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Trane ctv-prc007-en User's Manual

1. Compressor Figure O 6 Free Cooling Operation Schematic Ze Cond Hh Econ o o Refri 7 Tank D Compressor 19 e TRANE 20 System Options Auxiliary Condenser The Trane auxiliary condenser provides economical heat recovery for applications with small heating demand It s well suited to preheat applications including domestic hot water boiler makeup water and swimming pools The Trane auxiliary condenser option consists of a separate condenser connected in parallel with the standard condenser to provide simple heat recovery capability for applications where full heat recovery or high heating water temperatures are not required Heat which normally would be rejected to the regular condenser water is picked up in the auxiliary condenser before the water enters the hot water heating system Typical uses for this water include domestic water preheat boiler makeup water preheat and reheat air conditioning systems as opposed to traditional heat recovery applications where higher temperature water is used to satisfy a building heating load provide full heat input for domestic hot water or provide the typically larger flow rates of hot water for process applications The a
2. EVAPORATOR NON MARINE i i i END 1 PASS LELE 2 PASS RERE 2 PASS END 3 PASS CONDENSER NON MARINE 2 PASS ONLY PANEL LELE RERE CONDENSER MARINE LEFT HAND 2 PASS ONLY hj CONTROL PANEL LRLR LFLR LRLF LFLF CONDENSER MARINE RIGHT HAND 2 PASS ONLY 1 5 1 RFRF RRRF RFRR RRRR These graphics are intended to help you visualize the possible connections combinations that may be available for your unit You must contact your local Trane office who can configure your selection as an as built drawing to confirm it is available and to provide appropriate dimensions CTV PRC007 EN 45 e TRANE Waterbox Lengths English Units Physical Dimensions RETURN RETURN SHELL PRESSURE EVAP PASSES LENGTH LENGTH COND NO PASSES LENGTH LENGTH 320 150 PSIG MAR 1 16 12 MAR 2 16 674 6 125 320 150 PSI
3. Shell Bundle One Pass Two Pass Three Pass Size Size SBCU TECU IECU SBCU TECU IECU SBCU TECU IECU EVSZ EVBS Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max 032S 200 216 1187 230 1237 143 1050 108 593 115 618 72 525 72 396 77 412 48 350 032S 230 242 1331 258 1388 165 1212 121 666 129 694 83 606 81 444 86 463 55 404 0325 250 267 1465 284 1527 177 1293 134 733 142 764 88 646 89 488 95 509 59 431 032S L 280 304 1672 324 1743 201 1474 152 836 162 871 101 737 102 557 108 581 67 491 032S L 320 340 1868 362 1947 229 1676 170 934 181 973 115 838 114 623 121 649 76 559 032S L 350 j 251 1838 126 919 84 613 0505 320 340 1868 362 1947 232 1696 170 934 181 973 116 848 114 623 121 649 77 565 0505 360 383 2105 399 2194 254 1858 192 1052 200 1097 127 929 128 702 133 731 85 619 050 400 424 2332 442 2431 284 2080 212 1166 221 1215 142 1040 142 777 148 810 95 693 050S L 450 482 2652 503 2764 322 2363 241 1326 252 1382 161 1181 161 884 108 921 108 788 050S L 500 535 2941 558 3066 361 2646 268 1470 279 1533 181 1323 178 980 186 1022 121 882 050S L 550 397 2908 198 1454 132 969 0805 500 535 2941 558 3066 361 2646 268 1470 279 1533 181 1323 178 980 186 1022 121 882 0805 560 602 3312 628 3453 400 2928 301 1656 314 1726 200
4. Soft loading the soft loading function minimizes the number of chillers that are operated to satisfy the building 34 CTV PRC007 EN Optimal Performance Regardless of the system level being designed the unit controls become critical not just in making every level operate reliably but in facilitating optimal performance UCP2 provides more capability and more intelligence to make this operation optimization possible Chiller Level e Factory mounted water temperature sensors Variable speed drive for those installations in which the chiller is operating at part load conditions a significant percentage of the time and where cold condenser water is available Hot gas bypass for those process installations where the chiller will need to respond quickly to sudden load increases ASHRAE Guideline 3 Report incorporated into the Chiller Report and Printer Report Guideline 3 aids operators in managing refrigerant assets Chiller Plant Level Heat recovery to take advantage of waste heat from the chiller for heating applications Heat pump for those applications in which heating is the primary mission of the chiller and cooling is a waste product requiring an endless source of heat such as a well or lake water Free cooling for use in those parts of the country where cold condenser water is available to eliminate the need to operate the compressor Variable flow for applications where either the condens
5. CenTraVac Liquid Chillers Centrifugal Liquid Chillers Water Cooled 170 3500 Tons 50 and 60 Hz Built For the Industrial and Commercial Markets CVHE Three Stage CVHG Three Stage 170 500 450 1300 CVHF Two Stage CenTraVac 325 1750 LHCV Module CenTraVac 1300 3500 April 2001 CTV PRC007 EN e TRANE What We Mean By Earth Wise Breaking the 48 kW Ton Efficiency Barrier The Trane EartheWise CenTraVac has a proven track record as literally the world s most efficient lowest emissions chiller In fact a portion of the product line is selectable at an unmatched efficiency level of 48 kW ton at standard ARI rated conditions This is an efficiency level of 16 to 25 percent better than competitive chillers using other alternative refrigerants which are typically in the 56 to 60 kW ton range On a 1000 ton chiller this efficiency difference can provide savings of over 24 000 per year or nearly three quarters of a million dollars over the life of the machine typically more than twice the initial cost of the machine And at part load conditions the kW ton ratings are even better a fact that can be seen by comparing Trane s ARI certified applied part load values NPLV s to those of competitive units The development of the 48 kW ton chiller also has a positive environmental impact Consider this If every centrifugal chiller in the world were able to operate at 48 vs 56 k
6. 0501 20789 9430 18326 8313 CVHE 360 500 453 050S 050S 19180 8700 17229 7815 CVHE 360 500 453 050S 0501 20148 9139 18044 8185 CVHE 360 500 453 050L 050L 21439 9725 18976 8608 CVHE 360 500 453 0805 0805 26327 11942 23212 10529 CVHE 360 500 453 080S 080L 27914 12662 24555 11138 CVHE 360 500 453 080L 080L 30027 13620 26135 11855 CVHF 350 485 453 050S 0505 18175 8244 16224 7359 CVHF 350 485 453 050S 0501 19143 8683 17039 7729 CVHF 350 485 453 0501 0501 20434 9269 17971 8152 CVHF 350 485 453 0805 0805 25297 11475 22182 10062 CVHF 350 485 453 080S 080L 26884 12195 23525 10671 CVHF 350 485 453 080L 080L 28997 13153 25105 11388 CVHF 555 640 588 050S 050S 19800 8981 17849 8096 CVHF 555 640 588 050S 0501 20768 9420 18664 8466 CVHF 555 640 588 0501 0501 22059 10006 19596 8889 CVHF 555 640 588 080S 080S 26947 12223 23832 10810 CVHF 555 640 588 080S 080L 28534 12943 25175 11419 CVHF 555 640 588 080L 080L 30647 13901 26755 12136 CVHF 650 910 745 0805 0805 28117 12754 25002 11341 CVHF 650 910 745 080S 080L 29704 13474 26345 11950 CVHF 650 910 745 080L 080L 31817 14432 27925 12667 CVHF 650 910 745 142M 142L 41646 18891 36068 16360 CVHF 650 910 745 142L 142L 42816 19421 36882 16730 CVHF 650 910 745 1425 1421 44762 20304 38299 17372 CVHF 1060 1280 1062 142M 142L 42246 19163 36668 16633 CVHF 1060 1280 1062 142L 142L 43416 19693 37482 17002 CVHF 1060 1280 1062 1425 1421 45362 20576 38899 17645 CVHF 1060 1280 1062 210L 210L 53043 24060 45196 20501 CVHF 1060
7. By making starter to chiller electrical connections under factory controlled conditions By testing the entire chiller starter combination in the factory By providing control components designed to operate with the unique CenTraVac motor compressor start and protection subsystem Single Source Responsibility Trane retains complete responsibility for the starter and associated chiller starter interconnecting wiring 13 e TRANE System Design Time Cost Savings System design time is reduced since all starter components and interconnecting wiring are pre engineered and selected Complete package available with Agency Approval Application The Trane unit mounted starter can be applied on low voltage 600 volts and below applications up to approximately 1300 tons capacity To determine the unit mounted starter to be used with a particular selection it is necessary to know the current draw of the compressor motor The starter current draw must be greater than or equal to the compressor motor current draw Unit Options Reliability The unit mounted starter is a star delta closed transition electromechanical starter Motor starters of this configuration have proven reliability in thousands of centrifugal chiller applications around the world The proven electromechanical concept plus the use of industrial quality components makes the CenTraVac unit mounted starter dependable in all kinds of service app
8. available a specific chiller combination may be laboratory tested for the first time Trane offers two levels of CenTraVac performance testing A performance test at design conditions plus a certified test report e customer witnessed performance test at design conditions plus a certified test report Trane is part of the ARI 550 590 certification program The selection program and machines bear the ARI seal of approval Performance testing is a key part of this program While the certification program is technically sound a factory run test with your machine on the test stand is still the best way to confirm machine performance and a trouble free start up 10 Features and Benefits The single package design of the CenTraVac chiller allows testing of each assembled chiller at the factory Actually all components including the evaporator condenser compressor and control d panel tested before final assembly After assembly performance testing of the chiller can confirm proper operation and virtually eliminate jobsite start up problems Wo a 7 AE RS ect m PANS During customer witnessed performance tests of Trane CenTraVac chillers a nickel can be balanced on the edge of the compressor motor assembly demonstrating the extremely low vibrations generated by the unit while operating at full and part load conditions CTV PRC007 EN Three Stage Re
9. cost effective chiller starter package This single source responsibility for the CenTraVac chiller and unit mounted starter package is a real advantage Potential scheduling problems associated with separate starter and chiller installations are eliminated When the CenTraVac chiller arrives at the jobsite with the unit mounted starter the only remaining wiring is the main power wiring to the disconnect switch and a few simple electrical interlocks to the chilled water and condenser water flow sensing devices To ensure a trouble free start up on the electrical side the unit mounted starter is tested with the chiller as part of the factory performance testing program Our commitment to customer and equipment safety offers the Underwriters Laboratories Inc UL mark of safety on both chiller and starter and available accessories Compressor Motor Starting Equipment Features Trane can provide compressor motor starting equipment built to rigid Trane specifications The types of starters available include Low Voltage 200 to 600 volts Star wye delta closed transition Full voltage CTV PRC007 EN Unit Options e TRANE e Autotransformer closed transition e Solid state starters Medium Voltage 2300 to 6000 Volts Full voltage Primary reactor closed transition Autotransformer closed transition Medium voltage starters are provided as standard with a non load break isolation switch and current l
10. less heat generated increased motor winding life This translates into longer time between compressor maintenance and less downtime throughout the life of the machine Application Certain system characteristics favor installation of an AFD because of energy cost savings and shorter payback Among them are A large number of part load operating hours annually Figure O 4 based on a CVHE500 500 ton load at standard ARI conditions shows that major kW savings occur at part load conditions typically below 90 percent load 16 Unit Options Figure O 4 CVHE500 Part Load Efficiencies with without AFD 0 8 0 7 0 6 IPLV 525 KW T no AFD 0 5 FD 0 wA wt IPLV 353 KW TON 0 3 0 2 0 1 0 0 0 10 20 30 40 50 60 70 80 90 100 LOAD CTV PRC007 EN Unit Options e TRANE Condenser water temperature relief of chilled water reset Compressor lift reduction is required for a chiller application both to provide stable chiller operation at part loads and to achieve greater energy savings Intelligent control to reduce condenser water temperature or chiller water reset strategies are key to AFD savings in chiller applications High kW Charges Electric utility bills normally include both demand and energy components The demand or kW portion is established by usage during utility peak hours by individual peak usage or a combination This portion may or may not be influenced by i
11. 10 06 1420 300 PSIG MAR 3 25 8 1420 300 PSIG NMAR 1 15 59 1420 300 PSIG NMAR 2 15 59 9 84 1420 300 PSIG NMAR 3 15 59 210 150 PSIG MAR 1 N A N A MAR 2 29 632 9 382 210 150 PSIG MAR 2 27 25 8 88 NMAR 2 16 38 9 382 210 150 PSIG MAR 3 25 25 210 150 PSIG NMAR 1 15 88 210 150 PSIG NMAR 2 15 88 8 88 210 150 PSIG NMAR 3 15 88 210 300 PSIG MAR 1 N A MAR 2 35 10 71 210 300 PSIG MAR 2 29 64 9 84 NMAR 2 17 71 10 71 210 300 PSIG MAR 3 29 64 210 300 PSIG NMAR 1 16 84 210 300 PSIG NMAR 2 16 84 9 84 210 300 PSIG NMAR 3 16 84 250 150 PSIG MAR 1 N A MAR 2 32 10 75 250 150 PSIG MAR 2 N A N A NMAR 2 17 75 10 75 250 150 PSIG MAR 3 N A 250 150 PSIG NMAR 1 18 75 250 150 PSIG NMAR 2 18 75 11 75 250 150 PSIG NMAR 3 18 75 250 300 PSIG MAR 1 N A MAR 2 38 3 11 75 250 300 PSIG MAR 2 N A N A NMAR 2 18 75 11 75 250 300 PSIG MAR 3 N A 250 300 PSIG NMAR 1 20 25 250 300 PSIG NMAR 2 20 25 13 25 250 300 PSIG NMAR 3 20 25 46 CTV PRC007 EN Waterbox Lengths Metric Units Physical Dimensions e TRANE RETURN RETURN SHELL PRESSURE EVAP PASSES LENGTH LENGTH COND NO PASSES LENGTH LENGTH 320 150 PSIG MAR 1 409 MAR 2 424 156 320 150 PSIG MAR 2 409 176 NMAR 2 235 cast 156 320 150 PSIG MAR 3 409 320 150 PSIG NMAR 1 329 320 150 PSIG NMAR 2 329 176 320 150 PSIG NMAR 3 329 320 300 PSIG MAR 1 409 MAR 2 432 203 320 300 PSIG MAR 2 409 176 NMAR 2 337 515 203 320 300 PSIG MAR 3 409 3
12. 1280 1062 250E 250L 66146 30003 55176 25027 CVHF 1470 1340 210L 210L 57820 26227 49980 22671 CVHF 1470 1340 2505 2501 70930 32173 59960 27197 Note Values represent maximum unit weights including unit mounted starters shells with TECU 028 tubes max bundles and 150 psig non marine waterboxes and compressors with the largest low voltage motors for each family High voltage motors to include the 1228 cpkw high voltage motor for the CVHF 1060 1280 weigh less than the low voltage motors shown in the table 39 e TRANE Weights Operating Weight Shipping Weight TYPE NTON CPKW EVSZ CDSZ Ibs kg Ibs kg CVHE 190 270 242 0325 0325 14259 6468 13071 5929 CVHE 190 270 242 0328 032L 14898 6758 13615 6176 CVHE 190 270 242 032L 032L 15772 7154 14261 6469 CVHE 190 270 242 0505 0505 17880 8110 15929 7225 CVHE 190 270 242 0505 0501 18848 8549 16744 7595 CVHE 190 270 242 050L 050L 21039 9135 17676 8018 CVHE 300 420 379 0505 0505 19180 8700 17229 7815 CVHE 300 420 379 0505 0501 20148 9139 18044 8185 CVHE 300 420 379 050L 050L 21439 9725 18976 8607 CVHE 300 420 379 0805 0805 26327 11942 23212 10529 CVHE 300 420 379 0805 0801 27914 12662 24555 11138 CVHE 300 420 379 080L 080L 30027 13620 26135 11855 CVHG 480 565 548 0505 0505 20930 9494 18979 8609 CVHG 480 565 548 050S 050L 21898 9933 19794 8978 CVHG 480 565 548 050L 050L 23189 10518 20726 94
13. 1464 201 1104 210 1151 133 976 0805 630 676 3715 704 3872 452 3312 338 1857 352 1936 226 1656 226 1238 235 1291 151 1104 080S L 710 758 4169 790 4346 517 3756 379 2084 395 2173 259 1878 253 1390 264 1449 171 1252 080S L 800 861 4736 898 4937 576 4221 431 2368 449 2469 288 2110 288 1579 300 1646 192 1407 080S L 890 1 642 4706 321 2353 214 1569 142M L 890 863 4746 900 4948 645 4726 432 2373 450 2474 323 2363 288 1582 300 1649 215 1575 142M L 980 966 5314 1008 5540 716 5251 483 2657 504 2770 358 2625 322 1771 336 1847 239 1750 142M L 1080 1075 5912 1121 6163 807 5917 538 2956 561 3082 404 2959 358 1971 374 2054 269 1972 142M L E 1220 1208 6645 1260 6927 895 6564 604 3323 630 3464 448 3282 403 2215 420 2309 299 2188 142M L E 1420 1345 7398 1402 7712 1041 7634 673 3699 701 3856 521 3817 449 2466 468 2571 347 2545 2101 1610 1318 7244 1373 7551 1146 8402 659 3622 687 3775 573 4201 440 2415 458 2517 382 2801 2101 1760 1471 8090 1534 8433 1286 9432 736 4045 767 4216 643 4716 490 2697 512 2811 429 3144 2101 1900 1634 8987 1704 9369 1421 10421 817 4494 852 4684 711 5211 545 2996 568 3123 474 3474 210 2100 1802 9906 1878 10326 1509 11067 901 4953 939 5163 755 5534 601 3302 626 3442 503 3689 2505 2300 1948 10710 2030 11165 N A 974 5355 1015 5583 650 3570 677 3722 N A 250E 250
14. 899 032S L 280 267 980 261 958 273 1000 032S L 320 295 1083 289 1059 306 1121 0505 360 336 1233 329 1205 347 1272 050S L 400 378 1388 370 1357 391 1434 050S L 450 426 1563 417 1528 441 1616 050S L 500 473 1733 462 1695 490 1797 0805 500 473 1733 462 1695 490 1797 0805 560 529 1940 517 1896 548 2010 0805 630 595 2182 582 2133 614 2252 080S L 710 673 2466 657 2411 689 2525 080S L 800 756 2770 739 2708 774 2838 1421 890 853 3126 833 3056 876 3211 1421 980 948 3477 927 3399 975 3575 142L 1080 1060 3885 1036 3798 1091 3999 1421 1220 1185 4344 1158 4246 1217 4463 1421 1420 1335 4896 1305 4786 1407 5160 210L 1610 1331 4881 1301 4771 1495 5483 2101 1760 1473 5402 1440 5280 1655 6069 2101 1900 1615 5923 1579 5790 1812 6645 2101 2100 1760 6454 1721 6309 1964 7200 2501 2100 1760 6454 1721 6309 250L 2300 1935 7094 1891 6934 N A 250L 2500 2113 7749 2066 7575 N A Note The minimum maximum condenser water velocity is 3 11 ft sec Minimum Maximum Condenser Flow Rates Liters Second Shell Bundle Two Pass Size Size SBCU TECU IECU CDSZ CDBS Min Max Min Max Min Max 0325 230 13 49 13 48 14 50 032S L 250 15 55 15 54 15 57 032S L 280 17 62 16 60 17 63 032S L 320 19 68 18 67 19 71 0505 360 21 78 21 76 22 80 050S L 400 24 88 23 86 25 90 050S L 450 27 99 26 96 28 102 050S L 500 30 109 29 107 31 113 080S 500 30 109 29 107 31 11
15. Compressor motors are hermetically sealed two pole low slip squirrel cage induction type They are built in accordance with Trane specifications and guaranteed by the manufacturer for continuous operation at the nameplate rating A load limit system provides protection against operation in excess of this rating The rotor shaft is of heat treated carbon steel and designed such that the first critical speed is well above the operating speed The control circuit prevents motor energization unless positive oil pressure is established Impellers are keyed directly to the motor shaft and locked in position Nonferrous labyrinth type seals minimize recirculation and gas leakage between the stages of the compressor 200 through 600 volt three phase 60 hertz and 380 through 415 volt three phase 50 hertz motors are supplied with six terminal posts for full voltage across the line or reduced voltage Star Delta or autotransformer starting For low 48 Mechanical Specification voltage full voltage starting connecting links are furnished to convert the motor to a 3 lead motor 2 300 through 4 160 volt three phase 60 hertz and 3300 through 6600 volt three phase 50 hertz motors are supplied with three terminal posts for full voltage across the line or reduced voltage primary reactor or autotransformer starting Motor terminal pads are supplied A removable sheet metal terminal box encloses the terminal board area
16. Motor Cooling Cooling is accomplished by liquid refrigerant pumped through the motor with a patented refrigerant pump The refrigerant circulates uniformly over the stator windings and between the rotor and stator The windings of all motors are specifically insulated for operation within a refrigerant atmosphere Lubrication A direct drive system positive displacement oil pump driven by a low voltage 3 4 horsepower 120 60 1 or 120 50 1 motor is submerged in the oil sump to assure a positive oil supply to the two compressor bearings at all times A low watt density heater maintains the oil temperature which minimizes its affinity for refrigerant Oil cooling is provided by refrigerant Evaporator Shell and Waterboxes The evaporator shell is formed of carbon steel plate and incorporates a carbon rupture disc in accordance with the ANSI ASHRAE 15 Safety Code A refrigerant temperature coupling is provided for customer use or for use with a low limit controller For all units pass arrangements are available at 150 psig or 300 psig water side working pressures with grooved connections Flanged connections are also available Marine type waterboxes are available Tube Sheets Athick carbon steel tube sheet is welded to each end of the shell and is drilled and reamed to accommodate the tubes Three annular grooves are machined into each tube hole to provide a positive liquid and vapor seal between the refrigerant and wa
17. Refrigerant Report and Compressor Report Each report contains data that is accessed by scrolling through the menu items Each grouping will have a heading which describes the type of data in that grouping This data includes All water temperatures and setpoints as standard factory mounted temperature sensors Current chiller operating mode Diagnostic history Control source i e local panel external source remote BAS Current limit setpoint Water flows optional Water pressure drops optional Outdoor air temperature optional e Saturated refrigerant temperatures and pressures Purge suction temperature Evaporator refrigerant liquid level Condenser liquid refrigerant temperature Compressor starts and hours running Phase currents Phase voltages optional Watts and power factor optional Oil temperature and flow e Motor winding temperatures Bearing temperatures optional e Refrigerant detection external to chiller in ppm optional All necessary settings and setpoints are programmed into the microprocessor controller via the keypad of the operator interface The controller is capable of receiving signals from a variety of control sources which are not mutually exclusive i e any combination of control sources can coexist simultaneously and of being programmed at the keypad as to which control source has priority Control sources can be The local operator
18. The modular concept of glycol ice storage systems and the proven simplicity of Trane Tracer controls allow the successful blend of reliability and energy saving performance in any ice storage application Ice Storage Demand Cost Savings TONS 300 200 CHILLER 100 NOON 6 PM MN MN 6 A M The ice storage system is operated in six different modes each optimized for the utility cost of the hour 1 Provide comfort cooling with chiller 2 Provide comfort cooling with ice 3 Provide comfort cooling with ice and chiller 4 Freeze ice storage 5 Freeze ice storage when comfort cooling is required 6 Off Tracer optimization software controls operation of the required equipment and accessories to easily transition from one mode of operation to another For example Even with ice storage systems there are numerous hours when ice is neither produced or consumed but saved In this mode the chiller is the sole source of cooling For example to cool the building after all ice is produced but before high electrical demand charges take effect Tracer sets the centrifugal chiller leaving fluid setpoint to its most efficient setting and starts the chiller chiller pump and load pump When electrical demand is high the ice pump is started and the chiller is either demand limited or shut down completely Tracer controls have the intelligence to optimally balance the contribution of ice and chiller in meeting the coo
19. lowest temperature When condenser water is available at temperatures lower than the required leaving chilled water temperature typically 50 to 55 F the unit control panel starts the free cooling cycle automatically When the free cooling cycle can no longer provide sufficient capacity to meet cooling requirements mechanical cooling is restarted automatically by the unit control panel For example a building with a high internal cooling load is located in a climate with cold winters It is possible to cool the building exclusively with free cooling three to six months of the year Free cooling payback can easily be less than a year Free cooling is completely factory installed and requires no more floor space or piping than the standard CenTraVac chiller unlike plate frame heat exchangers Benefits The Trane patented free cooling accessory for Trane CenTraVac chillers adapts the basic chiller so it may function as a simple heat exchanger using refrigerant as the working fluid When condenser water is available at temperatures lower than the desired chilled liquid temperature free cooling can provide up to 45 percent of nominal chiller capacity without operation of the compressor This feature may result in substantial energy cost savings on many installations 18 Unit Options Free Cooling Operation Schematic Reliability Two simple valves are the only moving parts Single Source Responsibility
20. motor The unit control panel monitors motor current during operation via current transformers located in the starter enclosure When during acceleration the line current drops to approximately 0 85 times rated load current transition is initiated The closed transition feature provides for a continuous motor current flow during transition by placing resistors in the circuit momentarily This prevents buildup of damaging torques to the system during this period With the completion of transition the motor windings are connected in the delta configuration with full line voltage Three precision current transformers monitor phase current Contactor position and various voltage signals provide extensive interlocking between the starter and the microcomputer in the CenTraVac control panel All logic and subsequent instruction originate in the unit control panel Protection against the following starter defects is provided High motor current starting and running Improper starter circuitry Excessive accelerating time Incomplete starting sequence Loss of phase Phase amperage unbalance Phase reversal Distribution fault Features The Trane CenTraVac Unit Mounted Starter includes the following standard features NEMA 1 enclosure designed to accommodate padlock e KVA control power transformer with 120V secondary Fused 120V control circuit 3 phase incoming line terminals 6 out
21. or English Remote display interface optional For more information on the Trane centrifugal chiller unit control panel please contact your local Trane sales engineer CTV PRC007 EN Modules Conventional relay logic circuits have been replaced by software and hardware imbedded in the CenTraVac microprocessor controller The functions of the microprocessor are divided into six standard modules Optional modules are available for those applications that require additional control capability Optional communication interface modules are available for alternative control sources All modules communicate with each other on the interprocessor communication bus IPC All information is available and all setpoint setup adjustments can be accomplished at the operator interface An optional remote display permits the operator to monitor and operate the chiller from a remote location The six standard modules consist of a chiller module a circuit module a starter module a stepper module a purge module and local display module The chiller module is the master of the chiller It communicates commands to other modules and collects data status diagnostic information from other modules over the IPC The chiller module performs the leaving evaporator fluid temperature and limit control algorithms arbitrating capacity against any operating limit the chiller may find itself working against The circuit module is assigned i
22. power bills are now constituted of 1 3 demand charge and 2 3 usage charge The full load power consumption of the chiller plant is likely to set the KW peak and demand charge for the billing period This places an increased emphasis on the need to keep the full load consumption of the chiller plant low There are a number of variables that should be considered in developing an accurate chiller load profile to use for measuring how one machine compares with another machine at part load The use of outdoor air economizers variations in chiller sequencing and chiller plant load optimization strategies should be considered The use of a decoupled or primary secondary water loop is generally acknowledged as the simplest most efficient way to control multiple chiller water plants This control strategy results in one chiller operating at a more fully loaded condition rather than multiple chillers operating at part load which would require more pumping energy ARI Standard 550 590 provides chiller performance certification for the full load condition and the NPLV non standard part load value The NPLV uses a generic weighted chiller load profile to simplify certification of part load performance data Although these values are not necessarily a precise indicator of actual energy use they do provide a valuable basis for comparison 29 e TRANE Minimum Maximum Evaporator Flow Rates GPM Performance Data
23. the input side of the AFD to reduce harmonic distortion and help meet IEEE 519 guidelines NEMA 1 enclosure 596 impedance 51 TRANE The Trane Company An American Standard Company www trane com For more information contact your local sales office or e mail us at comfort trane com 150 9001 Quality System Certified Cent The Trane Company is a participant in the La Crosse Green Seal Program Business Unit REFRIGERANTS Literature Order Number CTV PRC007 EN File Number PL RF CTV 000 PRC007 EN 0401 Supersedes CTV DS 1 0500 Stocking Location La Crosse Since The Trane Company has a policy of continuous product and product data improvement it reserves the right to change design and specifications without notice
24. warning leak detector that also takes purge refrigerant emissions to an industry low CTV PRC007 EN CTV PRC007 EN Contents Introduction Features and Benefits Components Standard and Optional Features Factory Performance Testing Refrigeration Cycle Control Panel Unit Options Unit Mounted Starter Adaptive Frequency Drives Free Cooling System Options Auxiliary Condenser Ice Storage Heat Recovery Chilled Water Resets Application Considerations Selection Procedure Performance Data Jobsite Connections Controls Weights Physical Dimensions Mechanical Specifications 13 21 26 28 30 32 33 39 41 e TRANE A Tradition of Innovation The first Trane centrifugal chiller the Turbovac was introduced in 1938 The simple direct drive slow speed design of the Turbovac revolutionized the air conditioning industry The chiller was attractive to customers because its hermetic design reduced frequent service requirements In 1951 the Trane CenTraVac centrifugal chiller was introduced Its unique two stage compressor with multiple inlet guide vanes and patented economizer reduced energy consumption on typical applications to less than 0 8 kW ton The model PCV CenTraVac chiller that was introduced in 1966 allowed quality air conditioning for applications as small as 120 tons In 1982 the CenTraVac chiller solidified its position as the industry leader by introducing a three stage com
25. without waterbox covers is proof tested at 45 psig vacuum leak tested and pressure leak tested The water side of the shell with waterboxes in place is hydrostatically tested at one and one half times the design working pressure but not less than 225 psig These tests are not to be repeated at installation CTV PRC007 EN Condenser Heat Recovery Condenser Shell and Waterboxes The condenser shell is formed of carbon steel plate designed and constructed in accordance with ANSI ASHRAE 15 Safety Code For all units all pass arrangements are available at 150 psig or 300 psig water side working pressures with grooved connections Flanged connections are also available Marine type waterboxes are available Tube Sheets A thick carbon steel tube sheet is welded to each end of the shell and is drilled and reamed to accommodate the tubes Three annular grooves are machined into each tube hole to provide a positive liquid and vapor seal between the refrigerant and water sides of the shell after tube rolling Intermediate tube support sheets are positioned along the length of the shell to avoid contact and relative motion between adjacent tubes Tubes Individually replaceable externally finned seamless copper tubing either internally enhanced one inch nominal diameter or three quarter inch nominal diameter is utilized as the condenser heat transfer surface Refrigerant Gas Distribution A baffle between the tube bu
26. 0 2145 11794 2236 12295 N A 1073 5897 1118 6147 N A 715 3931 746 4098 N A Note The minimum evaporator water velocity is 1 5 ft sec for IECU tubes and 2 0 ft sec for all other tubes GPME is generally not applicable at full load Minimum Maximum Evaporator Flow Rates Liters Second For a variable evaporator water flow system the minimum Shell Bundle One Pass Two Pass Three Pass Size Size SBCU TECU IECU SBCU TECU IECU SBCU TECU IECU EVSZ EVBS Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max 0325 200 14 75 14 78 9 66 7 37 8 39 5 33 5 25 5 26 3 22 0325 230 16 84 16 88 11 76 8 42 8 44 5 38 6 28 6 29 4 25 0325 250 17 92 18 96 11 82 9 46 9 48 6 41 6 31 6 32 4 27 032S L 280 20 105 20 110 13 93 10 53 10 55 7 47 7 35 7 37 4 31 032S L 320 22 118 22 123 15 106 11 59 12 61 7 53 8 39 8 41 5 35 032S L 350 j 16 116 8 58 gt 6 39 0505 320 22 118 22 123 15 107 11 59 12 61 8 54 8 39 8 41 5 36 0505 360 24 133 26 138 16 117 12 66 13 69 6 59 8 44 9 46 6 0505 400 27 147 28 153 18 131 14 74 14 77 9 66 9 49 10 51 6 44 050S L 450 31 167 32 174 22 149 16 84 16 87 10 75 10 56 11 58 7 50 050S L 500 34 186 36 193 23 167 17 93 18 97 12 83 12 62 12 64 8 56 050S L 550 25 183 S 13 92 9 61 0805 500 34 186 36 193 23 167 17 93 18 97 12 83 12 62 12 64 8 56 0805 560 38 209 40 218 25 185 19 104 20 109 13 92 13 70 14 73
27. 0 270 320 SS 8052 3207 3467 3581 104 3429 2380 1759 2019 190 270 320 SL amp LL 10344 3207 3467 4724 1041 4578 2380 1759 2019 190 270 500 SS 8087 3470 3832 3581 1076 3429 2494 2022 2384 C 190 270 500 SL amp LL 10379 3470 3832 4724 1076 4578 2494 2022 2384 V 300 420 500 SS 8087 3470 3797 3581 1076 3429 2502 2022 2350 H 300 420 500 SL amp LL 10379 3470 3797 4724 1076 4578 2502 2022 2350 E 300 420 800 SS 8338 3867 4080 3581 1327 3429 2905 2419 2632 300 420 800 SL amp LL 10630 3867 4080 4724 1327 4578 2905 2419 2632 480 565 500 SS 8087 3470 3804 3581 1076 3429 2624 2022 2356 480 565 500 SL amp LL 10379 3470 3804 3581 1076 4578 2624 2022 2356 480 565 800 55 8338 3867 4080 4724 1327 3429 2946 2419 2632 C 480 565 800 SL amp LL 10630 3867 4080 4724 1327 4578 2946 2419 2632 V 670 780 800 SS 8338 3912 4235 3581 1327 3429 2915 2540 2788 H 670 780 800 SL amp LL 10630 3912 4235 4724 1327 4578 2915 2540 2788 G 670 780 1420 ML amp LL 10754 4413 4594 4724 1499 4578 3077 3042 3146 920 1067 1420 ML amp LL 10754 4413 4594 4724 1499 4578 3077 3042 3146 920 1067 2100 LL 10801 4667 4750 4724 1499 4578 3375 3296 3302 CL1 CAN BE AT EITHER END OF MACHINE AND IS REQUIRED FOR TUBE PULL CLEARANCE CL2 IS ALWAYS AT THE OPPOSITE END OF MACHINE FROM CL1 AND IS REQUIRED FOR SERVICE CLEARANCE CENTRAVAC WATER CONNECTION PIPE SIZE Water Shell Size Passes 032 050 080 142 210 EVAPORATOR Metric Pipe Size Millimeters 1 PASS DN200 DN250 DN300 DN40
28. 0 272 210 300 PSIG MAR 3 753 210 300 PSIG NMAR 1 428 210 300 PSIG NMAR 2 428 250 210 300 PSIG NMAR 3 428 250 150 PSIG MAR 1 N A MAR 2 813 273 250 150 PSIG MAR 2 N A N A NMAR 2 451 273 250 150 PSIG MAR 3 N A 250 150 PSIG NMAR 1 476 250 150 PSIG NMAR 2 476 298 250 150 PSIG NMAR 3 476 250 300 PSIG MAR 1 N A MAR 2 973 298 250 300 PSIG MAR 2 N A N A NMAR 2 476 298 250 300 PSIG MAR 3 N A 250 300 PSIG NMAR 1 514 250 300 PSIG NMAR 2 514 337 250 300 PSIG NMAR 3 514 CTV PRC007 EN 47 e TRANE Compressor Guide Vanes Fully modulating variable inlet guide vanes provide capacity control The guide vanes are controlled by an externally mounted electric vane operator in response to refrigeration load on the evaporator Impellers Fully shrouded impellers are high strength aluminum alloy and directly connected to the motor rotor shaft operating at 3 600 rom 60 hertz 3 000 rpm 50 hertz Impellers are dynamically balanced and over speed tested at 4 500 rpm the motor compressor assembly is balanced to a maximum vibration of 15 inch second at 3600 rpm as measured on the motor housing Compressor Casing Separate volute casings of refrigerant tight close grained cast iron are used on the centrifugal compressor each incorporating a parallel wall diffuser surrounded by a collection scroll The diffuser passages are machined to ensure high efficiency casings are proof tested and leak tested Motor
29. 0 DN400 2 PASS DN150 DN200 DN250 DN300 DN350 3 PASS DN125 DN150 DN200 DN250 DN300 CONDENSER 2 PASS DN150 DN200 DN250 DN300 DN350 42 CTV PRC007 EN Physical Dimensions SPACE ENVELOPE CUIR Gl tI FPR Re ne 1 18 RECOMMENDED a CLEARANCE Ew WIDTH HEIGHT Es 1 0 2 LENGTH C 1 6 2 9 _ 323 REQUIRED WIDTH CLEARANCE E ENGLISH UNITS Envelope Clearance Unit Dimensions W O Unit With Unit W O Unit With Unit Shell Mounted Mounted Tube Mounted Mounted Shell Arrange Starters Starters Pull Starters Starters COMP Size ment EL EW EW CL1 CL2 Length Height Width Width 230 320 320 SS 26 5 10 6 1 4 1147 119 3 5 11 3 7 934 5 9 14 67 1 230 320 320 SL amp LL 33 11 14 10 6 4 1147 15 6 3 5 15 0 1 4 7934 5 9 1 4 6 7 230 320 500 55 26 6 3 5 11 455 12 6 s 11 9 3 65 11 2 82 6 7 5 8 7 97 230 320 500 SL amp LL 34 0 58 11 45 12 6 7 15 6 3 655 15 0 14 8 2 14 6 7 5 8 7 97 360 500 500 55 26 635 11 45 12 5 12 11 9 3 635 113 8 2 5 6 7 5 7 8 10 360 500 500 SL amp LL 34 0 58 11 45 12 5 12 15
30. 01 CVHG 480 565 548 0805 0805 28077 12736 24962 11323 CVHG 480 565 548 0805 0801 29664 13455 26305 11932 CVHG 480 565 548 080L 080L 31777 14414 27885 12648 CVHG 670 780 716 0805 0805 28677 13008 25562 11595 CVHG 670 780 716 0805 0801 30264 13728 26905 12204 CVHG 670 780 716 080L 080L 32377 14686 28485 12921 CVHG 670 780 716 142M 142L 42735 19384 37157 16854 CVHG 670 780 716 142L 142L 43905 19915 37971 17223 CVHG 920 1067 892 142M 142L 44135 20019 38557 17489 CVHG 920 1067 892 142L 142L 45305 20550 39371 17858 CVHG 920 1067 892 210L 210L 54932 24917 47085 21357 Note Values represent maximum unit weights including unit mounted starters shells with TECU 028 tubes max bundles and 150 psig non marine waterboxes and compressors with the largest low voltage motors for each family High voltage motors weigh less than the low voltage motors shown in the table 40 CTV PRC007 EN Physical Dimensions SPACE ENVELOPE Cae ht a ee 5 RIXA UE Cay i 1 16 RECOMMENDED RECOMMENDED CLEARANCE Q Ew WIDTH HEIGHT Hk 0 1 2 323 REQUIRED WIDTH CLEARANCE EX a at E E ENGLISH UNITS Envelope Clearance Unit Dimensions W O Unit With Unit W O Unit With Unit Shell Mounted Mounted Tube Mounted Mounted Shell Arrange
31. 20 300 PSIG NMAR 1 329 320 300 PSIG NMAR 2 329 176 320 300 PSIG NMAR 3 329 500 150 PSIG MAR 1 470 MAR 2 414 200 500 150 PSIG MAR 2 470 171 NMAR 2 267 cast 200 500 150 PSIG MAR 3 470 500 150 PSIG NMAR 1 323 500 150 PSIG NMAR 2 323 171 500 150 PSIG NMAR 3 323 500 300 PSIG MAR 1 483 MAR 2 466 193 500 300 PSIG MAR 2 483 171 NMAR 2 327 520 193 500 300 PSIG MAR 3 483 500 300 PSIG NMAR 1 323 500 300 PSIG NMAR 2 323 171 500 300 PSIG NMAR 3 323 800 150 PSIG MAR 1 590 MAR 2 603 211 800 150 PSIG MAR 2 539 183 NMAR 2 361 211 800 150 PSIG MAR 3 488 800 150 PSIG NMAR 1 335 800 150 PSIG NMAR 2 335 183 800 150 PSIG NMAR 3 335 800 300 PSIG MAR 1 635 MAR 2 871 227 800 300 PSIG MAR 2 584 202 NMAR 2 366 591 227 800 300 PSIG MAR 3 533 800 300 PSIG NMAR 1 355 800 300 PSIG NMAR 2 355 202 800 300 PSIG NMAR 3 355 1420 150 PSIG MAR 1 718 MAR 2 718 235 1420 150 PSIG MAR 2 635 237 NMAR 2 406 235 1420 150 PSIG MAR 3 584 1420 150 PSIG NMAR 1 391 1420 150 PSIG NMAR 2 391 237 1420 150 PSIG NMAR 3 391 1420 300 PSIG MAR 1 789 MAR 2 842 256 1420 300 PSIG MAR 2 706 250 NMAR 2 401 256 1420 300 PSIG MAR 3 655 1420 300 PSIG NMAR 1 396 1420 300 PSIG NMAR 2 396 250 1420 300 PSIG NMAR 3 396 210 150 PSIG MAR 1 N A N A MAR 2 753 238 210 150 PSIG MAR 2 692 226 NMAR 2 416 238 210 150 PSIG MAR 3 641 210 150 PSIG NMAR 1 403 210 150 PSIG NMAR 2 403 226 210 150 PSIG NMAR 3 403 210 300 PSIG MAR 1 N A MAR 2 889 272 210 300 PSIG MAR 2 753 250 NMAR 2 45
32. 3 080S 560 33 122 33 120 35 127 080S L 630 38 138 37 135 39 142 0805 710 42 156 41 152 43 159 080S L 800 48 175 47 171 49 179 142L 890 54 197 53 193 55 203 1421 980 60 219 58 214 62 226 142L 1080 67 245 65 240 69 252 142L 1220 75 274 73 268 77 282 1421 1420 84 309 82 302 89 326 2101 1610 84 308 82 301 94 346 210L 1760 93 341 91 333 104 383 210L 1900 102 374 100 365 114 419 210L 2100 111 407 109 398 124 454 2501 2100 111 407 109 398 N A 250L 2300 122 447 119 437 N A 250L 2500 133 489 130 478 N A 31 e TRANE 32 Jobsite Connections Supply and Motor Lead Wiring and Connections Copper conductors only should be connected to the compressor motor due to the possibility of galvanic corrosion as a result of moisture if aluminum conductors are used Copper conductors are recommended for supply leads in the starter panel Suggested starter panel line and load side lug sizes when lugs are provided are noted in the starter submittals These submitted lug sizes should be carefully reviewed for compatibility with conductor sizes specified by the electrical engineer or contractor If they are not compatible the electrical engineer or contractor should specify the required lug sizes for the particular application Ground lugs are provided in the motor terminal box and starter panel The motor terminals are supplied with connection pads which will accommodate bus bars or standard termina
33. 4 4724 1499 4578 3077 3042 3146 1060 1280 1420 ML amp LL 10754 4413 4594 4724 1499 4578 3077 3042 3146 1060 1280 1420 EL 11909 4413 4594 5309 1499 5150 3077 3042 3146 1060 1280 2100 LL 10801 4667 4750 4724 1499 4578 3375 3296 3302 1060 1280 2500 EL 11069 5055 5055 5309 1578 5150 3477 3645 3645 1470 2100 LL 10801 4667 4750 4724 1499 4578 3479 3296 3302 1470 2500 EL 11069 5055 5055 5309 1578 5150 3585 3645 3645 CL1 CAN BE AT EITHER END OF MACHINE AND IS REQUIRED FOR TUBE PULL CLEARANCE CL2 IS ALWAYS AT THE OPPOSITE END OF MACHINE FROM CL1 AND IS REQUIRED FOR SERVICE CLEARANCE CENTRAVAC WATER CONNECTION PIPE SIZE Water Shell Size Passes 032 050 080 142 210 250 EVAPORATOR Metric Pipe Size Millimeters 1 PASS DN200 DN250 DN300 DN400 DN400 DN400 2 PASS DN150 DN200 DN250 DN300 DN350 DN350 3 PASS DN125 DN150 DN200 DN250 DN300 DN300 CONDENSER 2 PASS DN150 DN200 DN250 DN300 DN350 DN350 44 CTV PRC007 EN e TRANE Physical Dimensions lt WATER FLOW EVAPORATOR MARINE 1 PASS 2 PASS REAR FRONT RFRR RRRF LFLR LRLF TOPVIEW 1 AND 3 PASS LL i RRLF LRRF RFLR
34. 5 34 15 0 75 15 6 4 11 15 0 10 1 Ye 9 1134 10 3 7 5 920 1067 1420 ML amp LL 35 5 1 4 14 534 15 0 7 15 6 4 11 15 0 1 4 10 1 Ve 9 11 3 4 10 3 7 920 1067 2100 LL 355 1 4 15 335 15 7 15 6 4 11 15 0 1 4 11 0 7 10 9 34 10 10 CL1 CAN BE AT EITHER END OF MACHINE AND IS REQUIRED FOR TUBE PULL CLEARANCE CL2 IS ALWAYS AT THE OPPOSITE END OF MACHINE FROM CL1 AND IS REQUIRED FOR SERVICE CLEARANCE CENTRAVAC WATER CONNECTION PIPE SIZE Water Shell Size Passes 032 050 080 142 210 EVAPORATOR Nominal Pipe Size Inches 1 PASS 8 10 12 16 16 2 PASS 6 8 10 12 14 3 PASS 5 6 8 10 12 CONDENSER 2 PASS 6 8 10 12 14 CTV PRC007 EN 41 e TRANE Physical Dimensions SPACE ENVELOPE eU LS 814mm 457 mm RECOMMENDED 1 RECOMMENDED CLEARANCE 1 CLEARANCE 1 1 Ew WIDTH HEIGHT 1 2 1 IC 2 1 991 i REQUIRED CLEARANCE EI Id LI ns WIDTH E METRIC UNITS Envelope Clearance Unit Dimensions W O Unit With Unit W O Unit With Unit Shell Mounted Mounted Tube Mounted Mounted Shell Arrange Starters Starters Pull Starters Starters COMP Size ment EL EW EW CL1 612 Length Height Width Width 19
35. 6 3 65 15 0 14 82h 6 7 5 8 7 87 E 360 500 800 SS 2744 12 5 4 13 4 5 11 9 4 447 113 9 6 3 7 111 8 758 360 500 800 SL amp LL 34 10 12 12 5 4 13 4 55 15 6 4 447 15 0 14 9 63 5 7114 8 7 5 350 485 500 SS 26 6 3 5 11 45 12 5 12 11 9 3 655 113 8 4 6 7 5 8 7 81 350 485 500 51 amp LL 34 0 5 11 45 12 5 12 15 6 3 635 15 0 14 8 4 6 7 5 8 7 834 350 485 800 SS 274 12 5 4 13 4 58 11 9 4 447 113 9 6 12 711 8 758 350 485 800 SL amp LL 34 10 12 12 5 4 13 4 55 15 6 4 447 15 0 1 4 9 6 12 7 1114 8 7 5 8 555 amp 640 500 55 26 6 3 11 45 12 5 3 4 11 9 3 65 11 3 8 7 14 6 7 5 8 7834 555 amp 640 500 SL amp LL 34 0 58 11 45 12 5 34 15 6 3 635 15 0 1 4 8 7 14 6 7 5 8 7 834 V 555 amp 640 800 SS 27 41 12 5 4 13 4 55 11 9 4 447 11 3 9 8 7114 8 7 5 H 555 amp 640 800 SL amp LL 34 10 12 12 5 4 13 4 5 15 6 4 457 15 0 14 9 8 7114 8 75 F 650 910 800 SS 27 4 Ya 12 10 13 10 34 11 9 4 44 113 9 634 8 4 9 134 650 910 800 SL amp LL 34 10 12 12 10 13 1034 15 6 4 44 15 0 14 9 6 3 4 8 4 9 134 650 910 1420 ML amp LL 35 5 1 4 14 5 34 15 0 75 15 6 4 11 15 0 1 4 10 1 Ve 9 1134 10 3 7 1060 1280 1420 ML amp LL 35 5 1 4 14 534 15 0 7 15 6 4 11 15 0 4 10 1 Ve 9 1134 10 3 7 1060 1280 1420 EL 39 2 7
36. 9 62 0805 630 43 234 45 244 29 209 22 117 22 122 14 104 14 78 15 81 10 70 080S L 710 48 263 50 274 33 237 24 131 25 137 16 118 16 88 17 91 11 79 080S L 800 54 299 57 311 37 266 28 149 28 156 18 133 18 100 19 104 12 89 080S L 890 1 41 297 20 148 14 99 142M L 890 55 299 57 312 41 298 28 150 29 156 21 149 18 100 19 104 14 99 142M L 980 61 335 63 349 45 331 31 168 32 175 23 166 20 112 22 116 15 110 142M L 1080 68 373 71 389 51 373 34 186 36 194 26 187 23 124 24 130 17 124 142M L E 1220 76 419 80 437 57 414 38 210 40 218 28 207 26 140 27 146 19 138 142M L E 1420 85 467 89 487 66 482 43 233 44 243 33 241 28 156 30 162 22 161 210L 1610 84 457 87 476 73 530 42 228 44 238 36 265 28 152 29 159 24 177 210L 1760 86 510 97 532 81 595 47 255 49 266 41 297 31 170 32 177 27 198 210L 1900 104 567 108 591 90 657 52 283 54 296 45 329 35 189 36 197 30 219 210L 2100 114 625 119 651 95 698 57 312 60 326 48 349 38 208 40 217 32 233 250E 2300 123 676 128 704 N A 62 338 64 352 N A 41 235 43 235 N A 250E 2500 136 744 142 776 N A 68 372 71 388 N A 46 248 48 259 N A 30 CTV PRC007 EN CTV PRC007 EN Performance Data Minimum Maximum Condenser Flow Rates GPM e TRANE Shell Bundle Two Pass Size Size SBCU TECU IECU CDSZ CDBS Min Max Min Max Min Max 0325 230 214 784 209 767 218 798 032S L 250 239 877 234 857 245
37. Free cooling is Trane engineered manufactured and installed Ease of Operation Changeover on free cooling by single switch control Ease of Installation Completely factory installed and leak tested components All valve operators and controls are factory wired Application Modern buildings often require some form of year round cooling to handle interior zones solar loads or computer loads As the outside air temperature decreases below the inside air design temperature it is often possible to use an outside air economizer to satisfy the cooling requirements There are a number of instances however where CenTraVac free cooling offers a number of advantages over the use of an outside air economizer It is possible for the free cooling chiller to satisfy the cooling load for many hours days or months during the fall winter or spring seasons without operation of the compressor motor This method of satisfying the cooling requirement can result in significant total energy savings over other types of systems The savings available are most easily determined through the use of a computer energy analysis and economic program such as TRACE Trane Air Conditioning and Economics The suitability of free cooling for any particular installation depends upon a number of factors The availability of low temperature condensing water the quality of the outside air the type of airside system the temperature and humidity contr
38. G MAR 2 16 12 6 94 NMAR 2 9 25 cast 6 125 320 150 PSIG MAR 3 16 12 320 150 PSIG NMAR 1 12 94 320 150 PSIG NMAR 2 12 94 6 94 320 150 PSIG NMAR 3 12 94 320 300 PSIG MAR 1 16 12 MAR 2 17 8 320 300 PSIG MAR 2 16 12 6 94 NMAR 2 13 28 20 28 8 320 300 PSIG MAR 3 16 12 320 300 PSIG NMAR 1 12 94 320 300 PSIG NMAR 2 12 94 6 94 320 300 PSIG NMAR 3 12 94 500 150 PSIG MAR 1 18 5 MAR 2 16 31 7 875 500 150 PSIG MAR 2 18 5 6 73 NMAR 2 10 5 cast 7 875 500 150 PSIG MAR 3 18 5 500 150 PSIG NMAR 1 12 73 500 150 PSIG NMAR 2 12 73 6 73 500 150 PSIG NMAR 3 12 73 500 300 PSIG MAR 1 19 MAR 2 18 363 7 6 500 300 PSIG MAR 2 19 6 73 NMAR 2 12 86 20 46 7 6 500 300 PSIG MAR 3 19 500 300 PSIG NMAR 1 12 73 500 300 PSIG NMAR 2 12 73 6 73 500 300 PSIG NMAR 3 12 73 800 150 PSIG MAR 1 23 225 MAR 2 23 75 8 32 800 150 PSIG MAR 2 21 225 7 21 NMAR 2 14 2 8 32 800 150 PSIG MAR 3 19 225 800 150 PSIG NMAR 1 13 19 800 150 PSIG NMAR 2 13 19 7 21 800 150 PSIG NMAR 3 13 19 800 300 PSIG MAR 1 25 MAR 2 28 14 8 93 800 300 PSIG MAR 2 23 7 96 NMAR 2 14 4 23 27 8 93 800 300 PSIG MAR 3 21 800 300 PSIG NMAR 1 13 96 800 300 PSIG NMAR 2 13 96 7 96 800 300 PSIG NMAR 3 13 96 1420 150 PSIG MAR 1 28 25 MAR 2 28 25 9 25 1420 150 PSIG MAR 2 25 9 33 NMAR 2 16 9 25 1420 150 PSIG MAR 3 23 1420 150 PSIG NMAR 1 15 41 1420 150 PSIG NMAR 2 15 41 9 33 1420 150 PSIG NMAR 3 15 41 1420 300 PSIG MAR 1 31 056 MAR 2 33 16 10 06 1420 300 PSIG MAR 2 27 8 9 84 NMAR 2 15 79
39. I Standard 580 Those applications in this catalog specifically excluded from the ARI certification program are e Low temperature applications including ice storage Glycol Chillers above 2000 tons Free cooling Heat recovery Auxiliary condenser Chillers that are 50 Hertz CTV PRC007 EN Introduction 1992 The two stage CVHF Cen TraVac 1982 The three stage CVHE CenTraVac Chiller Chiller 1992 The LHCV Cen TraVac Modular Chiller system 3 Phase Power Control Interface L 115 VAC 60 Hz 50 Hz it 1997 The Gas Powered CenTraVac GPC Chiller Package Control Interface e TRANE Features and Benefits Comparing the Attributes of environment friendly HCFC 123 Trane Low Pressure Chiller Operation CenTraVac chillers provide the safety of low pressure with continued product to High Pressure Chiller improvement in leak proof design Operation Consider the following benefits of low Trane CenTraVac chillers continue to offer Pressure over high pressure chillers time tested and proven low pressure refrigerants including the alternative Low Pressure Medium High Pressure Evaporator Always at low negative pressure Air leaks inward at low rate e Refrigerant lost 4 air leak in x purge efficiency No refrigerant loss is into equipment room vented to the outside via purge Always at positive pressure Refrigerant lea
40. Impellers are selected to produce the maximum required refrigerant pressure difference between the evaporator and condenser Figure O 8 Usually that meant the impeller diameters were determined by the heat recovery operating conditions During cooling only operation the condensing pressures and temperatures are normally lower than during the heat recovery operation So in essence the impeller diameters were oversized This would result in a compressor efficiency during cooling only season which was lower than if the impellers had been selected for a cooling only application The multi stage compressor and advanced impeller design on the CenTraVac chiller reduce this costly energy penalty Neither the capacity nor the power consumption changes substantially as the heat recovery operating conditions divert from the cooling only condition The multi stage compressor allows a closer match of impeller size to the operating condition In addition the computer designed impellers and crossover are designed to reduce losses as the kinetic energy of the refrigerant gas is converted to static pressure These advances make the Trane Heat Recovery CenTraVac chillers even more attractive now than in the past The CenTraVac heat recovery chiller was designed for efficient operation with kW ton efficiencies among the best in the industry for heat recovery chillers The energy penalty paid in the past to operate a heat recovery m
41. Patented Two Stage Economizer and Refrigerant Orifice System Liquid refrigerant leaving the condenser at state point 6 flows through the first orifice and enters the high pressure side of the economizer The purpose of this orifice and economizer is to preflash a small amount of refrigerant at an intermediate pressure called P1 P1 is between the evaporator and condenser pressures Preflashing some liquid refrigerant cools the remaining liquid to state point 7 Refrigerant leaving the first stage economizer flows through the second orifice and enters the second stage economizer Some refrigerant is preflashed at intermediate pressure P2 Preflashing the liquid refrigerant cools the remaining liquid to state point 8 Another benefit of preflashing refrigerant is to increase the total evaporator refrigeration effect from RE to RE The two stage economizer provides a seven 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 third orifice system Here refrigerant pressure and temperature are reduced to evaporator conditions at state point 1 Two Stage CenTraVac P H Diagram CONDENSER COMPRESSOR SECOND STAGE 93 COMPRESSOR FIRST STAGE PRESSURE PSI NO ECONOMIZER ENTHALPY BTU LBM CenTraVac Two Stage P H Diagram The pressure enthalphy P H diagram describes refrigerant flow t
42. Starters Starters Pull Starters Starters COMP Size ment EL EW EW CL1 CL2 Length Height Width Width 190 270 320 Ss 26 5 10 6 14 111452 11 9 3 5 11 3 7 934 5 9 14 6 7 1 190 270 320 SL amp LL 33 111 4 10 6 4 1147 15 6 3 5 15 0 4 7 934 5 9 1 4 6 7 190 270 500 55 26 635 11 45 12 6 7 11 9 3 655 113 8 2 1 4 6 7 5 8 7 97 190 270 500 SL amp LL 34 055 11 455 12 6 s 15 6 3 65 15 0 14 6 2 6 7 5 8 7 97 300 420 500 55 26 6355 11 45 12 5 12 11 9 3 6355 11 37 81212 6 7 5 8 7 8 12 H 300 420 500 SL amp LL 34 055 11 45 12 5 12 15 6 3 635 15 0 14 8 2 h 6 7 5 7 8 E 300 420 800 SS 274 12 5 4 13 4 55 11 9 4 457 11 3 9 635 7114 8 758 300 420 800 51 8 1 1 34 101 12 5 4 13 4 5 15 6 4 447 15 0 14 9 6 55 711 8 75 480 565 500 SS 26 6 3 11 455 12 5 3 4 11 9 3 65 11 2 8 7 14 6 7 5 8 7834 480 565 500 SL amp LL 34 0 55 11 45 12 534 15 6 3 655 15 0 14 8 7 14 6 7 5 8 7 834 480 565 800 SS 274 12 5 4 13 4 55 11 9 4 414 113 9 8 711 8 758 480 565 800 SL amp LL 34 101 12 5 4 13 4 5 15 6 44 15 0 14 9 8 711 4 8 7 5s V 670 780 800 SS 27 4 a 12 10 13 10 34 11 9 4 44 11 37 9 634 8 4 9 134 H 670 780 800 SL amp LL 34 105 12 10 13 1034 15 6 4 44 15 0 14 9 6 3 4 8 4 9 134 G 670 780 1420 ML amp LL 35 5 4 14
43. TS Envelope Clearance Unit Dimensions W O Unit With Unit W O Unit With Unit Shell Mounted Mounted Tube Mounted Mounted Shell Arrange Starters Starters Pull Starters Starters COMP Size ment EL EW EW CL1 CL2 Length Height Width Width 230 320 320 SS 8052 3207 3467 3581 1041 3429 2380 1759 2019 230 320 320 SL amp LL 10344 3207 3467 4724 1041 4578 2380 1759 2019 230 320 500 SS 8087 3470 3832 3581 1076 3429 2494 2022 2384 C 230 320 500 SL amp LL 10379 3470 3832 4724 1076 4578 2494 2022 2384 V 360 500 500 SS 8087 3470 3797 3581 1076 3429 2502 2022 2350 H 360 500 500 SL amp LL 10379 3470 3797 4724 1076 4578 2502 2022 2350 E 360 500 800 SS 8338 3867 4080 3581 1327 3429 2905 2419 2632 360 500 800 SL amp LL 10630 3867 4080 4724 1327 4578 2905 2419 2632 350 485 500 SS 8087 3470 3797 3581 1076 3429 2540 2022 2350 350 485 500 SL amp LL 10379 3470 3797 4724 1076 4578 2540 2022 2350 350 485 800 SS 8338 3867 4080 3581 1327 3429 2908 2419 2632 350 485 800 SL amp LL 10630 3867 4080 4724 1327 4578 2908 2419 2632 555 amp 640 500 SS 8087 3470 3804 3581 1076 3429 2624 2022 2356 555 amp 640 500 SL amp LL 10379 3470 3804 4724 1076 4578 2624 2022 2356 555 amp 640 800 SS 8338 3867 4080 3581 1327 3429 2946 2419 2632 H 555 amp 640 800 SL amp LL 10630 3867 4080 4724 1327 4578 2946 2419 2632 F 650 910 800 SS 8338 3912 4235 3581 1327 3429 2915 2540 2788 650 910 800 SL amp LL 10630 3912 4235 4724 1327 4578 2915 2540 2788 650 910 1420 ML amp LL 10754 4413 459
44. W ton utility generated greenhouse gas emissions could be reduced annually by nearly 17 billion pounds of CO while SO and NO could be reduced by over 64 and 27 billion grams respectively This reduction is equivalent to removing more than two million cars from the road or to planting nearly 500 million trees each year OAmerican Standard Inc 2001 Introduction Lowest Total Refrigerant Emissions In The Industry Furthermore the Trane near zero emissions EartheWise chiller also has the lowest total refrigerant emissions in the industry So low that it s essentially a closed system The key to the industry s highest energy efficiency and lowest leak rate is the use of a low pressure refrigerant DuPont calls SUVA 123 a refrigerant that has the lowest direct effect global warming potential and the highest thermodynamic efficiency of all non CFC refrigerants a refrigerant in use in more new centrifugals today than all other alternatives combined Balancing Our Accountability for Ozone Depletion Global Warming and Energy Efficiency Reduced power plant emissions and the industry s lowest refrigerant emission rate put the Trane 48 kW ton Earth Wise centrifugal chiller in a class by itself from both a business and an environmental standpoint The future lies in the prudent balance that takes into account the importance of ozone depletion global warming and energy efficiency A balance that is right for both busin
45. achine in the cooling only mode is essentially eliminated 23 e TRANE Figure O 7 Typical Operating Cycles Heat Recovery Machine Pressure Psi Evaporator Re Standard Machine Re Heat Recovery Machine Pressure Differential Enthalpy Btu Lbm Heat Recovery Operating Cycle Standard Operating Cycle Simultaneous Heating and Cooling The Trane Heat Recovery CenTraVac chiller is an excellent choice for applications requiring simultaneous heating and cooling CenTraVac models save energy by recovering heat normally rejected to the atmosphere and putting that energy to use providing space heating building hot water or process hot water This heat is provided at a fraction of conventional heating systems cost A heat recovery CenTraVac can provide 95 to 120 F hot water An advanced computer selection program chooses a heat recovery condenser to match your needs Two separate condenser shells are used with the Heat Recovery CenTraVac chiller The heating circuit and cooling tower circuit are separate preventing cross 24 System Options contamination Refrigerant gas from the compressor flows into both condenser shells allowing heat rejection to one or both condenser water circuits The reliability of the Heat Recovery CenTraVac chiller has been proven in installations around the world This option is completely factory packaged To further reduce the system energy requi
46. actor for power control SCR s An SCR will conduct current in one direction only when a control signal gate signal is applied Because the solid state starter is for use on AC alternating current two SCR s per phase are connected in parallel opposing each other so that current may flow in both directions For three phase loads a full six SCR configuration is used The connection is shown in Figure O 3 During starting control of current or acceleration time is achieved by gating the SCR on at different times within the half cycle The gate pulses are originally applied late in the half cycle and then gradually applied sooner in the half cycle If the gate pulse is applied late in the cycle only a small increment of the wave form is passed through and the output is low Figure O 3 Six SCR Configuration Figure O 4 Wave Forms 25 VOLTAGE 50 VOLTAGE If the gate pulse is applied sooner in the cycle a greater increment of the wave form is passed through and the output is increased So by controlling the SCR s output voltage the motor s acceleration characteristic and current inrush can be controlled These forms are shown in Figure O 4 Integral Bypass Contactors When the are fully phased on the integral bypass contactors are energized The current flow is transferred from the power pole to the contactors This reduces the energy loss associated with the power pole which is otherwise a
47. aker with Ground Fault Ground fault protection is available with either standard or high interrupting capacity circuit breakers An indicator light is provided to indicate if ground fault has occurred Current Limiting Circuit Breaker A standard circuit breaker incorporating three current limiters with fuse links is available A fault current in excess of the circuit breaker capacity will blow the fuse links and interrupt the fault current The circuit breaker cannot be reset until the blown current limiters are replaced CTV PRC007 EN Trane Adaptive Frequency Drive AFD The Trane AFD is a closed loop liquid cooled microprocessor based PWM design that converts fixed utility voltage and frequency to a variable voltage and frequency via a two step operation The AFD is both voltage and current regulated Output power devices IGBT transistors The AFD is factory mounted on the chiller and ships completely assembled wired and tested Patented Trane AFD control logic is specifically designed to interface with the centrifugal water chiller controls AFD control adapts to the operating ranges and specific characteristics of the chiller and chiller efficiency is optimized by coordinating compressor motor speed and compressor inlet guide vane position Chilled water control and AFD control work together to maintain the chilled water setpoint improve efficiency and avoid surge If a surge is detected AFD surge avoidan
48. ally be rejected through the standard condenser to the atmosphere through the cooling tower No controls are needed to balance heat rejection in the two condensers Good system design will include a heated water bypass to ensure that water does not circulate through the auxiliary condenser when the chiller is de energized There are several ways to bypass the auxiliary condenser When the hot water system is installed as shown in the figure below the bypass is automatic if the heating water pump is interlocked with the chiller compressor motor Another bypass arrangement is to install a diverting valve When interlocked with the compressor motor this valve diverts the heating water flow to the conventional heating system whenever the chiller is not operating These are only examples of the many ways of accomplishing a bypass Contact your local Trane sales office for further specific information Table O 1 Auxiliary Condenser Flow Limits and Connection Sizes Auxiliary Two Pass Condenser Inter Enhanced Smooth Bore Connection Bundle Minimum Maximum Minimum Maximum Size Size Gpm Gpm Gpm Gpm In Standard 74 276 70 258 5 Large 121 453 115 423 5 21 e TRANE Ice Storage Provides Reduced Electrical Demand Ice storage is the hottest thing in cooling today It has been accepted by building owners and tenants who are concerned about utility costs An ice storage system uses a standard chiller to mak
49. ators for vibration sensitive installations Building automation systems BAS interface Variable speed drives Internally enhanced tubes Various tube wall thicknesses UL Label Three pass evaporator one pass evaporator Special construction to facilitate chiller disassembly at the job CuNi Tubes Special paint and controls for outdoor use or corrosive environments Unit mounted refrigerator monitor e TRANE Factory Testing for Assured Performance To prove that your chiller will perform as promised Trane offers factory performance testing which you can witness Trane provides laboratory grade calibrated performance testing on ARI approved test loops that proves the performance of the chiller tailored to your application The test provides Confirmed efficiency Confirmed capacity Smooth trouble free start up confirmed through factory testing and commissioning of both chiller and controls Trane believes centrifugal chiller testing is so important that we invested over 2 million in CenTraVac testing facilities Testing is in accordance with ARI Standard 550 590 and calibration of instrumentation meets or exceeds the National Institute of Standards Technology NIST The industry has responded to the demand for more efficient chillers by developing machines with component mix matching and many money saving options It s possible that with the thousands of component combinations
50. bout one watt per amp per phase When the starter is given the stop command the bypass contactors are de energized which transfers the current flow from the contactors back to the power poles Two hundred fifty milliseconds later the SCR s are turned off and the current flow is stopped FULL VOLTAGE 15 e TRANE Benefits Trane Adaptive Frequency drives provide motor control but they are much more than just starters They also control the operating speed of the chiller compressor motor by regulating output voltage in proportion to output frequency Varying the speed of the compressor motor can translate into significant energy cost savings Reliable Optimized Compressor Efficiency for Energy Savings Conventional chillers use inlet vanes to provide stable operation at part load conditions Capacity is reduced by closing the vanes while maintaining a constant motor speed The drive can be used to significantly reduce power consumption by reducing motor speed at low load conditions Trane patented AFD Adaptive Control logic safely allows inlet guide vane and speed control combinations that optimize part load performance To Avoid Mechanical Stress Controlled soft start with linear acceleration results in limited starting current to eliminate motor stress reduce power line disturbance and provide a lower power demand on start Reduced motor speed as a result of reduced chiller load means less current drawn
51. ce logic will make adjustments to move away from and avoid surge at similar conditions in the future AFD is capable of operating at an altitude of 3300 feet rated output current For every 300 feet above 3300 feet the rated output current will be decreased by 196 AFD Design Features NEMA 1 ventilated enclosure with a hinged locking door and door mounted circuit breaker with shunt trip is tested to a short circuit withstand rating of 65 000 amps per UL 508 The entire package is UL CUL listed CTV PRC007 EN Mechanical Specification e TRANE Digital keypad displays DC bus voltage drive output motor current output frequency Hz RPM kW percent motor torque and elapsed time LED s also display drive status running remote jog auto forward reverse or program One programmable analog output signal 0 10 Vdc or 4 20 mA for customer use Three programmable relay outputs for customer use e Simple modular construction The drive is rated for 480 60 3 input power 10 with a motor thermal overload capability of 11096 continuous for 25 minutes to 15096 for 60 seconds linear between 110 and 150 Input displacement power factor will exceed 96 regardless of speed and load Minimum efficiency of 97 at rated load and 60 hertz Soft start linear acceleration coast to stop e Standard DC bus filter choke to limit harmonic distortion All control circuit voltages are physically a
52. d two stage economizer provides up to seven percent efficiency increase and similar energy cost decrease 26 Application Considerations CVHF 325 To 1750 Tons 60 Hz The two stage CenTraVac chiller built with the same tradition and commitment to quality Two stage compressor for continued superior efficiency over single stage designs e Exceptionally quiet operation lowest sound level in the industry Patented single stage economizer provides up to five percent efficiency increase and similar energy cost decrease For Applications Requiring 1300 3500 Tons 60 Hz Choose LHCV The LHCV chiller system is the modern solution for large central plant applications It offers significant first cost and operating cost advantages compared to field assembled very large chillers The Trane Integrated Comfort system ICS is the key to high performance for the LHCV system Applications software takes advantage of Trane chiller and chiller plant expertise delivering sophisticated chiller plant sequencing capabilities in an easy to use prepackaged system The LHCV extends the CenTraVac chiller line from 1300 to 3000 tons The hermetic direct drive design delivers the quality and reliability you need and have come to expect from large chillers The dependability is especially critical for the large central plants that the LHCV is ideally suited for The modular design concept of the LHCV chiller syst
53. d with 3 4 Armaflex II or equal thermal conductivity 0 28 Btu hr ft including the evaporator waterboxes and suction elbow The economizer and motor cooling lines are insulated with 3 5 and 1 2 insulation respectively Refrigerant Pumpout Reclaim Connections Connections are factory provided as standard to facilitate refrigerant reclaim removal required during maintenance or overhaul in accordance with ANSI ASHRAE 15 Painting All painted CenTraVac surfaces are coated with two coats of air dry beige primer finisher prior to shipment Unit Mounted Starter Option The unit mounted starter can either be a star delta or a solid state starter in a NEMA 1 type enclosure The starter is factory mounted and completely prewired to the compressor motor and the control panel The CenTraVac chiller starter assembly is factory tested Starter is provided with a 3 KVA control power transformer 120 volt secondary The starter door is designed to accommodate a padlock Available options include Circuit Breaker A standard interrupting capacity circuit breaker is available The circuit breaker is mechanically interlocked to disconnect line power from starter when the starter door is open High Interrupting Capacity Circuit Breaker High interrupting capacity circuit breaker is available This breaker is also interlocked to disconnect line power from the starter when the starter door is open Circuit Bre
54. e ice at night when utilities charge less for electricity The ice supplements or even replaces mechanical cooling during the day when utility rates are at their highest This reduced need for cooling results in big utility cost savings Another advantage of ice storage is standby cooling capacity If the chiller is unable to operate one or two days of ice may still be available to provide cooling In that time the chiller can be repaired before building occupants feel any loss of comfort The Trane CenTraVac chiller is uniquely suited to low temperature applications like ice storage because it provides multiple stages of compression Competitive chillers provide only one stage This allows the CenTraVac chiller to produce ice efficiently with less stress on the machine Simple and smart control strategies are another advantage the CenTraVac chiller has for ice storage applications Trane Tracer building management systems can actually anticipate how much ice needs to be made at night and operate the system accordingly The controls are integrated right into the chiller Two wires and preprogrammed software dramatically reduce field installation cost and complex programming Trane centrifugal chillers are well suited for ice production The unique multi stage compressor design allows the lower suction temperatures required to produce ice and the higher chiller efficiencies attributed to centrifugal chillers Trane three sta
55. e local or remote workstations and or requirements of the end user Trane can a pager in the following cases undertake full responsibility for an Analog parameter exceeding a optimized automation and energy programmed value management for the entire chiller plant 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 The main functions are Chiller sequencing equalizes the number of running hours of the chillers Different control strategies are available depending on the configuration 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 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 c and comfort of the occupants Em Qu TRACER SUMMIT
56. ect i e active setpoints A control source is the device that determines setpoints and whether the chiller is auto off such as local control panel remote control display 4 20 mA external device Tracer generic BAS Sequence of Operation For this sequence of operation it will be assumed that the control source has signaled the chiller to be in Automatic i e when there is a load present the chiller will turn on and when the load disappears the chiller will turn off It is also assumed that no diagnostic has occurred either prior to start up or during I run time and that no specia applications exist Power Off Power On Auto Evaporator Pump On In Parallel Restart Inhibit Prelubrication Condenser Flow Established Start Run Normal Softloading Evaporator Limit Condenser Limit Current Demand Limit Unload Stop In Parallel Close Inlet Guide Vanes Run Compressor Post Lube Auto Automatically Ready to Start Waiting for Need to Cool Restart Temporarily Prevented Time Remaining Establishing Condenser Flow and Oil Pressure Starting Compressor Running Normal or Softloading or Running Capacity Limited by Low Evaporator Temperature or Running Capacity Limited by High Condenser Pressure Machine is Preparing to Shutdown Operator Initiated Stop Press Auto to Restart Post Lubricating Time Remaining Automatically Read to Sta
57. el connections Marine or standard gt Full complement of electrical waterboxes starters and accessories 1 2 3 pass evaporator unit mounted or remotely Panel chilled water reset Factory installed insulation External chilled water and current limit setpoints Evaporator Condenser differential Special construction to facilitate pressure chiller disassembly for construction Condenser relief request projects with tight space clearances Maximum capacity or component weight limitations Communication link to BAS Printer module 8 CTV PRC007 EN CTV PRC007 EN Features and Benefits e TRANE Standard Features The following features are provided as standard with all Trane CenTraVac chillers Motor compressor assembly with integral lubrication system Evaporator condenser assembly Two stage economizer assembly on CVHE CVHG style units single stage on CVHF style units Prewired instrument and control panel Oil and refrigerant charge Oil heater solation pads e Wiring and conduit for purge and oil system interconnection to the main control panel Installation operation and maintenance instructions Start up and operator instruction service Advanced motor protection CenTraVac Motor The motor provided in the Trane CenTraVac chiller is a specially designed squirrel cage two pole induction motor suitable for 50 and 60 hertz three phase current Trane Ce
58. em paired with the chiller plant optimization capability of Trane Integrated Comfort systems ICS provides the flexibility you need to optimize your central chiller water plant design This system configuration is ideally suited to deliver the highest performance for free cooling heat recovery and combined energy source systems CTV PRC007 EN Condenser Water Limitations Trane CenTraVac chillers start and operate over a range of load conditions with controlled water temperatures Reducing the condenser water temperature is an effective method of lowering the chiller power input However the effect of lowering the condenser water temperature may cause an increase in system power consumption In many applications Trane CenTraVac chillers can start and operate without control of the condenser water temperature However for optimum system power consumption and for any applications with multiple chillers control of the condenser water circuit is recommended Integrated control of the chillers pumps and towers is easily accomplished with Trane s UCP2 and or Tracer system Water Treatment The use of untreated or improperly treated water in a chiller may result in scaling erosion corrosion algae or slime It is recommended that the services of a qualified water treatment specialist be used to determine what treatment if any is advisable The Trane Company assumes no responsibility for the results of untreated or im
59. er water or the system water flows must vary Ice making for demand charge avoidance or for additional capacity needs and where no cooling requirements exist for considerable periods of time Low condenser gpm for chiller plant optimization Cooling tower reset based on head pressure for tower optimization Low evaporator fluid temperature for process applications kW demand limiting for those installations where avoidance of demand charges is more critical than maintaining capacity CTV PRC007 EN Controls e TRANE Chilled water reset based on return water temperatures or ambient temperature or based on a 4 20 mA signal for those installations where energy savings is more critical than maintaining design leaving chilled water temperature at part loads Applied Systems Low evaporator fluid temperature for cold air humidity control applications Variable fluid flow where evaporator flow is modulated by a device outside the control of the chiller or the chiller plant Control Functions Constant Evaporator Leaving Fluid Temperature Current Limit Demand Limit Condenser Limit Softloading Hot Gas Bypass optional Leaving Condenser Water Temperature programmable setting heat pump only optional Ability to Control with Varying Water Loop Flow Heat Recovery Temperatures optional Constant Entering Fluid Temperature programmable setting Variable Speed Drive optional drive with adaptive tu
60. erages 125 percent of the compressor motor Rated Load Amps plus the Full Load Amps FLA of all remaining loads on the same circuit For starter to motor wiring there are no other remaining loads For main power supply to the starter there is a remaining load consisting of the 4 KVA control power transformer which supplies power to the controls the oil pump motor oil sump heater and the purge unit motor Therefore the remaining load FLA equals 4000 divided by the unit design voltage As an example calculate the minimum circuit ampacity of a machine which has a design RLA of 350 amps and is to be operated on a 460 volt power supply Minimum Circuit Ampacity 4000 VA 460 V 437 5 Amps 8 7 Amps 446 2 Amps After the minimum circuit ampacity has been determined the electrical engineer or contractor will refer to the appropriate conductor sizing table in the NEC to determine the exact conductors required A typical table for 75 F conductors is included in the Trane submittal The selection of conductors is based on a number of jobsite conditions i e type of conductor number of conductors length of conductors ambient temperature rating of conductors Branch Circuit Short Circuit and Ground Fault Protection Circuit breakers and fused disconnects should be sized by the electrical engineer or contractor in strict accordance with NEC Article 440 21 and in accordance with all local codes This protection sh
61. es the evaporator refrigerant pressure This increased evaporator pressure reduces the pressure differential the compressor must generate while in the heat recovery mode A secondary benefit of chilled water reset is that it enables the chiller to produce higher heating water temperature than would normally be possible CTV PRC007 EN e TRANE System Options Figure O 9 Heating Water Control Heating Water Control 100 Load 100 Load 50 Load 100 Holding Supply Heating Water Temperature 105 50 Load 100 Mean Condenser Water Temperature F 98 Holding Return Heating Water Temperature Figure O 10 Chilled Water Reset 95 105 85 95 Heating Cooling Water Tower Water P 54 44 Water Recovery Chilled Cooling Refrigerant Water Only Pressure Refrigerant Pressure Difference Difference 25 e TRANE For Applications Requiring CVHE 170 500 Tons 60 Hz CVHG 450 1300 Tons 50 Hz The Trane multi stage CenTraVac chiller is built with a commitment to quality which has made it the world s premier centrifugal chiller A multi stage compressor for superior efficiency compared to single stage designs Multi stages also provide stable surge resistant operation Exceptionally quiet operation lowest sound levels in the industry Patente
62. ess and the environment Built For The Industrial Market Direct drive for reliability e Multi stage compressor for efficiency Near Zero refrigerant emission design Evaporator and condenser designed to maximize efficiency and reduce operating costs Proven shell and tube design offering a variety of high performance heat transfer surfaces Evaporator condenser and compressor combinations allow selection of a chiller that best meets the system requirements Options like heat recovery free cooling auxiliary condensers ice storage and a unit mounted starter for expanded capability and maximum efficiency Complete factory assembly of the Cen TraVac options for reduced jobsite assembly labor and expense Machines designed for operating with environmentally acceptable HCFC 123 Trane patented fixed orifice system for ensuring proper refrigerant flow at all load conditions This eliminates the need for other moving parts such as float valves expansion valves Low speed direct drive capability offers up to 5 percent more energy efficiency at full load than gear drive chillers Also low speed direct drive operation improves reliability and maintenance costs are also lower e CenTraVac control panel Adaptive Control e Microprocessor based Complete operating status and diagnostics display Interfaces with building management system High efficiency Purifier Purge works as an early
63. frigerant Flow Design Simplicity Impellers are keyed directly to the motor shaft for high reliability and performance and low life cycle costs Reliable Motor Cooling The motor is engulfed in liquid refrigerant to provide efficient complete cooling at all load conditions This system is reliable and easy to maintain Fixed Orifice Flow Control For proper refrigerant flow control at all load conditions the CenTraVac design incorporates the Trane patented fixed orifice system It eliminates float valves thermal expansion valves and other moving parts Since there are no moving parts reliability is increased Quiet Operation With only one moving component the rotor and impeller assembly the Trane low speed direct drive design operates exceptionally quietly The smoothly rotating CenTraVac compressor is inherently quieter than other compressor types Typical CenTraVac chiller sound measurements are among the quietest in the industry Trane can guarantee sound levels with factory testing and measurements in accordance with ARI standard 575 The Reliability Standard Just as a multi stage turbine is more efficient than a single stage turbine the CenTraVac multi stage compressors are more efficient and reliable than single stage designs CTV PRC007 EN Features and Benefits e TRANE The CenTraVac Chiller Operating Cycle Direct Drive Design No Gear Losses The direct drive compressor operates w
64. ge and two stage centrifugal chillers produce ice by supplying ice storage vessels with a constant supply of 22 to 24 F glycol Centrifugal chillers selected for these lower leaving fluid temperatures are also 22 System Options selected for efficient production of chilled fluid at nominal comfort cooling conditions The ability of Trane chillers to serve double duty in ice production and comfort cooling greatly reduces the capital cost of ice storage systems A glycol solution is used to transfer heat from the ice storage tanks to the centrifugal chiller and from the cooling coils to either the chiller or ice storage tanks The use of a freeze protected solution eliminates the design time field construction cost large refrigerant charges and leaks associated with ice plants Ice is produced by circulating 22 24 F glycol through modular insulated ice storage tanks Each tank contains a heat exchanger constructed of polyethylene tubing Water in each tank is completely frozen with no need for agitation The problems of ice bridging and air pumps are eliminated When cooling is required ice chilled glycol is pumped from the ice storage tanks directly to the cooling coils No expensive heat exchanger is required The glycol loop is a sealed system eliminating expensive annual chemical treatment costs The centrifugal chiller is also available for comfort cooling duty at nominal cooling conditions and efficiencies
65. gerant return are automatic functions of the purge The purge can be operated at any time independent of chiller operation ASHRAE GUIDELINE 3 recommends that the purge should be able to run even while the chiller is idle Purge unit includes lights to indicate condenser running fault indication and service operation An elapsed time meter is included as standard to monitor any amount of leak rate and running time Unit Control Panel The microcomputer control panel is factory installed and tested on the CenTraVac unit All controls necessary for the safe and reliable operation of the chiller are provided including oil management purge operation and interface to the starter The control system is powered by a control power transformer included in the starter panel The microcomputer control system processes the leaving evaporator fluid temperature sensor signal to satisfy the system requirements across the entire load range The microprocessor controller is compatible with reduced voltage or full voltage electromechanical starters variable speed drives or solid state starters Depending on the applicability the drives may be factory mounted or remote mounted The controller will load and unload the chiller via control of the stepper motor actuator which drives the inlet guide vanes open or closed The load range can be limited either by a current limiter or by an inlet guide vane limit whichever controls the lower lim
66. ges will include information about limit modes when the 38 Controls micro controller identifies potential fail conditions This allows the CenTraVac to continue safe operation even though some other part of the system is not operating properly UNIT IS RUNNING CAPACITY LIMITED BY HIGH CURRENT This condition means that a motor current limitation prevents further opening of the compressor inlet guide vanes in response to the temperature controller UNIT IS RUNNING CAPACITY LIMITED BY HIGH COND PRES The condenser high pressure limit has been approached that further loading of the compressor may result in a trip out optional UNIT IS RUNNING CAPACITY LIMITED BY LOW EVAP TEMP The evaporator low temperature limit has been approached that further loading of the compressor may result in atrip out This Adaptive Control prevents nuisance trip alerts the operator to the condition and takes the following corrective action 1 the control will limit the rate of inlet vane opening If the condition worsens then 2 the control will hold the inlet vane position If the condition worsens then 3 the control will close the inlet vanes at a controlled rate until the condition stabilizes If however the condition worsens the final step will be to close the vanes even further Therefore even though operating in a controlled limit mode the chiller may be opening or closing the guide va
67. he marketplace is subjected to formal planning review and validation The system is designed to assure maximum consistency in meeting customer requirements The Beauty of Simplicity The reliability of a centrifugal chiller starts with its basic product design At Trane we ve found that the straightest path to reliability is simplicity Years of research and field testing have honed the design of the CenTraVac chiller to a simple precise solution to a complex engineering problem This simple design provides efficiency and reliability benefits The Trane CenTraVac chiller has only one moving part no gear boxes couplings or extra shafts The single rotating shaft is supported by two aircraft turbine grade rated bearings This direct drive concept minimizes the chance of failure for moving parts It also reduces wear and drag on parts resulting in more efficient operation CTV PRC007 EN 1939 The Trane Turbovac 1951 The original Trane CenTraVac chiller 1965 The Model PCV CenTraVac chiller Specific Trane centrifugal chiller performance is certified by ARI Standard 550 590 Trane centrifugal chillers tested within the scope of the ARI program display the ARI symbol of compliance shown on back cover to certification sections of ARI Standard 550 590 Purifier purge with Purifier Plus are rated in accordance with AR
68. her drives faults Distribution faults Cil pressures and temperatures out of range High condenser pressure cutout Low and high differential pressure Emergency stop Loss of communications to other sources Microprocessor memory errors High motor winding temperature Excessive purge activity Operator Interface The Trane CenTraVac chiller control panel UCP2 is easy to use understand to access information to read to change setpoints to diagnose problems to maintain and to reset after shutdown Convenience Enunciation of all information is at the front panel display including power voltage amps purge pressures refrigerant monitoring and number of starts data Messages displayed using clear language Readability LCD multi language display that is easy to read from a distance anywhere within a 60 degree angle LCD backlight so that the display can be read in a variety of equipment room lighting Customizable reports with understandable messages Maintainability and Serviceability e Keypad programmability no setpoint potentiometers No batteries configuration stored in nonvolatile memory Logically arranged report groups with report header and setpoint groups Selectable security e Variable points updated every two seconds Messages that direct user to problem source via a menu item Application Flexibility Eight languages available Metric SI units
69. hrough the major CVHF chiller components This diagram confirms the superior operating cycle efficiency of the two stage compressor and economizer Evaporator A liquid gas 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 then flows into the compressor first stage Compressor First Stage Refrigerant gas is drawn from the evaporator into the first stage compressor The first stage impeller accelerates the gas increasing its temperature and pressure to state point 3 Compressor Second Stage Refrigerant gas leaving the first stage compressor is mixed with cooler refrigerant gas from the economizer This mixing lowers the enthalpy of the mixture entering the second stage The second stage impeller accelerates the gas further increasing its temperature and pressure to state point 4 Condenser Refrigerant gas 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 gas to a liquid at state point 6 Economizer and Refrigerant Orifice System Liquid refrigerant leaving the condenser at state point 6 flows through the first orifice and enters the economizer The purpose of this orifice and economizer is to preflash a small amount of refrigerant at an intermediate pressu
70. imiting fuses All starters provided by Trane include the following standard features for safe efficient application and ease of installation NEMA 1 starter enclosure 120 volt 60 hertz 1 phase fused pilot and safety circuits Control power transformer 4 0 KVA with 120 volt 50 or 60 hertz single phase One pilot relay to initiate start sequence from CenTraVac control circuit signal Starter enclosures capable of being padlocked Automatic transfer from wye to delta on any two step starter In addition Trane offers a wide selection of optional starter features Starters with standard or high interrupting capacity circuit breakers to provide disconnect means and short circuit protection low voltage only Ammeters and voltmeters Special function pilot lights Special NEMA enclosures Ground fault protection Power factor correction capacitors O Data Plus monitor device If the CenTraVac compressor starting equipment is provided by others the starter must be designed in accordance with the current Trane standard engineering specification Water Cooled CenTraVac Starter Specification It is also recommended that two copies of the interconnecting and control circuit wiring diagrams be forwarded to The Trane Company for review This service is provided at no charge and is intended to help minimize the possibility that Trane CenTraVac chillers will be applied in impr
71. interface standard The remote operator interface optional A 4 20 mA or 2 10 vdc signal from an external source interface optional control source not supplied by chiller manufacturer Tracer interface optional Tracer supplied by Trane 50 Mechanical Specification Process computer interface optional control source not supplied by chiller manufacturer Generic BAS interface optional control source not supplied by chiller manufacturer The control source with priority will then determine the active setpoints via the signal that is sent to the control panel Isolation Pads Isolation pads are supplied with each CenTraVac chiller for placement under all support points They are constructed of molded neoprene Refrigerant and Oil Charge A full charge of refrigerant and oil is supplied with each unit The oil ships in the unit s oil sump and the refrigerant ships directly to the jobsite from refrigerant suppliers Thermometer Wells and Sight Glasses In addition to the thermowells provided for use with the standard unit safety controls a well is provided for measurement of the liquid refrigerant condensing temperature and a coupling for the evaporating temperatures Sight glasses are provided for monitoring oil charge level oil flow compressor rotation and purge condenser drum Insulation Factory applied insulation is available on all units All low temperature surfaces are covere
72. ints ASHRAE Guideline 3 Report Operating mode i e run status Setpoint source or reset source 35 e TRANE e Evaporator leaving fluid temperature setpoint e Evaporator entering and leaving fluid temperatures Condenser water entering and leaving water temperature Current limit setpoint Evaporator flow and condenser flow optional Outdoor temperature optional e Fluid or water pressure drops optional evaporator and condenser Active ice making setpoint if applicable Active hot water setpoint if applicable Auxiliary heat recovery temperature if applicable Refrigerant Report Refrigerant Temperatures and Pressures ppm of refrigerant from multiple points outside of machine Saturated condenser temperature e Condenser pressure Saturated evaporator temperature Evaporator pressure Compressor discharge temperature optional Purge suction temperature Purge elapsed time e Pumpout activity Compressor Report Starts and hours counters Phase currents Phase voltages optional Oil temperature and flow Motor winding temperature Bearing temperatures optional Kilowatts power factor optional 36 Controls Diagnostics Water and refrigerant temperatures out of range Loss of flows Sensor and switch faults Overload trips Over under voltage if applicable Surge extended surge Compressor acceleration failure Transition failure Ot
73. ional information Contact the local Trane sales office for submittal and template information Evaporator and Condenser Data Tables Evaporator and condenser data is shown in the Performance Data section Data includes minimum and maximum water flow limits and water connection sizes for all standard pass configurations and tube type Pressure drops are calculated by the CenTraVac computer selection program CTV PRC007 EN Selection Procedure e TRANE Part Load Performance The CenTraVac chiller possesses excellent performance characteristics over its full range of operation The multi stage direct drive compressor enables stable and efficient operation over a wide range of capacities virtually eliminating the need for energy wasting hot gas bypass typically found on single stage chillers An in depth examination of project specific conditions and energy rate structures should be performed to appropriately evaluate total energy costs over a period of time TRACE Trane s unique energy analysis program is particularly well suited for this type of analysis as well as for economic evaluation of equipment and system alternatives Local utilities may offer substantial monetary rebates for centrifugal chillers with specific operating kW ratings Contact your local utility representative or Trane sales office for further information The electrical rate structure is a key component of an economic evaluation Most
74. it It will also control the evaporator and condenser pumps to insure proper chiller operation The panel features machine protection shutdown requiring manual reset for low evaporator refrigerant temperature high condenser refrigerant pressure low evaporator condenser differential pressure low differential oil pressure low oil flow high oil temperature critical sensor or detection circuit faults motor overload high motor winding temperature high compressor discharge temperature option starter contactor fault starter transition failure compressor failure to accelerate external and local emergency stop electrical distribution faults phase loss phase unbalance phase reversal inter processor communications lost high bearing temperature optional e free cooling valve closure failure free cooling applications only extended compressor surge actuator drive circuit fault Over 100 diagnostic checks are made and displayed when a fault is detected The display indicates the fault the type of reset required the time and date the diagnostic occurred the mode in which the machine was operating at the time of the diagnostic and a help message A diagnostic history will display the last 10 diagnostics with the time and date of their occurrence 49 e TRANE The display also provides over 20 reports that are organized into four groupings Custom Report Chiller Report
75. ithout speed increasing gears thus eliminating gear energy losses Compressors using gears suffer mesh losses and extra bearing losses in the range of three to five percent at full load Since these losses are fairly constant over the load range increasingly larger percentage losses result as load decreases Multiple Stages of Compression The compressor operates more efficiently over a wide range of capacities virtually eliminating the need for energy wasting hot gas bypass as typically found on single stage chillers The radial component of velocity determines the ability of the chiller to resist interruption of smooth refrigerant flow when operating at light loads and with high condensing temperatures This interruption in flow and unstable operation called surge is avoided with the two stage design Inlet Guide Vanes Part load performance is further improved through use of moveable designed variable inlet guide vanes Inlet guide vanes improve performance by throttling refrigerant gas flow to exactly meet part load requirements and by prerotating refrigerant gas for optimum entry into the impeller Prerotation of refrigerant gas minimizes turbulence and increases efficiency Two Stage Refrigerant Flow Two Stage Economizer The CVHE CVHG CenTraVac chiller has a two stage economizer providing up to seven percent greater efficiency than designs with no economizer Since the CVHE CVHG uses three i
76. ks outward at moderate rate e Refrigerant loss is into equipment room Condenser At positive pressure during operation Usually at negative pressure during inactivity air leaks inward e Refrigerant leaks outward at very low rate during operation Always at high positive pressure e Refrigerant leaks outward at very high rate Monitoring Trane Purifier Purge is able to continuously monitor of leak rate in leakage with a purge timer e Refrigerant monitor as required by ASHRAE Purge timer can be connected to building automation system for notification of increased purge operation in leak Similarly the refrigerant monitor can be connected to the building automation system Only ways to monitor leak rate on high pressure chiller are periodic leak checks purchase refrigerant monitor e Refrigerant monitor as required by ASHRAE Normally the only time that a leak is detected on a high pressure chiller is during spring start up This means that a chiller which develops a leak in the summer may leak continuously until the following spring HCFC 123 Typical Pressures Evap 18 7 inches of Mercury 38 F evap Cond 6 1 psig 100 F cond HFC 134a Evap 33 1 psig Cond 124 1 psig Trane Purifier Purge efficiency does not exceed 0 002 Ibs refrigerant Ibs air CTV PRC007 EN CTV PRC007 EN Features and Benefits e TRANE Operator Control Panel Trane has multi language support for al
77. l chillers controlled by the UCP2 including but limited to CVHE CVHF CVHG GPC and LHCV alarm The standard Clear Language Display CLD supports eight languages including English French German Spanish Katakana Italian Portuguese and Dutch The Complex Character CLD was added to support languages such as Traditional and Simplified Chinese Japanese Thai and Korean The Complex Character CLD is available as a retrofit kit for the standard CLD on the UCP2 panel With the same wiring and mounting it is as simple as disconnecting two wires unbolting the existing CLD bolting on the Complex Character CLD and reconnecting the two wires Capabilities include e Super twist LCD display with backlighting for readability Chiller data more than 200 items including Status Setpoints Field start up items Machine configuration items Service test items e Status reports Chiller Report Refrigerant Report Compressor Report Custom report capability More than 100 diagnostic messages including a history log of the last 20 diagnostics An alarm indicator Expanded help messages Operator security Internationally recognized symbols ADAPTIVE CONTROL e TRANE Features and Benefits Controls and paints for outdoor use or corrosive environments Internally enhanced or Various tube materials smooth bore tubes and thicknesses Victaulic or flanged UL lab
78. l lugs crimp type recommended Terminal lugs are field supplied These connection pads provide additional surface area to minimize improper electrical connections Also a 3 s inch bolt is provided on all connection pads for mounting the lugs Figure J 1 illustrates the connection between the motor connection pads and the terminal lugs Figure J 1 Electric Connections Terminal Lugs Field Supplied Connection Pad T LLL Motor Terminal s gor Stud Shipment and Assembly style hermetic CenTraVac units ship as a factory assembled factory tested package ready to rig into place on factory supplied isolation pads CTV PRC007 EN Advanced Controls Trane set the standard for unit microprocessor controls in 1985 with the first generation Unit control panel Associated with this standard have been Proportional Integral Derivative PID control strategies which provide stable operation and higher accuracy for better performance Adaptive Control to keep the chiller on line during adverse operating conditions and at the same time keep the chiller from a major failure e Software based safeties that do not depend on electromechanical hardware hardware that means questionable reliability and added cost Operator interface that accesses chiller information and control adjustments at the front of the panel Flexibility UCP2 adds more flexibility more reliability and bet
79. lant Manager CPM can be used for automatic free cooling control When condenser water is available at a temperature lower than the required leaving chilled water temperature the CPM starts the free cooling cycle If the load cannot be satisfied with free cooling the CPM or a customer supplied system can automatically switch to the powered cooling mode If desired the chiller can be manually switched to the free cooling mode at the unit control panel Upon changeover to free cooling the shutoff valves in the liquid and gas lines are opened and a lockout circuit prevents compressor energization Liquid refrigerant drains by gravity from the storage tank into the evaporator flooding the tube bundle Since the refrigerant temperature and pressure will be higher in the evaporator than in the condenser due to the water temperature difference the refrigerant gas boiled off in the evaporator will flow to the condenser The gas then CTV PRC007 EN Unit Options e TRANE condenses and flows by gravity back to the evaporator This automatic refrigeration cycle is sustained as long as a temperature difference exists between the condenser water and evaporator water The difference in temperature between the condenser and evaporator determines the rate of refrigerant flow between the two shells and hence the free cooling capacity If the system load becomes greater than the free cooling capacity either the operator manually
80. ler is backed by a team of experienced field sales engineers with support from headquarters experts No other manufacturer can offer that degree of support to its customers In the design phase application engineers can help answer your questions or solve your problems During the selection phase software engineers are available to help you evaluate equipment alternatives At the installation stage field start up of the CenTraVac chiller is included in the purchase price Trane offers this support and more when you need it Delivery And Design Flexibility If delivery time is a priority Trane can meet your needs with a variety of quick shipment choices Most fast track building schedules can be met with one of these choices Design flexibility means Trane can custom build a unit to specific job requirements Design parameters such as shell type compressor kW ton waterside pressure drop as well as full and part load performance can be built to meet requirements ISO 9001 Certification ISO 9001 Certification applies to the Trane La Crosse Business Unit This process is based on the La Crosse Business Unit s ISO 9001 certified quality system This system is documented in procedures which define how quality assurance activities are managed performed and continuously monitored Included in the system are verification checkpoints from the time the order is entered until final shipment In addition product development for t
81. lications Operation The unit mounted starter is a star wye delta closed transition reduced voltage starter When starting and during acceleration the motor is connected in its wye configuration Because of this arrangement the voltage applied to the Figure O 1 Typical Equipment Room Layout Conventional Remote Star Delta Starter Concrete Pad 5 lt P Star Delta Load Side Power Conduit po ra 2 Closed Transition E Starter L aS Control Wire Conduit Line Side Power Conduit Disconnect Switch Motor Junction Box Control Panel Figure O 2 Typical Equipment Room Layout Unit Mounted Star Delta Starter Line Side Power Conduit Field Provided Unit Mounted Starter with Circuit Breaker Control Circuit Wire Factory Wired Control Panel 14 motor windings is reduced to one divided by the square root of three or 0 58 times line voltage This reduction in winding voltage results in a reduction in inrush current The inrush current is 0 33 times the full voltage locked rotor current rating of the motor The accelerating torque of the motor is also reduced to 0 33 times the full voltage torque rating This is sufficient to fully accelerate the compressor
82. ling load The capacity of the chiller plant is extended by operating the chiller and ice in tandem Tracer rations the ice augmenting chiller capacity while reducing cooling costs When ice is produced Tracer will lower the centrifugal chiller leaving fluid setpoint and start the chiller chiller and ice pumps and other accessories Any incidental loads that persists while producing ice can be addressed by starting the load pump and drawing spent cooling fluid from the ice storage tanks For specific information on ice storage applications contact your local Trane sales office CTV PRC007 EN CTV PRC007 EN System Options e TRANE Heat Recovery Use of the Heat Recovery CenTraVac can significantly reduce the energy operating costs of many buildings by using heat which normally would be rejected to the atmosphere Typical uses for this heat are perimeter zone heating reheat air conditioning systems and any hot water requirements Any building with a simultaneous heating and cooling load is a potential candidate Most heating applications require water temperatures higher than the 85 F to 95 F typically sent to the cooling tower Therefore most heat recovery chillers are required to produce higher leaving condenser water temperatures and thus will not duplicate the energy efficiencies of cooling only machines Figure O 7 illustrates the typical operating cycles of a cooling only machine and a heat reco
83. mpellers it is possible to flash refrigerant gas at two intermediate pressures between the evaporator and condenser pressures significantly increasing chiller efficiency This improvement in efficiency is not possible in single stage chillers since all compression is done by one impeller Single Stage Economizer The CVHF CenTraVac chiller has a single stage economizer providing up to 4 2 percent greater efficiency than designs with no economizer Since the CVHF CenTraVac uses two impellers it is possible to flash refrigerant gas at an intermediate pressure between the evaporator and condenser pressures significantly increasing chiller efficiency This improvement in efficiency is not possible in single stage chillers since all compression is done by one impeller 11 e TRANE Three Stage CenTraVac P H Diagram CONDENSER 5 COMPRESSOR THIRD STAGE COMPRESSOR SECOND STAGE COMPRESSOR FIRST STAGE TWO STAGE ECONOMIZER EJ PRESSURE PSI EVAPORATOR 2 RE NO ECONOMIZER ENTHALPY BTU LBM CenTraVac Three Stage P H Diagram The pressure enthalphy P H diagram describes refrigerant flow through the major CVHE CVHG chiller components This diagram confirms the superior operating cycle efficiency of the three stage compressor and two stage economizer Evaporator A liquid gas refrigerant mixture enters the e
84. n HCFC 123 28 Selection Procedure Performance The CenTraVac computer selection program provides performance data for each chiller selection at the full load design point and part load operating points as required The Trane computer selection program is certified by ARI in accordance with ARI Standard 550 590 To assure that the specific chiller built for your project will meet the required performance and to ensure a more troublefree start up it is recommended that the chiller be performance tested The CenTraVac computer selection program has the flexibility to select chillers for excessive field fouling allowances Fouling Factors ARI Standard 550 590 includes a definition of clean tube fouling Recommended field fouling allowances have not changed on a relative basis the standard fouling adjustment is a 0 0001 increment from 0 0000 clean on the evaporator and 0 00025 increment from 0 0000 clean on the condenser Chiller specifications should be developed using the most current standard fouling factors It should be noted that changing the number of water passes or water flow rates may significantly alter the performance of a particular chiller To obtain the maximum benefit from the wide range of selections available designers are encouraged to develop performance specifications and use the computer selection program to optimize their selections This will allow the selection of the particular com
85. nTraVac motors are cooled by liquid refrigerant surrounding the motor windings and rotor Use of liquid refrigerant results in uniform low temperatures throughout the motor thereby promoting long motor life Refrigerant Oil Pump Motor The oil pump motor is a 120 volt 50 60 hertz 2 4 hp 1 phase motor with protective fusing and panel mounted contactor Purge The purge unit motor is a 120 volt 50 60 hertz 2 4 hp 1 phase motor with integral overload protection and panel mounted contactor The use of an air cooled condensing unit obtains separation temperatures in the purge drum as low as 0 F Normal operating efficiency does not exceed 0 002 Ibs of refrigerant lost per pound of dry air removed The purge system can be operated at any time independent of chiller operation Optional Features Trane offers a selection of optional features to either complete the basic chiller installation or to allow modification for special purpose applications Medium voltage over 600 volts hermetic compressor motor construction Complete line of compressor motor starters Unit mounted starter accessory on low voltage units up to an RLA of 1080 amps Marine waterboxes for evaporators and condensers High pressure 300 psig working pressure water side construction Free cooling Heat recovery or auxiliary condensers e Smooth bore tubing Factory applied thermal insulation e One inch deflection spring isol
86. ncludes all feedback sensors required for stability in the system and any required shutdown due to a fault Soft Start Inrush Current and Torque Trane AFD s are programmed to start the compressor motor from low frequency and low voltage The motor is brought up to speed by increasing both frequency and voltage at the same ratio Thus current and torque are much lower during start up and acceleration than the high current high torque associated with across the line or even reduced voltage starters Note that the actual torque developed by the AFD is the total of the torque required by the load and the accelerating torque The AFD is rated by output current and is limited to a maximum of 100 percent continuous RLA through the chiller control UCP2 A 100 percent output current capability results in 100 percent torque generated by the motor In other words the drive regulates output voltage in proportion to output frequency to maintain ideal motor flux and constant torque producing capability 17 e TRANE Free Cooling Allows Reduced Operating Costs Consider a CenTraVac chiller option that can provide up to 45 percent of the nominal chiller capacity without operating the compressor Think of the significant energy and cost savings possible in many applications This option is available on all Trane chillers factory installed Free cooling operation is based on the principle that refrigerant migrates to the area of
87. nd electrically isolated from power circuit voltage e 150 instantaneous torque available for improved surge control Critical frequency avoidance Output line to line and line to ground short circuit protection e Restart into a rotating motor AFD can be started without a motor connected Chiller Unit Control Features for AFD The chiller unit control panel standard control capabilities provide for the control configuration interface to and the retrieval display of the collaterally additional AFD related data AFD standard design features controlled through the starter module of UCP2 include Current limited to 10096 Auto restart after an interruption of power limited to four starts per hour 30 seconds between starts Output speed reference signal 2 10 vdc Digital display on UCP2 panel output speed in hertz output speed in rpm fault amps input line voltage Motor overload protection Loss of follower signal in the event of loss of input speed signal the AFD will default to 38 hertz or hold speed based on last reference received Phase loss reversal imbalance protection Power loss ride through Overvoltage undervoltage protection Motor overtemperature protection Environmental ratings 32 F to 104 F 0 C to 40 F operating temperature Altitude to 3300 feet 1000 m Humidity 9596 non condensing Input Line Reactor Option Field installed option mounts on
88. ndle and the condenser shell distributes the hot gas longitudinally throughout the condenser downward over the tube bundle preventing direct impingement of high velocity compressor discharge gas upon the tubes Shell Tests The refrigerant side of the condenser shell with tubes but without waterbox covers is proof tested at 45 psig vacuum leak tested and pressure leak tested The water side of the shell with waterboxes in place is hydrostatically tested at one and a half times the design working pressure but not less than 225 psig These tests are not to be repeated at installation CTV PRC007 EN Mechanical Specification e TRANE Economizer The CVHE CVHG style CenTraVac two stage economizer single stage economizer on CVHF style units is a series of interstage pressure chambers which utilize a multiple orifice system to maintain the correct pressure differential between the condenser economizer and evaporator over the entire range of loading This patented system contains no moving parts Purge System The CenTraVac chiller utilizes a purge system operating with a 120 60 1 or 120 50 1 power supply The purge system using an air cooled condensing unit operates automatically to remove any noncondensables and water vapor which may be present in the refrigerant system Normal operating efficiency does not exceed 0 002 Ibs of refrigerant lost per pound of dry air removed Noncondensable discharge and refri
89. nes to keep the chiller on line as long as possible When UCP2 detects that the chiller is entering surge the message UNIT IS RUNNING SURGE DETECTED is enunciated Optional surge protection energizes the head relief request relay If corrective action is not taken and surge continues for 15 minutes a latching shutdown will occur with a diagnostic message Under normal conditions and when the control source maintains an Auto signal a stop signal originates from the chiller module which senses no further cooling demand At this time a UNIT IS PREPARING TO SHUT DOWN message appears as the guide vanes close Then the compressor motor starter and condenser pump starter are de energized while the oil pump continues to run for approximately two minutes The CenTraVac can be manually stopped at any time by pushing the Stop key once for a friendly stop coastdown and twice within five seconds for an emergency stop CTV PRC007 EN CTV PRC007 EN e TRANE Weights Operating Weight Shipping Weight TYPE NTON CPKW EVSZ CDSZ Ibs kg Ibs kg CVHE 230 320 287 0325 0325 14909 6763 13721 6224 CVHE 230 320 287 0325 0321 15548 7053 14265 6471 CVHE 230 320 287 032L 032L 16422 7449 14911 6764 CVHE 230 320 287 050S 050S 18530 8405 16579 7520 CVHE 230 320 287 050S 050L 19498 8844 17394 7890 CVHE 230 320 287 0501
90. ning for safe operation and maximum efficiency Loss of Load for Sudden Load Loss nuisance trip prevention Note capacity control can be accomplished in several ways entering or leaving evaporator fluid temperature leaving condenser water temperature Machine Protections Starter Compressor Contactor Failure Detection Solid state starter heat sink included with SSS Compressor Smart Shutdown Sequence High Compressor Discharge Temperature optional Surge Detection Extended Surge Protection Oil Temperature Bearing Temperatures optional Condenser Loss of flow High condenser pressure limit High pressure cutout Evaporator Loss of flow Low refrigerant temperature limit Low evaporator leaving fluid cutout Motor Current limit Current overload High motor winding temperatures High vacuum operation lockout Momentary power loss phase unbalance phase loss reverse rotation Over under voltage is optional Smart short cycling protection Purge Tank full protection Low current detection Continuous or excessive pumpout detection Excessive air leakage detection Monitored Points Chiller information is available at the operator interface that can access a variety of reports Custom Chiller Refrigerant and Compressor Custom Report User Defined Custom Report operator may choose up to 20 points from a list of over 100 choices Chiller Report Status Fluid Temperatures and Setpo
91. nputs and outputs associated with the refrigerant and lubrication circuits The starter module provides control of the starter when starting running and stopping the motor It provides interface to and control of wye delta across the line primary reactor auto transformer solid state starters and Trane Adaptive Frequency drive The starter module also provides protection to both the motor and the compressor in the form of running overload phase reversal phase loss phase unbalance momentary power loss and compressor surge All diagnostics are communicated across the IPC to the human interface The stepper module is designed to drive the stepper motor inlet guide vane actuator and other flow control devices within a system This module receives CTV PRC007 EN e TRANE Controls from the chiller module the direction and distance to drive the inlet guide vanes and then generates the appropriate signals to operate the stepper motor The purge module provides control of the purge including all the inputs and outputs to control the purge to optimize both purge and chiller efficiency and to communicate purge diagnostics to the human interface Before anything can begin 115 volt 50 or 60 Hz power is applied to the control panel In that several control source devices may coexist the operator determines which device has priority via the operator interface All control settings at that control source are then in eff
92. nstallation of an AFD But the energy or kWh portion will almost certainly be reduced because of the improved efficiency of the chiller plant during part load conditions throughout the year The greater the kWh charge the shorter the payback Operation The Trane AFD controls the speed of the chiller compressor by regulating the output voltage in proportion to the output frequency to provide a nominally constant rate of voltage to frequency as required by the characteristics of the compressor motor Motor speed is proportional to this applied frequency The Trane AFD is a voltage source pulse width modulated PWM design It consists of three basic power sections Converter Semi conductor bridge rectifier takes incoming AC power and converts it to a fixed voltage DC bus DC bus filter The converted DC bus voltage contains a significant amount of ripple The DC bus filter smooths the voltage ripple from the converter with capacitors and a DC link reactor to supply a fixed constant voltage to the inverter section It 8150 minimizes the electrical harmonics generated by the drive back to the distribution system Inverter Converts the DC voltage into a sinusoidal synthesized output AC voltage This synthesized output controls both the voltage and frequency which is applied to the motor A fourth element of AFD design is the microprocessor control logic which is the intelligence for the power section It also i
93. ol requirements and the cost of electricity all have a direct impact on the decision to use a free cooling chiller The use of CenTraVac free cooling depends on the availability of cold condenser water from a cooling tower river lake or pond As a general rule of thumb locations which have a substantial number of days with ambient temperatures below 45 F wet bulb or more than 4000 degree days per year are well suited to free cooling operation A cooling tower usually must be winterized for off season operation and the minimum sump temperature is limited by some cooling tower manufacturers Cooling tower manufacturers should be consulted for recommendations on low temperature operation With river lake or pond supply condenser water temperatures down to freezing levels are possible Areas which have badly fouled air may be more conducive to free cooling operation than the use of an outside air economizer Airside systems which both heat and cool the air can often effectively use a free cooling chiller Dual duct multizone and reheat systems fall into this general category As the outside temperature begins to fall the cool outside air satisfies the cooling requirements through an outside air economizer As the outdoor air temperature becomes very low the outdoor air may need to be heated in order to maintain the design supply air temperature when it is mixed with return air This heating penalty can be eliminated by u
94. oper starting and control systems However the responsibility for providing proper starting and control systems must remain with the system designer and the installer Contact your local Trane sales office for further information The typical equipment room layout for a Trane CenTraVac unit or remote mounted starter are shown in Figures O 1 and O 2 A NEMA 1 star delta wye delta type closed transition reduced voltage motor starter is mounted as an optional accessory on Trane CenTraVac chillers rated up to and including 1080 RLA on low voltage 600 volts and below systems All power and control wiring between the starter and the chiller are factory assembled Factory assembly enhances total system reliability and integrity Total installed chiller starter costs are significantly reduced by the unit mounted starter option rather than a conventional remote mounted starter Benefits Reduces starter installation costs 20 to 35 percent By eliminating chiller to starter field wiring By eliminating starter to disconnect switch field wiring when optional circuit breaker is used By eliminating field installed disconnect switch when optional circuit breaker is used By eliminating starter mounting pad and required equipment room floor space By eliminating control wiring from starter to control panel Electrical system reliability is enhanced By reducing the number of field electrical connections
95. ould be for motor type loads and should not be less than 150 percent of the compressor motor rated load amps RLA 12596 x 350 Amps 27 e TRANE Selection The CenTraVac centrifugal chiller product line provides more than 200 000 individual unit selections over a capacity range of 170 through 3500 tons Chiller selections and performance data can be obtained through the use of the CenTraVac chiller selection program available in local Trane sales offices This program can provide a list of chiller selections optimized to closely match specific project requirements Nominal data and physical data for typical compressor evaporator condenser combinations are given by product family Trane Model Number The Trane model number defines a Trane CenTraVac with its particular component combination These components along with the project design conditions are required to determine chiller performance from the CenTraVac computer selection program Compressor size and voltage Evaporator bundle size bundle length and number of water passes Condenser bundle size bundle length and number of water passes Leaving chilled water temperature evaporator water flow rate temperature drop through the chiller Entering condenser water temperature condenser water flow rate and temperature rise through the condenser e Water side fouling factors for the evaporator and condenser Refrigerant type for operating o
96. p the chiller running as long as possible even when non standard conditions exist Conditions such as bad power or bad water flow temperature fouling or system component failure With Enhanced Adaptive Control the controller does everything it can to avoid taking the chiller off line senses potential overload freeze and condenser overpressure conditions displays a warning message about the potential condition safety trip takes the following corrective action sequentially as the condition worsens limits loading prevents further loading unloads until condition improves takes chiller off line With the ability to detect surge UCP2 can call for corrective action to be taken to prevent a surge failure If the system can respond within 15 minutes the chiller will continue to operate until further corrective action can be taken With the ability to function across a broader operating map UCP2 in conjunction with the multiple stage compressor can provide safe operation when undesirable inputs to the chiller are encountered This capability includes cold condenser start running with hot condenser water low condenser water flow hot evaporator start varying water fluid loop flow operation return from momentary power losses in less than one minute smart restart inhibit designed to get the chiller back on line fast With more diagnostics and diagnostic history
97. pressor evaporator condenser combination which most closely meets the job requirements All selections should be made by using the computer selection program Unit Performance With Fluid Media Other Than Water CenTraVac chillers can be selected with wide variety of media other than water Typically used media include ethylene glycol or propylene glycol either in the evaporator condenser or both Chillers using media other than water are excluded from the ARI 550 590 Certification Program but are rated in accordance with ARI 550 590 Trane factory performance tests are only performed with water as the cooling and heat rejection media For media other than water contact the local Trane sales office for chiller selections and information regarding factory performance testing Flow Rate Limits Flow rate limits for all pass combinations for evaporators and condensers are tabulated in the data section for the appropriate chiller family For applications outside of these limits contact your local Trane office CTV PRC007 EN Roughing in Dimensions The dimensional drawings illustrate overall measurements of the chiller The recommended space envelope indicates clearances required to easily service the CenTraVac chiller A view of the unit is superimposed on this drawing with unit support feet shown All catalog dimensional drawings are subject to change Current submittal drawings should be referred to for detailed dimens
98. pressor and a two stage economizer As a result this chiller was 5 to 20 percent more efficient than previous designs Today s CenTraVac chiller still relies on the dependability of the proven direct drive and exclusive slow speed operation Low operating costs and high reliability continue to be the CenTraVac chiller hallmark When a source of energy other than electricity is required The Trane Cen TraVac has the standard option of being coupled to a Waukesha Enginator to quite simply convert natural gas to chilled water With COPs in the range of 1 5 to 2 2 depending on options selected makes this option a very simple and attractive alternative when an alternative fuel source is desired Introduction Trane GPC Benefits Combines two industry recognized and proven products the Trane Earth Wise CenTraVac and Waukesha Enginator Ability to do both base and peak shaving No oncsite piping connections Refrigerant leaks minimized No need to remove refrigerant charge from chiller during downtime Installations more flexible simpler and cost effective Ability to place the engine generator set in a location remote of the chiller Allows for efficient use of plant floor space Provides flexibility in sound sensitive work areas Limited availability for International orders Please contact International CenTraVac Marketing Group Unmatched Expertise The performance and reliability of a CenTraVac chil
99. properly treated water Water Pumps Avoid specifying or using 3600 rpm condenser and chilled water pumps Such pumps may operate with objectionable noises and vibrations In addition a low frequency beat may occur due to the slight difference in operating rpm between water pumps and CenTraVac motors Where noise and vibration free operation are important The Trane Company encourages the use of 1750 rpm pumps Chillers are designed to ARI conditions of 85 F but Trane CenTraVac chillers can operate to a 3 psig pressure differential between the condenser and evaporator at any steady state load without oil loss oil return motor cooling refrigerant hang up or purge problems And this differential can equate to safe minimum entering condenser water temperatures at or below 55 F dependent on a variety CTV PRC007 EN Application Considerations e TRANE of factors such as load leaving evaporator temperature and component combinations Start up below this differential is possible as well especially with UCP2 soft start features Water Flow Today s technology challenges ARI s traditional design of three gpm per ton through the condenser Reduced condenser flows are a simple and effective way to reduce both first and operating costs for the entire chiller plant This design strategy will require more effort from the chiller But pump and tower savings will typically offset any penalty This is especially true when
100. put load terminals factory connected to the motor CTV PRC007 EN Available options include Circuit Breaker A standard interrupting capacity circuit breaker is available The circuit breaker is mechanically interlocked to disconnect line power from the starter when the starter door is open High Interrupting Capacity Circuit Breaker A high interrupting capacity circuit breaker is available This breaker is also interlocked to disconnect line power from the starter when the starter door is open Circuit Breaker with Ground Fault Ground Fault protection is available with either standard or high interrupting capacity circuit breakers An indicating light is provided to indicate if a ground fault has occurred Current Limiting Circuit Breaker A standard circuit breaker incorporating the current limiters with fuse links is available A fault current in excess of the circuit breaker capacity will blow the fuse links and interrupt the fault current The circuit breaker cannot be reset until the blown current limiters are replaced Ground fault detection and protection available only with circuit breaker options CTV PRC007 EN Unit Options e TRANE The solid state starter controls the starting characteristics of a motor by controlling the current that flow to the motor It does so through the use of SCRs Silicon Controlled Rectifiers which are solid state switching devices and an integral bypass cont
101. quipment room refrigerant ppm monitoring can be integrated into the control panel by employing a chiller mounted monitor or a wall mounted monitor UCP2 is modular in design which offers the ability to adapt to changes easily and effectively without adding prohibitive cost To provide flexibility the controller responds to a wide variety of needs for System Designs including equipment operating conditions and controls variations that are either existing or being considered for new installations Key to designing non traditional systems is the ability to evaluate the cost and reliability issues of these systems in comparison to the more traditional systems Trane recommends the use of C D S Network Equipment Economics the Trane Applications Manuals and consultation with a Trane sales engineer for help in this analysis System Upgrades including the ability to accommodate changes in the chilled water system design or equipment room requirements or to accommodate new technologies that become available Reliability To most people reliability means dependable giving the same result on successive trials However to our customers it has come to mean keep chilled water flowing In other words when turn the switch on cold water comes out In order to do this the micro controller must be aware of what is happening in the system But more importantly it must be able to make decisions and adjustments to kee
102. re called P1 P1 is between the evaporator and condenser pressures Preflashing 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 a 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 system Here refrigerant pressure and temperature are reduced to evaporator conditions at state point 1 CTV PRC007 EN Unit Mounted Starters Trane factory installed options make installation of a CenTraVac chiller easier faster and less costly Another example of the Trane packaged concept is the factory installed unit mounted star delta starter available on CenTraVac chillers up to 1300 tons capacity or solid state starters up to 1000 tons depending on jobsite electrical requirements It s a single chiller starter package designed for years of reliable operation and low life cycle costs Installation cost is reduced by eliminating chiller to starter starter to disconnect and starter to control panel field wiring All this wiring is completed and tested in the factory ensuring electrical integrity Since most wiring is factory completed electrical system design time is reduced Starter components are pre engineered and selected to provide a reliable
103. rements the following design considerations should be incorporated into any heat recovery system System Design Considerations Heating Water Temperatures and Control It is always desirable to use as low a heating water temperature as the application allows Experience has shown that a design heating water temperature of 105 110 can satisfy most heating requirements Lower heating water temperatures increase the chiller operating efficiency both in the heating mode and in the cooling mode In general the heat recovery power consumption will increase 7 to 14 percent for every 10 F increase in the design heating water temperature A consideration which is just as important as the design heating water temperature is how that temperature is controlled In most cases the heating water temperature control should be designed to maintain the return heating water temperature By allowing the supply water temperature to float the mean water temperature in the system drops Figure O 8 Refrigerant Pressure Difference as the chiller load decreases and less heat is rejected to the condenser As the mean heating water temperature drops so does the refrigerant condensing temperature and pressure difference which the compressor is required to produce at part load This increases the unloading range of the compressor When the supply heating water temperature to
104. rt Waiting for Need to Cool 37 e TRANE A demand for chilled water is determined by a temperature differential between the evaporator fluid setpoint and the supply fluid temperature Start is inhibited and the condition enunciated if high condenser pressure or low oil temperature or high motor winding temperature is detected Restart defined as successive unsuccessful attempts to start also called short cycling Inhibit and the time remaining before restart can be attempted will be enunciated if this condition exists The next step issues a command to start the condenser water pump to confirm that the guide vanes are closed and to start the oil pump motor When flow is proven after confirmation that the guide vanes are closed and after establishing oil pressure a 15 second start signal is sent to the motor starter A successful start and acceleration of the motor is followed by the UNIT IS RUNNING message Any failure to complete a successful start causes the sequence to abort and the CenTraVac to coast to a stop A diagnostic describing the reason for failure time and date of failure a help message and reset action required will tell the operator that the micro controller has detected a problem during the attempted start As soon as the fail condition is corrected and reset either manual or automatic is accomplished the chiller can go through the start up sequence again Normal operation messa
105. s 14 5 34 15 0 7 17 5 4 11 16 10 3 4 10 1 Ye 9 1134 10 3 7 1060 1280 2100 LL 35 5 1 4 15 3 3 4 15 7 15 6 4 11 15 0 1 4 11 0 72 10 9 34 10 10 1060 1280 2500 EL 39 57 16 7 16 7 17 5 527 X 16103 14 MeV 117117 1470 2100 LL 35 5 1 4 15 334 15 7 15 6 4 11 15 0 1 4 11 5 10 9 3 4 10 10 1470 2500 EL 39 5 7 16 7 16 7 17 5 525 16 10 3 4 11 47 2 11 1125 11 11 77 CL1 CAN BE AT EITHER END OF MACHINE AND IS REQUIRED FOR TUBE PULL CLEARANCE CL2 IS ALWAYS AT THE OPPOSITE END OF MACHINE FROM CL1 AND IS REQUIRED FOR SERVICE CLEARANCE CENTRAVAC WATER CONNECTION PIPE SIZE Water Shell Size Passes 032 050 080 142 210 250 EVAPORATOR Nominal Pipe Size Inches 1 PASS 8 10 12 16 16 16 2 PASS 6 8 10 12 14 14 3 PASS 5 6 8 10 12 12 CONDENSER 2 PASS 6 8 10 12 14 14 CTV PRC007 EN TRANE Physical Dimensions SPACE ENVELOPE coe terr 8 REDE CHEN RECOMMENDED RECOMMENDED CLEARANCE CLEARANCE 1 Ew WIDTH HEIGHT 11 12 11 2 1 991 mm i REQUIRED CLEARANCE NE MESES WIDTH 5 METRIC UNI
106. sing CenTraVac free cooling Warm chilled water temperatures provided by the free cooling chiller would allow a warmer air temperature off the chilled water coils eliminating the heating energy required by using only an outside air economizer With today s high cost electricity in most areas of the country this heating penalty can be very significant CTV PRC007 EN Temperature and humidity control requirements are important considerations when evaluating the use of CenTraVac free cooling Low temperature outside air from the outside air economizer often requires a large amount of energy for humidification purposes Free cooling operation helps to reduce these humidification costs on many applications It is important to note that those applications which require extremely precise humidity control typically cannot tolerate warmer than design chilled water temperatures Therefore since free cooling chillers normally deliver warmer than design chilled water temperatures free cooling operation is usually not applicable with systems which require precise humidity control Also free cooling is generally not used in conjunction with heat recovery systems since mechanical cooling must be used to recover heat that will be used elsewhere in the building for simultaneous heating Operation Free cooling operates on the principle that refrigerant flows to the area of lowest temperature in the system The Tracer system Chiller P
107. stops free cooling a binary input from a customer supplied system disables free cooling or the CPM can automatically perform this function The gas and liquid valves close and the compressor starts Refrigerant gas is drawn out of the evaporator by the compressor compressed and introduced into the condenser Most of the condensed liquid first takes the path of least resistance by flowing into the storage tank which is vented to the high pressure economizer sump by a small bleed line When the storage tank is filled liquid refrigerant must flow through the bleed line restriction The pressure drop through the bleed line is greater than that associated with the orifice flow control device hence liquid refrigerant flows normally from the condenser through the orifice system and into the economizer The free cooling accessory consists of the following factory installed or supplied components A refrigerant gas line including an electrically actuated shutoff valve installed between the evaporator and condenser A valved liquid return line including an electrically activated shutoff valve between the condenser sump and evaporator A liquid refrigerant storage vessel Added refrigerant charge Manual free cooling controls on the unit control panel For specific information on free cooling applications contact the local Trane sales office Figure O 5 Compressor Operation Schematic ZB Cond
108. ter side of the shell after tube rolling Intermediate tube support sheets are positioned along the length of the shell to avoid contact and relative motion between adjacent tubes Tubes Individually replaceable externally finned seamless copper tubing either internally enhanced one inch nominal diameter or three quarter inch nominal diameter is utilized as the evaporator heat transfer surface Tubes are mechanically expanded into the tube sheets and affixed to the intermediate support sheets with the clips to provide a leak free seal and eliminate tube contact and abrasion due to relative motion Eliminators Multiple layers of metal mesh screen form the eliminators and are installed over the tube bundle along the entire length of the evaporator to prevent liquid refrigerant carryover into the compressor Refrigerant Distribution A refrigerant distribution compartment in the base of the evaporator assures uniform wetting of the heat transfer surface over the entire length of the shell and under varying loads High velocity refrigerant spray impingement on the tubes is prevented through this design Refrigerant Flow Control A multiple orifice flow control system maintains the correct pressure differential between the condenser economizer and evaporator over the entire range of loading This patented system contains no moving parts Shell Tests The refrigerant side of the evaporator shell complete with tubes but
109. ter system performance than even our most demanding customers expect The modular structure of UCP2 makes it possible for the designer to select the system controls and associated interfaces to Tracer or other building automation systems that are required for the chiller plant design With this modular concept capability can be added or upgraded at any time with only temporary interruption of chilled water production The operator can quickly program his Custom Report so that only what is considered to be the most frequently accessed important reports are available at any time right at the front of the panel With easy front panel programmability of Daily Service Start up and Machine Configuration settings and setpoints the operator serviceman and system designer can customize the use of the micro controller to the unique conditions of the chiller plant whether the purpose of chilled water is for comfort cooling or for process cooling All data that is necessary for the safe operation and easy serviceability of the chiller is provided as standard on all CenTraVac chillers Options are available that provide additional controls data that are required for CTV PRC007 EN Controls e TRANE an industrial process system design applications outside of the typical chilled water system design the need for redundant machine protection or the desire for more system information E
110. that are time date stamped and with help messages the operator or serviceman can take faster and more effective corrective action e With the new stepper motor inlet guide vane actuator the same technology used in the machine tool industry offers highly reliable and precise inlet vane control Systems Performance Chilled Water System encompasses many levels of control Stand alone Chiller Chiller Plant Applied System Central Building Automation System 33 e TRANE Controls Building Automation and Chiller Plant morning pull down thus preventing an Remote communication through a Control overshoot of the actual capacity modem As an option a modem can For building automation and control of required Unnecessary starts are be connected to communicate the chilled water plants Trane has avoided and the peak current demand plant operation parameters through developed the Tracer Summit It can is lowered voice grade phone lines control the operation of the complete Communication capabilities several The remote terminal is a PC workstation installation chillers pumps cooling communication levels are provided modem arid software to towers isolating valves air handlers and local through a PC workstation di E ihe remote slam parameter terminal units It is a pre programmable keyboard Summit can be but flexible control system module programmed to send messages to configured according to th
111. the plant is partially loaded or condenser relief is available In new systems the benefits can include dramatic savings with e Size and cost for condenser lines and valves Size and cost of the cooling tower e Size and cost of the water pumps e Pump energy 30 to 35 reduction Tower fan energy 30 to 35 reduction Replacement chiller plants can reap even greater benefits from low flow condensers Because the water lines and tower are already in place reduced flows would offer a tremendous energy advantage Theoretically a 2 GPM ton design applied to a system that originally used 3 GPM ton would offer a 7096 reduction in pump energy At the same time the original tower would require a nozzle change but would then be able to produce about two degrees colder condenser water than before These two benefits would again typically offset any extra effort required by the chiller Contact your local Trane Sales Office for information regarding optimum condenser water temperatures and flow rates for a specific application Electrical Information Minimum Circuit Ampacity To properly size field electrical wiring the electrical engineer or contractor on a project needs to know the minimum circuit ampacity of the CenTraVac machine The National Electrical Code NEC in Article 440 33 defines the method of calculating the minimum circuit ampacity The minimum circuit ampacity is defined as the sum of two amp
112. the building system is maintained and the return heating water temperature to the condenser is allowed to float the mean heating water temperature actually rises as the chiller load decreases and less heat is rejected to the condenser As Figure O 8 illustrates when the compressor unloads the pressure difference that it must oppose to prevent surging remains essentially the same while the compressor s capability to handle the pressure difference decreases Therefore the unit s capability to unload without the use of hot gas bypass is reduced Hot gas bypass artificially increases the load on the compressor cfm of refrigerant gas by diverting refrigerant gas from the condenser back to the compressor Although hot gas bypass increases the unit s power consumption by forcing the compressor to pump more refrigerant gas it will increase the heat available to recover for those applications where significant heating loads remain as the cooling load decreases 95 105 Heating Water 85 95 Cooling Tower Water 54 44 x Chilled Heat Water pi Recovery ud Cooling Refrigerant Only Pressure Refrigerant Difference Pressure Difference CTV PRC007 EN Chilled Water Reset Chilled water reset is often a practical means of reducing energy consumption during periods of the year when heating loads are high but cooling loads are reduced Resetting the chilled water temperature increas
113. uxiliary condenser not only captures energy otherwise lost it also increases chiller efficiency Auxiliary condensers are available in two sizes standard and large Because the auxiliary condenser is a separate condenser there is no cross contamination between the cooling tower water and the heat recovery water circuits No temperature controls are required Auxiliary condensers are factory mounted and tested Benefits Simplicity No temperature controls are required Auxiliary condensers are factory mounted and tested Flexibility Two auxiliary condenser sizes are available standard and large Either auxiliary condenser can be applied to any size CenTraVac Safe Because the auxiliary condenser is a separate condenser there is no possibility of cross contamination between the cooling tower water and the auxiliary condenser water circuits Efficient Use of the auxiliary condenser option actually increases the chiller s efficiency by increasing condenser heat transfer surface area and lowering the pressure differential the compressor must generate Decreased life cycle operating costs result through use of the auxiliary condenser option because heat which normally would be rejected by the cooling tower circuit is now used for building heating requirements Application A simultaneous demand for heating and cooling is necessary to apply any heat recovery system Common uses for heated water from an au
114. vaporator at state point 1 Liquid refrigerant is vaporized to state point 2 as it absorbs heat from the system cooling load The vaporized refrigerant then flows into the compressor first stage Compressor First Stage Refrigerant gas is drawn from the evaporator into the first stage compressor The first stage impeller accelerates the gas increasing its temperature and pressure to state point 3 Compressor Second Stage Refrigerant gas leaving the first stage compressor is mixed with cooler refrigerant gas from the low pressure side of the two stage economizer This mixing lowers the enthalpy of the mixture entering the second stage The second stage impeller accelerates the gas further increasing its temperature and pressure to state point 4 Compressor Third Stage Refrigerant gas leaving the compressor second stage is mixed with cooler refrigerant gas from the high pressure side of the two stage economizer This mixing lowers the enthalpy of the gas mixture entering the third stage compressor The third stage impeller accelerates the gas 12 Features and Benefits further increasing its temperature and pressure to state point 5 then discharges it to the condenser Condenser Refrigerant gas 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 gas to a liquid at state point 6
115. very machine The most noticeable differences are 1 The pressure differential provided by the compressor is much greater for the heat recovery cycle 2 The amount of heat rejected from the heat recovery condenser is greater than that which would be rejected in cooling only operation 3 There is a decrease in the refrigeration effect RE Higher condensing pressures increase the intermediate pressure in the economizer Therefore the liquid in the economizer has a higher enthalpy during the heat recovery mode than during standard chiller operation and the refrigeration effect is slightly decreased Because of this decreased refrigeration effect the compressor must pump more gas per ton of refrigeration The effect of this increased pressure differential and decreased refrigeration effect is a heat recovery machine which has a higher kW ton energy consumption during heat recovery operation Typical catalog kW ton for heat recovery machines operating in the heat recovery mode range from 64 to 84 kW ton compared to a range of 61 to 79 for a cooling only machine Not only can there be an energy consumption penalty paid due to the inherent differences in operating cycles for heat recovery machines but traditional machine design can add to that energy handicap In the past a heat recovery machine s operating efficiency was normally penalized year round by having the capability to produce high heating water temperatures
116. xiliary condenser include domestic water preheat reheat air conditioning systems and boiler makeup water Building use is not limited to the traditional heat recovery candidates Schools hospitals office buildings and hotels have all proved to be excellent applications for the auxiliary condenser option CTV PRC007 EN CTV PRC007 EN System Options e TRANE Controls The auxiliary condenser was designed for simplicity of operation Machine load water flow rate and temperature determine the amount of heat recovered There are no controls needed for heating water temperature because no attempt is made to maintain a specific hot water temperature in or out of the auxiliary condenser Operation The auxiliary condenser is a factory mounted separate shell and tube heat exchanger available on water cooled CenTraVac chillers Because hot refrigerant gas always migrates to the area of lowest temperature auxiliary condenser operation is simple As hot gas leaves the compressor it is free to flow to the auxiliary condenser or the standard condenser Since water entering the auxiliary condenser is normally colder than that entering the standard condenser the auxiliary condenser will have a lower bundle temperature and will attract the refrigerant gas The auxiliary condenser will recover as much heat as the machine cooling load heating water temperature and flow rate will allow All remaining heat will automatic

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