Chiller performance

testing program
Proven performance under your watchful eye
 The proof is in the testing
Ensure chiller performance
Businesses around the world are being
challenged to improve energy efficiency.
According to the World Business Council for
Sustainable Development, buildings worldwide
account for 40% of global energy consumption.
Of that amount, between 45% to 65% is used
by the HVAC systems that keep building
environments comfortable and healthy. The
slightest inefficiencies in cooling and heating
equipment create a huge energy drain and the
financial impact is significant.

The first step in meeting your energy

management goals is a Trane performance test.
This verifies that your chiller will perform as
specified under job site conditions.

Trane is the global chiller leader

Our primary focus in new HVAC systems is energy management, and it Trane has manufactured centrifugal chillers
is critical to ensure that our systems will perform as designed. Using a in La Crosse since 1938. Much more than a
witness performance test gives us the documentation to prove that we chiller manufacturing location, La Crosse is the
can operate as designed. birthplace of Trane and the site of the worlds
Larry Hood, senior construction manager for leading building comfort research location.
Volusia County Schools, Florida
Equipment and systems developed and tested in
La Crosse are found in hundreds of thousands of
A witness performance test confirms to our customers what we say buildings around the world.
about our energy efficiency and performance. It is one great step
towards earning their trust. In 1987 a new manufacturing facility was
Kelly Strokes, LEED accredited professional, Trane sales engineer constructed in Pueblo, Colorado to produce
Series R screw compressor water chillers. Since
then, the Pueblo facility has doubled in size
and produces both air-cooled and water-cooled
chillers. Visitors come to La Crosse and Pueblo
from all over the globe to see our world class
manufacturing and testing facilities first hand.

2 Chiller performance testing

La Crosse, Wisconsin is located on the Mississippi AHRI 550/590 certification
River, the second largest river in the world, with AHRI Standard 550/590 requires specific types
scenic landscapes of limestone and bluffs that of instrumentation and specifies chiller testing
soar high above both sides of the river. The procedures and tolerances.
drive along the upper Mississippi is one of the
most beautiful in the United States. Trane chillers are AHRI certified. AHRI requires
a copy of the computer selection program used
Pueblo, Colorado is located at the base of
to predict the chiller performance. Several times
the Rocky Mountains. The mountains create
a year, AHRI tests random production chillers to
a beautiful backdrop and provide many
verify that the predicted performance falls within
exciting activities for every season.
the defined tolerance.

Performance testing to match your All Trane test stands in La Crosse and Pueblo are
specifications approved by AHRI for certification testing. Trane
Computer selection programs predict chiller Pueblo is the first chiller manufacturer to have
performance based on laboratory testing. Factory an AHRI approved air-cooled test facility. Each
performance tests confirm that the actual chiller test facility undergoes an extensive and rigorous
performance matches the predicted performance, inspection process conducted by AHRI to gain
and the results serve as a benchmark during the approval for conducting AHRI certification tests.
commissioning process.
AHRI 575 factory sound test
We are committed to the highest level of design If the sound pressure test per AHRI Standard
and manufacturing accuracy to make sure your 575 is specified, we will discuss the procedure
chiller performs as expected. with you.

3
 Testing is our way of life
Measurement that counts Part load conditions per AHRI standard,
Accurate measurement is an integral part or at your specified conditions
of performance testing. All the following Large chillers are tested at full load to
instrumentation is calibrated and traceable to determine the capability and efficiency of the
NIST, the National Institute of Standards and unit at design duty. The full load performance
Technology: wattmeter, temperature sensors, often affects demand charges. For part-load
flow meters, and pressure transmitters. This measurements, AHRI 550/590 defines the
Research and ensures the instrumentation meets or exceeds entering condenser water temperatures or
development the accuracy requirements of AHRI Standard ambient air temperature for 75 percent, 50
The testing process 550/590. A copy of the latest calibration report percent, and 25 percent load. If you prefer
starts in research and is available upon request. to have your chiller tested at other part load
development. We
look at environmental conditions the measurements are taken using the
performance, acoustic A poly-phase wattmeter measures the volts same methods.
characteristics, operating
and amps per phase and the kW. Two platinum
longevity, and overall
operating efficiency. resistance temperature detectors (RTDs) measure
After the chiller goes temperature at each location (entering and
into production, we
leaving evaporator water, entering and leaving
keep looking for ways
to make it better, condenser water for water-cooled, ambient air
quieter, more reliable for air-cooled). Magnetic flow meters measure
and more efficient.
the evaporator and condenser water flow, where
applicable. For air-cooled units, the ambient
temperature system averages multiple readings
from sensors throughout the controlled test
environment. Differential pressure transmitters
measure the water pressure drop.

Redundant measurements: Per industry practices,

redundant measurement devices are designed
into test loops to verify test data. Redundant
sensors are used to measure evaporator water
flow, evaporator water temperatures and unit
power consumption. Agreement between the
calibrated sensors confirms the data taken is
accurate. Continuous real-time monitoring
of these measurements is done for all
performance and witness tests.

4 Chiller performance testing

Testing at more difficult operating
conditions to account for clean tubes
Tubes in the chiller serve as the heat transfer
surface. A certain amount of fouling will occur
on the walls of the tubes after the chiller is
operational. Fouling impedes heat transfer and
makes the chiller work harder.

The predicted chiller performance anticipates

slightly reduced heat-transfer performance
due to the fouling factor specified. The test
conditions will be adjusted so that the chiller
works as hard during the test as it will after
fouling has occurred.

The evaporator leaving water temperature is

adjusted slightly lower. For water-cooled
condensers the condensing entering water
temperature is adjusted slight higher.

We meet AHRI tolerances

When you select a Trane chiller, a product report
The tolerance for tons, kW/ton, and heat balance
is provided from the computer selection program
varies based on the chiller load and the operating
that predicts performance. The purpose of a
conditions of the system. The specific tolerances
factory test is to verify the chiller operates at
for the test are listed on the test target sheet.
this performance level, plus or minus a tolerance
as defined by AHRI.
Recording of test data for your review
This tolerance is applicable to all manufacturers. The computer data acquisition system records
The following AHRI tolerances are consistent for three sets of data at five minute intervals. It
all tests: displays the result of each data set. Following
Flow rates 5% the third set, the results are averaged and a
Water pressure drop < 115% report is printed showing this data.
Leaving evaporator and entering condenser
water temperatures 0.5F of target We will review this report with you to confirm
Voltage 10% of nameplate that your chiller meets the test requirements.
Frequency 1% of nameplate

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5
 Proven performance and quality workmanship

Full-load vibration test available Energy that comes into our system must
Trane performs a vibration test on the assembled equal the energy that comes out
centrifugal chiller compressor at the time of the Energy comes into the system at the evaporator
100 percent load test. Advise us if you would and the motor. The energy leaves the system at
like to see the vibration test results. the condenser. For a hermetic chiller, the energy
absorbed from, or given to, the equipment room
A nickel can be balanced on the edge of the or ambient air is ignored.
main compressor-motor assembly, demonstrating
the extremely low vibrations generated by the Heat balance calculation: While it is collecting
unit while operating. We can arrange for the data for water-cooled performance tests, the
famous nickel test. computer calculates a heat balance to confirm
that the test data is valid.

Energy In = Energy Out: A good heat balance

does not verify that the chiller performance is
good or bad. Instead, it verifies that the quality
of the data is good.

We typically expect that the 100% load heat

balance will be 1.5%. The allowed tolerance
for your tests heat balance is listed on the test
target sheets.

6 Chiller performance testing

How does the water-cooled
test loop work?
Each test loop has an evaporator section
and a condenser section. An interconnecting
water distribution system allows us to create a
cooling load for the chiller by adding hot
leaving condenser water to the leaving
evaporator water. At the same time, an equal
amount of cold leaving evaporator water
is added to the leaving condenser water to
create the desired entering condenser water
temperature. Usually this does not adequately
reduce the water temperature, so some cold A performance test will ensure your chiller will start up
and operate without problems when it reaches the job
water is added to obtain the target entering
site. You can confirm your chiller performance at design
condenser water temperature. An equal amount conditions before it ships to the job site.
of hot water is discharged from the system.

Water-cooled test loop

Hot Warm Cool Cold Water

Hot Cold Refrigerant Entering condenser Condenser refrigerant temperature

water temperature

Flow meter Adjusted entering

condenser water
temperature -
Condenser test target
water pump Leaving condenser
water temperature
Entering condenser
water temperature -
Waste sales order
water
Polyphase
wattmeter Compressor
Orifice
Automatic system
Motor
mixing
butterfly Leaving evap Leaving evaporator
valve water temp water temperature -
sales order

Evaporator Manual drop

water pump butterfly valve
Entering evaporator Adjusted leaving
water temperature evaporator water
Flow meter temperature -
test target
Remote
GPM control Evaporator refrigerant temperature

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 How does the air-cooled test loop work?
The air-cooled test loop has an evaporator section
and a condenser section. Inter-connected water
and air loops create a cooling load for the chiller by
adding heat from the discharge air to the leaving-
evaporator water.

Design ambient operating conditions are controlled

by pulling the discharge condenser airflow through
a set of water-cooled coils. The first coil transfers
heat from the discharge air to the leaving-evaporator
water. The second coil bank, with water from an
auxiliary chiller, further cools the air to the design
ambient before returning it to the test environment.

The ambient air temperature within the test facility

will be compensated for air density at 4,700 feet
above sea level.

.
Air-cooled test loop Coils Coils
(water control) (ambient control)

Air flow

Upper room

Lower room

Return air Control

valves
Test unit

Auxiliary chiller Ice bank

Test room Pump room

Ingersoll Rand (NYSE:IR) is a world leader in creating and sustaining safe, comfortable and efficient environments in commercial, residential and
industrial markets. Our people and our family of brandsincluding Club Car, Hussmann, Ingersoll Rand, Schlage, Thermo King and Tranework
together to enhance the quality and comfort of air in homes and buildings, transport and protect food and perishables, secure homes and commercial
properties, and increase industrial productivity and efficiency. We are a $13 billion global business committed to sustainable business practices within
our company and for our customers.

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