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Trane CG-PRC007-EN manual

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Table of contents for the manual

  • Page 1

    Air -Cooled Liquid Chillers 1 0 to 60 T ons CG-PRC007 -EN Apr il 20 04[...]

  • Page 2

    © 20 03 American Standard Inc. All rights reserved CG-PRC007 -EN Intr oduction Air -Cooled Liquid Chillers 1 0, 15 T ons 20–60 T ons Design and manufacturing excellence makes T rane a leader in the air -cooled c hiller marketplace. For over 40 years, T rane has been using the best engineering available in development, manufacturing, and marketin[...]

  • Page 3

    3 Contents CG-PRC001 -EN Intr oduction F eatur es and Benefits Application Consider ations Selection Pr ocedur e Model Number Description Gener al Data P erfor mance Data P erformance Adjustment F actor s Contr ols Electr ic P ow er Dimension and W eights Mec hanical Specifications 2 4 9 14 15 16 21 17 30 37 39 48[...]

  • Page 4

    CG-PRC007 -EN 4 F eatures and Benef its Installation Small siz e, complete factory wiring, easy lif ting provisions, factory installed options and star t-up control provide fast, easy installation. A complete factory run test is performed on eac h unit, eliminating potential star t-up problems. Int egrated Comf ort Syst ems All T rane c hillers are[...]

  • Page 5

    5 CG-PRC007 -EN F eatures and Benef its The 1 0 and 1 5-ton air -cooled Cold Generator ™ c hillers, with T rane direct drive hermetic scroll compressor s, has outstanding standard features and additional benefits that make selection, installation, and servicing easy . Flexibility Footpr int Central to the design of any project is the operating en[...]

  • Page 6

    CG-PRC007 -EN 6 F eatures and Benef its (20–60 T on) Other Standard F eatur es • T rane 3-D Scroll compressors • Advanced motor protection • 30 0 psi w ater side evaporator • Evaporator insulation (¾-inc h Armaflex II or equivalent) • Evaporator heat tape (thermostat controlled) • Condenser coil guards • Operation down to 30°F wit[...]

  • Page 7

    7 CG-PRC007 -EN F eatures and Benef its Enhanced Contr ols Int elliPak Chiller Unit Contr ol Module (UCM) Micr oprocessor Contr ol The brain of the 20 to 60 ton air -cooled c hiller is its Unit Control Module (UCM). The UCM is an inno vati ve, modular microprocessor control design, whic h coordinates the actions of the c hiller in an ef ficient man[...]

  • Page 8

    CG-PRC007 -EN 8 F eatures and Benef its T r ane 3-D Scroll Compr essor Simple Design with 70% Few er Par ts Fewer par ts than an equal capacity reciprocating compressor means significant reliability and ef ficiency benefits. The single orbiting scroll eliminates the need for pistons, connecting rods, wrist pins and valves. Fewer par ts lead to incr[...]

  • Page 9

    9 CG-PRC007 -EN Application Considerations Cer tain application constraints should be considered when sizing, selecting and installing T rane air -cooled c hillers. Unit and system reliability is of ten dependent upon proper and complete compliance with these considerations. Where the application varies from the guidelines presented, it should be r[...]

  • Page 10

    CG-PRC007 -EN 10 Application Considerations c Pr ovide Later al Clearance The condenser coil inlet must not be obstructed. A unit installed closer than the minimum recommended distance to a wall or other ver tical riser may experience a combination of coil starvation and warm air recirculation, resulting in unit capacity and efficiency reductions a[...]

  • Page 11

    11 CG-PRC007 -EN CONTROLS 1 T emperat ure Controller In order to provide stable system operation and to prevent excessive compressor cycling, the temperature control sensor in all 20-60 ton c hillers is located in the supply (outlet) solution. The temperature sensor in all 1 0 and 1 5 ton c hillers is located in the return (inlet) solution. This se[...]

  • Page 12

    CG-PRC007 -EN 12 point and adequate ethylene glycol concentration for safe operation. The maximum catalog leaving solution temperature from the evaporator is 65°F for outdoor ambients up to 1 15°F . High leaving water temperatures exceeding this may result in excessive suction temperatures and, therefore, inadequate motor cooling. For application[...]

  • Page 13

    13 CG-PRC007 -EN Application Considerations Figur e AC-1 — Recommended Piping Components F or T ypical Evaporat or Installation 20–60 T on 1 0, 15 T on Note: Provide shutoff valves in the evaporator inlet and outlet to facilitate water temperature sensor removal. See unit dimensional drawings for inlet and outlet locations.[...]

  • Page 14

    CG-PRC007 -EN 14 S election P rocedure The c hiller capacity tables presented in the “P erformance Data” section cover the most frequently encountered leaving water temperatures. The tables reflect a 1 0°F temperature drop through the evaporator . For temperature drops other than 1 0°F , fouling factor s other than 0.0 0 0 1 (in accordance wi[...]

  • Page 15

    15 CG-PRC007 -EN Model Number Description CGA 120 B 3 00 B A 123 456 7 8 9,10 11 12 DIGIT 1 0 — Leaving Solution Set point 0 = Standard Expansion V alve 40-60°F Leaving W ater (CGA100 & CGA120 models) 20-60°F Leaving Solution (CGA150 & CGA180 Models) V = Nonstandard Expansion V alve 20-39°F Leaving Solution (CGA100 & CGA120 models)[...]

  • Page 16

    CG-PRC007 -EN 16 General Data T able GD-1 — General Data — 1 0–60 T on Units 1 0 T on 15 T o n 20 T on 25 T o n 30 T o n 40 T on 50 T o n 60 T on Model Number CGA120 CGA180 CGAF-C20 CGAF-C25 CGAF-C30 CGAF-C40 CGAF-C50 CGAF-C60 Compressor Data Model Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Quantity 2 2 2 1/ 1 2 4 2/ 2 4 Nominal [...]

  • Page 17

    17 CG-PRC007 -EN Chilled Altitude Fouling Water Sea Level 2,0 00 Feet 4,0 00 Feet 6,0 00 Feet Factor ∆ T CAP GPM KW CAP GPM KW CAP GPM KW CAP GPM KW 6 1 .0 0 1 .66 1 .0 0 0.98 1 .63 1 .0 1 0.95 1 .59 1 .02 0.93 1 .54 1 .05 8 1 .0 0 1 .25 1 .0 0 0.98 1 .22 1 .0 1 0.96 1 .1 9 1 .02 0.93 1 .16 1 .05 0.00 025 1 0 1 .0 0 1 .0 0 1 .0 0 0.98 0.98 1 .01 [...]

  • Page 18

    CG-PRC007 -EN 18 Chart P AF-1 — Ev aporator Wat er Pressur e Drop 1 0 to 60 T on Air -Cooled Chillers P erf ormance A djustment F actor s 1 . 5 2 2 . 5 3 3 . 5 4 4 . 5 5 5 . 5 6 6 . 5 7 7 . 5 8 8 . 5 9 9 . 5 1 0 1 0 1 0 1 5 1 0 T o n 1 5 T o n 6 0 T o n 5 0 T o n 4 0 T o n 3 0 T o n 2 0 & 2 5 T o n Pres sure Drop ( Ft of W ater) Flo w (GP M) [...]

  • Page 19

    19 CG-PRC007 -EN Chart P AF-2— Eth ylene Glycol P erformance F act ors Chart P AF-3— Pr opylene Glycol Perf o r mance F actors P erf ormance A djustment F actor s[...]

  • Page 20

    CG-PRC007 -EN 20 Chart P AF-4— Eth ylene Glycol and Prop ylene Glycol Perf ormance F actors P erf ormance A djustment F actor s[...]

  • Page 21

    21 CG-PRC007 -EN P erf ormance Data — 60 HZ (1 0–1 5 T on) F ull Load Entering Condenser Air T emperature (Deg ree F) 75.0 85.0 95.0 105.0 115.0 L WT P ercent Capacity System Capacity System Capacity System Capacity System Capacity System (Deg F) Glycol (T ons) KW EER (T ons) KW EER (T ons) KW EER (T ons) KW EER (T ons) KW EER 20 28 6.0 7.6 9.4[...]

  • Page 22

    CG-PRC007 -EN 22 P erf ormance Data — 60 HZ T able PD-3 — 20 T on — CGAF-C20 Entering Condenser Air T emperature (Deg ree F) 75.0 85.0 95.0 105.0 115.0 L WT P ercent Capacity System Capacity System Capacity System Capacity System Capacity System (Deg F) Glycol (T ons) KW EER ( T ons) KW EER (T ons) KW EER (T ons) KW EER (T ons) KW EER 20 28 1[...]

  • Page 23

    23 CG-PRC007 -EN P erf ormance Data — 60 HZ (30–40 T on) F ull Load Entering Condenser Air T emperature (Degree F) 75.0 85.0 95.0 105.0 115.0 L WT P ercent Capacity System Capacity System Capacity System Capacity System Capacity System (Deg F) Glycol (T ons) KW EER (T ons) KW EER (T ons) KW EER ( T ons) KW EER ( T ons) KW EER 20 28 18.8 25.7 8.[...]

  • Page 24

    CG-PRC007 -EN 24 P erf ormance Data — 60 HZ Entering Condenser Air T emperature (Deg ree F) 75.0 85.0 95.0 105.0 115.0 L WT P ercent Capacity System Capacity System Capacity System Capacity System Capacity System (Deg F) Glycol (T ons) KW EER (T ons) KW EER (T ons) KW EER (T ons) KW EER (T ons) KW EER 20 28 37.2 50.1 8.9 35.3 55.0 7.7 33.4 60.7 6[...]

  • Page 25

    25 CG-PRC007 -EN P erf ormance Data — 50 HZ (1 0–30 T on) F ull Load Entering Condenser Air T emperature (Degree F) 85.0 95.0 105.0 115.0 120.0 L WT P ercent Capacity System Capacity System Capacity System Capacity System Capacity System (Deg F) Glycol (T ons) KW EER ( T ons) KW EER (T ons) KW EER ( T ons) KW EER (T ons) KW EER 40 0 7.2 7.6 11.[...]

  • Page 26

    CG-PRC007 -EN 26 Entering Condenser Air T emperature (Deg ree F) 85.0 95.0 105.0 115.0 120.0 L WT Percent Capacity System Capacity System Capacity System Capacity System Capacity System (Deg F) Glycol (T ons) KW EER (T ons) KW EER (T ons) KW EER (T ons) K W EER ( T ons) KW EER 40 0 28.8 30.0 11.5 27.3 33.5 9.8 25.7 37.6 8.2 24.0 42.2 6.8 23.1 44.6 [...]

  • Page 27

    27 CG-PRC007 -EN P erf ormance Data — 60 HZ T able PD-18— P art Load Data, ARI Points (1 0-60 T ons) Entering Condenser Air T emperature (Degrees F) Model 95 86.9 84.5 77 .7 77 .3 72.5 72.3 71 .5 T ons Number 100% Load 86% Load 82% Load 71% Load 70% Load 62% Load 62% Load 61% Load EER 1 0.0 — — — — — — — 1 0 CGA 120 2 Capacity (T [...]

  • Page 28

    CG-PRC007 -EN 28 P erf ormance Data — 50 HZ (1 0–30 T on) P ar t Load P ercent Entering Condenser Air T emperature (Deg rees F) Load 75 85 95 105 115 120 EER 14.2 12.3 10.6 9.0 7.6 7.0 100 Capacity 21.7 20.7 19.7 18.6 17.4 16.8 System KW 18.3 20.1 22.3 24.8 27.5 29.0 EER 15.7 13.7 11.9 10.2 8.7 7.9 60 Capacity 13.8 13.2 12.6 11.9 11.2 10.8 Syst[...]

  • Page 29

    29 CG-PRC007 -EN P ercent Entering Condenser Air T emperature (Deg rees F) Load 75 85 95 105 1 15 120 Percent Entering Condenser Air T emperature (Deg rees F) Load 75 85 95 105 1 15 120 EER 14.1 12.2 10.4 8.8 7.4 6.7 100 Capacity 52.2 49.8 47.3 44.5 41.6 40.1 System KW 44.4 49.2 54.6 60.8 67.7 71.4 EER 14.9 12.9 11.0 9.4 7.9 7.2 75 Capacity 40.5 38[...]

  • Page 30

    CG-PRC007 -EN 30 Contr ols (Interface with Other Contr ol S ystems) Stand-Alone Unit Interface to stand-alone units is very simple; only a remote auto-stop or c hilled water flow interloc k signal for sc heduling is required for unit operation. Signals from the c hilled water pump contactor auxiliary or a flow switc h are wired to the c hilled wate[...]

  • Page 31

    31 CG-PRC007 -EN ELECTRICAL CONTROL S Y STEM The controls used on CGA 1 0 and 15-ton units are classified either as “safety” controls or “ operational” controls. Brief descriptions of the specific safety and operating controls used in the CGA control sc heme are provided in the following paragraphs. R efer to the following control descripti[...]

  • Page 32

    CG-PRC007 -EN 32 If compressor number one can’t satisfy the cooling demand, WTT’ s second stage switc h closes, allowing power to pass through the CWFIR contacts, the DBC, the ASCT2, the RR2 contacts, the LPC02, and the HPC02 to energize the CC2 coil. This star ts compressor number two and outdoor fan number two. L OW AMBIENT OPERA TION Field I[...]

  • Page 33

    33 CG-PRC007 -EN Simple Int erface with All Control Syst ems The IntelliP ak controls afford simple interface with T rane T racer ™ systems, pro viding broad control capabilities for Building Automation systems. For control systems other than T rane, two generic building automation system interfaces are available and of fer simplicity and flexibi[...]

  • Page 34

    CG-PRC007 -EN 34 Standard Contr ol F eatur es Human Interf ace (HI) Panel The Human Interface (HI) P anel provides a 2 line X 40 c haracter clear English language liquid crystal display and a 16 but ton k eypad for monitoring, set ting, editing and controlling. The Human Interface P anel is mounted in the unit’ s main control panel and is accessi[...]

  • Page 35

    35 CG-PRC007 -EN Head Pr essure Control — Condenser head pressure control is pro vided in the UCM by staging condenser fans on or of f to maintain the saturated condensing temperature. This function will allow cooling operation down to 30°F as standard. Minimum on and of f timing is built into the algorithm to prevent rapid cycling. Pump down ?[...]

  • Page 36

    CG-PRC007 -EN 36 Gener ic Building A utomation S ystem Module (GBAS) — T wo Generic Building Automation System Modules (GBAS) are available as an option to provide broad control capabilities for building automation systems, other than the T rane ’ s T racer system. The 0-5 vdc input GBAS Module contains 4 analog inputs, one binary input for dem[...]

  • Page 37

    37 CG-PRC007 -EN T able ED-1 — Electrical Data Unit Wiring Motor Data Model Nameplate V oltage Max Fuse Rec. Dual Compressor (Ea) Fans (Ea) T on s Number V oltage Range M CA Size Element Qty . R LA LR A Qty K W F L A CGA120B1 208-230/60/1 187 -254 7 4 1 0 0 — 2 30 169 1 0.95 6 CGA120B3 208-230/60/3 187 -254 38.4 50 — 2 14.4 128 1 0.95 6 1 0 C[...]

  • Page 38

    CG-PRC007 -EN 38 T able ED-2 — Electrical D ata Unit Wiring Motor Data Model Nameplate V oltage Max Fuse Rec. Dual Compressor (Ea) Fans (Ea) T ons Number V oltage Range MCA Size Element Qty . RL A L RA Qty K W F L A 1 0 CGA1 0 0BD 380-415/50/3 342-456 24.1 30 — 2 9.5 63 1 0.57 2.7 1 5 CGA150BD 380-415/50/3 342-456 32.7 4 5 — 2 13.1 99.5 2 0.3[...]

  • Page 39

    39 CG-PRC007 -EN Dimensional Data Figur e DD-1 — CGA -120B Unit Dimensions (1 0 T on) Notes: 1. Minimum clearance around the perimeter of the unit is 3 feet. Minimum clearance between adjacent units is 6 feet. 2. When installing water pipes, be certain to route them away from the compressor access panels to allow for compressor servicing or repla[...]

  • Page 40

    CG-PRC007 -EN 40 Dimensional Data Figur e DD-2 — CGA-1 80B Unit Dimensions (1 5 T on) Notes: 1. Minimum clearance around the perimeter of the unit is 3 feet. Minimum clearance between adjacent units is 6 feet. 2. When installing water pipes, be certain to route them away from the compressor access panels to allow for compressor servicing or repla[...]

  • Page 41

    41 CG-PRC007 -EN Dimensional Data Figur e DD-3 — CGAF-C20 Unit Dimensions (20 T on)[...]

  • Page 42

    CG-PRC007 -EN 42 Dimensional Data Figur e DD-4 — CGAF-C25 Unit Dimensions (25 T on)[...]

  • Page 43

    43 CG-PRC007 -EN Dimensional (30 T on) Data Figur e DD-5 — CGAF-C30 Unit Dimensions[...]

  • Page 44

    CG-PRC007 -EN 44 Dimensional (40 T on) Data Figur e DD-6 — CGAF-C40 Unit Dimensions[...]

  • Page 45

    45 CG-PRC007 -EN Dimensional (50 T on) Data Figur e DD-7 — CGAF-C50 Unit Dimensions[...]

  • Page 46

    CG-PRC007 -EN 46 Dimensional (60 T on) Data Figur e DD-8— CGAF-C60 Unit Dimensions[...]

  • Page 47

    47 CG-PRC007 -EN W eights T able W -1 — Appro ximate Cor ner Weights (lbs) 1 0-T on Unit Isolator Loading T on s Model Number 1 2 3 4 Operating Wt. Shipping Wt. 10 CGA 120B 161 164 1 03 101 529 576 T able W -2 — Appro ximate Cor ner Weights (lbs) 15-T on Unit Isolator Loading T ons Model Number 1 2 3 4 Operating Wt. Shipping Wt. 15 CGA 180B 186[...]

  • Page 48

    CG-PRC007 -EN 48 Mec hanical Specif ications (1 0–1 5 T on) General Units shall be assembled on heavy gauge steel mounting/lif ting rails and shall be weatherproofed. Units shall include hermetic scroll compressors, plate fin condenser coil, fan(s) and motor(s), controls and complete factory installed operating c harge of oil and R-22 refrigerant[...]

  • Page 49

    49 CG-PRC007 -EN Mec hanical Specif ications (20–60 T on) GENERAL All c hillers are factory run-tested to confirm proper operation. Units are c hec k ed on a computer -based test stand at typical ambient and water conditions and control operation is monitored. Units ship with a full operating c harge of refrigerant and oil. Units are constructed [...]

  • Page 50

    CG-PRC007 -EN 50 hardw are, software and interconnecting wiring are in proper operating condition. The modules (boards) shall be protected to prevent RFI and voltage transients from affecting the board’ s circuits. All field wiring shall be terminated at separate, clearly marked terminal strip. Direct field wiring to the I/O boards is not accepta[...]

  • Page 51

    51 CG-PRC007 -EN[...]

  • Page 52

    T rane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. Literature Order Number CG-PRC0 07 -EN File Number PL - RF -CG-PRC0 07 -EN-0404 Supersedes CG-PRC0 07 -EN-0503 Stoc king Location W ebbMason T rane A business of American Standard Companies www.trane.com [...]