Trane CGAD020C User manual

CGAD
LiquidChillers
Air-Cooled
ScrollCompressor
20to150 Tons
CG-PRC002A-EN
Junho 2006
Models: 50 or 60 Hz
CGAD020C CGAD040C CGAD070C CGAD100C
CGAD025C CGAD050C CGAD080C CGAD120C
CGAD030C CGAD060C CGAD090C CGAD150C

© 2004. American Standard Inc. All rights reserved. CG-PRC002A-EN
Introduction
CGAD
Air-Cooled
LiquidChillers
Designed for great performance.
Built to last.
For more than 40 years Trane has
been using the best resources available
on development engineering, production
and marketing to produce quality equip-
ments.
All this tradition and know-how were
gathered to develop the new generation of
CGAD liquid chillers 20 to 150 Tons,
equipped with scroll compressors.

CG-PRC002A-EN 3
Contents
Introduction 02
Model Description 04
General Data CGAD 20-150TR 05
Selection Procedures 06
Application Considerations 07
Performance Adjustment Factors 09
Performance Data 11
Performance Data R-22 11
Performance Data R-407C 12
Electrical Data 13
Controls 16
Dimensional Data 20
CGAD 020C 20
CGAD 025C / 030C 21
CGAD 040C 22
CGAD 050C / 060C 23
CGAD 070C 24
CGAD 080 / 090C 25
CGAD 100C 26
CGAD 120C 27
CGAD 150C 28
CGAD 150C 29
Maintenance and Air Circulation Clearances 30
Mechanical Specifications 31
General Dimensions 32

4 CG-PRC002A-EN
Model
Description
The product code describes optional configuration, capacity and features. It is very important to
indicate the correct order of the equipment code in order to avoid future problems in the shipment.
Each digit of the product code is described above.
C G A D 0 7 0 C 3 2 0 0 A T 0 0
1, 2, 3 4 5, 6, 7 8 9 10 11 12 13 14 15,16
Digit 10 - Refrigerant Type
2 = Refrigerant R-22
4 = Refrigerant R-407C
Digit 11 - Piping Configuration
0 = Standard Piping
A = Piping with Service Valves
in Suction and Discharge Lines.
B = Piping with Solenoid Valve
C = Piping with Solenoid Valve and
Service Valves in Suction and
Discharge Lines.
Digit 12 - CH-530 Control Modules
0=Standard Control Module
1 = With Alarm Relay
2 = With Remoto Setpoint Adjustment
3 = With Ice Making / Demand Limit
4 = With Communication COMM3
5 = With Alarm + External Setp.
6 = With Alarm + Ice Making / Demand Limit
7 = With Alarm + Communication COMM3
8 = External Setp. + Ice Making / Demand Limit
9 = External Setp. + Communication COMM3
A = Ice Making / Demand Limit + COMM3
B = Alarm + Ext. Setp. + Ice Making /Dem. Lim.
C = Alarm + Ext. Setp. + COMM3
D = Alarm + Ice Making/Dem. Lim + COMM3
E = Ext. Setp. + Ice Making/Dem. Lim. + COMM3
F = All modules
Digit 13 - Coil Type
A = Coil with Aluminum Fins
S = Coil with Special protection
(Yellow Fin)
Digit 14 - Expansion Valve
T = Thermostatic Expansion Valve
E = Electronic Expansion Valve (only R-22)
Digits 15 and 16 - Accessories
Contact the Marketing Department.
Dígito 9 - Power Suply and Comand
Voltage
3 = 220V/60Hz/3ph - no accessories
K = 380V/60Hz/3ph - no accessories
4 = 440V/60Hz/3ph - no accessories
H = 380V/50Hz/3ph - no accessories
R = 220V/60Hz/3ph - with circuit breaker
S = 380V/60Hz/3ph - with circuit breaker
T = 440V/60Hz/3ph - with circuit breaker
U = 380V/50Hz/3ph - with circuit breaker
V = 220V/60Hz/3ph - with disconnect
switch
X = 380V/60Hz/3ph - with disconnect
switch
Y = 440V/60Hz/3ph - with disconnect
switch
Z = 380V/50Hz/3ph - with disconnect switch
Dígits 1,2,3 - Model
CGA - Cold Generation Air
Dígit 4 - Model Series
D = Série D
Dígits 5,6,7 - Nominal Capacity (Tons)
020 = 20 Tons
025 = 25 Tons
030 = 30 Tons
040 = 40 Tons
050 = 50 Tons
060 = 60 Tons
070 = 70 Tons
080 = 80 Tons
090 = 90 Tons
100 = 100 Tons
120 = 120 Tons
150 = 150 Tons
Dígit 8 - Service Digit
C = Versão “C”

CG-PRC002A-EN 5
General
Data
Tab. 01 - General Data - CGAD 20-90 TR - 50 or 60 Hz
Note s:
(1) Data b ased o n opera tion co ndition s ac o rding to s ta ndart AR I 59 0-92
(2) T hese current values refer to 220V / 6 0 H z power supply
(3) The se values to the glo bal equipment con sum ption (compressors and fans)
(4) T hese current values refer to 380 V / 50 H z power supply
(5) The m easurements show n take into account the depth of the eletrical frame coupled to the equ ipmen t (se e pag e 27 of this manual)
(6) The floor area mea surem ents do not take into accont the base of the electrical fram e cou pled to the equipment.
Model CGAD020 CGAD025 CGAD030 CGAD040 CGAD050 CGAD060 CGAD070 CGAD080 CGAD090 CGAD100 CGAD120 CGAD150
60 Hz
Nominal Capacity
Tons 18,5 23,5 27,1 37,3 46,9 53,8 67,3 77,0 84,1 95,9 117,7 145,2
Nominal System
kW 20,4 26,7 31,0 42,3 52,6 62,2 75,8 86,3 94,8 109,4 139,0 165,2
Nominal Current
A 72,6 89,3 105,7 148,8 177,0 211,8 251,2 286,4 319,2 277,1 377,4 422,1
Efficiency
(2)
kW/Tons 1,103 1,136 1,144 1,134 1,122 1,156 1,126 1,121 1,127 1,141 1,181 1,138
50 Hz
Nominal Capacity
Tons 15,2 19,3 22,7 30,6 38,5 45,1 55,2 64,5 70,5 86,1 105,8 129,8
Nominal System
kW 16,9 22,1 25,7 35,1 43,6 51,6 62,9 71,6 78,7 95,7 121,4 141,0
Nominal Current
A 42,7 52,4 62,1 87,3 103,9 124,3 147,5 168,1 187,3 131,2 160,8 192,6
Efficiency
(2)
kW/Tons 1,114 1,147 1,132 1,148 1,134 1,145 1,140 1,110 1,117 1,112 1,148 1,086
Compressor
Model
CSHA100
CSHA150
CSHA100
CSHA150 CSHA100 CSHA150
CSHA100
CSHA150 CSHA140
CSHA100
CSHA150
CSHA100
CSHA150 ZR300 ZR250 ZR300
Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll
Quantity 2 1 / 1 2 4 2 / 2 4 4 / 2 4 / 2 6 4 6 6
Nominal Capacity
Tons 10 15/10 15 10 15/10 15 14 / 10 15 / 10 15 25 20 25
Evaporator
Storage Volume
Liters 44 41 62 52 79 143 151 143 122 122 173 277
Min. water flow
m3/h 5,5 6,8 8,2 10,9 13,6 16,3 19,0 21.8 24.5 27,3 34,1 42,2
Max. water flow
m3/h 16,4 20,5 24,5 32,7 40,9 49,0 57.2 65.5 73.4 81,8 102,2 139,0
Inlet connection 2" 2" 2 1/2" 2 1/2" 3" 4" 4" 4" 4" 4" 6" 6"
Outlet connection 2" 2" 2 1/2" 2 1/2" 3" 4" 4" 4" 4" 4" 6" 6"
Condenser
Type Aluminum fins, 3/8"- OD copper tubes
No. of coils 2 2 2 4 4 4 4 4 4 4 4 4
Total face area
m2 4,7 4,7 4,7 8,5 11,0 11,0 14,0 14,7 14,7 13,1 16,9 19,5
Fins per inches 16 16 14 16 16 16 14 14 14 16 16 16
No. of rows 2 2 3 2 2 2 3 3 3 3 3 3
Fans
Quantity 2 3 3 4 6 6 6 8 8 6 8 10
Diameter mm 762 762 762 762 762 762 762 762 762 762 762 762
Air flow m3/h 32.620 45.870 44.170 64.560 95.140 95.140 97.690 122.330 122.330 98.118 130.824 163.530
RPM RPM 880 880 880 880 880 880 880 880 880 1140 1140 1140
Motor power kW 0,75 0,75 0,75 0,75 0,75 0,75 0,75 0,75 0,75 1,12 1,12 1,12
Transmission type Direct Direct Direct Direct Direct Direct Direct Direct Direct Direct Direct Direct
General Data
Standard R-22 R-22 R-22 R-22 R-22 R-22 R-22 R-22 R-22 R-22 R-22 R-22
Optional R-407C R-407C R-407C R-407C R-407C R-407C R-407C R-407C R-407C R-407C R-407C R-407C
No. of circuits 1 1 1 2 2 2 2 2 2 2 2 2
% 50/100 50/100 50/100 25 / 50 20/50 25 / 50 31/50 31/50 33/50 25/50 17/50 17/50
75 / 100 70/100 75 / 100 63/100 63/100 83/100 75/100 67/100 67/100
Operating weight
kg 1340 1420 1480 1910 2210 2500 3000 3240 3220 3775 4135 4653
Shipping weight
kg 1300 1380 1420 1860 2130 2360 2850 3100 3100 3653 3962 4376
Refrigerant type
Capacity stages

6 CG-PRC002A-EN
Selection
Procedures
Liquid chiller capacity tables 03 and 04, on
pages 11 and 12 show the most frequent
leaving water temperatures. The table
reflects a temperature drop of 5,5 ºC (10ºF)
through the evaporator. For low tempera-
ture selections, refer to figures 04 and 05
for Adjustment Factors of Ethylene and
Propylene Glycol.
To select a CGAD Air-Cooled Liquid Chiller
Trane, the following information is
required:
1
Thermal project load of project in tons of
cooling.
2
Chilled water temperature project drop.
3
Leaving chilled water project temperature.
4
Project ambient temperature and refriger-
ant type.
The evaporator flow is determined
through the following formulas:
NOTE 1:
The flow should be within the limits
specified in table 01, General Data
(page 05).
Selection example:
Data:
System load required= 70 Tons.
Leaving chilled water temp. = 7ºC
Chilled water temperature drop = 5,5ºC
(10°F)
Project ambient temperature = 35ºC
1
Calculate the required chilled water flow
using the formula below:
GPM = 70 Tons x 24 = 168 GPM
10ºF
2
Using table 03 (Performance Data - R-22), a
CGAD 080 unit at these conditions will
output 76,2 Tons with a compressor
consumption of 81,1 kW.
3
Determine the evaporator pressure drop
using the flow and the evaporator water
pressure drop curves, figure 05.
Introducing the curve at 168 GPM, the
pressure drop for an evaporator with the
nominal value of 80 Tons is 9 ft, or 2,74 m.
4
For selection of low temperature units, or
applications in which the altitude is
significantly above sea level, or the
temperature drop is different from 5,5 ºC,
contact a local Trane engineer for further
information.
For example:
Corrected capacity = Capacity (not
adjusted) x Glycol Capacity Adjustment
Factor
Corrected Flow = Flow (not adjusted) x
Glycol Flow Rate Adjustment Factor
5
The final unit selection is: CGAD 080B
Refrigerant Type: R-22
Cooling capacity =76,2 Tons.
Entering temperatures = 12,5 °C
Leaving chilled water temperature = 7ºC
Chilled water flow =168 GPM
Evaporator pressure drop =2,74 m
Compressor consumption = 81,1 kW
NOTE 2:
Minimum leaving chilled water tempera-
ture setpoint
The minimum leaving chilled water
temperature setpoint is 4ºC. For applica-
tions where a lower setpoint is required, a
glycol solution must be used. Contact the
local Trane engineer for further information.
Note:
The selection above is an example for manual equipment selection. Please note that a more accurate data check is required for a correct selection.
L/s = kW (Capacity) X 0,239
Temperature drop (°C)
GPM =
Temperature drop (°F)
Tons X 24

CG-PRC002A-EN 7
Unit Sizing
Unit capacities are listed in the Perfor-
mance Data section. Intentionally over-
sizing a unit to assure adequate capacity is
not recommended. The excess in the
system and compressor capacity calcula-
tion results in an over-sized liquid chiller. In
addition, an oversized unit is usually more
expensive to purchase, install and operate.
If over-sizing is desired, consider using two
units.
Unit Placement
1
Setting the Unit
2
Isolation and Sound Transmissions
The most effective isolation solution is to
locate the unit away from any sound
sensitive area. Structurally transmitted
sound can be reduced by vibration
eliminators. Spring isolators have proved
to be of little efficiency in CGAD Air-Cooled
Liquid Chiller installations and thus are not
recommended. An acoustical engineer
should always be consulted on applica-
tions with critical acoustic reduction levels.
For maximum isolation, water lines and
electrical conduits should also be isolated.
Wall sleeves and rubber-isolated piping
hangers can be used to reduce the sound
transmitted through water piping. To
reduce the sound transmitted through
electrical conduits, use flexible electrical
conduits. State and local codes on sound
emissions should always be considered.
As the environment in which a sound
source is located affects the sound
pressure, unit placement must be
carefully evaluated.
4
Unit Location
A
General
Unobstructed airflow for the condenser is
essential to assure efficient operation and
the liquid chiller capacity. When determin-
ing unit placement, careful considerations
must be given to assure enough air flow
across the condenser heat-transfer
surface.
Two conditions should be avoided in order
to achieve optimum performance: warm air
recirculation and coil starvation.
Warm air recirculation occurs when the
airflow from the condenser fans discharged
back at the condenser coil inlet, due to
installation site restrictions.
Application
Considerations
B - Provide Vertical Clearance
C - Provide Side Clearance
D - Provide enough clearance between devices
E - Installations in locations surrounded by walls
Coil starvation occurs when the free airflow
to the condenser coil is restricted. Both
warm air recirculation and coil starvation
cause reductions in unit efficiency and
capacity, due to the associated high
discharge pressures. See page 24 (Mainte-
nance and air circulation clearances).

8 CG-PRC002A-EN
34
10
8
11
12
5
9
7
2
6
13
14
E
S
1
Application
Considerations
Evaporator hydraulic piping
components
The figure below shows how to proceed
with the installation of the water piping.
An air purge is placed on the evaporator
and at the water outlet. Provide additional
air purges at high piping points to release
it from the chilled water system.
Evaporator Drain
The evaporator drain connection must be
piped to an available strainer in order to
drain the evaporator even during operati-
on. Install a gate valve in the drain line.
Thermometers and
Manometers
It is essential to install thermometers (ite-
ms 5 and 12 in the figure) and
manometers (item 9) at the chilled water
inlet and outlet. These instruments must
be installed close to the unit, with a maxi-
mum scale of 1°C for thermometers and
0,1 kgf/cm2 for manometers.
Important: In order to avoid evaporator
damages, do not exceed a 150-psig wa-
ter pressure.
The manometer with connection should
be installed at water inlet and outlet accor-
ding to item 9 in the figure below in order
to avoid reading mistakes. Manometers
and thermometers must be installed at the
appropriate height to avoid parallax errors*.
Thermometers must be of glass or mer-
cury-scale type, with colored contrasting
fluid, and provide easy reading.
- Manometers must be equipped with
siphons;
- Install gate valves to isolate the manome-
ters when they are not being used.
Use piping joints to facilitate assembly and
disassembly services.
Inlet and outlet must be equipped with
gate valves to isolate the evaporator during
service, and a globe valve must be instal-
led at the outlet to adjust the water flow.
Flow-Switch
Verify that safety interlockings, particularly
the flow-switch, are installed in straight and
horizontal runs, with vanes adequate to the
pipe diameter, and the distance from cur-
ves and valves must be at least 5 times its
diameter, on each side.
Water treatment
The use of untreated or improperly treated
water may result in scaling, erosion, corro-
sion, algae and slime. The services of a
qualified water treatment specialist should
be engaged to determine what treatment,
if any, is advisable. Trane do Brasil assumes
no responsibility for equipment failures
resulting from the use of untreated or
improperly treated water.
Legend
1 - Drain
2- Joint
3- Flexible Connection
4- Water Flow Switch
5- Thermometer
6- Globe Valve
7- Cage Valve
8 - Air Purge
9- Manometers with cage valves
10- Joint
11- Flexible Connection
12- Thermometer
13- Water Filter
14- Cage Valve
E- Water Inlet
S- Water Output
* Parallax error: Apparent displacement of an object, when the observation point changes. It is especially said of the apparent deviation of a measure instrument needle, when it is
not observed from a vertical point of view (parallax error).
Fig. 01 - Components

CG-PRC002A-EN 9
Load loss (Ft. of water)
Loadloss(kPa)
Performance
Adjustment Factors
Fig. 02 - Evaporator Pressure Drop - 20 to 60 Tons Units
Fig. 03 - Evaporator Pressure Drop - 70 to 90 Tons Units
Unit Conversion
From: To: Multiplier:
Gallons/min (GPM) L/s 0,06308
Feet of water (Ft Water) Pa 2990
Evaporator Water Flow (GPM)
Evaporator Water Flow (GPM)
Evaporator Water Flow ( L/s )
Load loss (Ft. of water)

10 CG-PRC002A-EN
Performance
Adjustment Factors
Conversão de Unidades
De: Para: Multiplicador:
Galões/min (GPM) L/s 0,06308
Pés de Água (Ft Água) Pa 2990
Fig. 03a - Evaporator Pressure Drop - 100 to 120 Tons Units
Fig. 03b - Evaporator Pressure Drop - 150 Tons Units