Trane CGAT Series Owner's manual

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
© American Standard Inc. 003
odel Nomenclature
C G A T 0 6 5 D 0 0 0 0 A A
1 2 3 4 5 6 7 8 9 10 11 12 13 14
DIGIT 1,2,3 - ODEL IDENTIFIER
CGA = COLD GENERATOR, AIR-COOLED
DIGIT 4 - DEVELOP ENT SEQUENCE
T = DEVELOPMENT SEQUENCE
DIGIT 5,6,7 - NO INAL CAPACITY
065 - 65 MBH
085 - 85 MBH
105 - 105 MBH
135 - 135 MBH
175 - 175 MBH
15 - 15 MBH
DIGIT 8 - ELECTRICAL CHARACTERISTICS
D = 380-415V/3pH/50Hz
DIGIT 9,10 - FACTORY INSTALLED OPTIONS
00 = NONE
0A = FACTORY INSTALLED OPTIONS
DIGIT 11,12 - 0, 0 FOR FUTURE USE
DIGIT 13 - INOR DESIGN SEQUENCE
A = FIRST DESIGN SEQUENCE
DIGIT 14 - SERVICE DIGIT
A = 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

4CGAT-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

6CGAT-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

8CGAT-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 30 113.6 98.0 1290 1.06 2.27
CGAT085D 380-415/3/50 342-440 27.3 30 120.7 130.0 1420 1.41 3.53
CGAT105D 380-415/3/50 342-440 29.8 30 122.9 145.0 1300 1.20 2.28
CGAT135D 380-415/3/50 342-440 32.7 30 213.6 98.0 2290 1.06 2.27
CGAT175D 380-415/3/50 342-440 49.4 30 220.7 130.0 2420 1.41 3.53
CGAT215D 380-415/3/50 342-440 53.9 30 222.9 145.0 2300 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.