CVHG CH530 Operator Training WSL 2009
CVHG CH530 Operator Training WSL 2009
CVHG CH530 Operator Training WSL 2009
TroubleshootingTraining
‹#›
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
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
‹#›
Purge System Overview – Components -Front View
Carbon tank temperature sensor
Carbon tank
Carbon tank heater
Automatic expansion 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
Condensing unit
Pressure-relief
valve (150 psi)
Regeneration
solenoid valve
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
‹#›
Purge System Operating Principles -
Air Removal Cycle
‹#›
Purge System Operating Principles -
Air Removal Cycle
‹#›
Purge System Operating Principles -
Air Removal Cycle
‹#›
Purge System Operating Principles -
Pump-out Cycle
(150 psi)
Running
Run
‹#›
Purge System Operating Principles -
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 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...
‹#›
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...
‹#›
DynaView
Daily Tasks
Auto/Stop
No History Diagnostics
Mode Overrides
‹#›
Dynaview – Operator Interface
‹#›
Dynaview – Operator Interface
‹#›
Dynaview – Operator Interface
‹#›
Dynaview – Operator Interface
Diagnostic Screen Latching - Machine Shutdown
Manual Reset Required (MMR)
or
Non-Latching - Machine Shutdown
Auto Reset (MAR)
‹#›
Dynaview – Operator Interface
Main Screen
‹#›
Dynaview – Operator Interface
Reports
‹#›
Dynaview – Operator Interface
Reports
‹#›
Dynaview – Operator Interface
Reports
‹#›
Dynaview – Operator Interface
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.
‹#›
Dynaview – Operator Interface
Setting Tab screens
‹#›
Dynaview – Operator Interface
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.
‹#›
Dynaview – Operator Interface
Setting Tab screens
‹#›
Dynaview – Operator Interface
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.
‹#›
Dynaview – Operator Interface
15 9
‹#›
Sequence of Operations
‹#›
Sequence of Operations
‹#›
Sequence of Operations
‹#›
Sequence of Operations
‹#›
Sequence of Operations
‹#›
Sequence of Operations
‹#›
Sequence of Operations
‹#›
Sequence of Operations
‹#›
Sequence of Operations
‹#›
Sequence of Operations
‹#›
Sequence of Operations
‹#›
operating log
ASHRAE Guideline 3
‹#›
Daily Logging and Checks
‹#›
Monthly Maintenance Service
‹#›
Monthly Maintenance Service
‹#›
Monthly Maintenance Service
Oil Tank
Oil Regulator
‹#›
Monthly Maintenance Service
‹#›
Monthly Maintenance Service
‹#›
Monthly Maintenance Service
UC800
‹#›
Monthly Maintenance Service
HAZARDOUS VOLTAGE!
NEVER OPEN ACCESS PANELS TO INSPECT OR SERVICE THE
UNIT WITHOUT FIRST OPENING ALL DISCONNECT SWITCHES.
‹#›
Monthly Maintenance Service
‹#›
Monthly Maintenance Service
Spring Isolators
– check upper housing clears lower housing 1/4’’(6 mm) and not
fully compressed
– check for any sign of corrosion
‹#›
Monthly Maintenance 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
‹#›
Annual Maintenance Service
- Typical Scope of Work
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
‹#›
Annual Maintenance Service
- Typical Scope of Work
‹#›
Annual Maintenance Service
- Typical Scope of Work
• Sensor Check Bearing Oil Temp. 1
Discharge
Refrig. Temp
Cond. Entering
Water Temp.
Cond. Leaving
Water Temp.
Cond. Sat.
Refrig. Temp.
Evap. Entering
Evap. Leaving Water Temp.
Water Temp.
‹#›
Annual Maintenance Service
- Typical Scope of Work
‹#›
Annual Maintenance Service
- Typical Scope of Work
Compressor Motor
Check motor terminals for any sign of overheating,
corrosion, or condensation and rectify accordingly
Tighten cable clamps
Meggar the motor
‹#›
Annual Maintenance Service
- Typical Scope of Work
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
‹#›
Annual Maintenance Service
- Typical Scope of Work
‹#›
Annual Maintenance Service
- Typical Scope of Work
Condenser Tube Cleaning
Chemical cleaning of tubes
Retube
‹#›
Annual Maintenance Service
- Typical Scope of Work
‹#›
Annual Maintenance Service
- Typical Scope of Work
Lubrication System
Drain out entire oil charge
Note condition of oil - good/fair/poor
Replace oil filter
‹#›
Annual Maintenance Service
- Typical Scope of Work
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
‹#›
Annual Maintenance Service
- Typical Scope of Work
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
‹#›
Annual Maintenance Service
- Typical Scope of Work
‹#›
Annual Maintenance Service
- Typical Scope of Work
‹#›
Annual Maintenance Service
- Typical Scope of Work
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.
‹#›
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
➥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
‹#›
Some “unforeseen” causes of tube
failures
‹#›
Some “unforeseen” causes of tube
failures
ID Pitting
Pitting is extremely localized corrosion that generally
produces sharply defined holes.
‹#›
“Unforeseen” Event of a Tube
Failure
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
➥An Eddy Current Tube Test can prevent unforeseen tube failure by
detecting, identifying and locating potential tube failures before they
actually becomes leaks
‹#›
Eddy Current Tube Analysis - Equipment
‹#›
Eddy Current Tube Analysis – set up in the
Field
‹#›
How an Eddy Current Test Works
‹#›
Eddy Current Test Report
‹#›
Eddy Current Tube Analysis– Evaluation
‹#›
How Often Should Tube Tests be
Made
‹#›
An Eddy Current Tube Analysis
– can save you $$$$$$$$$$
‹#›
An Eddy Current Tube Analysis
– can save you $$$$$$$$$$
◆ Any repairs that are necessary can be made when its most
economical, like during a normal equipment shutdown
‹#›
Any Questions ?
‹#›
‹#›