CGAT-IOM01-EN
January 2009
Installation
Operation
Maintenance
Air-Cooled Chiller 5-18 Tons
CGAT Model 50 Hz
Models;
CGAT 065 D, CGAT 135 D
CGAT 085 D, CGAT 175 D
CGAT 105 D, CGAT 215 D
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
General
All Trane Products are identified by
a model number that Precisely
identifies the unit. An explanation of
the alphanumeric identification codes
for CGAT units is provided on the next
page.
Its use will enable the owner /operator,
installing contractors and service
engineers to define the operation,
components and options for any
specific unit.
When ordering replacement parts or
requesting service, be sure to refer to
the serial number and specific model
number stamped on the unit name-
plate.
Unit Nameplate
The unit nameplate specifies the unit’s
specific model number, serial number,
electrical characteristics, type of
refrigerant and other pertinent unit
data.
General Information
All model CGAT air-cooled chillers are
designed for outdoor installation with
vertical air discharge. Each refrigerant
circuit is provided with an operating
charge of refrigerant and refrigerant
oil, a filler drier, high and low pressure
schraeder valve and externally
equalized thermostatic expansion
valve. All units are dehydrated, leak
tested, charged and tested for proper
control operation before shipment. An
access panel(s) provides access to the
compressor section(s), and a remov-
able cover allows access to the
control box.
The brazed plate heat evaporators
used in these units are with integral
distributor. Each evaporator is fully
insulated. Standard capacity and
safety controls are provided. Unit
operation is governed by chilled water
temperature entering the evaporator.
Rigging
WARNING: To prevent injury or death
and unit damage, observe handling
cautions and procedures given in
Figure 1 when lifting the unit. Always
test-lift the unit to determine actual
centre of gravity.
Before preparing the unit for lifting,
estimate the approximate centre
of gravity for lifting safety. Due to the
placement of internal components,
the unit weights may be unevenly
distributed. Unit shipping weights
are provided in the table below.
Lifting Recommendations
Before preparing the unit for lifting,
estimate the approximate center of
gravity for lifting safety. Because of
placement of internal components,
the unit weight may be unevenly
distributed. Approximate unit weights
are given in Table 1.
WARNING : On-sight lifting equipment
must be capable of lifting the unit
weight with an adequate safety factor.
The use of under-capacity lifting
devices may result in severe personal
injury or death and can seriously
damage the unit.
The crated unit can be moved using
a forklift of suitable capacity. For lifting
the unit, attach lifting straps or slings
securely to the lifting holes at each
corner. Use spreader bars to protect
the unit casing from damage. Test lift
the unit to determine proper balance
and stability.
CAUTION : Use spreader bars to
prevent lifting straps from damaging
the unit,. Install bars between lifting
straps. This will prevent the straps
from crushing the unit cabinet or
damaging 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 CGAT215D
Unit Performance
Cooling Capacity (1) MBH 65.2 86.3 104.4 133.1 175.4 214.9
Main Power supply V/Ph/Hz 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50
Min.Brch.Cir.Ampacity A 18.1 27.3 29.8 32.7 49.4 53.9
No.of Independent circuits 1 1 1 2 2 2
Compressor
Type Hermetic Scroll
Speeds number 1 1 1 1 1 1
Motors Number 1 1 1 2 2 2
Rated Amps (2) A 13.6 20.7 22.9 13.6 20.7 22.9
Locked rotor Amps (2) A 98 130 145 98 130 145
Motor RPM rpm 2900 2900 2900 2900 2900 2900
Evaporator
Type Brazed-plate Brazed-plate Brazed-plate Brazed-plate Brazed-plate Brazed-plate
Water flowrate GPM 13.0 17.3 20.9 26.6 35.1 43.0
Water Connections
Type Male Male Male Male Male Male
Diameter 1 1/2" 1 1/2" 1 1/2" 1 1/2" 1 1/2" 1 1/2"
Outdoor Coil
Type Uncoated Corrugate
Tube size inch 3/8 3/8 3/8 3/8 3/8 3/8
Tube type Smooth Smooth Smooth Smooth Smooth Smooth
Face Area Ft2 15.10 20.00 25.00 30.20 40.00 42.50
Rows # 2 2 2 2 2 2
Fins per inch (fpf) # 16 (192) 16 (192) 16 (192) 16 (192) 16 (192) 16 (192)
Outdoor Fan
Type Propeller Propeller Propeller Propeller Propeller Propeller
Number 1 1 1 2 2 2
Diameter inch 28 28 28 28 28 28
Drive type Direct Direct Direct Direct Direct Direct
Speeds number 1 1 1 1 1 1
Air flow CFM 4900 5800 6800 9800 11600 13600
Motors Number 1 1 1 2 2 2
Motor HP (1) hp 3/4 3/4 3/4 3/4 3/4 3/4
Rated Amps (1) A 1.06 1.41 1.20 1.06 1.41 1.20
Locked rotor Amps (1) A 2.27 3.53 2.80 2.27 3.53 2.80
Motor RPM rpm 750 830 875 750 830 875
Dimensions
Height mm 1050 1050 1050 1050 1050 1050
Length mm 1060 1060 1260 2200 2200 2200
Width mm 950 950 1050 1050 1050 1050
Weight 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
Installation
Verily completion of installation by
reviewing the following procedures.
Unit Dimensions And Weights
These are provided under General
Data on Page 5
Drainage
Locate the unit near a large-capacity
drain to allow system drainage during
unit shutdown or repair.
Location And Clearance
Requirements
1. The surface in to be level and of
sufficient strength to support
the unit.
2. Select a location that will permit
free air flow into the condensing
coils and from the vertical dis
charge. If however, the unit is to be
placed under an overhang, allow at
least 2.0 meters clearance above
the unit to prevent recirculation of
hot discharge air.
3. For ground level installation the unit
should be set on a level concrete
slab 100 mm thick and extending
a minimum of 200 mm beyond the
sides of the unit.
4. Mount vibration isolators to avoid
vibration or noise transmission.
Provide a gravelled apron at least
300 mm wide on all sides of the
slab unless other means are used
to prevent growth of vegetation
close to the unit. The slab should
be located as close to the building
as possible with a minimum
clearance conform to the
submittals in front of air entry and
access panels.
5. Provide a large capacity water drain
near the unit. It is used when the
evaporator in drained for shutdown
or repair. The water circuit is
drained thanks to the evaporator
water connections.
Foundation
Elevate the unit. Ensure the floor or
foundation of the unit is level, solid
and of sufficient strength to support
General Data Page 5 for information
on weights.
Unit water Piping
General Piping Recommendations
Thoroughly flush all water supply
piping before making the final piping
connections to the unit.
CAUTION : If using an acidic
commercial flushing solution,
construct a temporary bypass around
to unit to prevent damage to the
evaporator internal components.
Evaporator water inlet and outlet
types, sizes and locations are shown
in the Dimensional data section page
18-19 Figure 1 on page 7 illustrates
a typical water piping components.
Isolate the water pump from the
system to avoid vibration
transmission. All water piping are to
be insulated to minimize heat gain and
prevent condensation. Use a pipe
sealant or Teflon tape on all threaded
connections.
Net Positive Suction Head
Evaporator water pumps should be
located in their piping systems such
that they operate with a net positive
suction head. This is to reduce the
possibility of pump cavitation and
possible differential aeration in the
water system which can rapidly result
in chiller internal corrosion.
Air Vents
Vents must be installed at high points
in the piping system to facilitate air
purging during the filling process.
Pressure Gauges
Install pressure gauges to monitor
the entering and leaving chilled water
pressure.
CAUTION : To prevent evaporator
damage, do not exceed 350 psig
waterside working pressure.
Shutoff Valves
Provide shutoff valves in the Supply
and Return pipe near the chiller to
allow isolation of the gauge(s),
sensors, strainers, etc., during service.
Thermometers
Install thermometers in the lines to
monitor the evaporator entering and
leaving water temperatures.
Balancing Valves
The is required to establish regulation
and Balancing of the water flow.
Strainer
Install a pipe strainer in the water
return line to protect the components
from entrapped debris.
CGAT-IOM01-EN
7
Chiller Flow Switch
Used to prevent or stop compressor operation if the evaporator water flow drops
off dramatically.
Figure 1 - Typical Water Piping
Figure 2 : Evaporator pressure drops
Air Vent Pressure Gauge
Unions
Vibration
Eliminators
Thermometers
Water Strainer
Reeturn Line
(Inlet)
(See Note 1)
Gate Valves
(See Note 2
Balancing Valve
Flow Switch
Shutoff
Valves
Installation
1.00
10.00
100.00
10.0 100.0
Water flowrate, gpm
Pressure Drop, feet of water
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 source
before completing wiring connections
to unit.
Table below provides the electrical
data for each of the units. All wiring
should confirm to NEC or applicable
codes as per requirements of local
codes and regulations. Wiring dia-
grams are furnished with the units but
extra copies can be obtained from the
Trane Sales Offices. The installer must
provide fused disconnect switches.
Type and locations of disconnects
must comply with all applicable
codes.
CAUTION : To avoid component
failure, use copper conductor wire
only between the main power
distribution source and the unit’s
power terminals. This will prevent
galvanic corrosion or overheating at
the terminals.
1. Verify power supply available is
compatible with unit’s nameplate
ratings.
2. Refer to the unit wiring schematic
pasted to the control panel cover.
3. All factory supplied wiring are
coloured and numbered. Always
check the numbers on the wiring
to the unit terminal block against
that in the wiring diagram. Should
there be any inconsistency, please
do not hesitate to contact the
nearest Trane Service or Sales
Organization.
4. Chilled Water Pump Motor
The installer must provide a power
supply of proper voltage and
a fused disconnect switch to the
chilled water pump motor. Provide
proper equipment grounds.
5. Flow Switch Interlock
To avoid possible evaporator
freeze-up resulting from restricted
water flow, install a flow switch
(or other flow sensing device) in the
evaporator water line. This sensing
device must be adjusted to stop
compressor operation if water flow
to the evaporator drops 50% of the
design flow rate.
CGAT-IOM01-EN
11
Control Panel
LED Display for water
temperature and errors
Leaving Water Temp
status display
Water Freezed
Sensor#1display status
Compressor on/off
display status
Water Freeze
Sensor#2 display status
Pump on/off
display status
Power on/off button
Program selection button
Up/Down button
use to select which
sensor temperature or
settings to be shown on
LED display
12
CGAT-IOM01-EN
Pre-Start Procedure
Once the unit is installed, follow the
steps below to ensure the installation
procedure is complete. When all are
accomplished, the unit is ready for
operation.
WARNING : More than one discon-
nect switch may be required to
de-energize unit for servicing. Refer to
unit schematic and open all electrical
disconnects to prevent injury or death
due to electrical shock.
1. Inspect all wiring connections;
electrical connections should be
clean and tight.
WARNING : Use extreme care
when electrically troubleshooting
compressors. If electrical power is
applied to a damaged fusite terminal,
a fire or explosion could occur,
resulting in injury or death.
CAUTION : Check tightness of all
connections in the compressor power
circuit (disconnects, terminal block,
contactors, compressor junction box
terminals, etc.) to prevent overheating
at connections and under voltage
conditions at the motor.
2. Check power supply voltage to
the unit at the main power fused
disconnect switch; the voltage
reading should be within the
utilization range shown in Table 2
on page 9. Also, Voltage imbalance
must not exceed 2%. (Refer to item
10 Unit voltage and amperage
checks )
3. Check the condenser fan
assemblies; the fan blades should
rotate freely in the fan orifice, and
be securely attached to the fan
shaft.
4. Fill the chilled water circuit, leaving
the system air vents open. Close
vent after filling.
5. Start the chilled water pump. With
water circulating through the chilled
water system, inspect all piping
connections for leaks and make
any necessary repairs.
6. Adjust the water flow rate through
the chilled water circuit, and check
the water pressure drop through
the evaporator. Refer to water
pressure drop data on page 8.
7. Ensure flow switch is installed and
wired to the control panel. Adjust
the flow switch to provide proper
operation.
NOTE : Withe the water pump
operating, throttle the water flow to
approximately 50 percent of the full
flow rate. Following the manufacturer’s
instruction adjust the flow switch
contacts to open at this point. Use
an Ohmmeter to verify opening and
closure of the switch contacts.
8. Stop the chilled water pump.
9. Open all fused disconnect
switches.
WARNING : Use extreme care when
checking voltage at live terminals to
avoid serious injury or death due to
electrical shock.
10.Unit Voltage and Amperage
Checks Voltage supply
Measure each leg of supply voltage
(3-phase) at all ling voltage disconnect
switches. Readings must fall within
the voltage utilization range shown on
the unit nameplate.
Voltage Imbalance
Excessive voltage imbalance between
phase will cause motors to overheat
and eventually fail. Maximum allow-
able imbalance is 2%
where VA is the average voltage and
VD is the ling voltage that deviates
farthest from VA
11.Establish a balanced water flow
through the evaporator.
12.Measure the water pressure drop
through the evaporator at the
pressure gauge(s) on the system
water piping. Pressure drop
readings at the gauges should
approximate those indicated by
the pressure drop charts (figure 2)
on page 8
NOTE : Be sure to account for piping/
fittings that will create additional
pressure drop between the unit and
the pressure gauge locations.
% Voltage Imbalance = 100 x [V
A
-V
D
]
VA
CGAT-IOM01-EN
13
Operation
Start-up Procedure
1. Energize the evaporator water
pump.
2. Energize the CGAT unit.
3. Checking operating conditions
Once the unit has been operating
for at least 15 minutes and
the system has stabilized,
the following procedures are to be
done.
a. Re-check the evaporator water
flow and pressure drop.
b. Measure unit suction and
discharge pressures. The
normal operating suction
pressure is between 63 to 68
psig while the discharge
pressure range in between 270
psig to 300 psig.
c. Check compressor amp. Draw
NOTE : Many application variables
exists which can affect operating
pressures; these include ambient dry
bulb, wind velocity, restrictions in
airflow etc. As such, do not use
operating pressures as the sole check
of system operation.
4. Measure system superheat. Normal
system superheat is 12 to 15 deg. F
for each circuit at ARI conditions
(54 deg. F entering water, 44 deg.F
leaving water at 95 deg.F ambient
temperature).
5. Measure system subcooling
Normal subcooling for each circuit
is 12 to 16 deg.F at ARI conditions.
6. If operating pressure, superheat
and subcooling readings indicate
refrigerant shortage, find and repair
leaks and gas-charge refrigerant
into each circuit. Refrigerant
shortage is indicated it operating
pressures are low and subcooling
is also low.
CAUTION : If suction and discharge
pressures are low, but subcooling is
normal, no refrigerant shortage exists.
Adding refrigerant will result in
overcharging.
7. Add refrigerant vapor with the unit
running by charging through
the access port on the suction line
until operating pressures are
normal. Allow sufficient time
(between 15 to 30 minutes) before
taking readings.
CAUTION : To prevent compressor
damage, do not allow liquid refrigerant
to enter the suction line.
8. If operating pressures indicate
an overcharge, slowly (to minimize
oil loss) recover refrigerant at
the liquid line access port.
Important note : Do not release
refrigerant to the atmosphere.
Use proper refrigerant recovery
process.
WARNING : To prevent injury due to
frostbite, avoid skin contact with
refrigerant.
9. Check compressor oil levels. At full
load, oil level should be visible in
the oil level sight glass on the
compressor.
10.Inspect the unit. Remove any
debris, tools and hardware. Secure
all exterior panels.
14
CGAT-IOM01-EN
Electrical Control System
The controls used on CGAT065-215 chillers are classified either as safety or
operational 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 pressure
cutout (or high pressure cutout, the
reset relay locks out the compressor
contactor (1M, 2M). This prevents
the system from recycling until the
condition that caused the trip is
determined and corrected.
CAUTION : To prevent unit damage,
do not reset the control circuit until
the cause of the safety lockout is
identified and corrected.
To reset 1R and 2R, open and close
the unit Low Voltage Control Circuit
Breaker (MCB).
•Frost Controller or Low
Temperature Cutout (LTC)
The Low Temperature Cutout is
designed to protect the evaporator
from freeze damage in the event of
water temperature thermostat
malfunction or if the is a restricted
water flow condition. The LTC’s
remote sensing bulbs monitors
Leaving water temperature.
Manual reset is required. Factory
Setting : 2C.
• Motor Overloads
These units have internal compressor
and condenser fan motor overloads.
These overloads protect the motors
from overcurrent and overheating
conditions and automatically reset as
soon as they cool sufficiently.
Unit Operational Controls
•Water Temperature
Thermostat (WTT)
System operation for CGAT is
controlled either by single-stage
thermostat CGAT075 - 120 or two-
stage thermostat CGAT150 - 240
• Delay Between Compressors
Prevents compressors from starting at
the 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 start
1. 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 start
1. 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 continuously
1. 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 open
1. 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 compressor
1. 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 capacity
1. 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 compressor
H. Suction pressure too low
1. 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 Replace
I. Suction pressure too high
1. 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 compressor
J. Discharge pressure too low
1. Shortage of refrigerant Find and repair leak.
2. Broken or leaky compressor discharge valve Replace compressor
K.Discharge pressure too high
1. 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 Thailand
7th Floor, Ploenchit Center Building
2 Sukhumvit Road, Klongtoey
Bangkok 10110
Amair Limited
35 Mu 8, Poochaosamingprai Road
Samrong Tai, Samutprakarn 10130
http://www.trane.com
An American Standard Company
∫√‘…—∑ ·Õ¡·Õ√å ®”°—¥ 35 À¡Ÿà 8 ∂.ªŸÉ‡®â“¡‘ßæ√“¬ µ.”‚√ß„µâ Õ.æ√–ª√–·¥ß ®.¡ÿ∑√ª√“°“√ 10130
/
