Trane CVGF500 Instruction manual

Gear-Driven Centrifugal
Water-Cooled Liquid
Chillers with
AdaptiView Controls
X39641150010 CVGF-SVX03B-EN
Unit Model
CVGF 400-1000 Ton Units
(50 and 60 Hz)
Installation
Operation
Maintenance Manual

Copyright
© 2008 Trane All rights reserved
This document and the information in it are the property of Trane and may not be used
or reproduced in whole or in part, without the written permission of Trane. Trane reserves
the right to revise this publication at any time and to make changes to its content without
obligation to notify any person of such revision or change.
Trademarks
Trane, the Trane logo, are trademarks of Trane in the United States and other countries.
All other brands and products referenced in this document are acknowledged to be the
trademarks or registered trademarks of their respective holders.
Warnings and Cautions
Warnings and cautions are provided in appropriate places throughout this document:
Environmental Concerns!
Scientific research has shown that certain man-made chemicals can affect the earth’s
naturally occurring stratospheric ozone layer when released to the atmosphere. In
particular, several of the identified chemicals that may affect the ozone layer are
refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing
Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these
compounds have the same potential impact to the environment. Trane advocates the
responsible handling of all refrigerants—including industry replacements for CFCs
such as and HCFCs and HFCs.
Responsible Refrigerant Practices!
Trane believes that responsible refrigerant practices are important to the environment,
our customers, and the air conditioning industry. All technicians who handle
refrigerants must be certified. The Federal Clean Air Act (Section 608) sets forth the
requirements for handling, reclaiming, recovering and recycling of certain refrigerants
and the equipment that is used in these service procedures. In addition, some states
or municipalities may have additional requirements that must also be adhered to for
responsible management of refrigerants. Know the applicable laws and follow them.
NOTICE: Warnings and Cautions appear at appropriate sections through-
out this literature. 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.
© 2016 Trane All rights reserved

Contents
General Information 4
Installation: Mechanical 46
Installation: Electrical 76
Base Loading Control Algorithm 87
Control System Components 90
Machine Protection and Adaptive Control 102
Unit Startup 112
Periodic Maintenance 116
CVGF-SVX03B-EN 3

Literature History
CVGF-SVX03B-EN
(March 2016)
This is a new manual.
About this manual
This manual describes proper installation
of Model CVGF, 50 Hz and 60 Hz chillers
with the AdaptiView Controls platform.
See Figures 2 and 3 for an illustration of
a CVGF Centrifugal Chiller with the Adap-
tiView Unit Control Panel. These chillers
are equipped with microcomputer-based
control systems. A careful review of this
information along with the submittal
package provided for the unit will assure
that the chiller is correctly installed.
Operation and maintenance information
for models CVGF are covered in this man-
ual.This includes both 50 and 60 Hz. CVGF
centrifugal chillers equipped with theTrac-
er AdaptiVew Chiller Controller system.
A typical product description block is
shown in the Manual.
Carefully review this information and fol-
low the instructions given to successfully
install 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.
Unit Nameplate
When the unit arrives, compare all name-
plate data with order, submittal and ship-
ping information. A typical unit nameplate
is shown in Figure 1.
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.
Figure 1.Typical unit nameplate
MODEL: CVGF500
MODEL NO:
CVGF0500RA0U33809405C1B5C1C23A1A201E3AA0
SERIAL NO: S.O. NO:
ELECTRICAL CHARACTERISTICS:
RATED VOLTAGE: 380 VOLTS50HZ 3PH
NAMEPLATE NMKW:338 kW
VOLTAGE UTILIZATION RANGE: 345- 422 VAC
MINIMUM CIRCUIT AMPACITY: 726 AMPS
MAXIMUM FUSE:1200 AMPS
MAXIMUM CIRCUIT BREAKER 1200 AMPS
MAXIMUM OVERLOAD TRIP:617 AMPS
MAX MAX
VOLTS-AC HZ PH RLA LRAY LRAD
COMPRESSOR MOTOR 380 50 3 577 1048 3286
OIL PUMP MOTOR 380 50 31.43 FLA
OIL TANK HEATER 115 50 1000 WATTS TOTAL
CONTROL CIRCUIT 115 50 1500 VA MAX
WHEN MOTOR CONTROLLER PROVIDED BY OTHERS
TRANE ENGINEERING SPEC. S6516-0360 APPLIES
GENERAL CHARACTERISTICS:
REFRIGERANT SYSTEM
TO BE FIELD CHARGED ACTUALLY CHARGED
WITH 340 KG OF R-134A WITH KG OF R-134A
MAXIMUM REFRIGERANT WORKING PRESSURE
HI SIDE 15.2 BAR LOW SIDE 15.2 BAR
FACTORY TEST PRESSURE
HI SIDE 16.7 BAR LOW SIDE 16.7 BAR
FIELD LEAK TEST PRESSURE5.17 BAR MAX.
TESTED AT BAR
LEAK TEST AND CHARGING SPECIFICATION ARE SUPPLIED
IN CONTROL PANEL (SERVICE LITERATURE MANUAL)
MANUFACTURED UNDER ONE OR MORE OF THE FOLLOWING
U.S. PATENTS: 4686834 4689967 4715190 5056032
5058031 5434738 5563489 5836382
SERVICE LITERATURE
INSTALLATION, OPERATION AND MAINTENANCE MANUAL:
CVGF-SVN02C-EN AND CVGF-SVU02B-EN
“FOR INSTALLATION REQUIREMENTS, USE ELECTRICAL
CHARACTERISTICS NOT PRODUCT DESCRIPTION”
PRODUCT DESCRIPTION:
MODL CVGF DSEQ A0 NTON 500 VOLT 380
HRTZ 50 CPKW 338 CPIM 940EVSZ 500
EVBS C EVTB TE25 EFLD WATE EVWB NM15
EVWP 2EVCO FLGE EVWA RERE CDSZ 500
CDBS C CDTB TE28 CFLD WATE CDWB NM15
CDCO FLGE CDWA RERE ORSZ 23 AGLT UL
SPKGEXPSINSL YESOPTM YES WVUO YES
TRMM TRMS LCLD CLDC LANG ENGL SRTY USTR
SRRL 952PNCO DISC TEST PTR3
General Information
CVGF-SVX03B-EN
4

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
AdaptiView=Tracer AdaptiView Controller
CWR = Chilled Water Reset
CWR’ = Chilled Water Reset Prime
DTFL = Design Delta-T at FullLoad (for example, the difference between entering and
leaving chilled water temperatures)
ADPV = AdaptiView™
ELWT = Evaporator Leaving WaterTemperature
ENT = Entering Chilled WaterTemperature
EXOP = Extended Operation
GBAS = Generic Building Automation Interface
GPM = Gallons-per-minute
HLUV = High Lift UnloadingValve.
Hp = Horsepower
HVAC = Heating, Ventilating, and Air Conditioning
IE = Internally-EnhancedTubes
IPC = Interprocessor Communication
LCD = Liquid Crystal Display
LED = Light Emitting Diode
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.)
UC800 = 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 = OutdoorTemperature
OPST = Operating Status Control
RLA = Rated Load Amps
RTD = ResistiveTemperature DeviceTracer
AdaptiView= Controls Platform used on this Chiller
CVGF-SVX03B-EN 5
General Information

TRMM =Tracer
Communications
UCP = Unit Control Panel
CVGF-SVX03B-EN
6
General Information

Condenser
Two-Stage Compressor
Unit-Mounted Starter (Optional)
Relief V
alves
Unit Nameplate
Control Panel AdaptiView
Oil Pump
Evaporator
Figure 2. General CVGF unit component
Figure 3. Component location for typical CVGF unit (back view)
Motor
Unit nameplate
Relief valve
s
Oil cooler
Economizer
CVGF-SVX03B-EN 7
General Information

Unit Nameplates
The CVGF unit nameplate (Figure 2 shows the nameplate location) is applied to the
exterior surface of the control panel.The starter nameplate is located inside the starter
panel.
The unit nameplate provides the following information:
unit electrical requirements - Lists correct operating charges of HFC-134a and lubrica-
tion oil - Lists unit test pressures and maximum working pressures The starter name-
plate provides the following information:
Unit Inspection
When the unit is delivered, verify that it is the correct unit and that it is properly
equipped.
Inspect all exterior components for visible damage. Report any apparent damage or
material shortage to the carrier and make a "unit damage" notation on the carrier’s de-
livery receipt. Specify the extent and type of damage found and notify the appropriate
Trane Sales Office.
Do not proceed with installation of a damaged unit without sales office approval.
Inspection Checklist
To protect against loss due to damage incurred in transit, complete the pre-commis-
sioning checklist, which can be obtained from yourTrane representative.
-
vious damage to the unit
it is stored. Concealed damage must be reported within 10 days after receipt.
damaged material from the receiving location.Take photos of the damage, if possible.
The owner must provide reasonable evidence that the damage did not occur after de-
livery.
however, until damage is inspected by the damage is inspected by the transportation
Loose Parts Inventory
The loose parts items ship in the motor junction box for units without a unit-mount-
ed starter, or in the starter panel for units equipped with a unit-mounted starter. This
includes the isolation pads, extra oil filter, and any optional optional factory-shipped items.
CVGF-SVX03B-EN
8
General Information

Unit Description
The CVGF units are singlecompressor, gear-type, watercooled liquid chillers designed
for installation indoors. Each unit is a completely assembled, hermetic package that is
factorypiped, wired, leak-tested, dehydrated, oil-charged, and tested for proper control
operation before shipment.
Note: high-voltage starters are not unit-mounted before shipment.
Figure 2 and Figure 3 show a typical CVGF unit and its components. Water inlet and
outlet openings are covered before shipment. The oil tank is factory-charged with 15
gallons (56.8L) ofTrane Oil 37 and a holding charge of 5 psig (34 kPa) of dry nitrogen at
70°F (21°C).
CVGF-SVX03B-EN 9
General Information

Model number digits are selected and assigned in accordance with the following definitions using the
typical model number example shown below:
CVGF0500HA0C31609005B1B5B1C2306G4A1E2CC0A0CL
C = (1st digit)
V = (2nd digit) Hermetic Centrifugal Compressor
G = (3rd digit) Gear Drive
F = (4th digit) Development sequence
0500 = (5th, 6th, 7th, and 8th digit) Nominal compressor tonnage
0400 = 400 tons
0500 = 500 tons
0650 = 650 tons
0800 = 800 tons
1000 = 1000 tons
SSSS = Special
H = (9th digit) Unit Voltage
D = 380V-60 Hz
F = 460V-60 Hz
H = 575V-60 Hz
N = 4160V-60 Hz
P = 3300V-60 Hz
R = 380V-50 Hz
T = 400V-50 Hz
U = 415V-50 Hz
V = 3300V-50 Hz
X = 6600V-60 Hz
Z = 6600V-50 Hz
S = Special
A0 = (10th and 11th digit) Design Sequence
C = (12th digit) Control Enclosure
C = Standard Control Enclosure
S = Special
316 = (13th, 14th, and 15th digit) Compressor Motor Power (kw)
221 = 221 CPKW
254 = 254 CPKW
285 = 285 CPKW
316 = 316 CPKW
357 = 357 CPKW
401 = 401 CPKW
240 = 240 CPKW
266 = 266 CPKW
301 = 301 CPKW
338 = 338 CPKW
374 = 374 CPKW
430 = 430 CPKW
444 = 444 CPKW
484 = 484 CPKW
511 = 511 CPKW
532 = 532 CPKW
574 = 574 CPKW
594 = 594 CPKW
641 = 641 CPKW
CVGF-SVX03B-EN
10
General Information