Trane CGCL 200 Owner's manual

Installation
Operation
Maintenance
CGCL
Air Cooled Water Chiller With
Centrifugal Fans
Sizes 200 - 250 - 300 - 350 - 400 - 450 -
500 - 600
CGCL-SVX01B-E4

CGCL-SVX01B-E4
General information
Foreword
These instructions are given as a
guide to good practice in the
installation, start-up, operation, and
maintenance by the user, ofTrane
CGCL chillers.They do not contain
full service procedures
necessary for the continued
successful operation of this
equipment.The services of a
qualified technician should be
employed through the medium of a
maintenance contract with a
reputable service company. Read
this manual thoroughly before unit
start-up.
Units are assembled, pressure
tested, dehydrated, charged and run
tested before shipment.
Warnings and cautions
Warnings and Cautions appear at
appropriate sections throughout this
manual.Your personal safety and the
proper operation of this machine
require that you follow them
carefully.The constructor assumes
no liability for installations or
servicing performed by unqualified
personnel.
WARNING! : Indicates a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
CAUTION! : Indicates a potentially
hazardous situation which, if not
avoided, may result in minor or
moderate injury. It may also be
used to alert against unsafe
practices or for equipment or
property-damage-only accidents.
Safety
recommendations
To avoid death, injury, equipment or
property damage, the following
recommendations should be
observed during maintenance and
service visits:
1.The maximum allowable pressures
for system leak testing on low and
high pressure side are given in the
chapter "Installation". Always
provide a pressure regulator.
2. Disconnect the main power supply
before any servicing on the unit.
3. Service work on the refrigeration
system and the electrical system
should be carried out only by
qualified and experienced
personnel.
©American Standard Inc. 2006

3
CGCL-SVX01B-E4
General information
Reception
On arrival, inspect the unit before
signing the delivery note.
Reception in France only:
In case of visible damage:The
consignee (or the site
representative) must specify any
damage on the delivery note, legibly
sign and date the delivery note, and
the truck driver must countersign it.
The consignee (or the site
representative) must notifyTrane
Epinal Operations - Claims team and
send a copy of the delivery note.
The customer (or the site
representative) should send a
registered letter to the last carrier
within 3 days of delivery.
Note: for deliveries in France, even
concealed damage must be looked
for at delivery and immediately
treated as visible damage.
Reception in all countries except
France:
In case of concealed damage:The
consignee (or the site
representative) must send a
registered letter to the last carrier
within 7 days of delivery, claiming
for the described damage. A copy of
this letter must be sent toTrane
Epinal Operations - Claims team.
Warranty
Warranty is based on the general
terms and conditions of the
manufacturer.The warranty is void if
the equipment is repaired or
modified without the written
approval of the manufacturer, if the
operating limits are exceeded or if
the control system or the electrical
wiring is modified. Damage due to
misuse, lack of maintenance or
failure to comply with the
manufacturer's instructions or
recommendations is not covered by
the warranty obligation. If the user
does not conform to the rules of this
manual, it may entail cancellation of
warranty and liabilities by the
manufacturer.
Refrigerant
The refrigerant provided by the
manufacturer meets all the
requirements of our units. When
using recycled or reprocessed
refrigerant, it is advisable to ensure
its quality is equivalent to that of a
new refrigerant. For this, it is
necessary to have a precise analysis
made by a specialized laboratory. If
this condition is not respected, the
manufacturer warranty could be
cancelled.

4CGCL-SVX01B-E4
General information
Maintenance contract
It is strongly recommended that you
sign a maintenance contract with
your local Service Agency.This
contract provides regular
maintenance of your installation by
a specialist in our equipment.
Regular maintenance ensures that
any malfunction is detected and
corrected in good time and
minimizes the possibility that
serious damage will occur. Finally,
regular maintenance ensures the
maximum operating life of your
equipment. We would remind you
that failure to respect these
installation and maintenance
instructions may result in immediate
cancellation of the warranty.
Training
To assist you in obtaining the best
use of it and maintaining it in perfect
operating condition over a long
period of time, the manufacturer has
at your disposal a refrigeration and
air conditioning service school.The
principal aim of this is to give
operators and technicians a better
knowledge of the equipment they
are using, or that is under their
charge. Emphasis is particularly
given to the importance of periodic
checks on the unit operating
parameters as well as on preventive
maintenance, which reduces the cost
of owning the unit by avoiding
serious and costly breakdown.

CGCL-SVX01B-E4 5
Contents
General information 2
General unit characteristics 6
Installation
Unit name plate 8
Installing the unit 8
Duct connections 9
Water to evaporator connection 11
Minimum water volume 11
Water treatment 12
Antifreeze protection 12
Electrical connections 13
General start-up
Start-up preparation 14
Start-up 14
Operation
Unit operation 16
Weekly start up and week-end shutdown 16
Seasonal start-up and shutdown 16
Maintenance
Maintenance instructions 17
Installation checklist 18
Troubleshooting guide 19

6 CGCL-SVX01B-E4
General unit characteristics
Table 1 - CGCL general data
CGCL 200 CGCL 250 CGCL 300 CGCL 350 CGCL 400 CGCL 450 CGCL 500 CGCL 600
R407C R407C R407C R407C R407C R407C R407C R407C
Eurovent Performances (1)
Net cooling capacity (kW) 49.2 61.1 74.0 86.9 101.0 111.0 126.0 152.0
Total power input in cooling (kW) 21.9 26.9 34.6 38.3 46.8 55.5 59.7 73.1
Evaporator water pressure drop (kPa) 42 41 42 41 39 46 56 68
Main power supply 400/3/50
Sound power level 300 Pa (dB(A)) 88 84 87 89 91 95 90 94
Sound power level 400 Pa (dB(A)) 90 86 89 90 93 96 92 95
Sound power level 500 Pa (dB(A)) 91 88 90 92 94 97 93 96
Units Amps
Nominal (4) (A) 48 61.4 76.7 86.1 102.3 117.7 120.8 151.3
Start-up amps (A) 150 209 224 234 250 265 268 299
Recommended fuse size (Am) (A) Depends on installation
Max supply cable size (mm2)3535505095959595
Max. wire length (m) Depends on installation
Compressor
Number(circ1/circ2) 2223332/22/2
Type Scroll
Model 10T+10T 10T+15T 2x15T 2x10T+15T 10T+2x15T 3x15T 2x(10T+15T) 4x15T
Numberofspeeds 11111111
Numberofmotors 11111111
Rated amps (2)(4) (A) 37 46 55 65 74 83 92 110
Locked rotor amps (2) (A) 139 194 203 212 221 230 240 258
Motor RPM (rpm) 2900 2900 2900 2900 2900 2900 2900 2900
Sump heater (2) (W) --------
Evaporator
Number 1
Type Brazed plate
Water volume (total) (l) 4.7 5.9 7.0 8.2 10.5 10.5 12.3 16.1
Antifreeze Heater (W) 65 65 65 65 65 65 130 130
Water connection type Male ISO R7
Water connection diameter 1"1/2 1"1/2 1"1/2 2" 2" 2" 2"1/2 2"1/2
Coil
Type Plate Fin
Tube size (mm) 9.52
Tube type Smooth
Height (mm) 914 1219 1219 1219 1219 1219 1626 1626
Length (mm) 1829 1829 1829 2743 2743 2743 2743 2743
Face Area (m2)1.672.232.233.343.343.344.464.46
Number of rows 4
Fins per inch (fpf) 180
Fan
Type Centrifugal
Number 12222233
Diameter AT 18-18
Drive type Belt Drive
Number of speeds 2
Number of motors 1
Dimensions
Height (mm) 1997 1997 1997 1997 1997 1997 1997 1997
Length (mm) 2268 2268 2268 3230 3230 3230 3230 3230
Width (mm) 866 866 866 866 866 866 1216 1216
Weight uncrated (kg) 710 830 890 1080 1140 1200 1380 1500
Weight crated (kg) 750 870 930 1130 1190 1250 1450 1570
Refrigerant circuit data
Numberofcircuits 11111122
Refrigerant charge A/B (kg) 12/- 15/- 15/- 24/- 24/- 24/- 15/15 15/15
Oil charge A/B (l) 7.6/- 10/- 12.4/- 13.8/- 16.2/- 18.6/- 10/10 12.4/12.4
(1) at Eurovent Conditions at nominal airflow (Evap 12°C/7°C - Air. 35°C)
(2) per motor
(3) per circuit
(4) 5°C saturated suction temperature - 60°C saturated discharge temperature

Table 2 - CGCL Fan performance
Size Airflow Total Fan Static Pressure (Pa)
(m3/h) 300 400 500
CGCL 200 15300
Fan Motor Nominal Power Low Speed* (kW) 0.75 1.1 1.1
Fan Motor Nominal Power High Speed (KW) 4.0 5.5 5.5
Nominal Amps Low speed * (A) 3.2 3.7 3.7
Nominal Amps High speed (A) 8.9 11 11
Starting Amps * (A) 14 12 12
CGCL 250 17800
Fan Motor Nominal Power Low Speed* (kW) 0.75 1.1 1.5
Fan Motor Nominal Power High Speed (KW) 4.0 5.5 7.5
Nominal Amps Low speed * (A) 3.2 3.7 5.0
Nominal Amps High speed (A) 8.9 11 15.3
Starting Amps * (A) 14 12 17
CGCL 300 23800
Fan Motor Nominal Power Low Speed* (kW) 1.5 1.5 2.8
Fan Motor Nominal Power High Speed (KW) 7.5 7.5 11.0
Nominal Amps Low speed * (A) 5.0 5.0 7.7
Nominal Amps High speed (A) 15.3 15.3 21.5
Starting Amps * (A) 17 17 33
CGCL 350 26800
Fan Motor Nominal Power Low Speed* (kW) 1.5 2.8 2.8
Fan Motor Nominal Power High Speed (KW) 7.5 11.0 11.0
Nominal Amps Low speed * (A) 5.0 7.7 7.7
Nominal Amps High speed (A) 15.3 21.5 21.5
Starting Amps * (A) 17 33 33
CGCL 400 30600
Fan Motor Nominal Power Low Speed* (kW) 2.8 2.8 3.8
Fan Motor Nominal Power High Speed (KW) 11 11 15
Nominal Amps Low speed * (A) 7.7 7.7 10.1
Nominal Amps High speed (A) 21.5 21.5 28.6
Starting Amps * (A) 33 33 43
CGCL 450 34500
Fan Motor Nominal Power Low Speed* (kW) 3.8 3.8 4.8
Fan Motor Nominal Power High Speed (KW) 15.0 15.0 18.5
Nominal Amps Low speed * (A) 10.1 10.1 12.1
Nominal Amps High speed (A) 28.6 28.6 34.6
Starting Amps * (A) 43 43 45
CGCL 500 39100
Fan Motor Nominal Power Low Speed* (kW) 2.8 3.8 3.8
Fan Motor Nominal Power High Speed (KW) 11.0 15.0 15.0
Nominal Amps Low speed * (A) 7.7 10.1 10.1
Nominal Amps High speed (A) 21.5 28.6 28.6
Starting Amps * (A) 33 43 43
CGCL 600 47600
Fan Motor Nominal Power Low Speed* (kW) 4.8 4.8 5.3
Fan Motor Nominal Power High Speed (KW) 18.5 18.5 22.0
Nominal Amps Low speed * (A) 12.1 12.1 13.2
Nominal Amps High speed (A) 34.9 34.9 40.9
Starting Amps * (A) 45 45 48
*: Fan motor always starts in Low speed
Unit nominal amps = nominal fan amps (according to static pressure) + compressor nominal amps
Unit starting amps = nominal fan amps (according to static pressure) + compressor starting amps
Table 3 - Pressure drop through condenser coil and air filter
Unit Airflow Chiller internal pressure drop (Pa)
m3/h Cds coil AR300 filter A150 Filter M8 Filter
CGCL 200 15300 96 100 66 28
CGCL 250 17800 77 85 56 22
CGCL 300 23800 124 122 84 40
CGCL 350 26800 77 85 56 22
CGCL 400 30600 96 100 68 28
CGCL 450 34500 117 117 80 36
CGCL 500 39100 124 95 64 26
CGCL 600 47600 163 122 84 40
For minimum clearance, consult the certified submittals, which are available on request from your localTrane sales office.
Available static pressure =Total fan static pressure (from table 2) - Chiller internal pressure drop (from table 3)
IMPORTANT:The setting of the external static pressure supplied by the CGCL chiller must correspond to the actual ductwork (inlet and outlet) pressure drop +/- 50Pa.
Failure to comply to this condition could lead to operational problems such as excessive sound levels, vibrations, or early wear of motor, fan or bearings. Adjustment of the
airflow through the unit must be performed at chiller commissioning or warranty will not apply.
CGCL-SVX01B-E4 7
General unit characteristics

Installation
Water drain hole
Install a drain hole wide enough to
drain away water from the unit in
the event of shut-down or repair.
Clearance
Respect recommended clearance
around the unit to allow
maintenance operation to take place
without obstruction and
recommended clearance around
condenser.
CAUTION!: Unit operation is
function of the air temperature. Any
recycling of the air fed out by the
fans will increase the air intake
temperature over the condenser fins
and can result in high pressure cut-
out.
In this case the standard operating
conditions are modified.
Operation of the unit may be
affected by an increase in air
temperature on the condenser.
See submittals
Unit nameplate
The unit nameplate gives the
complete model reference numbers.
The unit power rating is shown, and
power supplies should not deviate
by more than 5 % from the rated
power.
Compressor motor amperage is
shown in box I.MAX.
The customer's electrical installation
must be able to withstand this
current.
Installing the unit
Foundations
No special foundations are required,
provided the supporting surface is
flat and level, and can withstand the
weight or the unit.
Isolation rubber pads
They are supplied as standard with
the machine, and should be placed
between the supporting floor and
the unit to isolate the base from the
ground.
- 4 pads for the sizes 200 to 300
- 6 pads for the sizes 350 to 600
- Trane does not allow to install
spring isolators.
8 CGCL-SVX01B-E4
Selection of the Proper Available
Static Pressure:
Static pressure indicated only takes
into account the available pressure
of the fan. It is necessary to subtract
the pressure drop of the
components fromTable 3. Failure to
do so will end up in increasing
constraint on the bearings and on
the motor which will result up in a
drastic reduction of the lifespan of
the fan.
For example:
CGCL 350
- with 400 Pa available static
pressure fans
- with 77 Pa condenser coil
- with A150 Filter of 56 Pa
Available Static Pressure =
400 Pa -77 Pa - 56 Pa = 267 Pa
The tolerance is +/- 50 Pa.
In this example the pressure drop of
the ductwork will have to be
between 217 Pa and 317 Pa.
Table 4 - Fan speed (rpm) : high speed (low speed)
Available fan static pressure (Pa)
Unit size 300 400 500
200 655 (328) 728 (364) 808 (404)
250 655 (328) 728 (364) 857 (429)
300 650 (325) 768 (384) 857 (429)
350 686 (343) 768 (384) 857 (429)
400 686 (343) 768 (384) 815 (408)
450 812 (406) 831 (416) 931 (466)
500 728 (364) 812 (406) 815 (408)
600 728 (364) 831 (416) 935 (468)
Figure 1 - Handling
Note :
The plates welded at the end of the bases must not be used for handling.
Table 5 - Dimensions of recommended slings and swing-bar
CGCL 200 250 300 350 400 450 500 600
A ( m m) 1150 1150 115 0 115 0 11 5 0 1150 15 0 0 15 0 0
B (mm) 2550 2550 2550 2700 2700 2700 2700 2700
Weight (kg) 750 870 930 1130 1190 1250 1450 1570
B
A

Duct connections
Duct connections of suction and
discharge of the unit and accessories
must be made of flexible hose.The
duct connection must be flexible
enough to prevent transmitting
vibrations to the tube network (see
Figures 2, 3 and 4).
CAUTION!: When fixing the duct to
the condenser inlet, make sure the
fixing screws do not pierce the coil.
Figure 2
1. Accessory
2.Attachment bolts
3.Unit frame
4.Sealing strip
5.Accessory (filter)
Figure 3 - Inlet
1. Unit body
2.Flexible coupling
3.Ductwork
4.Seal
4
1
2
3
CGCL-SVX01B-E4 9
Installation
54
12
3
Figure 4 - Outlet
1. Unit body
2. Flexible coupling (field supply)
3. Ductwork
To prevent a reduction in fan
efficiency, which would reduce the
air flow and the unit's cooling
capacity, the duct connections must
be designed and connected
according to normal trade practice.
1
2
3

CAUTION! If the duct network does
not provide the external static
pressure stipulated on selection, it
will have repercussions on the air
flow and therefore on the unit's
performance.
Please refer to "Selection of the
Proper Available Static Air Pressure".
This type of problem may if
necessary be referred to theTrane
service office, which may be able to
advise you as to the necessary
modifications, if any.
On all units, a straight duct section
connected to a fan must have at
least the same cross sectional area
as the output panel orifice, and its
minimum length must be one and a
half times the fan diameter, before
any bend or deviation.
There must be no tight bends,
particularly at the fan output where
the air velocity gradient is high. A
large proportion of the air initially
flows at the top of the duct. If a bend
is close to the fan it must be
installed so that its external
curvature radius is in the trajectory
of the air discharged by the high
speed side of the fan (see figures 5
and 6).
10 CGCL-SVX01B-E4
Installation
10 CGCL-SVX01B-E4
Figure 5
RIGHT
Figure 6
WRONG