CGAT-IOM-Aug-2010.pdf - Trane

CGAT-IOM01-ENJanuary 2009

InstallationOperationMaintenance

Air-Cooled Chiller 5-18 TonsCGAT Model 50 Hz

Models;CGAT 065 D, CGAT 135 DCGAT 085 D, CGAT 175 DCGAT 105 D, CGAT 215 D

2 CGAT-IOM01-EN© American Standard Inc. 2003

Model Nomenclature

C G A T 0 6 5 D 0 0 0 0 A A1 2 3 4 5 6 7 8 9 10 11 12 13 14DIGIT 1,2,3 - MODEL IDENTIFIERCGA = COLD GENERATOR, AIR-COOLEDDIGIT 4 - DEVELOPMENT SEQUENCET = DEVELOPMENT SEQUENCEDIGIT 5,6,7 - NOMINAL CAPACITY065 - 65 MBH085 - 85 MBH105 - 105 MBH135 - 135 MBH175 - 175 MBH215 - 215 MBHDIGIT 8 - ELECTRICAL CHARACTERISTICSD = 380-415V/3pH/50HzDIGIT 9,10 - FACTORY INSTALLED OPTIONS00 = NONE0A = FACTORY INSTALLED OPTIONSDIGIT 11,12 - 0, 0 FOR FUTURE USEDIGIT 13 - MINOR DESIGN SEQUENCEA = FIRST DESIGN SEQUENCEDIGIT 14 - SERVICE DIGITA = FIRST PARTS LIST

CGAT-IOM01-EN 3

Contents

Model Nomenclature 2

General Information 4

General Data 5

Installation 6

Electrical 8

Typical Wiring Diagram 9

Trouble Shooting 10

Dimensional Data 12

4 CGAT-IOM01-EN

General Information

GeneralAll Trane Products are identified bya model number that Preciselyidentifies the unit. An explanation ofthe alphanumeric identification codesfor CGAT units is provided on the nextpage.Its use will enable the owner /operator,installing contractors and serviceengineers to define the operation,components and options for anyspecific unit.When ordering replacement parts orrequesting service, be sure to refer tothe serial number and specific modelnumber stamped on the unit name-plate.

Unit NameplateThe unit nameplate specifies the unit’sspecific model number, serial number,electrical characteristics, type ofrefrigerant and other pertinent unitdata.

General InformationAll model CGAT air-cooled chillers aredesigned for outdoor installation withvertical air discharge. Each refrigerantcircuit is provided with an operatingcharge of refrigerant and refrigerantoil, a filler drier, high and low pressureschraeder valve and externallyequalized thermostatic expansionvalve. All units are dehydrated, leaktested, charged and tested for propercontrol operation before shipment. Anaccess panel(s) provides access to thecompressor section(s), and a remov-able cover allows access to thecontrol box.The brazed plate heat evaporatorsused in these units are with integraldistributor. Each evaporator is fullyinsulated. Standard capacity andsafety controls are provided. Unitoperation is governed by chilled watertemperature entering the evaporator.

Rigging

WARNING: To prevent injury or deathand unit damage, observe handlingcautions and procedures given inFigure 1 when lifting the unit. Alwaystest-lift the unit to determine actualcentre of gravity.

Before preparing the unit for lifting,estimate the approximate centreof gravity for lifting safety. Due to theplacement of internal components,the unit weights may be unevenlydistributed. Unit shipping weightsare provided in the table below.

Lifting RecommendationsBefore preparing the unit for lifting,estimate the approximate center ofgravity for lifting safety. Because ofplacement of internal components,the unit weight may be unevenlydistributed. Approximate unit weightsare given in Table 1.

WARNING : On-sight lifting equipmentmust be capable of lifting the unitweight with an adequate safety factor.The use of under-capacity liftingdevices may result in severe personalinjury or death and can seriouslydamage the unit.

The crated unit can be moved usinga forklift of suitable capacity. For liftingthe unit, attach lifting straps or slingssecurely to the lifting holes at eachcorner. Use spreader bars to protectthe unit casing from damage. Test liftthe unit to determine proper balanceand stability.

CAUTION : Use spreader bars toprevent lifting straps from damagingthe unit,. Install bars between liftingstraps. This will prevent the strapsfrom crushing the unit cabinet ordamaging the unit finish.

Table 1 : Total Unit Weight and Corner Weights

Corner Weight-Kgs

Shipping Maximum Net maximum

Model Kgs Lbs Kgs Lbs #1 #2 #3 #4

CGAT065 201 442.2 181 398.2 67.5 38.1 44.0 31.4

CGAT085 224 492.8 204 448.8 76.1 42.9 49.6 35.4

CGAT105 270 594.0 250 550.0 100.4 38.2 91.0 20.4

CGAT135 441 970.2 406 893.2 107.3 97.8 95.8 105.3

CGAT175 487 1071.4 452 994.4 119.5 108.5 106.5 117.5

CGAT215 507 1115.4 472 1038.4 125.0 113.0 111.0 123.0

CGAT-IOM01-EN 5

General Data

CGAT065D CGAT085D CGAT105D CGAT135D CGAT175D CGAT215DUnit Performance

Cooling Capacity (1) MBH 65.2 86.3 104.4 133.1 175.4 214.9Main Power supply V/Ph/Hz 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50Min.Brch.Cir.Ampacity A 18.1 27.3 29.8 32.7 49.4 53.9No.of Independent circuits 1 1 1 2 2 2

CompressorType Hermetic ScrollSpeeds number 1 1 1 1 1 1Motors Number 1 1 1 2 2 2Rated Amps (2) A 13.6 20.7 22.9 13.6 20.7 22.9Locked rotor Amps (2) A 98 130 145 98 130 145Motor RPM rpm 2900 2900 2900 2900 2900 2900

EvaporatorType Brazed-plate Brazed-plate Brazed-plate Brazed-plate Brazed-plate Brazed-plateWater flowrate GPM 13.0 17.3 20.9 26.6 35.1 43.0

Water ConnectionsType Male Male Male Male Male MaleDiameter 1 1/2" 1 1/2" 1 1/2" 1 1/2" 1 1/2" 1 1/2"

Outdoor CoilType Uncoated CorrugateTube size inch 3/8 3/8 3/8 3/8 3/8 3/8Tube type Smooth Smooth Smooth Smooth Smooth SmoothFace Area Ft2 15.10 20.00 25.00 30.20 40.00 42.50Rows # 2 2 2 2 2 2Fins per inch (fpf) # 16 (192) 16 (192) 16 (192) 16 (192) 16 (192) 16 (192)

Outdoor FanType Propeller Propeller Propeller Propeller Propeller PropellerNumber 1 1 1 2 2 2Diameter inch 28 28 28 28 28 28Drive type Direct Direct Direct Direct Direct DirectSpeeds number 1 1 1 1 1 1Air flow CFM 4900 5800 6800 9800 11600 13600Motors Number 1 1 1 2 2 2Motor HP (1) hp 3/4 3/4 3/4 3/4 3/4 3/4Rated Amps (1) A 1.06 1.41 1.20 1.06 1.41 1.20Locked rotor Amps (1) A 2.27 3.53 2.80 2.27 3.53 2.80Motor RPM rpm 750 830 875 750 830 875

DimensionsHeight mm 1050 1050 1050 1050 1050 1050Length mm 1060 1060 1260 2200 2200 2200Width mm 950 950 1050 1050 1050 1050Weight uncrated kg 181 204 250 406 452 472

R-22 Refrigerant Charge (2) kg 4.0 4.3 6.0 4.0 5.0 6.0

Notes:(1) per motor(2) per circuit

6 CGAT-IOM01-EN

Installation

InstallationVerily completion of installation byreviewing the following procedures.

Unit Dimensions And WeightsThese are provided under GeneralData on Page 5

DrainageLocate the unit near a large-capacitydrain to allow system drainage duringunit shutdown or repair.

Location And ClearanceRequirements1. The surface in to be level and of

sufficient strength to supportthe unit.

2. Select a location that will permitfree air flow into the condensingcoils and from the vertical discharge. If however, the unit is to beplaced under an overhang, allow atleast 2.0 meters clearance abovethe unit to prevent recirculation ofhot discharge air.

3. For ground level installation the unitshould be set on a level concreteslab 100 mm thick and extendinga minimum of 200 mm beyond thesides of the unit.

4. Mount vibration isolators to avoidvibration or noise transmission.Provide a gravelled apron at least300 mm wide on all sides of theslab unless other means are usedto prevent growth of vegetationclose to the unit. The slab shouldbe located as close to the buildingas possible with a minimumclearance conform to thesubmittals in front of air entry andaccess panels.

5. Provide a large capacity water drainnear the unit. It is used when theevaporator in drained for shutdownor repair. The water circuit isdrained thanks to the evaporatorwater connections.

FoundationElevate the unit. Ensure the floor orfoundation of the unit is level, solidand of sufficient strength to supportGeneral Data Page 5 for informationon weights.

Unit water PipingGeneral Piping RecommendationsThoroughly flush all water supplypiping before making the final pipingconnections to the unit.

CAUTION : If using an acidiccommercial flushing solution,construct a temporary bypass aroundto unit to prevent damage to theevaporator internal components.

Evaporator water inlet and outlettypes, sizes and locations are shownin the Dimensional data section page18-19 Figure 1 on page 7 illustratesa typical water piping components.

Isolate the water pump from thesystem to avoid vibrationtransmission. All water piping are tobe insulated to minimize heat gain andprevent condensation. Use a pipesealant or Teflon tape on all threadedconnections.

Net Positive Suction HeadEvaporator water pumps should belocated in their piping systems suchthat they operate with a net positivesuction head. This is to reduce thepossibility of pump cavitation andpossible differential aeration in thewater system which can rapidly resultin chiller internal corrosion.

Air VentsVents must be installed at high pointsin the piping system to facilitate airpurging during the filling process.

Pressure GaugesInstall pressure gauges to monitorthe entering and leaving chilled waterpressure.

CAUTION : To prevent evaporatordamage, do not exceed 350 psigwaterside working pressure.

Shutoff ValvesProvide shutoff valves in the Supplyand Return pipe near the chiller toallow isolation of the gauge(s),sensors, strainers, etc., during service.

ThermometersInstall thermometers in the lines tomonitor the evaporator entering andleaving water temperatures.

Balancing ValvesThe is required to establish regulationand Balancing of the water flow.

StrainerInstall a pipe strainer in the waterreturn line to protect the componentsfrom entrapped debris.

CGAT-IOM01-EN 7

Chiller Flow SwitchUsed to prevent or stop compressor operation if the evaporator water flow dropsoff dramatically.

Figure 1 - Typical Water Piping

Figure 2 : Evaporator pressure drops

Air Vent Pressure Gauge

Unions

VibrationEliminators

Thermometers

Water Strainer

Reeturn Line(Inlet)

(See Note 1)

Gate Valves(See Note 2

Balancing Valve

Flow Switch

ShutoffValves

Installation

1.00

10.00

100.00

10.0 100.0

Water flowrate, gpm

Pre

ssur

e D

rop,

feet

of w

ater

065 085 105 135 175 215

8 CGAT-IOM01-EN

Electrical

Table 2 - CGAT Unit Electrical Data

Compressor Motor Outdoor Fan Motor

Allowable MinimumMaximum Amps(each) Amps(each)

Model Electrical Voltage Circuit Fuse

Number Characteristics Range Ampacity Size Qty. RLA LRA Qty. Watt output(each) RLA LRA

CGAT065D 380-415/3/50 342-440 18.1 30 1 13.6 98.0 1 290 1.06 2.27

CGAT085D 380-415/3/50 342-440 27.3 30 1 20.7 130.0 1 420 1.41 3.53

CGAT105D 380-415/3/50 342-440 29.8 30 1 22.9 145.0 1 300 1.20 2.28

CGAT135D 380-415/3/50 342-440 32.7 30 2 13.6 98.0 2 290 1.06 2.27

CGAT175D 380-415/3/50 342-440 49.4 30 2 20.7 130.0 2 420 1.41 3.53

CGAT215D 380-415/3/50 342-440 53.9 30 2 22.9 145.0 2 300 1.20 2.28

Electrical Wiring

WARNING: To prevent injury or death,disconnect electrical power sourcebefore completing wiring connectionsto unit.

Table below provides the electricaldata for each of the units. All wiringshould confirm to NEC or applicablecodes as per requirements of localcodes and regulations. Wiring dia-grams are furnished with the units butextra copies can be obtained from theTrane Sales Offices. The installer mustprovide fused disconnect switches.Type and locations of disconnectsmust comply with all applicablecodes.

CAUTION : To avoid componentfailure, use copper conductor wireonly between the main powerdistribution source and the unit’spower terminals. This will preventgalvanic corrosion or overheating atthe terminals.1. Verify power supply available is

compatible with unit’s nameplateratings.

2. Refer to the unit wiring schematicpasted to the control panel cover.

3. All factory supplied wiring arecoloured and numbered. Alwayscheck the numbers on the wiringto the unit terminal block againstthat in the wiring diagram. Shouldthere be any inconsistency, pleasedo not hesitate to contact thenearest Trane Service or SalesOrganization.

4. Chilled Water Pump MotorThe installer must provide a powersupply of proper voltage anda fused disconnect switch to thechilled water pump motor. Provideproper equipment grounds.

5. Flow Switch InterlockTo avoid possible evaporatorfreeze-up resulting from restrictedwater flow, install a flow switch(or other flow sensing device) in theevaporator water line. This sensingdevice must be adjusted to stopcompressor operation if water flowto the evaporator drops 50% of thedesign flow rate.

CGAT-IOM01-EN 11

Control Panel

12 CGAT-IOM01-EN

Pre-Start Procedure

Once the unit is installed, follow thesteps below to ensure the installationprocedure is complete. When all areaccomplished, the unit is ready foroperation.

WARNING : More than one discon-nect switch may be required tode-energize unit for servicing. Refer tounit schematic and open all electricaldisconnects to prevent injury or deathdue to electrical shock.

1. Inspect all wiring connections;electrical connections should beclean and tight.

WARNING : Use extreme carewhen electrically troubleshootingcompressors. If electrical power isapplied to a damaged fusite terminal,a fire or explosion could occur,resulting in injury or death.

CAUTION : Check tightness of allconnections in the compressor powercircuit (disconnects, terminal block,contactors, compressor junction boxterminals, etc.) to prevent overheatingat connections and under voltageconditions at the motor.

2. Check power supply voltage tothe unit at the main power fuseddisconnect switch; the voltagereading should be within theutilization range shown in Table 2on page 9. Also, Voltage imbalancemust not exceed 2%. (Refer to item10 Unit voltage and amperagechecks )

3. Check the condenser fanassemblies; the fan blades shouldrotate freely in the fan orifice, andbe securely attached to the fanshaft.

4. Fill the chilled water circuit, leavingthe system air vents open. Closevent after filling.

5. Start the chilled water pump. Withwater circulating through the chilledwater system, inspect all pipingconnections for leaks and makeany necessary repairs.

6. Adjust the water flow rate throughthe chilled water circuit, and checkthe water pressure drop throughthe evaporator. Refer to waterpressure drop data on page 8.

7. Ensure flow switch is installed andwired to the control panel. Adjustthe flow switch to provide properoperation.

NOTE : Withe the water pumpoperating, throttle the water flow toapproximately 50 percent of the fullflow rate. Following the manufacturer’sinstruction adjust the flow switchcontacts to open at this point. Usean Ohmmeter to verify opening andclosure of the switch contacts.

8. Stop the chilled water pump.9. Open all fused disconnect

switches.

WARNING : Use extreme care whenchecking voltage at live terminals toavoid serious injury or death due toelectrical shock.

10. Unit Voltage and AmperageChecks Voltage supply

Measure each leg of supply voltage(3-phase) at all ling voltage disconnectswitches. Readings must fall withinthe voltage utilization range shown onthe unit nameplate.

Voltage ImbalanceExcessive voltage imbalance betweenphase will cause motors to overheatand eventually fail. Maximum allow-able imbalance is 2%

where VA is the average voltage andVD is the ling voltage that deviatesfarthest from VA

11. Establish a balanced water flowthrough the evaporator.

12. Measure the water pressure dropthrough the evaporator at thepressure gauge(s) on the systemwater piping. Pressure dropreadings at the gauges shouldapproximate those indicated bythe pressure drop charts (figure 2)on page 8

NOTE : Be sure to account for piping/fittings that will create additionalpressure drop between the unit andthe pressure gauge locations.

% Voltage Imbalance = 100 x [VA -VD]VA

CGAT-IOM01-EN 13

Operation

Start-up Procedure1. Energize the evaporator water

pump.2. Energize the CGAT unit.3. Checking operating conditions

Once the unit has been operatingfor at least 15 minutes andthe system has stabilized,the following procedures are to bedone.a. Re-check the evaporator water

flow and pressure drop.b. Measure unit suction and

discharge pressures. Thenormal operating suctionpressure is between 63 to 68psig while the dischargepressure range in between 270psig to 300 psig.

c. Check compressor amp. Draw

NOTE : Many application variablesexists which can affect operatingpressures; these include ambient drybulb, wind velocity, restrictions inairflow etc. As such, do not useoperating pressures as the sole checkof system operation.

4. Measure system superheat. Normalsystem superheat is 12 to 15 deg. Ffor each circuit at ARI conditions(54 deg. F entering water, 44 deg.Fleaving water at 95 deg.F ambienttemperature).

5. Measure system subcoolingNormal subcooling for each circuitis 12 to 16 deg.F at ARI conditions.

6. If operating pressure, superheatand subcooling readings indicaterefrigerant shortage, find and repairleaks and gas-charge refrigerantinto each circuit. Refrigerantshortage is indicated it operatingpressures are low and subcoolingis also low.

CAUTION : If suction and dischargepressures are low, but subcooling isnormal, no refrigerant shortage exists.Adding refrigerant will result inovercharging.

7. Add refrigerant vapor with the unitrunning by charging throughthe access port on the suction lineuntil operating pressures arenormal. Allow sufficient time(between 15 to 30 minutes) beforetaking readings.

CAUTION : To prevent compressordamage, do not allow liquid refrigerantto enter the suction line.

8. If operating pressures indicatean overcharge, slowly (to minimizeoil loss) recover refrigerant atthe liquid line access port.

Important note : Do not releaserefrigerant to the atmosphere.Use proper refrigerant recoveryprocess.

WARNING : To prevent injury due tofrostbite, avoid skin contact withrefrigerant.

9. Check compressor oil levels. At fullload, oil level should be visible inthe oil level sight glass on thecompressor.

10.Inspect the unit. Remove anydebris, tools and hardware. Secureall exterior panels.

14 CGAT-IOM01-EN

Electrical Control System

The controls used on CGAT065-215 chillers are classified either as safety oroperational controls.

Refer to the following control description for control setting

Unit Safety Controls

• Low Pressure Cutout (LPC01,LPC02)

• High Pressure Cutout (HPC01,HPC02)

• Reset relays (1R, 2R)

If the unit is shutdown the low pressurecutout (or high pressure cutout, thereset relay locks out the compressorcontactor (1M, 2M). This preventsthe system from recycling until thecondition that caused the trip isdetermined and corrected.

CAUTION : To prevent unit damage,do not reset the control circuit untilthe cause of the safety lockout isidentified and corrected.

To reset 1R and 2R, open and closethe unit Low Voltage Control CircuitBreaker (MCB).

• Frost Controller or LowTemperature Cutout (LTC)

The Low Temperature Cutout isdesigned to protect the evaporatorfrom freeze damage in the event ofwater temperature thermostatmalfunction or if the is a restrictedwater flow condition. The LTC’sremote sensing bulbs monitorsLeaving water temperature.Manual reset is required. FactorySetting : 2C.

• Motor OverloadsThese units have internal compressorand condenser fan motor overloads.These overloads protect the motorsfrom overcurrent and overheatingconditions and automatically reset assoon as they cool sufficiently.

Unit Operational Controls• Water Temperature

Thermostat (WTT)System operation for CGAT iscontrolled either by single-stagethermostat CGAT075 - 120 or two-stage thermostat CGAT150 - 240

• Delay Between CompressorsPrevents compressors from starting atthe same time.

Operation

Control Electrical Contacts Contact

Description designation open close

High Press. Cutout HPCO1,HPC02 398+-19 psig 310+-21 psig

Low Press. Cutout LPC01,LPC02 27+-7 psig 45.5+-7 psig

Frost controller A27m <35.6 deg.F -

Delay between TDR1,TDR2 Normally - open 3,4.5 minute

comp. Timed to close

CGAT-IOM01-EN 15

Symptom Recommended action

A. Compressor neither starts nor hums.Probable Cause

1. No power a. Check for disconnect switch open.

b. Check for blown fuse

2. No call for cooling a. Check for defective thermostat or

b. Broken or improper control wiring

3. Unit locked out by reset relay a. Check for excessive discharge pressure

b. Check for defective thermostat

4. Compressor contactor will not close a. Check for open reset relay

b. See for defective thermostat

5. Compressor winding thermostat open a. Check compressor amp. Draw

b. See compressor winding thermostat open

B. Compressor hums, but will not start1. Low voltage at compressor a. Check for low fine voltage

b. Check for defective compressor contactors

2. Defective compressor a. Check fro open motor winding

b. Check for excessive amp. draw on all phases.

C. 2nd. stage compressor fails to start1. Time delay contacts fail to close Replace time delay relay

2. No call for cooling a. Check for defective thermostat

b. Check for improper control wiring

3. Locked out by reset relay a. see Symptom A.

4. Compressor contactor will not close a. see Symptom A.

D. Compressor runs continuously1. Unit undersized for load a. Check cause of excessive load.

2. Thermostat setpoint too low a. Re-adjust thermostat setting.

3. ”Welded” contacts on compressor contactor a. Repair or replace contactors.

4. Leaky valves in compressor Replace compressor

(indicated by abnormally low discharge and

high suction pressure)

5. Refrigerant shortage (as indicated by reduced Find and repair leak. Recharge system.

capacity, high superheat, low subcooling and

low suction pressure)

E. Compressor motor winding thermostat open1. Excessive load on evap. a. Check for excessive water flow.

b. Check for high return water temp.

2. Lack of motor cooling a. Check for improper expansion valve setting or faulty

expansion valve.

b. Check for restriction in liquid line.

3. Improper voltage at compressor a. Check for low or imbalanced line voltage, loose power

wiring or defective compressor contactor.

Trouble Shouting

16 CGAT-IOM01-EN

Trouble Shouting

Symptom Recommended action

F. Noisy compressor1. Damaged internal parts Replace compressor

2. Liquid floodback (abnormally cold suction Check and adjust superheat

line and low superheat)

3. Liquid refrigerant in compressor at start-up a. Check crankcase heater

b. Check for refrigerant overcharge.G. System short of capacity1. Low charge Add refrigerant

2. Clogged filter drier Replace filter drier

3. Incorrect expansion valve setting Replace expansion valve

4. Expansion valve stuck or obstructed Replace expansion valve

5. Low evaporator water flow Check strainers. Adjust water flow

6. Noncondensibles in the system Evacuate and recharge system

7. Leaky valves in compressor Replace compressorH. Suction pressure too low1. Short of refrigerant Find and repair leak; recharge system

2. Thermostat set too low Readjust thermostat

3. Low water flow Check strainers and adjust balancing valve.

4. Clogged filter drier Replace

5. Expansion valve faulty ReplaceI. Suction pressure too high1. Excessive cooling load Check for cause of excessive load

2. Expansion valve overfeeding a. Verify remote bulb is properly attached

b. Adjust superheat setting

3. Suction valve broken (i.e. noisy compressor) Replace compressorJ. Discharge pressure too low1. Shortage of refrigerant Find and repair leak.

2. Broken or leaky compressor discharge valve Replace compressorK.Discharge pressure too high1. Condenser airflow restricted Check fan motor, clean coil

2. Air or noncondensible gas in system Evacuate and recharge system

3. Refrigerant overcharge Recover excess refrigerant

4. Excessive system load Check cause

CGAT-IOM01-EN 19

Note

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.

Literature Order Number: CGAT-IOM01-EN0303

New

Stocking Location: Bangkok, Thailand

Trane Thailand7th Floor, Ploenchit Center Building2 Sukhumvit Road, KlongtoeyBangkok 10110

Amair Limited35 Mu 8, Poochaosamingprai RoadSamrong Tai, Samutprakarn 10130

http://www.trane.comAn American Standard Company

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