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

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

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

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

CGCL-SVX01B-E4 9

Installation

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.

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

This manual suits for next models

Table of contents

Other Trane Chiller manuals

Trane

Trane CGWH 115 Owner's manual

Trane

Trane Koolman R410A Installation and operating instructions

Trane

Trane CWE 600 x 600 Quick start guide

Trane

Trane RTAF-SVX001K-EN User manual

Trane

Trane CVGF-SVN02B-E4 User manual

Trane

Trane RTHD series Owner's manual

Trane

Trane Optimus RTHD Installation and operating instructions

Trane

Trane CGAM020 User manual

Trane

Trane Tracer AdaptiView User manual

Trane

Trane City RTSF050 Owner's manual

Trane

Trane RTHA Installation and operating instructions

Trane

Trane RTAA-130 Installation and operating instructions

Trane

Trane AquaStream2 CGAN 200 Owner's manual

Trane

Trane RTAA User manual

Trane

Trane CCUF-R454B Owner's manual

Trane

Trane BAYECCK001 Assembly instructions

Trane

Trane CenTraVac CDHH Installation and operating instructions

Trane

Trane Manhattan Gen II Installation and operating instructions

Trane

Trane Cold Generator CG-SVX044F-EN Installation and operating instructions

Trane

Trane CVRD User manual

Trane

Trane Tracer TD7 User manual

Trane

Trane UNT-SVX16I-XX User manual

Trane

Trane Picco R32-SL16T User manual

Trane

Trane Picco R32-140 Instruction Manual

Popular Chiller manuals by other brands

Aqua Optima

Aqua Optima Corona Instructions for use

York

York YGWH 115 Installation, commissioning & operation

Galletti

Galletti PERFORMA MPE Series Technical manual

SMC Networks

SMC Networks HRR Series manual

Daikin

Daikin EWAQ016CAW Installation and operation manual

Moffat

Moffat Friginox TSR-11SC Specification sheet

Gree

Gree GWH07AGA-K6DNA1C Service manual

Denali

Denali M1 user manual

MP Systems

MP Systems PURGE Series manual

AEC

AEC PCA SERIES Operation and installation manual

Carrier

Carrier AquaEdge 19XRV series Start-up and service instructions

Telemark

Telemark TVP-2000 Operation, installation and service manual

TICA

TICA MINI VRF CHR Series Installation & operation manual

Penguin

Penguin COLD THERAPY CHILLER owner's manual

MAXA

MAXA A68 Installation and operation manual

SABROE

SABROE ChillPAC operating manual

Daikin

Daikin EWWQ-AJYNN Service manual

AERMEC

AERMEC NRL FC 2000 installation manual