Air-Cooled Liquid Chillers 10 to 60Tons April 2004 CG-PRC007-EN
Introduction Air-Cooled Liquid Chillers Design and manufacturing excellence makesTrane 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 theTrane 10 to 60-ton air-cooled chillers. 10, 15 Tons 20–60 Tons © 2003 American Standard Inc.
Contents Introduction Features and Benefits 2 Application Considerations 9 4 Selection Procedure 14 Model Number Description General Data 15 16 Performance Data 21 Performance Adjustment Factors CG-PRC001-EN Controls 17 30 Electric Power 37 Dimension and Weights 39 Mechanical Specifications 48 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 AllTrane chillers are ICS compatible. A simple twisted wire pair is all it takes to hook an air-cooled chiller into aTracer system.
The 10 and 15-ton air-cooled Cold Generator™ chillers, withTrane 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.The Trane CGA model chillers are extremely compact.
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) Microprocessor Control The brain of the 20 to 60 ton air-cooled chiller is its Unit Control Module (UCM). The UCM is an innovative, modular microprocessor control design, which coordinates the actions of the chiller in an efficient manner, providing standalone operation of the unit. Access to the unit controls is via a Human Interface (HI) Panel, a standard component of the IntelliPak chiller.
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.
Application Considerations Certain application constraints should be considered when sizing, selecting and installingTrane 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 localTrane 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 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 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 CG-PRC007-EN See unit dimensional drawings for inlet and outlet locations.
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.
Model Number Description 10, 15 Tons CGA 120 B 123 456 7 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 10 Ton 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 Coil Size (ea., Inches)4 28 x 108 Number of Rows 2 Subcooler Size (ea.
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 15 9.5 10 8 9 7.5 8.5 7 6 6. 5 5.5 4.5 5 3.5 4 3 2.5 2 1.
Performance Adjustment Factors Chart PAF-2— Ethylene Glycol Performance Factors CG-PRC007-EN Chart PAF-3— Propylene Glycol Performance Factors 19
Performance Adjustment Factors Chart PAF-4— Ethylene Glycol and Propylene Glycol Performance Factors 20 CG-PRC007-EN
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.
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 28 12.0 15.6 24 13.4 16.0 19 14.8 16.4 14 16.4 16.9 0 18.1 17.4 0 18.8 17.6 0 19.5 17.8 0 19.8 17.9 0 20.1 18.0 0 20.8 18.2 0 21.5 18.4 0 23.3 18.9 0 25.2 19.4 EER 9.2 10.0 10.8 11.6 12.5 12.8 13.2 13.3 13.5 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 28 24 19 14 0 0 0 0 0 0 0 0 0 75.0 Capacity System (Tons) KW 18.8 25.7 21.0 26.3 23.3 26.8 25.8 27.4 28.7 28.0 29.7 28.3 30.8 28.5 31.4 28.6 31.9 28.8 33.0 29.0 34.1 29.3 37.0 29.9 40.1 30.6 EER 8.8 9.6 10.4 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 28 28.5 39.7 24 31.9 40.5 19 35.6 41.4 14 39.5 42.4 0 44.1 43.5 0 45.7 43.9 0 47.4 44.3 0 48.2 44.5 0 49.1 44.7 0 50.8 45.1 0 52.6 45.5 0 57.1 46.6 0 61.8 47.7 EER 8.6 9.4 10.3 11.2 12.2 12.5 12.8 13.0 13.2 13.5 13.9 14.7 15.5 85.0 Capacity System (Tons) KW 27.1 43.4 30.4 44.3 33.9 45.3 37.7 46.4 42.1 47.6 43.6 48.0 45.3 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 Capacity System Capacity EER (Tons) KW EER (Tons) 9.7 6.4 9.4 8.2 6.0 10.0 6.7 9.5 8.4 6.3 10.2 6.9 9.6 8.7 6.5 10.3 7.1 9.7 8.8 6.6 10.5 7.2 9.7 8.9 6.8 10.7 7.5 9.8 9.1 7.0 11.0 7.7 10.0 9.3 7.3 115.0 System KW 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 28.8 30.0 42 0 29.8 30.2 44 0 30.9 30.5 45 0 31.5 30.6 46 0 32.0 30.8 48 0 33.1 31.1 50 0 34.3 31.3 EER 11.5 11.8 12.2 12.3 12.5 12.8 13.1 Entering Condenser Air Temperature (Degree F) 105.0 115.0 Capacity System Capacity System EER (Tons) KW EER (Tons) KW 9.8 25.7 37.6 8.2 24.0 42.2 10.0 26.7 37.9 8.4 25.0 42.5 10.3 27.7 38.2 8.7 25.9 42.8 10.5 28.2 38.4 8.8 26.
Performance Data — 60 HZ (10–60 Ton) Part Load Table PD-18— Part Load Data, ARI Points (10-60 Tons) Entering Condenser Air Temperature (Degrees F) Model Tons Number 10 CGA 1202 15 CGA 180 20 CGAF-C20 25 CGAF-C25 30 CGAF-C30 40 CGAF-C40 50 CGAF-C50 60 CGAF-C60 EER Capacity (Tons) KW Input EER Capacity (Tons) KW Input EER Capacity (Tons) KW Input EER Capacity (Tons) KW Input EER Capacity (Tons) KW Input EER Capacity (Tons) KW Input EER Capacity (Tons) KW Input EER Capacity (Tons) KW Input 9
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 14.2 32.4 27.4 14.9 25.2 20.3 16.3 17.8 13.2 14.3 8.4 7.1 12.2 30.9 30.5 12.8 24.0 22.5 14.2 17.1 14.5 12.2 8.0 7.9 10.3 29.3 34.1 10.9 22.8 25.0 12.2 16.3 16.0 10.3 7.6 8.9 8.7 27.7 38.2 9.2 21.5 27.9 10.4 15.4 17.7 8.6 7.1 9.
Controls Stand-Alone Unit (Interface with Other 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 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. Pump down — This feature can be enabled or disabled through the Human Interface.
Controls Generic Building Automation System Module (GBAS) — Two Generic Building Automation System Modules (GBAS) are available as an option to provide broad control capabilities for building automation systems, other than theTrane’sTracer system. The 4 analog outputs can be assigned to: The 0-5 vdc input GBAS Module contains 4 analog inputs, one binary input for demand limit, and 5 binary outputs. 4. EvaporatorTemp.
Electrical Data - 60 HZ (10–60 Ton) Table ED-1 — Electrical Data Tons 10 Model Number CGA120B1 CGA120B3 CGA120B4 CGA120BW Nameplate Voltage 208-230/60/1 208-230/60/3 460/60/3 575/60/3 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 460/60/3 575/60/3 200/60/3 230/60/3 CGAF-C60 460/60/3 575
Electrical Data - 50 HZ (10–60 Ton) Table ED-2 — Electrical Data Tons Model Number Nameplate Voltage Unit Wiring Voltage Range MCA Max Fuse Size Rec. Dual Element Motor Data Compressor (Ea) Fans (Ea) Qty. RLA LRA Qty KW FLA 10 15 CGA100BD 380-415/50/3 CGA150BD 380-415/50/3 342-456 342-456 24.1 32.7 30 45 — — 2 2 9.5 13.1 63 99.5 1 2 0.57 0.33 2.7 1.6 20 CGAF-C20 380/50/3 415/50/3 342-418 373-456 44 44 60 60 50 50 2 2 17.2 17.2 110 110 2 2 0.75 0.75 1.7 1.
Dimensional Data (10Ton) 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 (15Ton) 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 (20Ton) Figure DD-3 — CGAF-C20 Unit Dimensions CG-PRC007-EN 41
Dimensional Data (25 Ton) Figure DD-4 — CGAF-C25 Unit Dimensions 42 CG-PRC007-EN
Dimensional Data (30 Ton) Figure DD-5 — CGAF-C30 Unit Dimensions CG-PRC007-EN 43
Dimensional Data (40Ton) Figure DD-6 — CGAF-C40 Unit Dimensions 44 CG-PRC007-EN
Dimensional Data (50 Ton) Figure DD-7 — CGAF-C50 Unit Dimensions CG-PRC007-EN 45
Dimensional Data (60Ton) Figure DD-8— CGAF-C60 Unit Dimensions 46 CG-PRC007-EN
(10–60 Ton) Weights 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.
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.
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.
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. All field wiring shall be terminated at separate, clearly marked terminal strip. Direct field wiring to the I/O boards is not acceptable. The microprocessor’s memory shall be nonvolatile EEPROM type requiring no battery or capacitive backup while maintaining all data.
CG-PRC007-EN 51
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.
