HEAT

HEAT EXCHANGER
EXCHANGER

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 CONDENSER

Discharge Gas

Chicane

Cooling Water

Tube
bundle Liquid Line

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 CONDENSER

Water
Entering 10 %

60 % 40 %

Refrigerant Liquid

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 EVAPORATOR

Orifice
Distributor Eliminator
Liquid Line

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 EVAPORATOR
Suction
Chicane Eliminator

Tubes bundle
Oil cooler

Distributor
Orifice

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EVAPORATOR

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DISTRIBUTOR

Evaporator

Distributor

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 ECONOMISER
Suction to Second Stage

HP Liquid

Liquid

to Evaporator

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EXPANSION
EXPANSION DEVICE
DEVICE

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ORIFICE

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ORIFICE

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 ORIFICE

to
H1
Evaporator

Orifice

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 ORIFICE

to

H2 Evaporator

Orifice

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 PERFORATED PLATES
■ T saturation EVP = f ( T in , T out EVP )
■ Absorbed power COMP = f ( refrigerant
flow)
■ The function of perforated plates is to limit
the amount of gaseous refrigerant produced
during the expansion process. Gas doesn't
contribute to cooling effect.
■ Orifice plates are designed for specific full
load operating conditions. More and more
gas is produced when operating at part load
conditions, this will increase absorbed
power .
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PERFORATED PLATES

Refrigerant Direction

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EVP APPROACH TEMPERATURE

! Approach = LCWT - T sat.

! depends on capacity :
approach increases with
capacity
! depends on tubes cleanliness
! approach increases when there is a
refrigerant shortage
! approach increases if too much
Refrigerant or Oil TRAINING CENTRE
 APPROACH - ∆T
• Evaporator - water (CVGE/CVAE)
Temperature

Water Inlet

Water Outlet

Evap. Sat. Temp. ∆Τ

Surface
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 APPROACH - ∆T
• Condenser - water (CVGE)
Temperature

Cond. Sat. Temp.

∆Τ
Water Outlet

Water Inlet

Surface
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 APPROACH - ∆T

• Condenser - air (CVAE)

Cond. Sat. Temp.

Temperature

∆Τ Air Outlet

Air Inlet

Surface
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 VALUES
• Approach Evaporator

R 12 ~ 2,5°C

R134a ~ 2°C

• Approach Condenser
– water cooled
R 12 ~ 1,5°C / 5°C

R134a ~ 1,0°C / 4°C

– air cooled R 12 ~ 15°C

R134a ~ 15°C

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 SOME DATA

⌦ LP: 2,1 to 2,4 bar for R134a

2,3 to 2,5 bar for R12
⌦ HP: 7,3 to 12,5 bar for R134a Expans. at
Motor
7,0 to 12,0 bar for R12 entering
⌦ ∆P Oil : 1 ot 2 bar or more
⌦ Oil Tank has to be the lowest pressure point from the
machine
⌦ Distillation by Start: close IGV + open the valve at
the bottom of the Evaporator
⌦ Expansion at the motor entering to cool the electrical
motor.
Warning: ∆P = 2 to 3 bar is necessary COND./EVAP.
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REFRIGERANT OPTIMAL CHARGING
• Indicators:
– Approach
– Sat. EVP Temperature
– LP, HP
– Discharge Superheat
– Everything has to be checked by full load

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 OIL CHANGE HIGH SPEED UNIT

# Drain the oil using internal pressure

$ unit should have run at full load before
$ measure recovery oil volume
$ power supply to heaters should be disconnected
$ do not blow refrigerant to atmosphere
$ change filter and gasket

# Clean oil tank each five years

$ refrigerant recovery is needed

# Charge with a pump that is able to produce

higher pressure than internal pressure and a
transparent hose
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 MECHANICAL OVERHAUL
HIGH SPEED

• inspection of gear drive

– paint on high speed gear for surfaces wear
inspection
– refrigerant recovery is needed
• inspection of bearings every
40000 hours of operation
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 OIL LEVEL AND DISTILLATION
% Oil level should be visible in the sight
glass (1/2 to 3/4 according to load )
% If oil level higher than 3/4 :
& too much oil
& or refrigerant presence in oil tank
% If refrigerant is present, oil temperature
becomes too low and chiller doesn't
start without an oil heating period
% If oil level is too low, a distillation cycle
should be performed
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 DISTILLATION CYCLE

• Add oil to reestablish oil level

• Operate the unit a few hours to ensure
oil return, vanes should be closed
• Open the Vent Line
• Open Distillation valve

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 NORMAL DISTILLATION CYCLE

• Check opening of distillation and vent line

valves
– distillation valve should be open 3/4 to 1 1/2 of total
opening
– vent line valve should be open at minimum 2 times of
distillation valve opening (3 to 4 is normal)
– when valves are properly adjusted, oil temperature in
the tank should be around 50°C and distillation line
should be cold whatever the load is
• After distillation, drain added oil and adjust
level
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OIL CHANGE AND OIL ANALYSIS

• oil should be changed every

year
• it is strongly recommended to
test oil acidity regularly
• it is strongly recommended to
perform a complete oil
analysis regularly

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 OIL SAMPLING FOR OIL
ANALYSIS

• Should performed at bearing oil return line when

machine is running at full load
• Installation of a pipe with isolating valve on
bearing oil return line is recommended
• Purge flexible hoses used for oil sampling

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 OIL SAMPLING
• Minimum sample volume required is 100 ml, fill
bottle with maximum of 80% of its capacity to
avoid overpressure problems due temperature
change
• Use only small bottles supplied by TRANE
• Glass bottle, part number : BOT 002E

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 OIL SAMPLING

• Send identification form with sample bottle

" REFRIGERANT OIL SAMPLE
IDENTIFICATION ", fill in the form and
indicate very precisely :
– date of last oil change
– number of running hours and starts since last oil
change
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 OIL SAMPLING
• IMPORTANT :
• ester oil has a very high hygroscopicity, avoid
air contact to eliminate moisture
contamination of sample
• oil sample should be sent immediately,
storage of bottles is not recommended

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HYGROSCOPICITY COMPARISON

HUMIDITY (MG) HUMIDITY (PPM)

9000 1.500

6000 1.000

polyolester 500
3000

mineral oil
0 0
1 2 5 10 20 50 100 200

Time (hours)

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 OIL SELECTION TABLE

REFRIGERANT R123 R134a R22-R11-R12

oil charge
UNITS
(liter)

CVGD 023 to 045 42 OIL 021E

OIL 015E
CVGD 050 to 080 55 Non applicable or/and
OU OIL 025E*
CVAD 013 to 032 42 OIL 020E

LCV 30 Non OIL 015E

OIL 0022
CVHE 27 applicable OU OIL 025E*

* same oils with diferrent packaging ( 5 or 10 liters)

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