Trane CGAT175D Installation Operation & Maintenance

Brand: Trane

Model: CGAT175D

Category: Split-system air conditioners

Type: Installation Operation & Maintenance

This manual is also suitable for

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

Contents

Model Nomenclature 2

General Information 4

General Data 5

Installation 6

Electrical 8

Typical Wiring Diagram 9

Trouble Shooting 10

Dimensional Data 12

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

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

CGAT-IOM01-EN

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

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

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

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

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

-V

]

CGAT-IOM01-EN

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.

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

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

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

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

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Trane CGAT175D Installation Operation & Maintenance

Brand: Trane

Model: CGAT175D

Category: Split-system air conditioners

Type: Installation Operation & Maintenance

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Trane CGAT175D Installation Operation & Maintenance

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