Air-Cooled Liquid Chillers Models CGA and CGAF 10 to 60 Tons June 2006 CG-PRC007-EN
Introduction Design and manufacturing excellence makes Trane a leader in the air-cooled chiller marketplace. For over 40 years, Trane has been using the best engineering available in development, manufacturing, and marketing to produce quality products. This tradition of using excellence to meet market demands is illustrated with the Trane 10 to 60-ton air-cooled chillers. 10, 15 Tons 20–60 Tons © 2006 American Standard Inc.
Contents CG-PRC001-EN Introduction Features and Benefits 2 Controls 9 4 Application Considerations 16 Model Number Description 21 General Data 22 Selection Procedure 23 Performance Adjustment Factors 24 Performance Data 28 Electrical Data 38 Dimension Data 40 Weights 48 Mechanical Specifications 49 3
Features and Benefits Installation Small size, complete factory wiring, easy lifting provisions, factory installed options and start-up control provide fast, easy installation. A complete factory run test is performed on each unit, eliminating potential start-up problems. Integrated Comfort Systems All Trane chillers are ICS compatible. A simple twisted wire pair is all it takes to hook an air-cooled chiller into a Tracer system.
Features and Benefits The 10 and 15-ton air-cooled Cold Generator™ chillers, with Trane direct drive hermetic scroll compressors, has outstanding standard features and additional benefits that make selection, installation, and servicing easy. Flexibility Footprint Central to the design of any project is the operating envelope of the air-cooled packaged chiller. With this in mind, Trane builds the chillers to make the most efficient use of the available installation space.
Trane’s 20-60 ton chillers offer the same time-tested and proven control technology that is applied to the IntelliPak Air Cooled rooftops. Superior control makes the IntelliPak a truly advanced chiller. Standard Features Microprocessor Control The IntelliPak chiller’s Unit Control Module (UCM) is an innovative, modular microprocessor control design. It coordinates the actions of the chiller in an efficient manner and provides stand-alone operation of the unit.
Features and Benefits 20–60 Ton Enhanced Controls IntelliPak Chiller Unit Control Module (UCM) The brain of the 20 to 60 ton air-cooled chiller is its Unit Control Module (UCM). Access to the unit controls is via a Human Interface (HI) Panel, a standard component of the IntelliPak chiller. This panel provides a high degree of control. Superior monitoring capability and unmatched diagnostic information is provided through a 2 line 40 character per line, English language display.
Features and Benefits Trane 3-D Scroll Compressor Simple Design with 70% Fewer Parts Fewer parts than an equal capacity reciprocating compressor means significant reliability and efficiency benefits. The single orbiting scroll eliminates the need for pistons, connecting rods, wrist pins and valves. Fewer parts lead to increased reliability. Fewer moving parts, less rotating mass and less internal friction means greater efficiency than reciprocating compressors.
Controls Stand-Alone Unit Interface with Control Systems Figure C-1 — Stand-Alone Unit Interface to stand-alone units is very simple; only a remote auto-stop or chilled water flow interlock signal for scheduling is required for unit operation. Signals from the chilled water pump contactor auxiliary or a flow switch are wired to the chilled waterflow interlock. Signals from a time clock or some other remote device are wired to the external auto-stop input.
ELECTRICAL CONTROL SYSTEM The controls used on CGA 10 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 scheme are provided in the following paragraphs. Refer to the following control descriptions for control settings.
Controls 10, 15 Ton SEQUENCE OF UNIT OPERATION If compressor number one can’t satisfy the cooling demand, WTT’s second stage switch 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 starts compressor number two and outdoor fan number two. Refer to the unit wiring schematic pasted to the inside of the control panel cover when reviewing the control sequence described below.
Customized Control With IntelliPak controls, Trane can customize controls around the chiller application and the specific components used in the CGAF. For instance, the compressor protection system is specifically designed for the Trane 3-D™ Scroll compressor. A leaving chilled solution temperature control algorithm maintains accurate temperature control, for both comfort and process applications, minimizing the drift from set point.
Controls Standard Control Features Human Interface (HI) Panel The Human Interface (HI) Panel provides a 2 line X 40 character clear English language liquid crystal display and a 16 button keypad for monitoring, setting, editing and controlling. The Human Interface Panel is mounted in the unit’s main control panel and is accessible through a hatch built into the unit’s control panel door.
Controls six (6) seconds or longer, the compressors will shut down and after five (5) minutes an automatic resettable diagnostic alarm will be sent. Head Pressure Control — Condenser head pressure control is provided in the UCM by staging condenser fans on or off to maintain the saturated condensing temperature. This function will allow cooling operation down to 30°F as standard. Minimum on and off timing is built into the algorithm to prevent rapid cycling.
Controls LonTalk Chiller Communication Module — LonTalk is a communications protocol developed by the Echelon Corporation. The LonMark association develops control profiles using the LonTalk communication protocol. LonTalk is a unit level protocol, unlike BACNet used at the system level. LonTalk Communications Interface for Chillers (LCI-C) provides a generic automation system with the LonMark chiller profile inputs/outputs.
Application Considerations Certain application constraints should be considered when sizing, selecting and installing Trane air-cooled chillers. Unit and system reliability is often dependent upon proper and complete compliance with these considerations. Where the application varies from the guidelines presented, it should be reviewed with your local Trane sales engineer. Note: The terms water and solution are used interchangeably in the following paragraphs.
Application Considerations b d WATER TREATMENT Provide Vertical Clearance Provide Sufficient Unit-to-Unit Clearance Vertical condenser air discharge must be unobstructed. While it is difficult to predict the degree of warm air recirculation, a unit installed as shown below would have its capacity and efficiency significantly reduced — possibly to the degree of nuisance high head pressure trip outs. Performance data is based on free air discharge.
Application Considerations AMBIENT LIMITATIONS CONTROLS Trane chillers are designed for yearround applications in ambients from 0°F to 115°F. For operation below 0°F or above 115°F, contact the local Trane sales office. If hot gas bypass is used, operating ambients vary depending upon unit size (see the “General Data” section of this catalog).
Application Considerations The maximum catalog leaving solution temperature from the evaporator is 65°F for outdoor ambients up to 115°F. High leaving water temperatures exceeding this may result in excessive suction temperatures and, therefore, inadequate motor cooling. For applications requiring high leaving water temperatures, contact your local Trane sales office for suggested alternatives.
Application Considerations 10, 15 Ton Figure AC-1 — Recommended Piping Components For Typical Evaporator Installation Note: Provide shutoff valves in the evaporator inlet and outlet to facilitate water temperature sensor removal. 20–60 Ton 20 See unit dimensional drawings for inlet and outlet locations.
Model Number Description 10, 15 Tons CGA 123 DIGIT 1,2,3 — Unit Type CGA = Air-Cooled Cold Generator™ DIGITS 4,5,6 — Nominal Capacity (MBh) 100 120 150 180 = = = = 8 Tons (50 Hz Model only) 10 Tons (60 Hz Model only) 12.
General Data Table GD-1 — General Data — 10–60 Ton Units 10Ton Model Number CGA120 Compressor Data Model Scroll Quantity 2 Nominal Tons per Compressor 5 Evaporator Nominal Size (Tons) 10 Water Storage Capacity (Gallons)² 1.4 Min. Flow Rate (GPM) 12.0 Max. Flow Rate (GPM) 36.0 Max EWT At Start-Up — Deg F³ 100 Condenser Nominal Size (Tons) 10 Number of Coils 1 28 x 108 Coil Size (ea., Inches)4 Number of Rows 2 Subcooler Size (ea.
Selection Procedure The chiller capacity tables presented in the “Performance Data” section cover the most frequently encountered leaving water temperatures. The tables reflect a 10°F temperature drop through the evaporator. For temperature drops other than 10°F, fouling factors other than 0.
Performance Adjustment Factors Table PAF-1— Performance Adjustment Factors (10 & 15 Ton Units Only) Fouling Factor 0.00025 0.001 0.002 Chilled Water ∆ T 6 8 10 12 14 6 8 10 12 14 8 10 12 14 Altitude CAP 1.00 1.00 1.00 1.00 0.99 0.96 0.96 0.96 0.96 0.96 0.93 0.90 0.90 0.90 Sea Level GPM 1.66 1.25 1.00 0.83 0.71 1.60 1.20 0.96 0.80 0.68 1.15 0.90 0.75 0.64 KW 1.00 1.00 1.00 1.00 1.00 0.98 0.98 0.98 0.98 0.98 0.95 0.94 0.94 0.94 CAP 0.98 0.98 0.98 0.98 0.97 0.94 0.94 0.94 0.94 0.94 0.91 0.89 0.88 0.
Performance Adjustment Factors Chart PAF-1 — Evaporator Water Pressure Drop 10 to 60 Ton Air-Cooled Chillers CG-PRC007-EN 25
Performance Adjustment Factors Chart PAF-2— Ethylene Glycol Performance Factors 26 Chart PAF-3— Propylene Glycol Performance Factors CG-PRC007-EN
Performance Adjustment Factors Chart PAF-4— Ethylene Glycol and Propylene Glycol Performance Factors CG-PRC007-EN 27
Performance Data — 60 HZ 10–15 Ton Full Load Table PD-1 — 10 Ton — CGA 1205 LWT (Deg F) 20 25 30 35 40 42 44 45 46 48 50 55 60 75.0 Percent Capacity System Glycol (Tons) KW 28 6.0 7.6 24 6.6 7.8 19 7.3 8.0 14 8.0 8.2 0 8.9 8.4 0 9.2 8.5 0 9.5 8.6 0 9.7 8.6 0 9.8 8.7 0 10.2 8.8 0 10.5 8.9 0 11.4 9.1 0 12.4 9.4 EER 9.4 10.2 11.0 11.8 12.6 13.0 13.3 13.4 13.6 13.9 14.2 15.0 15.8 85.0 Capacity System (Tons) KW 5.6 8.5 6.3 8.6 6.9 8.8 7.7 9.0 8.5 9.3 8.8 9.4 9.1 9.5 9.3 9.5 9.4 9.6 9.8 9.7 10.1 9.8 11.0 10.
Performance Data — 60 HZ 20–25 Ton Full Load Table PD-3 — 20 Ton — CGAF-C20 LWT (Deg F) 20 25 30 35 40 42 44 45 46 48 50 55 60 75.0 Percent Capacity System Glycol (Tons) KW 31 12.1 15.7 27 13.4 16.1 22 14.9 16.5 17 16.4 16.9 0 18.2 17.4 0 18.8 17.6 0 19.5 17.8 0 19.8 17.9 0 20.2 18.0 0 20.9 18.2 0 21.6 18.4 0 23.4 19.0 0 25.3 19.5 EER 9.2 10.0 10.8 11.6 12.5 12.8 13.1 13.3 13.4 13.8 14.1 14.8 15.5 Entering Condenser Air Temperature (Degree F) 85.0 95.0 105.
Performance Data — 60 HZ 30–40 Ton Full Load Table PD-5— 30 Ton — CGAF-C30 LWT (Deg F) 20 25 30 35 40 42 44 45 46 48 50 55 60 Percent Glycol 31 27 22 17 0 0 0 0 0 0 0 0 0 75.0 Capacity System (Tons) KW 18.9 25.8 21.1 26.3 23.4 26.8 25.9 27.4 28.7 28.1 29.7 28.3 30.8 28.5 31.4 28.7 31.9 28.8 33.0 29.0 34.1 29.3 37.0 30.0 40.0 30.6 EER 8.8 9.6 10.5 11.3 12.3 12.6 13.0 13.1 13.3 13.6 14.0 14.8 15.7 Entering Condenser Air Temperature (Degree F) 85.0 95.0 105.
Performance Data — 60 HZ 50–60 Ton Full Load Table PD-7— 50 Ton — CGAF-C50 LWT (Deg F) 20 25 30 35 40 42 44 45 46 48 50 55 60 75.0 Percent Capacity System Glycol (Tons) KW 31 28.2 39.6 27 31.6 40.4 22 35.4 41.4 17 39.3 42.3 0 43.9 43.4 0 45.6 43.8 0 47.4 44.3 0 48.3 44.5 0 49.2 44.7 0 51.0 45.1 0 52.8 45.6 0 57.6 46.7 0 62.5 47.9 EER 8.5 9.4 10.3 11.2 12.1 12.5 12.8 13.0 13.2 13.6 13.9 14.8 15.7 85.0 Capacity System (Tons) KW 26.8 43.2 30.1 44.2 33.7 45.2 37.5 46.3 41.9 47.5 43.6 48.0 45.2 48.4 46.
Performance Data — 50 HZ 10–30 Ton Full Load Table PD-10— 10 Ton — CGA 120 LWT (Deg F) 40 42 44 45 46 48 50 EER 11.4 11.7 12.0 12.1 12.2 12.5 12.8 95.0 Capacity System (Tons) KW 6.8 8.4 7.1 8.5 7.3 8.6 7.5 8.7 7.6 8.7 7.9 8.8 8.2 9.0 Entering Condenser Air Temperature (Degree F) 105.0 115.0 Capacity System Capacity System EER (Tons) KW EER (Tons) KW 9.7 6.4 9.4 8.2 6.0 10.5 10.0 6.7 9.5 8.4 6.3 10.6 10.2 6.9 9.6 8.7 6.5 10.7 10.3 7.1 9.7 8.8 6.6 10.8 10.5 7.2 9.7 8.9 6.8 10.8 10.7 7.5 9.8 9.1 7.0 10.
Performance Data — 50 HZ 40–60 Ton Full Load Table PD-15 — 40 Ton — CGAF-C40 85.0 LWT Percent Capacity System (Deg F) Glycol (Tons) KW 40 0 28.4 29.8 42 0 29.5 30.1 44 0 30.6 30.4 45 0 31.2 30.5 46 0 31.8 30.7 48 0 32.9 31.0 50 0 34.1 31.3 EER 11.4 11.8 12.1 12.3 12.4 12.8 13.1 Entering Condenser Air Temperature (Degree F) 105.0 115.0 Capacity System Capacity System EER (Tons) KW EER (Tons) KW 9.7 25.4 37.4 8.1 23.7 41.9 10.0 26.4 37.7 8.4 24.7 42.3 10.3 27.4 38.0 8.6 25.6 42.6 10.4 27.9 38.2 8.8 26.
Performance Data — 60 HZ 10–30 Ton Part Load Table PD-19 — 10 Ton — CGA 120 Percent Load 100 52 EER Capacity System KW EER Capacity System KW Entering Condenser Air Temperature (Degrees F) 95 66.2 10.0 8.7 10.5 10.1 3.5 4.2 Table PD-20 — 15 Ton — CGA 180 Percent Load 100 50 EER Capacity System KW EER Capacity System KW Entering Condenser Air Temperature (Degrees F) 95 66.2 13.8 12.6 11.0 10.7 5.5 6.
40–60 Ton Part Load Performance Data — 60 HZ Table PD-24— 40 Ton — CGAF-C40 Percent Entering Condenser Air Temperature (Degrees F) Load 100 75 50 25 EER Capacity System KW EER Capacity System KW EER Capacity System KW EER Capacity System KW 75 85 95 105 115 120 13.0 37.9 35.0 13.4 28.9 26.0 14.2 20.5 17.3 13.0 9.5 8.8 11.3 36.2 38.5 11.7 27.6 28.5 12.6 19.6 18.7 11.2 9.1 9.7 9.7 34.4 42.6 10.1 26.3 31.3 11.0 18.7 20.5 9.6 8.6 10.7 8.3 32.4 47.1 8.6 24.8 34.6 9.5 17.7 22.5 8.1 8.1 11.9 7.
Performance Data — 50 HZ 10–30 Ton Part Load Table PD-19 — 10 Ton — CGA 120 Percent Load 100 50 EER Capacity System KW EER Capacity System KW 75 13.9 8.1 13.9 11.6 3.7 3.8 85 11.9 7.7 15.5 10.1 3.5 4.2 Entering Condenser Air Temperature (Degrees F) 95 105 10.2 8.6 7.3 6.9 17.3 19.3 8.7 7.4 3.4 3.1 4.6 5.1 115 7.3 6.5 21.6 6.3 3.0 5.7 120 6.7 6.3 22.9 5.8 2.9 6.0 75 13.8 12.6 11.0 12.5 5.8 5.5 85 11.7 12.0 12.4 10.7 5.5 6.3 Entering Condenser Air Temperature (Degrees F) 95 105 9.7 8.1 11.4 10.
Performance Data — 50 HZ 40–60 Ton Part Load Table PD-24— 40 Ton — CGAF-C40 Percent Entering Condenser Air Temperature (Degrees F) Load 100 75 50 25 EER Capacity System KW EER Capacity System KW EER Capacity System KW EER Capacity System KW 75 85 95 105 115 120 14.1 32.1 27.3 14.6 24.4 20.1 15.7 17.1 13.1 13.8 7.9 6.9 12.1 30.6 30.4 12.6 23.3 22.2 13.7 16.4 14.3 11.8 7.6 7.7 10.3 29.1 34.0 10.7 22.1 24.8 11.8 15.6 15.8 10.0 7.2 8.6 8.6 27.4 38.0 9.0 20.9 27.7 10.1 14.8 17.6 8.4 6.8 9.7 7.
Electrical Data - 60 HZ 10–60 Ton Table ED-1 — Electrical Data Tons 10 15 20 25 30 40 50 60 Model Nameplate Number Voltage CGA120B1 208-230/60/1 CGA120B3 208-230/60/3 CGA120B4 460/60/3 CGA120BW 575/60/3 CGA180B3 208-230/60/3 CGA180B4 460/60/3 CGA180BW 575/60/3 200/60/3 230/60/3 CGAF-C20 460/60/3 575/60/3 200/60/3 230/60/3 CGAF-C25 460/60/3 575/60/3 200/60/3 230/60/3 CGAF-C30 460/60/3 575/60/3 200/60/3 230/60/3 CGAF-C40 460/60/3 575/60/3 200/60/3 230/60/3 CGAF-C50 460/60/3 575/60/3 200/60/3 230/60
Electrical Data - 50 HZ 10–60 Ton Table ED-2 — Electrical Data Tons 10 15 20 25 30 40 Model Nameplate Number Voltage CGA100BD 380-415/50/3 CGA150BD 380-415/50/3 CGAF-C20 380/50/3 415/50/3 38050/3 CGAF-C25 415/50/3 CGAF-C30 380/50/3 415/50/3 CGAF-C40 380/50/3 415/50/3 50 CGAF-C50 60 CGAF-C60 380/50/3 415/50/3 380/50/3 415/50/3 Unit Wiring Voltage Range MCA 342-456 24.1 342-456 32.
Dimensional Data 10 Ton Figure DD-1 — CGA-120B Unit Dimensions 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 replacement.
Dimensional Data 15 Ton Figure DD-2 — CGA-180B Unit Dimensions 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 replacement.
Dimensional Data 20 Ton Figure DD-3 — CGAF-C20 Unit Dimensions 2 3/8 “ 8 5/8” 11 3/4” 42 CG-PRC007-EN
Dimensional Data 25 Ton Figure DD-4 — CGAF-C25 Unit Dimensions 2 3/8 “ 8 5/8” 11 3/4” CG-PRC007-EN 43
Dimensional Data 30 Ton Figure DD-5 — CGAF-C30 Unit Dimensions 2 3/8 “ 8 5/8” 9 3/4” 44 CG-PRC007-EN
Dimensional Data 40 Ton Figure DD-6 — CGAF-C40 Unit Dimensions 8 5/8 “ 9 3/8” 9 3/4” CG-PRC007-EN 45
Dimensional Data 50 Ton Figure DD-7 — CGAF-C50 Unit Dimensions 9 3/8” 46 8 5/8 “ CG-PRC007-EN
Dimensional Data 60 Ton Figure DD-8— CGAF-C60 Unit Dimensions 9 3/8” CG-PRC007-EN 8 5/8 “ 47
Weights 10–60 Ton Table W-1 — Approximate Corner Weights (lbs) 10-Ton Unit Tons 10 Model Number CGA 120B 1 161 Isolator Loading 2 3 4 164 103 101 Operating Wt. 529 Shipping Wt. 576 4 Operating Wt. Shipping Wt.
Mechanical Specifications General Units shall be assembled on heavy gauge steel mounting/lifting 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 charge of oil and R-22 refrigerant. Operating range shall be between 115°F and 0°F. Units shall be either UL or CSA certified and rated in accordance with ARI Standard 550/590-98.
Mechanical Specifications General All chillers are factory run-tested to confirm proper operation. Units are checked on a computer-based test stand at typical ambient and water conditions and control operation is monitored. Units ship with a full operating charge of refrigerant and oil. Units are constructed of 14-gauge welded galvanized steel frame with 14 and 16-gauge galvanized steel panels and access doors. Unit surface is phosphatized and finished with an airdry paint.
Mechanical Specifications The microprocessor boards shall be stand-alone DDC controls not dependent on communications with an on-site PC or a Building Management Network.The microprocessors shall be equipped with onboard diagnostics, indicating that all hardware, 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.
The standard ARI rating condition full load and IPLV are ARI certified. All other ratings, including the following, are outside the scope of the certification program and are excluded: • Glycol • 50 Hz Trane A business of American Standard Companies www.trane.com For more information contact your local district office, or e-mail us at comfort@trane.
