CVHG CH530 Operator Training WSL 2009

Operating, Maintenace and
TroubleshootingTraining
Trane CVHG CenTraVac™ Chillers

With
CH530 Unit Controller
Objective of this Training
☻To enable the Operators to understand:

√ Operating principles of Trane’s CVHE/CVHG Water-Cooled
CenTraVac™ Chillers with CH530 Controller & Dynaview™
Display
√ How to make operational changes, access the screens and

types of information on the Dynaview Display
√ Maintenance required for efficient & reliable operation of the

Chiller
‹#›
Agenda
☻Trane CVHE/CVHG Chiller Components Overview
☻Operating Principles
☻CH530 Controller & Dynaview™ Display
☻Maintenance Considerations
☻Plant Room Exercise Plant Room Exercise
 Identification & Viewing of Major Components
 Refrigerant Flow
 Lubrication System
 Instruction for Starting & Stopping
 Instruction for logging
 Instruction for periodic maintenance
‹#›
CVHE/CVHG Chiller Components Overview
Compressor
Control Condenser
Panel
Evaporator
‹#›
Centrifugal Compressor – 3 Stage
blades
‹#›
Centrifugal Compressor
‹#›
centrifugal compressor
Energy Conversion
‹#›
Condenser
‹#›
expansion device
Orifice Plates
‹#›
3-stage chiller
Economizer
‹#›
Evaporator
‹#›
Motor
‹#›
Motor Cooling
‹#›
Compressor Lubrication
‹#›
Pressure-Enthalpy (p-h) Chart
‹#›
3-stage centrifugal chiller
Refrigeration Cycle
3 4
2
5
High-Side Low-Side
Economizer Economizer
8 7
7% Orifice
1
Plate B
Orifice Orifice
Plate A Plate C
‹#›
Capacity Control – Inlet Vanes
Multistage Compressor
‹#›
Impeller Dynamics
Vr ∝ refrigerant flow rate
R Vr Vt ∝ rotational speed × diameter
Vt
diameter
refrigerant
rotational flow rate
speed
‹#›
Compressor Unloading
‹#›
Surge
‹#›
Compressor Map
‹#›
Operating Point
‹#›
compressor map for a
3-Stage Compressor
‹#›
compressor map for a
3-Stage Compressor - Inlet Vanes Positions
A
90
pressure difference
B 75
C
51 63
36
10 14 25 vane position
(degrees)
unloading line
‹#› capacity
Low-Pressure Chillers
Refrigerant Operating Pressures
compressor
suction elbow
Air may leak into the machine through low pressure areas Evaporator
- accumulate in the condenser during machine operation
- reduces its ability to condense refrigerant
- increased condenser pressure
- lower chiller efficiency and capacity.
‹#›
EarthWise™ Purge System with
CH 530 Control
A purge system is required on all

low pressure centrifugal water
chillers to remove air, moisture, and
other non-condensable that may
leak into the machine
‹#›
Purge System Overview – Components -Front View
Carbon tank temperature sensor
Carbon tank
Carbon tank heater
Automatic expansion valve
Pump-out solenoid valve
Pressure-relief device
(fusible plug - fuse at 168°F)
Exhaust
Condensing unit solenoid valve
(includes compressor,
condenser coil, and fan)
Purge Tank
Pump-out compressor
Float switch
Compressor suction
Chiller refrigerant
Filter-drier canister temperature sensor
return line
‹#›
Purge System Overview – Components -Back View
Carbon tank heater Automatic expansion valve
Pump-out solenoid valve
Pump-out Pressure-relief device (fusible plug)

compressor
Carbon tank
Purge tank
Exhaust
solenoid valve
Condensing unit
Pressure-relief
valve (150 psi)
Regeneration
solenoid valve
Chiller refrigerant supply line

‹#›
Purge System Operating Principles
Running
‹#›
Purge System Operating Principles -
Refrigeration Circuit
85°F
70°F ambient
0.60 LBS of R404A 100°F condensing temperature
150°F
1/4 hp
34 psia
75°F
>60°F -16°F
few non condensable
‹#›
Air Removal Cycle
‹#›
Air Removal Cycle
‹#›
Air Removal Cycle
‹#›
Pump-out Cycle
(150 psi)
Running
Run
‹#›
Carbon Tank Regeneration Cycle
(150 psi)
Stop
Stop
‹#›
Purge Operating Modes
• Stop: The purge condensing unit does not run in this mode.
• On: The purge condensing unit runs continuously in this mode, regardless
of the chillers operational status.
• Auto: The purge condensing unit runs in this mode, if the main compressor
of the chiller is operating.
• Adaptive: The purge condensing unit operation depends on past purge

activity.
– Operates the purge continuously for the first 168 hours (chiller on or off)
to accumulate historical data, then..
 Adaptive Mode with Chiller ON
 Adaptive Mode with Chiller OFF
‹#›
Adaptive Mode Chiller “ON”
• If the purge has not pumped out within the last 60 minutes
and the historical daily pumpout time with the chiller “on”
is...
– <1 minute, the purge will shut down for 4 hours

– <3 minutes, the purge will shut down for 3 hours
– <5 minutes, the purge will shut down for 2 hours
– <8 minutes, the purge will shut down for 1 hour
– >8 minutes, the purge will not shut down
‹#›
Adaptive Mode Chiller “OFF”
• If the purge has not pumped out within the last 60 minutes
and the historical daily pumpout time with the chiller “on”
or “off” is...
– <=1 minute, the purge will shut down for 3 days

– <=3 minutes, the purge will shut down for 2 days
– <=5 minutes, the purge will shut down for 1 day
– >5 minutes, the purge will shut down for 6 hours
‹#›
DynaView
Daily Tasks
Auto/Stop
Status (All Sub-systems)
Setpoint Adjustments (Daily user points)
Active Diagnostics (qty 10 active list)
No History Diagnostics
Mode Overrides
‹#›
Dynaview – Operator Interface
‹#›
‹#›
‹#›
Diagnostic Screen Latching - Machine Shutdown
Manual Reset Required (MMR)
or
Non-Latching - Machine Shutdown
Auto Reset (MAR)
Latching (MMR) require corrective

action and manual reset.
Non-Latching (MAR) will restart

automatically when condition
corrects itself.
There are over 200 potential

Messages (diagnostics)
Alarm
Up to ten active diagnostics can be
displayed if required
‹#›
Main Screen
‹#›
Reports
‹#›
Reports
‹#›
Reports
‹#›
Setting Tab screens
(1) Temperatures will be adjustable to 0.1 degree F or C. The Main Processor provides the minimum and maximum allowable value.
(2) Adjustable to the nearest whole number percent. The Main Processor provides the minimum and maximum allowable value.
‹#›
Setting Tab screens
‹#›
Setting Tab screens
(7) Manual Compressor Control allows an operator to override the Auto Control and manually control the compressor while in operation.
This is not active during Stop mode.
(3) Terminates with 10 minutes if inactivity
‹#›
Setting Tab screens
‹#›
Setting Tab screens
(4) The Date and Time setup screen formats deviate slightly from the standard screens defined above.
(5) Enables a DynaView™ Lockout screen. All other screens timeout in 30 minutes to this screen when enabled. The DynaView™
Lockout Screen displays a 0-9 keypad to permit the user to exit the lockout with a fixed password (1-5-9 + Enter).
(6) Language choices are dependent on what has been setup in the Main Processor. Language selections will include English and qty 2
alternate as loaded by TechView™. Language shall always be the last setting listed on the Display Settings menu. This will allow a user
to find language selection if looking at an unrecognizable language.
‹#›
15 9
‹#›
Sequence of Operations
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operating log
ASHRAE Guideline 3
 Chilled water inlet and outlet  Oil pressures, temperature, and

temperatures and pressures levels
 Chilled water flow
 Evaporator refrigerant  Addition of refrigerant
temperature and pressures
 Evaporator approach  Addition of oil
temperature
 Vibration levels
 Condenser water inlet and outlet
temperatures and pressures
 Condenser water flow
 Condenser refrigerant
temperature and pressures
 Condenser approach
temperature
‹#›
Daily Logging and Checks
‹#›
Monthly Maintenance Service
 Preliminaries - co-ordinate service with Operator/Owner

 Operating Log - complete logging on Chiller
‹#›
 Water Flow - balance Evaporator & Condenser water flow
‹#›
 Check Lubrication System

- oil level
- check oil sump temp (115 -160 deg. F)
- check net oil pressure (18-22 psid)
Oil Tank
Oil Regulator
Re-adjust to a differential of 18 to 22 PSI (124 to 150 kPa) if necessary.
‹#›
 Vane Control Linkage - lubricate bearings, ball joints pilot points
‹#›
 Service EarthWise Purge

- check purge tank condensing activity
- check moisture indicator
- clean condenser coil
- inspect purge tank and carbon tank insulation for any damage or
degradation
‹#›
Stop Chiller and isolate incoming supply.

 Service Unit Control Panel
- tighten all terminals
- check for overheating on wires or terminal blocks
- check any sign of corrosion
- clean and get rid all dust or debris on components
UC800
‹#›
 Check Compressor Motor Terminals

- check for overheating on wires or cable clamps
- check any sign of corrosion
- check any sign of condensation
HAZARDOUS VOLTAGE!
NEVER OPEN ACCESS PANELS TO INSPECT OR SERVICE THE
UNIT WITHOUT FIRST OPENING ALL DISCONNECT SWITCHES.
‹#›
 Insulation - check for any condensation or deterioration
‹#›
 Spring Isolators
– check upper housing clears lower housing 1/4’’(6 mm) and not
fully compressed
– check for any sign of corrosion
‹#›
Clean Chiller and housekeeping of Plant room

Restart chiller and detailed logging
Listen to Chiller operation and note any different
or unusual noise
Discuss operation with customer
Review Customer’s log
Evaluate logs to determine operating trend
Note down any uncorrected abnormalities
observed during the Service.
‹#›
Annual Maintenance Service
- Typical Scope of Work
Preliminaries
 Inform Customer and co-ordinate the Annual service
 Discuss Chiller operation with Customer
 Review Customer’s log and evaluate logs to determine
operating trend
 Complete operating log and note any different or unusual
nois
 Note down any abnormalities and inform Customer
 Stop Chiller operation and disconnect electrical power
supply
‹#›
Refrigerant Recovery
 Recover entire charge with Recovery Machine and evacuate
to 4mm Hg. to remove all refrigerant vapor
 Pressurize with nitrogen to 1.0 psig
‹#›
Calibration of High Pressure Cutout Switch

 Cut out at 15 psig and cut in at 10 psig
‹#›
• Sensor Check Bearing Oil Temp. 1
Cond. Sat. Oil Pump Discharge Pressure

Refrig. Temp.
Bearing Oil Temp. 2
Discharge
Refrig. Temp
Cond. Entering
Water Temp.
Cond. Leaving
Water Temp.
Cond. Sat.
Refrig. Temp.
Oil Sump Pressure Oil Temp.

Evap. Sat. Refrig. Temp.
Evap. Entering
Evap. Leaving Water Temp.
Water Temp.
‹#›
Compressor Inlet Vane Linkage Assembly

 Remove pipe plug and top up oil for 1st Stage Tang Operator
 Lubricate universal joints at 1st & 3rd stage inlet vane
assembly
Inlet Vane Operator Mechanism

Pipe Plug
1st Stage Tang Operator
‹#›
Compressor Motor
 Check motor terminals for any sign of overheating,
corrosion, or condensation and rectify accordingly
 Tighten cable clamps
 Meggar the motor
‹#›
Compressor Motor
 Check motor stator coil continuity
 Check motor Resistive Temperature Detector (RTD) for any
sign of overheating, corrosion, or condensation and rectify
accordingly
 Check RTD terminals and stab-on connector’s of wire leads
are firm and tight
‹#›
Condenser and Evaporator Tube Cleaning

 Mechanical brush cleaning of tubes
 Visual inspection for scaling in tubes and pitting on tube-
sheet. Note findings and make recommendations
Safety Hoist Ring
‹#›
Condenser Tube Cleaning
 Chemical cleaning of tubes
Retube
‹#›
Condenser and Evaporator Tube Cleaning

 Check all isolation and balancing valves are in proper
functional order
 Check/calibrate thermometers and pressure gauges
 Check that all flow detection devices are calibrated to open
at approx. 50% of rated flow
‹#›
Lubrication System
 Drain out entire oil charge
 Note condition of oil - good/fair/poor
 Replace oil filter
‹#›
Lubrication System
 Oil pump motor to ground check and continuity test
 Check oil pump terminals and stab-on connectors of lead
wires are tight
 Check oil sump heaters terminals and stab-on connectors
of lead wires are tight
‹#›
Leak Test
 Pressurize with dry nitrogen till 8 psig for thorough leak
test
 Location of leak repaired to be noted down
 Relieve the nitrogen charge
‹#›
Evacuation & Charging

 Evacuate Chiller with vacuum pump capacity of at least 5 cfm
 As system goes into vacuum, new compressor oil can be readily
drawn in to oil sump - level mid-way of upper sight glass
 Evacuate till <500 microns - hold for valid vacuum standing test at
least 1 hour (max. allowable pressure rise is 100 microns in 1 hour
or 500 microns for 12 hours)
 Charge refrigerant as per amount on nameplate
‹#›
Preparation for Start-Up

 Clean Chiller and touch-painting
 Power up motor starter - check control voltage at UCP
 Perform dry test on starter
 Check current drawn by oil sump heater
 Check and balance condenser and evaporator water flow
 Counter check operator settings, service settings and
machine configuration
‹#›
Chiller Hand-Over
 When logging is complete, check refrigerant level
 Set Purge operating mode to “Adaptive”
 Remove all used oil and empty drums and clean plant room
 Hand-over Chiller operation to Customer and discuss
Chiller operation with Customer
 All uncorrected abnormalities observed are noted down on
Service Chit
 Customer’s acknowledgement of service rendered by
signing on service chit and log sheet
‹#›
maintenance considerations
Heat Transfer Surfaces
 Recommended maintenance
☑Use a qualified water treatment
specialist
☑Clean tubes as needed
☑Clean water-side strainers
☻Test tubes every 3 years
‹#›
Why are the tubes so
important?
➥ The tubes in the heat exchanger guarantee optimum
performance and efficiency of the chiller.
➥ Depending on their size, the heat exchangers contain

from one hundred to several thousand tubes, all
undergoing combinations of mechanical stress and
chemical corrosion.
➥ These tubes can be weakened or damaged by corrosion,

erosion, wear, stress and a number of other problems
➥ These destructive elements can eventually lead to leaks

in the tubes
‹#›
Why are the tubes so
important?
➥unscheduled
A tube leak in a chiller can be very expensive in terms of
downtime, major repairs to the equipment or
contamination of refrigerant
➥ofTube leaks can develop without the equipment showing any sign
a problem ……..until leak occurs
➥theWhen a tube fails in a chiller, water enters the refrigerant side of

chiller. Water mixes with the refrigerant and forms an acid
which attacks the internal metal surfaces of the machine. The
resulting damage can be catastrophic, rendering a unit beyond
repair.
➥heat
Standard maintenance techniques can check everything on a
exchanger except its most important components - tubes
‹#›
What can happen to these tubes?
✖ subjected to undetected destructive elements at work
‹#›
Some “unforeseen” causes of tube failures
Electrochemical corrosion: caused by Corrosion under deposits: deposits of

corroding water containing chemical silt and algae facilitate corrosion due to
substances. different aeration rates
Corrosion caused by traction: cracks on External corrosion of a condenser tube

an evaporator tube. The cause of this condition is generally
excessive moisture in the refrigerant,
over an extended period of time
‹#›
Some “unforeseen” causes of tube
failures
Tube Support Wear Freeze Rupture

It is a result of mechanical abrasion or The extremely low temperature is transferred
wear at the tube supports more quickly through the tube support and at
this point causing a rupture.
‹#›
Some “unforeseen” causes of tube
failures
ID Pitting
Pitting is extremely localized corrosion that generally
produces sharply defined holes.
It may result because of poor maintenance of water

treatment, or to the accumulation of acid residues
‹#›
“Unforeseen” Event of a Tube
Failure
What are the consequences to chilled water production?

• Unscheduled downtime
• Cause lengthy and costly halts in production
• Major unscheduled repairs and not budgeted for
Water
instead of Water
refrigerant instead of
oil
‹#›
The Solution – Eddy Current Tube
Analysis
➥Appropriate maintenance
➥ Tri Annual - Perform Eddy Current Test
➥Eddy Tube Test provide a real image about the tubes status in
Condenser & Evaporator
➥Erosion, corrosion, defects & other phenomena that could cause

tube failure has to be detected, located, recorded and their
significance assessed - before their consequences start to cause
leaks
➥An Eddy Current Tube Test can prevent unforeseen tube failure by
detecting, identifying and locating potential tube failures before they
actually becomes leaks
➥By “Finding the Leak Before It Occurs” - many of the problems

associated with a tube leak can be avoided
‹#›
Eddy Current Tube Analysis - Equipment
‹#›
Eddy Current Tube Analysis – set up in the
Field
‹#›
How an Eddy Current Test Works
➥Insert and pushes a probe through entire length of the tube

➥Eddy Current develop as a result of alternating current flowing
through coils inside probe
➥Eddy Current flow in a circular motion forming flux-field in the
probe and penetrate the entire wall of the tube
➥As the probe travels though the tube any variables in the eddy
current pattern are displayed on a small monitor
➥From the shape and direction of the signals, the type of problem
and its location anywhere within or on the tube can be identified
‹#›
Eddy Current Test Report
☑General Information Sheet
☑Summary Report of Defects
☑Record of Inspection
‹#›
Eddy Current Test Report
‹#›
Eddy Current Tube Analysis– Evaluation
◆ Support Wear ▬ Tubes indicating >20% wall penetration - rejected
◆ Pitting ▬ >40% wall penetration - rejected
◆ Erosion ▬ >40% wall penetration - rejected
◆ Corrosion ▬ >40% wall penetration - rejected
◆ Bulging ▬ >20% expansion - rejected
◆ Crack ▬ All cracks are rejected
◆ Restricted ▬ When restriction does not allow probe to move

through the entire length of the tube – rejected
‹#›
How Often Should Tube Tests be
Made
✚For proper preventive maintenance – it is

recommended that they be tested every 3 years
✚As a general rule, most manufacturers

recommend that testing be done at three year
intervals.
✚After the first test has been made, a realistic

testing schedule can be made concerning future
tests.
‹#›
An Eddy Current Tube Analysis
– can save you $$$$$$$$$$
 Used as a preventive tool – can spot potential tube failures

which otherwise go unnoticed until the failure actually
occurred
 If these tube problems are not detected and corrected in
good time, the cost that may result include:
▼ Expensive downtime while repairs are being made
▼ Lost production
▼ Major equipment damage
▼ Contamination of refrigerant
▼ Overtime costs
‹#›
An Eddy Current Tube Analysis
– can save you $$$$$$$$$$
◆ Used Eddy Current Tube Analysis to “ Find the Leak Before It

Occurs”
◆ Any repairs that are necessary can be made when its most
economical, like during a normal equipment shutdown
◆ The cost of an Eddy Current Test is very small when

compared to the expenses incurred with a tube failure
‹#›
Any Questions ?
‹#›
‹#›

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Operating, Maintenace and

Trane CVHG CenTraVac™ Chillers

☻To enable the Operators to understand:

√ How to make operational changes, access the screens and

√ Maintenance required for efficient & reliable operation of the

R Vr Vt ∝ rotational speed × diameter

A purge system is required on all

Pump-out solenoid valve

Pump-out Pressure-relief device (fusible plug)

Chiller refrigerant supply line

• Adaptive: The purge condensing unit operation depends on past purge

– <1 minute, the purge will shut down for 4 hours

– <=1 minute, the purge will shut down for 3 days

Status (All Sub-systems)

Setpoint Adjustments (Daily user points)

Active Diagnostics (qty 10 active list)

Latching (MMR) require corrective

Non-Latching (MAR) will restart

There are over 200 potential

(3) Terminates with 10 minutes if inactivity

 Chilled water inlet and outlet  Oil pressures, temperature, and

 Preliminaries - co-ordinate service with Operator/Owner

 Water Flow - balance Evaporator & Condenser water flow

 Check Lubrication System

Re-adjust to a differential of 18 to 22 PSI (124 to 150 kPa) if necessary.

 Vane Control Linkage - lubricate bearings, ball joints pilot points

 Service EarthWise Purge

Stop Chiller and isolate incoming supply.

 Check Compressor Motor Terminals

 Insulation - check for any condensation or deterioration

Clean Chiller and housekeeping of Plant room

Calibration of High Pressure Cutout Switch

Cond. Sat. Oil Pump Discharge Pressure

Bearing Oil Temp. 2

Oil Sump Pressure Oil Temp.

Compressor Inlet Vane Linkage Assembly

Inlet Vane Operator Mechanism

1st Stage Tang Operator

Condenser and Evaporator Tube Cleaning

Safety Hoist Ring

Condenser and Evaporator Tube Cleaning

Evacuation & Charging

Preparation for Start-Up

➥ Depending on their size, the heat exchangers contain

➥ These tubes can be weakened or damaged by corrosion,

➥ These destructive elements can eventually lead to leaks

➥theWhen a tube fails in a chiller, water enters the refrigerant side of

Electrochemical corrosion: caused by Corrosion under deposits: deposits of

Corrosion caused by traction: cracks on External corrosion of a condenser tube

Tube Support Wear Freeze Rupture

It may result because of poor maintenance of water

What are the consequences to chilled water production?

➥Erosion, corrosion, defects & other phenomena that could cause

➥By “Finding the Leak Before It Occurs” - many of the problems

➥Insert and pushes a probe through entire length of the tube

◆ Support Wear ▬ Tubes indicating >20% wall penetration - rejected

◆ Pitting ▬ >40% wall penetration - rejected

◆ Erosion ▬ >40% wall penetration - rejected

◆ Corrosion ▬ >40% wall penetration - rejected

◆ Bulging ▬ >20% expansion - rejected

◆ Crack ▬ All cracks are rejected

◆ Restricted ▬ When restriction does not allow probe to move

✚For proper preventive maintenance – it is

✚As a general rule, most manufacturers