This document describes the Trane Centrifugal Water Chillers, Model CVGF, which are water-cooled hermetic centrifugal refrigeration units. These chillers offer capacities ranging from 400 to 1000 Tons (1400~3510 kW) and operate on 50 and 60 Hz power. The design, introduced in 1976, is a gear-driven centrifugal water chiller, proven in thousands of installations, and Trane continues to enhance its reliability and energy efficiency with the Model CVGF.
Function Description:
The Trane Model CVGF chiller is designed for comfort cooling and industrial process cooling applications in various building types, including offices, hospitals, schools, hotels, retail stores, and industrial facilities. It provides chilled water for air conditioning and process cooling systems. The chiller uses a two-stage, gear-drive centrifugal compressor-motor assembly with an integral lubrication system and economizer cycle. The system is designed to use environmentally responsible HFC-134a refrigerant. The microcomputer control panel, factory-installed and tested, ensures safe and reliable operation, including oil management, interface to the starter, and three-phase motor overload protection. It also incorporates comprehensive status and diagnostic monitoring controls. The controller manages the chiller's loading and unloading via stepper-motor/actuator-driven inlet guide vanes, and controls evaporator and condenser pumps for proper chiller operation.
Important Technical Specifications:
- Refrigeration Capacities: 400 to 1000 Tons (1400~3510 kW).
- Power Supply: 50 and 60 Hz.
- Refrigerant: HFC-134a.
- Compressor: Hermetic two-stage centrifugal compressor with high-strength aluminum alloy, fully shrouded impellers. Impellers are tested at 25 percent over-design operating speed.
- Motor: Hermetic, liquid-refrigerant cooled, two-pole, low-slip, squirrel-cage induction motor. Winding-embedded sensors provide positive thermal protection.
- Heat Exchangers: Evaporator and condenser tubes use advanced heat transfer surfaces. Evaporator and condenser are designed, tested, and stamped in accordance with ASME Boiler and Pressure Vessel Code or PED (European Code.
- Evaporator Working Pressure: 10 bar (150 psi).
- Condenser Working Pressure: 15.2 bars (220 psig).
- Water-side Hydrostatic Test: ASME 1.5 times, PED 1.43 times, GB 1.25 times maximum working pressure.
- Efficiency: High efficiency, with 0.55 kW/Ton at ARI conditions. HFC-134a optimized inlet guide vanes and impellers for improved cycle efficiency.
- Motor Volt/Hz Options: 380/400/415/3300/6600 Volts - 50 Hz; 380/460/575/3300/4160 Volts - 60 Hz.
- Starters: Unit-mounted or remote-mounted options, including Wye-Delta, Solid-State Inside the Delta, Across-the-line, Primary Reactor, and Autotransformer. Medium voltage starters (3300, 4160, 6600) are also available.
- Water Connections: Grooved pipe connections are standard; flanged adaptors are optional.
- Approvals: UL-CUL Listed/ASME, CE Approval/PED (European Code).
- Physical Dimensions: Compact size, with 400 to 500 NTON sizes fitting through most double-width doors. Small footprint saves equipment room space.
- Oil System: Internal oil sump with heaters, positive displacement oil pump, brazed plate condenser-cooled oil cooler, and oil distillation/return line. Patented integral heaters imbedded into the compressor casting to prevent leaks. Patented internal oil filter.
- Orifice System: Simplified orifice system with improved part load performance down to 20 percent part load. Single calibrated orifice for liquid refrigerant admission to the evaporator.
Usage Features:
- High Reliability: Proven design with thousands of installations.
- Low Sound Levels: Designed for quiet operation.
- Compact Size: Facilitates retrofit and replacement, fitting through standard double-width doors for smaller units.
- High Efficiency: Achieved through two-stage gear drive with economized cycle, optimized inlet guide vanes and impellers, and motor cooling vented to the economizer cycle.
- Simple Installation: Simplified piping (only water piping for evaporator and condenser), simple power connection, and unit-mounted starter to reduce jobsite labor.
- Tracer AdaptiView™ Control Operator Interface: Unit-mounted, touch-sensitive 12.1" display with intuitive navigation. Displays key operating parameters, data graphs, mode overrides, status with animated graphics, Auto/Stop commands, 50 diagnostics, ASHRAE chiller log, and setpoint adjustment. Supports 24 selectable languages.
- Tracer TU Interface: PC-based service tool software for service technicians, offering advanced troubleshooting, configuration settings, and access to all chiller status, machine configuration, limits, and up to 100 active or historic diagnostics.
- Feedforward Adaptive Control: Predictive control strategy using evaporator entering-water temperature to anticipate and compensate for load changes, maintaining stable leaving-water temperatures.
- Soft Loading: Gradual adjustments to load or setpoint changes to prevent unnecessary compressor cycling and overshooting capacity.
- Multi-Objective Limit Arbitration: Controller prioritizes objectives, focusing on the most critical secondary objective when the primary (maintaining evaporator leaving-water temperature) cannot be met without triggering a protective shutdown.
- Fast Restart: Allows chiller to restart during postlube process or after momentary power losses (30-60 seconds for nonlatching diagnostics).
- Building Automation and Chiller Plant Control (Tracer SummitTM): Pre-engineered and flexible control for chiller plants, including chiller sequencing, control of auxiliaries (pumps, cooling towers, valves, air handlers), and optimized energy management for the entire plant.
- Chiller-Tower Optimization: Extends Adaptive Control to the chiller plant, optimizing tower setpoint temperature based on chiller load and ambient conditions to maximize subsystem efficiency.
- Integrated Comfort™ System (ICS): Combines system components, controls, and engineering expertise into a single, reliable, and efficient HVAC system.
- Extended Operation Package (Optional): Includes external hot water control, base-loading capabilities, and a 4-20 mA or 0-10 Vdc analog input for a refrigerant monitor.
- Base-Loading Control: Allows external controller to directly modulate chiller capacity, useful for industrial process applications and cogeneration plants.
- Hot-Water Control: Enables external controller to enable/disable and modulate hot-water control mode, providing heating as a primary mission.
- Refrigerant Monitor Input: Allows a refrigerant monitor to send a signal to the Tracer AdaptiView™ control display, with concentration levels displayed. Can also connect to Tracer Summit to increase ventilation in equipment room.
- Chilled-Water Reset: Reduces energy consumption by adjusting chilled-water temperature based on return chilled-water temperature, increasing evaporator refrigerant pressure.
Maintenance Features:
- Reduced Emissions: Over 30 percent joint reduction in compressor/motor assembly, beaded flat gasket technology instead of O-rings, minimal NPT pipe threads, SAE O-ring boss fitting for lower leak potential.
- Internal Oil Sump: Eliminates vent and drain lines, preventing leaks.
- Easy to Replace Motor Terminals: Simplifies motor maintenance.
- Removable Motor/Stator Assembly: Speed assembly can be removed independently of the high-speed assembly.
- Isolation Pads: Molded neoprene isolation pads are supplied as standard; spring isolators are optional.
- Advanced Motor Protection: Includes phase voltage sensors for monitoring and displaying phase voltage, providing over/undervoltage protection, compressor phase amperage, kilowatts, power factor, and kilowatt-hours.
- Oil-Temperature Protection: Shuts down compressor if oil temperature is too low (refrigerant dilution) or too high (overheating).
- Low Differential Oil-Pressure Protection: Shuts down if oil pressure drops significantly, indicating oil pump failure, leakage, or blockage.
- Phase-Unbalance Protection: Derates motor RLA or shuts down if phase unbalance exceeds limits (e.g., 30 percent trip point).
- Phase-Loss Protection: Shuts down if any of the three phase currents drop below 10 percent RLA.
- Phase Reversal/Rotation Protection: Detects and provides a latching diagnostic for reverse phase rotation.
- Momentary Power Loss (MPL) and Distribution Fault Protection: Detects MPLs of 2.5 cycles or longer, disconnecting the unit to prevent damage.
- Current Overload Protection: Monitors motor current and shuts down if it exceeds the trip curve.
- High Motor-Winding Temperature Protection: Monitors motor temperature and terminates operation if it exceeds 265°F (129.4°C).
- Surge Detection Protection: Based on current fluctuations, with adjustable detection criteria.
- Overvoltage and Undervoltage Protection: Monitors line-to-line voltages and resets the unit if voltage is outside ±10 percent of nominal.
- Short-Cycling Protection: Prevents too many rapid restarts using "Restart Inhibit Free Starts" and "Restart Inhibit Start-to-Start Timer" settings.
- Factory Testing: All units are factory assembled and tested.
- Insulation: Factory-applied insulation to all low-temperature surfaces (evaporator, water boxes, suction elbow) is optional.
- Rigging: Evaporator and condenser tube sheets provide rigging support points, with a rigging diagram affixed to the chiller.
- Quality: Chiller manufacturing facility is ISO 9001 certified.
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