Related Manuals for Trane CSRA010FAF0
Summary of Contents for Trane CSRA010FAF0
- Page 1 Installation Operation Maintenance 10 and 15 Ton Air-cooled Cold Generators® Models: CSRA010FAF0, CSRA015FAF0 CSRA-SVX01A-EN © 2002 American Standard Inc. All Rights Reserved...
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Page 2: Table Of Contents
Table of Contents General Information......... 4 Warnings and Cautions . - Page 3 Table of Contents Operation (Continued) Low Ambient Operation ......43 Freeze Protection ........43 Electrical Control System .
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Page 4: General Information
General Information NOTICE: Warnings and Cautions appear at appropriate sections throughout this manual. Read these carefully. 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. -
Page 5: Inspection Checklist
Request an immediate joint inspection of the damage by the carrier and the consignee. [ ] Notify the Trane sales representative and arrange for repair. Do not repair the unit, however, until damage is inspected by the carrier’s representative. CSRA-SVX01A-EN... -
Page 6: Model Number Description
Unit Model Number Description All standard Trane products are identified by a multiple character model number that precisely identifies a particular type of unit. An explanation of the alphanumeric identification codes used for chiller units is provided on this page. - Page 7 General Information Figure 1a — Model Number Description CSRA-SVX01A-EN...
- Page 8 General Information Figure 1 b — Unit Nameplate CSRA-SVX01A-EN...
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Page 9: Installation
Use a forklift, crane or helicopter of suitable capacity to move the unit to its mounting. Table 1: Unit Weights Model No. Tons Shipping Operational Weight (lbs) Weight (lbs) CSRA010FAF0 10 T 3800 3820 CSRA015FAF0 15 T 4030 4050 WARNING Heavy Objects! Do not use cables (chains or slings) except as shown. - Page 10 Installation Figure 2 — 10 Ton Details Note: Both the water inlet and outlet connections are 2 1/2” Victaulic CSRA-SVX01A-EN...
- Page 11 Installation Figure 3 — 15 Ton Details Note: Both the water inlet and outlet connections are 2 1/2” Victaulic CSRA-SVX01A-EN...
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Page 12: Location And Clearance Requirements
Installation Location and Clearance Requirements Select an installation site where air flow upward, unobstructed, through the condenser coil and away from the fan discharge. Protect the unit’s con- denser intakes from crosswinds exceeding 5 m.p.h. Position the unit above the snowline, and above the path of any windblown debris. Refer to Figures 2 and 3 for clearances. -
Page 13: Evaporator Water Piping
Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water. - Page 14 Installation Flexible Hose Guidelines WARNING Hose Failure! Failure to comply with installation instructions that follow may result in death or serious injury or equipment damage. • Do not support the hose ONLY by its couplings; support over half of the hose's length by ground or other supporting surface otherwise coupling clamps may fail.
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Page 15: Dixon Coupling
Installation Dixon Coupling • The Dixon coupling (See Figure 5), bolts are to be torqued prior to charging the hose with water to 40 ft-lbs. DO NOT EXCEED 40 ft-lbs. (The torque must be applied evenly between the bolts to ensure a consistent gap on each side of the coupling. - Page 16 Installation Figure 7 — Incorrect Horizontal Hose Installation In this configuration elbows are not installed. This causes the top of the hose to be in tension, which stretches the hose out of the coupling; and the bot- tom of the hose to be in compression, which causes it to crimp. It also causes the hose to crimp at the ground.
- Page 17 Installation Figure 9 — Incorrect Vertical Hose Installation Coupling In this configuration the hose is installed without an elbow and with an eleva- tion greater than 7 feet off the ground. This creates excessive stress at the hose coupling connection, causing the hose to stretch and separate from the coupling.
- Page 18 Installation Figure 11 — Incorrect Horizontal/Vertical Installation Couplings In this configuration, a number of improper installation techniques can be noted: • elbows are not installed • the hose is completely supported by the couplings • the vertical run of hose is greater than 7 feet •...
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Page 19: Hard Pipe Guidelines
Installation Hard Pipe Guidelines Certain installations may require the use of hard pipe (steel or PVC). Hard pipe is typically recommended for (1) INDOOR INSTALLATIONS, (2) semi- permanent installations (three months or more) and/or (3) installations with space limitations. When installing hard pipe: •... - Page 20 The 1/2 inch NPT drain plug is located in the leaving water tee near the bot- tom of the evaporator of the 15 ton (CSRA015FAF0). The 10 ton (CSRA010FAF0) features a drain valve rather than a plug. See “Extended Unit Shutdown/Winterization” on page 41 for draining instructions.
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Page 21: Freeze Protection
Installation Freeze Protection General Use the procedure described below to ensure that the chilled water system is adequately protected from freeze-up in those applications where the unit remains operational at subfreezing ambient temperatures. 1. Install chilled water piping heat tape along with a fused disconnect switch, refer to the instructions outlined under “Heat Tape Installation”. - Page 22 Installation 4 Wrap the pipe with weatherproof tape. On vertical pipe runs, start the wrap at the bottom and work up as shown in Figure 14. Be sure to over- lap the tape so that it will shed moisture. Note: If additional protection is required, insulate the pipe with fiberglass wrap before installing the outer wrap.
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Page 23: Table 2: Heat Tape Selection
Installation Table 2: Heat Tape Selection Table for Proper Pipe Protection with Fiberglass and Outer Wrap (Tape installed straight along pipe)* Method of Nominal Copper Pipe Size Wrapping 3/8” 1/2” 3/4” 1” 1-1/4” 1-1/2” 2” 3” 4” 6” Tape 1’ 1’... -
Page 24: Table 4: Electrical Data
Installation CSRA-SVX01A-EN... -
Page 25: Table 5: Min. Starting Ambient Temperatures
Installation Table 5: Minimum Starting Ambient Temperatures for CGA Units Low Ambient Units No HGBP 10 Ton 15 Ton Notes: 1. Minimum starting ambients in degrees F, based on unit at minimum step of unloading and 5 m.p.h. wind across condenser. Table 6: Control Settings and Time Delays for CGA Units Control Electrical... -
Page 26: Electrical Wiring
Installation Electrical Wiring WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. All wiring must comply with National Electric Code (NEC) and state and local requirements. -
Page 27: Installation Checklist
Installation Checklist Complete this checklist as the unit is installed to verify that all recommended procedures are accomplished before the unit is started. This checklist does not replace the detailed instructions given in the “Installation” section of this manual! Read the entire section carefully to become familiar with installation procedures before installing the unit. - Page 28 Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water.
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Page 29: Pre-Start Procedures
Pre-Start Procedures CAUTION Use Copper Conductors Only! Unit terminals are not designed to accept other types of conductors. Failure to use copper conductors may result in equipment damage. [ ] Connect unit power supply cord to fused disconnect switch. [ ] Connect power supply wiring, along with a fused disconnect switch, to auxiliary heat tape installed on system water piping. - Page 30 Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water.
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Page 31: Unit Voltage And Amperage Checks
Pre-Start Procedures Note: With the water pump operating, throttle the water flow to approxi- mately 50 percent of the full flow rate. Following the manufacturer's instruc- tions, adjust the flow switch contacts to open at this point. Use an ohmmeter to verify opening and closure of the switch contacts. -
Page 32: Table 7: Chiller Evaporator Data
Pre-Start Procedures Voltage Imbalance Excessive voltage imbalance between phases in a three-phase system will cause motors to overheat and eventually fail. Maximum allowable imbalance is 2 percent. Voltage imbalance is defined as follows: 100X V – % Voltage Imbalance = ------------------------------ - where (Avg. -
Page 33: Water Flow Rates
Pre-Start Procedures Water System: Water Flow Rates Establish a balanced water flow through the evaporator. Flow rates should fall between the minimum and maximum values indicated in Table 7. Evapo- rator water flow rates below the minimum acceptable values will result in a stratified flow;... - Page 34 Pre-Start Procedures Figure 15 — 10 and 15 Ton Evaporator Water Pressure Drop (English) CSRA-SVX01A-EN...
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Page 35: Table 8: Normal Operating Pressures
Pre-Start Procedures Table 8: Normal Operating Pressures (Approximate) 10 Ton 15 Ton Ambient (F) Suction Discharge Suction Discharge Pressure Pressure Pressure Pressure (psig) (psig) (psig) (psig) Ethylene Glycol Adjustment Factor The addition of ethylene glycol to the chilled water system reduces unit capacity. - Page 36 Pre-Start Procedures Figure 16 — Performance Adjustments and Solution Freezing Points (Ethylene Glycol in Evaporator) CSRA-SVX01A-EN...
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Page 37: Operation
Operation Start-up Procedure To properly start the unit, execute each step of the checklist that follows in the sequence indicated; check off each step as it is completed. Do not start the unit until the “Pre-Start Procedures” are complete. (Refer to Figure 17 for the unit operating controls locations.) [ ] Disconnect shore power cord if connected. -
Page 38: Checking Operating Conditions
Operation CAUTION Compressor Damage! Compressor crankcase heaters must be energized at least 8 hours before unit start-up. Failure to do so may result in compressor mechanical damage. [ ] After the compressor crankcase heaters have operated a minimum of 8 hours, open the unit circuit breaker, reinstall control circuit fuse (FU) in the unit control panel, and re-close the circuit breaker. - Page 39 Operation Important: A clear sight glass does not necessarily mean that the system is sufficiently charged; be sure to consider system superheat, subcooling, and unit operating pressures and ambient temperatures. Proper unit refrigeration charge -per circuit- is indicated on the unit name- plate and also under “Refrigerant Charge Information”...
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Page 40: Temporary Unit Shutdown And Restart
Operation CAUTION Compressor Damage! Do not allow liquid refrigerant to enter the suction line. Liquid charge at the liquid line only. Failure to follow all instructions could result in equipment damage. [ ] If operating pressures indicated an overcharge, slowly (to minimize oil loss) recover refrigerant at the liquid line service valve. -
Page 41: Extended Unit Shutdown/Winterization
Operation WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. Open unit disconnect switch before installing control circuit fuse (FU) in con- trol panel. -
Page 42: System Restart After Extended Shutdown
Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water. -
Page 43: Low Ambient Operation
Operation 6. Adjust the water flow rate through the chilled water circuit, and check the water pressure drop through the evaporator. Refer to “Water System”. 7. Adjust the flow switch (installed on the evaporator outlet piping) to pro- vide proper operation. Note: With the water pump operating, throttle the water flow to approxi- mately 50 percent of the full flow rate. -
Page 44: Freeze Protection
Operation Freeze Protection If the unit will remain operational at subfreezing ambient temperatures, fol- low the recommendations outlined below to ensure adequate protection for the chilled water system. 1. Energize the factory installed chilled water piping heat tape by energizing shore power supply. - Page 45 Operation Figure 17 — Typical Unit Control Panels CSRA-SVX01A-EN...
- Page 46 Operation Reset Relays (RR1, RR2) If the unit is shut down by the low pressure cutout (or high pressure cutout), the reset relay locks out the compressor contactor (CC1, CC2). This pre- vents the system from recycling until the condition that caused the low (or high) pressure cutout to trip is determined and corrected.
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Page 47: Unit Control System
Operation Note: A low ambient start timer checkout procedure is given on page 59 of this manual. Anti-Short Cycle Timers (ASCT1, ASCT2) An anti-short cycle timer is provided in each compressor control circuit to protect the compressors from starting too frequently. This can occur as a result of poor thermostat control associated with light loads and water loops that are too short. - Page 48 Operation 10 Ton Operation 1. Disconnect shore power supply to unit if 115 V supply cord is attached to shore power receptacle. 2. With unit circuit breaker closed, power is supplied to the crankcase heat- ers, factory supplied evaporator heat tape, and the 24 V control circuit. 3.
- Page 49 Operation CAUTION Chiller Damage! The minimum leaving water temperature (LWTmin) is not to be lower than 40° F. Failure to maintain this minimum temperature may result in ice formation in the chiller leading to unit damage. If the minimum leaving water temperature (LWTmin) is lower than 40° F, add the appropriate amount of ethylene glycol and adjust safety control settings.
- Page 50 Operation 4. Maximum Entering Water Temperature: EWTmax = WTTsetpoint + 10 EWTmax = 45 + 10 EWTmax = 55° F A. Average Leaving Water Temperature: LWTavg = WTTsetpoint -DT/2 + 5 LWTavg = 45 -10/2 + 5 LWTavg = 45° F B.
- Page 51 Operation Figure 18 — WTT Switching Action CSRA-SVX01A-EN...
- Page 52 Schematics Figure 19 — Unit Refrigeration Schematic for 10 Ton (CSRA010FAFO) CSRA-SVX01A-EN...
- Page 53 Schematics Figure 20 — Unit Refrigeration Schematic for 15 Ton (CSRA015FAFO) CSRA-SVX01A-EN...
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Page 54: Maintenance
Maintenance Periodic Maintenance Perform all of the indicated maintenance procedures at the intervals sched- uled. This will prolong the life of the unit and reduce the possibility of costly equipment failure. Note: Use an “Operator's Log” (such as the one at the back of this manual) to record a weekly operating conditions history for the unit. -
Page 55: Monthly Maintenance
Maintenance Note: Use an operating log (such as the one at the end of this manual) to record a weekly operating conditions history for the unit. A complete operat- ing log is a valuable diagnostic tool for service personnel. WARNING Hazardous Service Procedures! The maintenance and troubleshooting procedures recommended in this section of the manual could result in exposure to electrical,... -
Page 56: Maintenance Procedures
Maintenance [ ] Clean and repaint any corroded surfaces. [ ] Clean condenser coils. (Refer to “Coil Cleaning”). [ ] Inspect the expansion valve sensing bulbs for cleanliness; clean if required. These sensing bulbs must make good contact with the suction lines, and must be properly insulated. - Page 57 Maintenance WARNING Hazardous Chemicals! Coil cleaning agents can be either acidic or highly alkaline. Handle chemical carefully. Proper handling should include goggles or face shield, chemical resistant gloves, boots, apron or suit as required. For personal safety refer to the cleaning agent manufacturers Materials Safety Data Sheet and follow all recommended safe handling practices.
- Page 58 Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water.
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Page 59: Trouble Analysis
Trouble Analysis Low Ambient Start Timer (LAST) Checkout Procedure WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. To determine whether or not a low ambient start timer is defective, follow these steps. -
Page 60: Troubleshooting Charts
Note: The troubleshooting charts which follow are provided solely as a guide for determining the cause of mechanical failure or malfunction. When mechanical problems do occur, Trane recommends that qualified service personnel be contacted (ChillerSource, 800-755-5115) to help ensure proper diagnosis and repair of the unit. - Page 61 Troubleshooting Symptom Symptom A. Compressor neither starts nor hums B. Compressor hums, but will not start. Probable Cause Recommended Action Probable Cause Recommended Action 1. No power to unit. Check for the following: 1. Low voltage at Check for the following: compressor.
- Page 62 Troubleshooting Symptom 2. Lack of motor cooling Check for the following: indicated by excessive superheat). a. Improper expansion D. Compressor short cycles. valve setting. Probable Cause Recommended Action b. Faulty expansion valve. c. Restriction in liquid 1. Intermittent Contact Check for the following: line.
- Page 63 Troubleshooting 2. Clogged filter drier Replace filter drier or Symptom (indicated by tempera- filter drier core. ture change in J. Suction pressure too high. refrigerant line thru drier). Probable Cause Recommended Action 3. Incorrect expansion Re-adjust expansion valve. 1. Excessive cooling load See Symptom E. valve setting.
- Page 64 Troubleshooting 3. Refrigerant overcharge Recover excess refrigerant. (i.e., high subcooling, low superheat, high suction pressure). 4. Excessive system load. Reduce load. 5. Defective condenser fan Repair or replace switch. or fan pressure control (i.e., 1 fan off, high condenser pressure). CSRA-SVX01A-EN...
- Page 66 La Crosse Aftermarket Business Unit Trane has a policy of continuous product data and product improvement and reserves the right to change 3600 Pammel Creek Road design and specifications without notice. Only qualified technicians should perform the installation and servicing La Crosse, WI 54601 of equipment referred to in this bulletin.