ST
2
ST
1

CVGF-SVU02B-E4
10
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