Trane CSRA010FAF0, CSRA015FAF0 Installation And Maintenance Manual

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Installation Operation Maintenance

10 and 15 Ton Air-cooled Cold Generators®

Models: CSRA010FAF0, CSRA015FAF0

CSRA-SVX01A-EN

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Table of Contents

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Literature History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Model Number Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 1a — Model Number Description . . . . . . . . . . . . . . . . . . 7

Figure 1b — Unit Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 2 — 10 Ton Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Figure 3 — 15 Ton Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Location and Clearance Requirements . . . . . . . . . . . . . . . . . . 12

Unit Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Evaporator Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Flexible Hose and Hard Pipe Installation . . . . . . . . . . . . . . . . . 13

Figure 4 — Correct Vertical Hose Installation . . . . . . . . . . . . . 14

Dixon Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 5 — Dixon Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 6 — Correct Horizontal Hose Installation . . . . . . . . . . . 15

Figure 7 — Incorrect Horizontal Hose Installation . . . . . . . . . . 16

Figure 8 — Correct Vertical Hose Installation . . . . . . . . . . . . . 16

Figure 9 — Incorrect Vertical Hose Installation . . . . . . . . . . . . 17

Figure 10 — Correct Horiz/Vert Installation . . . . . . . . . . . . . . . 17

Figure 11 — Incorrect Horiz/Vert Installation . . . . . . . . . . . . . . 18

Figure 12 — Correct Unsupported Horiz Installation . . . . . . . . 18

Hard Pipe Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Figure 13 — Water Inlet/Outlet Connections . . . . . . . . . . . . . . 20

Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Heat Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Figure 14 — Heat Tape Installation . . . . . . . . . . . . . . . . . . . . . 22

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Pre-Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Unit Voltage and Amperage Checks . . . . . . . . . . . . . . . . . . . . 31

Water Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Pressure Drop Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Figure 15 — Evaporator Water Pressure Drop . . . . . . . . . . . . 34

Figure 16 — Solution Freezing Points . . . . . . . . . . . . . . . . . . . 36

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Checking Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . 38

Temporary Unit Shutdown and Restart . . . . . . . . . . . . . . . . . . 40

Extended Unit Shutdown/Winterization . . . . . . . . . . . . . . . . . . 41

System Restart after Extended Shutdown . . . . . . . . . . . . . . . . 42

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Table of Contents

Operation (Continued)

Low Ambient Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Figure 17 — 10 Ton Unit Control Panels . . . . . . . . . . . . . . . . . 45

Unit Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Figure 18 — WTT Switching Action . . . . . . . . . . . . . . . . . . . . . 51

Figure 19 — Unit Refrigeration Schematic (10 Ton) . . . . . . . . 52

Figure 20 — Unit Refrigeration Schematic (15 Ton) . . . . . . . . 53

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Periodic Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Annual Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Trouble Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

LAST Checkout Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Operator’s maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Tables

Table 1: Unit Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Table 2: Heat Tape Selection. . . . . . . . . . . . . . . . . . . . . . . . . . 23

Table 3: Heat Tape Selection. . . . . . . . . . . . . . . . . . . . . . . . . . 23

Table 4: Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Table 5: Min. Starting Ambient Temperatures . . . . . . . . . . . . . 25

Table 6: Control Settings and Time Delays . . . . . . . . . . . . . . . 25

Table 7: Chiller Evaporator Data . . . . . . . . . . . . . . . . . . . . . . . 32

Table 8: Normal Operating Pressures . . . . . . . . . . . . . . . . . . . 35

Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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General

NOTICE:

Information

Warnings and Cautions appear at appropriate sections throughout this manual. Read these carefully.

WARNING

if not avoided, could result in death or serious injury.

CAUTION

not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

CAUTION

property-damage-only accidents.

Indicates a potentially hazardous situation which,

Indicates a potentially hazardous situation which, if

–

Indicates a situation that may result in equipment or

Literature History

CSRA-SVX01A-EN (April 2002)

Original issue of manual. Describes the Installation, Operation and Maintenance procedures for the unit.

Reference: The following manual is referenced throughout the manual and provide useful information for installation, operation, and maintenance.

• CGA-IOM-4 (non-rental CGA chiller)

Installation Checklist

An Installation Checklist is provided at the end of the “Installation” section of this manual. Use the checklist to verify that all necessary installation procedures have been completed. Do not use the checklist as a substitute for reading the detailed information contained in the manual. Read the entire manual before beginning installation procedures.

Unit Description

10 and 15 ton model CGA air-cooled Cold Generators are designed for outdoor installation with a vertical air discharge. Each refrigerant circuit is provided with an operating charge of refrigerant and refrigerant oil, a filter drier, sight gas/moisture indicator and thermostatic expansion valve. All units are dehydrated, leak tested, charged and tested for proper control operation before shipment. Each unit is provided with an appropriately sized close coupled hydronic pump mounted to a common base with the Cold Generator. Piping is provided to the inlet of the pump, pump to inlet of the Cold Generator, and the Cold Generator outlet. All necessary pressure gages, water temperature gages, flow switches, and valves are mounted and ready for operation.

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General Information

An access panel(s) provides access to the compressor section(s), and a removable cover allows access to the control box. A unit circuit breaker enclosure is also provided with 100 feet of power cord for single power supply hook up to customer provided disconnect box. A separate circuit breaker/ control panel enclosure is provided for the pump.

A bag containing the installation/operation/maintenance manual and the unit wiring diagrams ships inside the unit control box. Be sure to read this literature before installing and operating the unit. Refer to Figures 2 and 3 for circuit breaker enclosure locations.

Unit Inspection

When the unit is delivered to the job site, verify that the correct unit has been shipped by comparing the information on the unit nameplate with ordering, submittal and shipping information. Refer to “Nameplates”.

Inspect the unit - inside and out - for damage. Rotate the condenser fan(s) to ensure they turn freely. Report any apparent damage or material shortage to the carrier and ChillerSource; make a “unit damage or shortage” notation on the carrier’s delivery receipt. Specify the extent and type of damage found, and notify ChillerSource. Do not proceed with installation of a damaged unit without ChillerSource approval (800-755-5115).

Inspection Checklist

To protect against loss due to damage incurred in transit, complete the following checklist upon receipt of the unit:

[ ] Inspect individual pieces of the shipment before accepting the unit. Check for obvious damage to the unit or packing material.

[ ] Check the unit for concealed damage before it is stored and as soon as possible after delivery. Concealed damage must be reported within 15 days.

[ ] If concealed damage is discovered, stop unpacking the shipment. Do not remove damaged material from the receiving location. Take photos of the damage, if possible. The owner must provide reasonable evidence that the damage did not occur after delivery.

[ ] Notify the carrier’s terminal of damage immediately by phone and by mail. 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.

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General Information

Nameplates

The nameplates on these machines provide valuable information pertaining to the identification of the unit and its components. Be sure to provide all pertinent nameplate data when ordering parts or literature, and when making other inquiries.

Unit Nameplates

The chiller unit nameplate is mounted on the end of the unit on the compressor access panel. This nameplate (shown in Figure 1b) specifies unit model number, serial number, electrical characteristics, heat tape power requirements and refrigerant charge information.

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. Its use will enable the owner/operator, installing contractors, and service engineers to define the operation, components and options for any specific unit. See Figure 1a.

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General Information

Figure 1a — Model Number Description

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General Information

Figure 1 b — Unit Nameplate

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Installation

Complete the “Installation Checklist” during installation to verify completion of all recommended procedures before unit start-up.

Unit Assembly Dimensions and Weights

The 10 and 15 ton assembly dimensions and weights are provided in Figure 2 and 3 and Table 1.

Handling

Each assembly is mounted on an assembly base with forklift tube slots easily accessible for wide and narrow forklift trucks with suitable capacity. At either end of the base is attached a tow-bar when additional pulling and pushing maneuvering is required. There is also an overhead lifting frame attached to the assembly base for overhead lifting without the need for additional spreader bars.

Drainage

Locate the unit so that the entire assembly can be allowed to drain during unit shutdown and repair.

Rigging

Use a forklift, crane or helicopter of suitable capacity to move the unit to its mounting.

Table 1: Unit Weights

Model No. Tons Shipping

Weight (lbs)

CSRA010FAF0 10 T 3800 3820

CSRA015FAF0 15 T 4030 4050

Operational

Weight (lbs)

WARNING

Heavy Objects!

Do not use cables (chains or slings) except as shown. Each of the cables (chains or slings) used to lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or slings) may not be of the same length. Adjust as necessary for even unit lift. Other lifting arrangements may cause equipment or propertyonly damage. Failure to properly lift unit may result in death or serious injury. See details below.

Rig the unit using either belt or cable slings. Fasten the slings to the unit at the four holes provided in the lifting frame. The point at which the slings meet at the lifting hook must be at least 6 feet above the unit. Test-lift the unit to ensure proper balance and rigging.

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Installation

Figure 2 — 10 Ton Details

Note: Both the water inlet and outlet connections are 2 1/2” Victaulic

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Installation

Figure 3 — 15 Ton Details

Note: Both the water inlet and outlet connections are 2 1/2” Victaulic

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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 condenser 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.

CAUTION Compressor Damage!

Installation of unit under an overhang will cause obstruction of the vertical air discharge, leading to pre-mature equipment failure.

If the unit is installed in a well or pit, the height of the pit walls must not exceed the height of the unit; the normal condenser air clearances must be doubled as well. In those applications as where multiple units are installed, the minimum distance between each unit is 6 feet, (entire perimeter).

Unit Isolation

Mounting methods that will minimize sound and vibration problems are:

1. Mount the assembly on a level surface, preferably an isolated concrete surface that completely supports the entire perimeter of the assembly base.

2. An optional neoprene pad can be installed between the assembly base and the mounting surface if assembly must be located in critical sound and vibration locations.

Unit Water Piping

General Piping Recommendations

Thoroughly flush all water supply piping before making the final piping connections to the unit.

CAUTION Pump Damage!

If using an acidic commercial flushing solution, construct a temporary bypass around the pump and unit. Failure to do so may lead to equipment damage.

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Installation

CAUTION Proper Water Treatment!

The use of untreated or improperly treated water in an Air-Cooled Cold Generator may result in scaling, erosion, corrosion, algae or slime. It is recommended that the services of a qualified water treatment specialist be engaged to determine what water treatment, if any, is required. Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water.

Evaporator Water Piping

The unit’s water connection sizes and locations are shown in Figure 13.

CAUTION Component Damage!

Evaporator pressure should not exceed 150 psig (i.e., maximum working pressure). Failure to do so may lead to equipment damage.

To prevent unit or pump damage, do NOT reverse system water piping connections to the unit or pump; water entering the evaporator is pre-piped to the discharge of the pump. If the pump is not required, open bypass valve and close inlet and discharge valves on pump. “Water Inlet” to the evaporator must enter on inlet connection to pump. Leaving water must exit the evaporator through the designated “Water Outlet” connection.

Flexible Hose and Hard Pipe Installation

General

Use the procedure described below to ensure the proper installation of flexible hose provided as part of a ChillerSource rental. It is critical that this procedure is followed to minimize premature or catastrophic failure of this hose.

CAUTION Hose Damage!

Hose must never be pressurized over 150 psi. If higher pressures are required, “hard” suction pipe must be utilized. Failure to do so may lead to hose damage.

CAUTION Hose Damage!

Hose must always be used in pressurized application. If a negative pressure application is required, “hard” suction pipe must be utilized. Failure to do so may lead to hose collapse and total system failure.

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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.

• Do not run hose vertically more than 7 feet otherwise coupling clamps may fail.

• Do not cut hose to “custom” fit pieces-this will affect the integrity of the hose.

• Bleed all air from the system prior to pressurizing hose to avoid couplings separating from the hose.

• Install elbows for a smooth hose transition on all vertical hose installations, see Figure 4.

• Never pressurize hose above 150 psi.

Figure 4 — Correct Vertical Hose Installation

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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. Some pinching of the excess hose in the gap area is considered normal and will not create a leak or premature failure.)

• Continually monitor and retighten, if necessary, on monthly inspection intervals.

Figure 5 — Dixon Coupling

Horizontal Hose Installation

The following Figures illustrate the correct and incorrect methods for installing hose in a horizontal hookup application.

Figure 6 — Correct Horizontal Hose Installation

90° Elbow

In this configuration either a 45° or 90° elbow can be installed. This elbow prevents stretching and crimping of the hose at the hose coupling connection. This elbow also directs the hose to the ground at an appropriate angle to minimize the crimping of the hose at the ground or supporting surfaces.

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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 bottom of the hose to be in compression, which causes it to crimp. It also causes the hose to crimp at the ground.

Vertical Hose Installation

The following figures illustrate the correct and incorrect methods for installing hose in a vertical hookup application.

Figure 8 — Correct Vertical Hose Installation

In this configuration, the hose is installed with an elevation less than 7 feet off the ground. A 45° elbow is installed to reduce the stress in the hose coupling connection. This elbow also directs the hose to the ground at an appropriate angle to minimize the crimping of the hose at the ground or supporting surface.

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Installation

Figure 9 — Incorrect Vertical Hose Installation

Coupling

In this configuration the hose is installed without an elbow and with an elevation 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. It also causes the hose to crimp at the ground.

Couplings

Horizontal/Vertical Installation

The following figures illustrate the correct and incorrect methods for installing hose in a horizontal and vertical combination application.

Figure 10 — Correct Horizontal/Vertical Installation

Couplings

In this configuration, correct installation techniques followed are:

• the hose is installed with elbows at both connection ends

• the vertical run of hose is less than 7 feet

• the hose is adequately supported by more than half its total length on the ground

These items minimize the stretching and separation at the hose-coupling interface and also the crimping of the hose at the ground.

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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

• the hose is not adequately supported by the ground

These items cause excessive stress to be generated at the hose-coupling interface, causing the hose to stretch and separate from the coupling.

Figure 12 — Correct Unsupported Horizontal Installation

Figure 12 illustrates a correct horizontal hose installation where there is a section of unsupported hose. The length of unsupported hose should be less than 7 feet. Also, the hose must be adequately supported by having more than half its total length on the ground.

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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) semipermanent installations (three months or more) and/or (3) installations with space limitations.

When installing hard pipe:

• construct and install the piping according to local and national codes

• isolate and support the piping as required to prevent stress on the unit and vibration to building piping

If there are any questions regarding how to install water piping, contact a ChillerSource Technical Service Advisor in Charlotte, NC (800-755-5115).

Exceptions

The ChillerSource Technical Service Advisor in Charlotte, NC (800-755-5115), must authorize any exceptions to the guidelines established in this bulletin in writing.

Material Disposition

In the event the hose fails or leaks, call the ChillerSource Technical Service Advisor in Charlotte, NC (800-755-5115); tag the hose “BAD” and place it back in the shipping box.

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Installation

Evaporator Drain

The 1/2 inch NPT drain plug is located in the leaving water tee near the bottom 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.

Note: If the system has been drained for shutdown, do not energize heat tapes.

Figure 13 — 10 and 15 Ton Water Inlet/Outlet Connections

Note: The water inlet and outlet connections are both 2 1/2” Victaulic.

10 Ton

Important: When installing water pipes, be certain to route them away from the compressor access panels to allow for compressor servicing or replacement.

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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”. Ensure that all exposed piping is adequately protected.

Note: Heat tape is factory-installed on the unit evaporator. This heat tape will protect the evaporator from freeze-up at ambient temperatures down to 20 ° F when used in conjunction with properly applied heat tape on the fieldinstalled water lines. Heat tape power draw is 84 watts on 10 ton units and 126 watts on 15 ton units.

2. Freeze-proof the chilled water system by adding a non- freezing, lowtemperature, heat-transfer fluid to the chilled water system. Provide protection against ice formation at 10° F below the lowest expected ambient temperature.

Note: Use of an ethylene glycol-type antifreeze reduces unit cooling capacity; this condition must be accounted for during total system design. (Refer to Figure 16, “Ethylene Glycol Adjustment Factor” on page 36).

Heat Tape Installation

Install heat tape on all water piping that may be exposed to freezing temperatures. Be sure to use heat tape that is recommended for low-temperature applications; it should be rated at 110/120 volts, thermostatically-controlled, and dissipate 6 to 7 watts per linear foot.

Heat tape selection should be based on the lowest expected ambient temperature-including any wind chill factor. For those tapes not automatically (i.e., thermostatically) controlled, be sure to install an accessory thermostat.

Refer to Tables 2 and 3 for typical heat tape characteristics.

To install the heat tape properly, follow the instructions provided by the heat tape manufacturer. If none are provided, use the recommendations outlined below:

1. Wrap the heat tape around the pipe-or apply it straight along the pipe-as necessary to provide the required protection. (See Tables 2 and 3).

2. Use friction tape to secure the heat tape to the water pipe.

3. Place the thermostat tightly against-and parallel to the water pipe. then tape it into place at both ends. Be sure to install the thermostat on the most exposed (i.e. coldest) portion of the pipe.

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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 overlap 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.

CAUTION Electrical Failure!

Do not install fiberglass insulation under the outer wrap when using non-thermostatically-controlled heat tape. Failure to do so may result in unit damage.

If freezing is a potential problem, all exposed piping, pumps and other components must be similarly protected with heat tape and insulation.

Figure 14 — Typical Insulated Heat Tape Installation (Spiralled Application)

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Installation

Table 2: Heat Tape Selection Table for Proper Pipe Protection with Fiberglass and Outer Wrap

(Tape installed straight along pipe)*

Method of

Wrapping

3/8” 1/2” 3/4” 1” 1-1/4” 1-1/2” 2” 3” 4” 6”

Tape

Required per

Foot of Pipe

Protection

Down to (°F)

* All values calculated at 0 MPH wind, metallic pipe. Fiberglass wrap should not be used with non-automatic models unless used in conjunction with properly installed thermostat.

Table 3: Heat Tape Selection Table for Proper Pipe Protection with Fiberglass and Outer Wrap

(Tape installed spiralled around pipe, 3 turns per foot)*

Method of

Wrapping

1’ 1’ 1’ 1’ 1’ 1’ 1’ 1’ 1’ 1’

-60 -41 -30 -19 -12 -6 0 +9 +14 +26

3/8” 1/2” 3/4” 1” 1-1/4” 1-1/2” 2” 3” 4” 6”

Nominal Copper Pipe Size

Tape

Required per

Foot of Pipe

Protection

Down to (°F)

* All values calculated at 0 MPH wind, metallic pipe. Fiberglass wrap should not be used with non-automatic models unless used in conjunction with properly installed thermostat.

NR = Not Recommended

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NR NR 1’ 6” 1’ 8” 1’ 10” 2’ 1” 2’ 4” 2’ 11” 3’ 11” 5’ 0”

NR NR -60 -55 -51 -50 -45 -41 -37 -35

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Installation

Amps

Qty. RLA LRA

Amps

Circuit

Maximum

Fuse Size

Range

Allowable Voltage

Circuit

Minimum

Ampacity

Unit

Range

Voltage

Allowable

Electrical

Characteristics

Basic Unit Characteristics Compressor Motor

Unit

Electrical

HP FLA

Characteristics

Model

Number

CSRA015FAF0 460/60/3 414-506 37.4 50 2 13.5 79

Table 4: Electrical Data for 10 and 15 Ton Units

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CSRA010FAF0 460/60/3 414-506 29 35 2 10.0 71

Table 4: Continued

Amps

1 1 2.7 1 3 3.8 115/60/3 104-126 2

Outdoor Fan Motor Pump Motor Shore Power

Qty. HP FLA Qty

2 0.5 1.6 1 3 3.8 115/60/3 104-126 2.4

NEC 440-33.

Notes:

1. Minimum circuit ampacity is 125% of the largest compressor RLA (see Table 4) plus 100% of the second compressor RLA plus the sum of the condenser fan FLAs per

2. Maximum fuse size is 225% of the largest compressor RLA plus 100% of the second compressor plus the sum of the condenser fan FLAs, per NEC 440-22.

Page 25

Installation

Table 5: Minimum Starting Ambient Temperatures for CGA Units

Low Ambient Units

No HGBP

10 Ton 0

15 Ton 0

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

Description

High Pressure Cutout HPC01, HPC02 400 ± 10 psig 250 ± 15 psig

Low Pressure Cutout LPC01, LPC02

Std. Units 38.5 ± 1 psig 44.5 ± 2 psig

Low Temperature Cutout LTC

Std. Units 36 ± 3 F Manual Reset

Control

Description

Anti-short Cycle Timer ASCT1, ASCT2 Normally-open

Delay Between

Compressors

Low Ambient Start Timer LAST1, LAST2 Normally-Closed

Electrical

Designation

Electrical

Designation

DBC Normally-open

Contacts

Open

Contacts

Status

timed to close

timed to open

Contacts Close

(Reset)

Time Delay

Duration

3 Minutes

30 Seconds

4 Minutes

CSRA-SVX01A-EN 25

Page 26

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. Outside the United States, the national and/or local electrical requirements of other countries shall apply. The installer must provide properly sized system interconnecting and power supply wiring with appropriate fused disconnect switches. Type and locations of disconnects must comply with all applicable codes.

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.

Figures 2 and 3 show the locations of the unit electrical access openings. Table 4 provides minimum circuit ampacity, recommended fuse sizes, and motor electrical data.

Shore Power Supply (115V)

The shore power male receptacle located above the unit circuit breaker enclosure (refer to Figure 2 and 3) is provided for customer convenience to supply power (refer to Table 4 for allowable voltage range) to compressor crankcase heaters and factory supplied evaporator heat tape. The crankcase heaters should operate at least 8 hours before the compressors are allowed to start.

Chiller Source Unit Power Supply

Refer to the unit wiring schematic pasted to the control panel cover of the cold generator. The installer must provide a power supply of proper voltage. Connect power cable provided on the unit to a properly sized fused disconnect switch required by local codes. Provide proper equipment grounds where required.

Heat Tape for Unit Evaporator

The evaporator is insulated from ambient air, and protected from freezing by thermostatically controlled heat tape(s). The evaporator heat tape circuit is energized when shore power (115 V) is connected as well as when the supply power (460V) to the unit is connected. Whenever the thermostat senses 40° F +/- 6° F, it closes, energizing the heat tape(s).

26 CSRA-SVX01A-EN

Page 27

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.

Receiving

[ ] Verify that unit nameplate data corresponds with ordering information.

[ ] Inspect unit for shipping damages and material shortages; report any damages or shortages found to ChillerSource, 800-755-5115.

Unit Location and Mounting

[ ] Inspect unit installation location for adequate ventilation.

[ ] Provide drainage facilities for evaporator water.

[ ] Remove and discard any shipping materials (e.g., cartons, crates, etc.)

[ ] Inspect to determine that service access clearances are adequate.

[ ] Install optional isolation neoprene pad between base and mounting surface.

[ ] Level the unit.

Evaporator Piping

[ ] Flush and clean all chilled water piping.

CAUTION Pump Damage!

If using an acidic commercial flushing solution, construct a temporary bypass around the pump and unit. Failure to do so may lead to equipment damage.

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Installation Checklist

CAUTION Proper Water Treatment!

[ ] Make water connections.

[ ] Vent chilled water system at high points in system piping.

[ ] Apply heat tape and insulation as necessary to protect all exposed field installed piping from freeze-up.

Electrical Wiring

WARNING

Hazardous Voltage!

28 CSRA-SVX01A-EN

Page 29

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.

Pre-Start Checklist

Once the unit is installed, complete each step in the checklist that follows, check off each step as it is completed. When all are accomplished, the unit is ready for operation.

WARNING

Hazardous Service Procedures!

The maintenance and troubleshooting procedures recommended in this section of the manual could result in exposure to electrical, mechanical or other potential safety hazards. Always refer to the safety warnings provided throughout this manual concerning these procedures. When possible, disconnect all electrical power including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. When necessary to work with live electrical components, have a qualified licensed electrician or other individual who has been trained in handling live electrical components perform these tasks. Failure to follow all of the recommended safety warnings provided, could result in death or serious injury.

Refer to unit schematics to check the number of disconnects required to deenergize the unit.

When electrically troubleshooting the compressor make sure electrical power is NOT applied.

[ ] Inspect all wiring connections; electrical connections should be clean and tight.

CAUTION Compressor Damage!

Check tightness of all connections in the compressor power circuit (disconnects, terminal block, contactors, compressor junction box terminals, etc.). Failure to do so may result in over-heating at connections and under voltage conditions at the compressor motor.

CSRA-SVX01A-EN 29

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Pre-Start Procedures

[ ] Check power supply voltage to the unit at the circuit breaker; the voltage reading obtained must be within the voltage utilization range shown in Table

4. Also, voltage imbalance must not exceed 2%. (Refer to “Unit Voltage and Amperage Checks”)

[ ] Check the condenser fan assemblies; the fan blades should rotate freely in the fan orifice, and be securely attached to the fan shaft.

[ ] Disconnect power supply to shore power. Remove control circuit Fuse (FU) from the main unit control panel; then energize the compressor crankcase heaters by closing the unit's circuit breaker. The crankcase heaters should operate at least 8 hours before the compressors are allowed to start.

Note: To prevent compressor operation during this 8-hour interval, control circuit fuse (FU) must be removed from the unit control panel.

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.

[ ] Fill the chilled water (evaporator) circuit, leaving the system air vents open. Close vents after filling.

CAUTION Proper Water Treatment!

[ ] Turn handle to “On” position on pump starter enclosure. Check the pump rotation.The pump should start water circulating through the chilled water system, inspect all piping connections for leaks and make any necessary repairs.

[ ] Adjust the water flow rate through the chilled water circuit, and check the water pressure drop through the evaporator. Refer to “Water System”.

[ ] Open the unit circuit breaker; then reinstall control circuit Fuse (FU) in the unit control panel (i.e., provided the compressor crankcase heaters have been energized at least 8 hours), and re-close the circuit breaker. Adjust the flow switch (installed on the evaporator outlet piping) to provide proper operation.

30 CSRA-SVX01A-EN

Page 31

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 instructions, adjust the flow switch contacts to open at this point. Use an ohmmeter to verify opening and closure of the switch contacts.

[ ] Stop the chilled water pump.

[ ] Open all circuit breakers.

Unit Voltage and Amperage Checks

WARNING

Live Electrical Components!

During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.

Electrical power to the unit must meet stringent requirements for the unit to operate properly. Total voltage supply and voltage imbalance between phases should be within the following tolerances.

Voltage Supply — 3-Phase Units Only

Measure each leg of supply voltage at all line voltage on circuit breaker. Readings must fall within the voltage utilization range shown on the unit nameplate. If voltage on any leg does not fall within tolerance, notify the power company to correct this situation before operating the unit. Inadequate voltage to the unit will cause control components to malfunction and shorten the life of electrical components and compressor motors.

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Pre-Start

100

–

V1V2V3++

V1V2V3,,

LineVoltages

VDVAV

453470467

100X463453

–

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:

% Voltage Imbalance =

where (Avg. Voltage)

Example: If the three voltages measured at the line voltage side of the cir-

cuit breaker are 453 volts, 470 volts, and 467 volts, the average () would

be:

= Line voltage that deviates farthest from

---------------------------------------

-------------------------------=

= 463 volts

AVD

The percentage of imbalance is then:

----------------------------------------

=2.2%

463

The 2.2 percent imbalance that exists in the example above exceeds maximum allowable imbalance by 2.0 percent.

This much imbalance between phases can equal as much as 20 percent current imbalance with a resulting increase in winding temperature that will decrease compressor motor life.

Table 7: Chiller Evaporator Data

Unit Water*

Volume

gal. gpm gpm

10 Ton 1.4 12 36

15 Ton 1.5 18 54

* Includes water tubing provided by the factory, on the cold generator only. Feet of Water = psi x 2.307

32 CSRA-SVX01A-EN

Minimum

Flow Rate

Maximum Flow Rate

Page 33

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. Evaporator water flow rates below the minimum acceptable values will result in a stratified flow; this reduces heat transfer and causes either loss of expansion valve control or repeated nuisance low pressure cutouts. Conversely, excessively high flow rates may cause erosion of components in the evaporator.

Pressure Drop Measurement

Measure the water pressure drop through the evaporator by closing the shutoff ball valve on the ¼” pipe connected to the inlet piping entering the evaporator and opening the shut-off ball valve on the ¼” pipe connected to the outlet piping leaving the evaporator. The pressure gage mounted on the ¼” pipe will indicate the pressure leaving the evaporator. Close the leaving shut-off valve and open the entering shut-off valve on the ¼” pipe assembly to record the entering pressure to the evaporator. Take the difference of the two pressures to obtain the water pressure drop. The pressure drop obtained should approximate those indicated by the pressure drop chart in Figure 15.

Note: The pressure drop curves shown in Figure 15 are calculated at the unit water inlet and outlets. Be sure to account for any piping or fittings that may create an additional pressure drop between the unit and the pressure gauge locations.

CSRA-SVX01A-EN 33

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Pre-Start Procedures

Figure 15 — 10 and 15 Ton Evaporator Water Pressure Drop (English)

34 CSRA-SVX01A-EN

Page 35

Pre-Start

∆

O∆P

Procedures

Table 8: Normal Operating Pressures (Approximate)

10 Ton 15 Ton

Ambient (F) Suction

Pressure

(psig)

45 58 128 56 139

60 59 163 58 174

75 60 204 59 214

85 61 234 60 244

95 62 266 61 276

105 63 301 62 310

115 64 339 63 347

Discharge

Pressure

(psig)

Suction

Pressure

(psig)

Discharge

Pressure

(psig)

Ethylene Glycol Adjustment Factor

The addition of ethylene glycol to the chilled water system reduces unit capacity. To determine pressure drop of a glycol solution, obtain the pressure drop adjustment factor from the chart in Figure 16 and multiply times the pressure drop of water without glycol, i.e.;

Glycol x Adj. Factor

Notes:

1. Based on steady state conditions with 54° F entering water temperature (EWT) and 44° F leaving water temperature (LWT).

2. An increase of 5° F in LWT while keeping the 10° F temperature drop will result in an increase of approximately 6 psi in discharge pressure when compared to the 54° F EWT, the 44° F LWT given in Table 8.

3. Pressure at low ambients will not match this table if a head pressure control is installed and operating.

CSRA-SVX01A-EN 35

Page 36

Pre-Start Procedures

Figure 16 — Performance Adjustments and Solution Freezing Points (Ethylene Glycol in Evaporator)

36 CSRA-SVX01A-EN

Page 37

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.

[ ] Position pump starter panel handle to the “Off” position.

[ ] Open the unit circuit breaker; then remove control circuit fuse (FU) from the unit control panel. (This will prevent the compressors from energizing when the disconnect switch is closed.)

WARNING

Hazardous Service Procedures!

Refer to unit schematics to check the number of disconnects required to deenergize the unit.

[ ] Position pump starter panel handle to the “On” position. If Chiller Source pump not being used, leave in “Off” position. Close the fused disconnect switch for the evaporator chilled water pump being used. Start the pump.

[ ] Close the circuit breaker for the chiller unit.

Note: The unit’s compressor crankcase heaters will energize when the disconnect switch is closed; these crankcase heaters must operate at least 8 hours before the compressors are allowed to start. The shore power supply also energizes the crankcase heaters prior to 460V supply. Disconnect shore power prior to 460 V supply to unit.

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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.

[ ] The factory-installed evaporator heat tape (HTTB) should be energized whenever there is water in the unit evaporator. Additional heat tape supplied in the field requiring its own fused disconnect box should be closed at this time.

[ ] Reset any control that requires a manual reset.

[ ] Set the water temperature thermostat (WTT) as described on page 46.

Checking Operating Conditions

Once the unit has operated for at least 30 minutes and the system has stabilized, complete the following checklist to ensure proper unit operation.

[ ] Re-check evaporator water flow and pressure drop. These readings should be stable at proper levels. Refer to “Water System”. If pressure differential drops off, clean all evaporator water supply strainers.

[ ] Measure unit suction and discharge pressures by installing pressure gauges on the discharge and suction line access ports. Refer to Table 8 for approximate normal operating pressures.

Note: Many application variables exist which can effect operating pressures; these include ambient dry bulb temperature. as well as the installation of such options as head pressure controls or hot gas bypass. Since these variables can give misleading results, do not use operating pressures as the sole check of system operation.

[ ] Check compressor amp draw.

[ ] Check electrical power supply.

[ ] Check the liquid line sight glasses/moisture indicators for the presence of moisture. Note: Bubbles in the liquid line may indicate either a low refrigerant charge, or excessive pressure drop in the liquid line. Such a restriction can often be identified by a noticeable difference in line temperature on either side of the restricted area. (Frost often forms on the outside of the liquid line at the point of restriction, as well.) Bubbles are not necessarily a symptom of improper system operation.

38 CSRA-SVX01A-EN

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 nameplate and also under “Refrigerant Charge Information” on page 39 of this manual.

[ ] Measure system superheat.

Normal system superheat is 12 to 15 degrees F for each circuit at ARI conditions (54° entering water, 44° leaving water, and 95° ambient temperature). If the superheat measured for either circuit does not fall within this range, alter the setting of the superheat adjustment on the thermal expansion valve to obtain the desired reading. Allow 15 to 30 minutes between adjustments for the expansion valve to stabilize at each new setting.

[ ] Measure system subcooling.

Normal subcooling for each circuit is 12 to 22 degrees F at ARI conditions (54° entering water, 44° leaving water, and 95° ambient temperature). If subcooling for either circuit is not in this range, check superheat for circuit and adjust, if required. If superheat is normal but subcooling is not, contact a qualified service technician.

[ ] If operating pressure, sight glass, superheat and subcooling readings indicate refrigerant shortage, find and repair leaks and, gas-charge refrigerant into each circuit. Refrigerant shortage is indicated if operating pressures are low and subcooling is also low.

Refrigerant Charge Information

The 10 ton units have 9 lbs. 8 oz. of refrigerant per circuit, and the 15 ton units have 12 lbs. 7 oz. of refrigerant per circuit.

CAUTION Equipment Damage!

Do not add refrigerant to unit when suction and discharge pressures are low and subcooling is normal. Failure to follow all instructions could result in equipment damage.

Add refrigerant vapor with the unit running by charging through the access port on the suction line until operating pressures are normal.

CSRA-SVX01A-EN 39

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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.

Important: Do NOT release refrigerant to the atmosphere! Refer to latest version of the general service bulletin MSCU-SB-1.

CAUTION

Freezing Temperatures!

Do not allow liquid refrigerant to contact skin. If it does, treat the injury similar to frostbite. Slowly warm the affected area with lukewarm water and seek immediate medical attention. Direct contact with liquid refrigerant may cause minor or moderate injury.

[ ] Be sure that all remote sensing bulbs are properly installed in bulb wells with heat transfer compound. Remote bulb capillary tubes must be secured (i.e., protected from vibration and abrasion) and undamaged.

[ ] Inspect the unit. Remove any debris, tools and hardware. Secure all exterior panels, including control and compressor access panels. Replace and tighten all retaining screws.

Temporary Unit Shutdown and Restart (Not Servicing)

To shut down the unit for a short time:

1. Open the unit circuit breaker; then remove Control Circuit Fuse (FU) from the main unit control panel. Once Control Circuit Fuse (FU) is removed, re-close the unit disconnect switch. This will ensure that the compressor

2. Stop operation of the chilled water pump. Turn handle on pump starter panel to “OFF”.

To restart the unit after a temporary shutdown:

1. Restart the chilled water pump, by turning handle on pump starter panel to “ON” position.

2. Open the unit circuit breaker; then reinstall Control Circuit Fuse (FU) in the main control panel. Once fuse (FU) is installed, close the unit circuit breaker.

40 CSRA-SVX01A-EN

Page 41

Operation

WARNING

Hazardous Voltage!

Open unit disconnect switch before installing control circuit fuse (FU) in control panel.

The unit will now operate normally provided that: (1) the water temperature thermostat (WTT) is calling for cooling, and (2) all system operating interlocks and safety circuits are satisfied.

Extended Unit Shutdown/Winterization

If the system is taken out of operation for long periods of time for any reason (e.g., seasonal shutdown), use this procedure to prepare the system for shutdown:

1. Check the refrigerant piping for leaks, fixing any that exist.

2. Service the chilled water pump and any air handling equipment according to the manufacturer’s recommendations.

3. Open both electrical circuit breakers for the unit and chilled water pump; lock both in the open position.

CAUTION Compressor Damage!

Lock both unit and chilled water pump circuit breakers in open position to prevent compressor or pump damage due to accidental start-up while system is in “shutdown” condition. Failure to do so may result in equipment damage.

Winterization: Close all evaporator water supply valves and drain the evaporator and water pump by removing the drain plug and opening the vent on the entering water line just outside the unit. Re-install the drain plug. Since the evaporator does not drain completely, add one quart of ethylene glycol antifreeze to the remaining water through the vent or evaporator drain hole, to keep the water from freezing, or refer to Table 7 and fill the evaporator with antifreeze. Protect system to 10° F below the expected ambient temperature and energize the evaporator heat tape(s) by closing the heat tape fused disconnect switch provided by the installer.

CSRA-SVX01A-EN 41

Page 42

Operation

CAUTION Evaporator Damage!

To prevent freeze damage to evaporator internal components, protect with adequate strength antifreeze, and be certain to energize evaporator heat tapes. Failure to do so may result in equipment damage.

Note: If system has been drained for shutdown do not energize heat

tapes(s).

System Restart After Extended Shutdown

Use this procedure to prepare the system for restart after an extended shutdown:

1. Remove winterization antifreeze as it can reduce system capacity.

2. Verify that both the unit and the chilled water pump circuit breakers are open; then remove control circuit Fuse (FU) from the unit control panel.

3. Close the unit circuit breakers to energize the compressor crankcase heaters.

Note: The unit's compressor crankcase heaters will energize when the circuit breaker is closed; these crankcase heaters must operate at least 8 hours before the compressors are allowed to start. Disconnect shore power prior to closing unit circuit breaker.

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.

4. Fill the chilled water (i.e., evaporator) circuit; evaporator storage capacities are indicated in Table 7 (see “Water System”). Be sure to vent the system while filling it, and close the vent when system is full.

CAUTION Proper Water Treatment!

5. Close the chilled water circuit breaker, and start the chilled water pump motor. With water circulating through the chilled water system, inspect all piping connections for leaks and make any necessary repairs.

42 CSRA-SVX01A-EN

Page 43

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 provide proper operation.

Note: With the water pump operating, throttle the water flow to approximately 50 percent of the full flow rate. Following the manufacturer's instructions, adjust the flow switch contacts to open at this point. Use an ohmmeter to check for contact opening and closure.

8. Stop the chilled water pump.

WARNING

Hazardous Voltage!

9. Open all circuit breakers; then reinstall control circuit fuse (FU) (removed in Step 1) in the main unit control panel.

The unit is now ready for normal operation; refer to “Start- Up Procedure”.

Low Ambient Operation

Field Installed Head Pressure Control Accessory

ChillerSource units will operate in outdoor ambient temperatures down to (50° F- 10 ton, 45° F -15 ton) w/o HGBP. This accessory will enable units to operate down to 0° F w/o HGBP. (See Table 5).

Head pressure control for chiller units is regulated by means of a field installed head pressure accessory which varies condenser fan speed in relation to discharge pressure.

When discharge pressure is 270 psig or higher, the condenser fan runs at full speed. At pressures between 270 psig and 180 psig, the fan speed is adjusted (increased or decreased) in direct relation to the pressure, with minimum fan speed (10% of rated motor RPM) occurring when the pressure reaches 180 psig. At pressures below 180 psig, the fan will not run.

When discharge pressure rises to 180 psig, the fan will start and run at the reduced speed. Fan speed will continue to increase as the pressure increases until full speed is reached at 270 psig.

CSRA-SVX01A-EN 43

Page 44

Operation

Freeze Protection

If the unit will remain operational at subfreezing ambient temperatures, follow 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. If additional heat tape was installed in the field, energize the fused disconnect switch supplied by the field. Verify that all exposed piping is adequately protected.

2. “Freeze-proof the chilled water system by adding a nonfreezing, low-temperature heat transfer fluid to the chilled water. The solution used must be strong enough to provide sufficient protection to prevent ice formation at 10° F below the lowest expected ambient temperature.

Follow the manufacturer's recommendations for installation and testing procedures for any freeze-proofing fluid used. Refer to Table 7 for evaporator liquid capacities.

Note: Use of an ethylene-glycol type fluid will reduce system capacity. This factor must be considered during system design. (See Figure 7).

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 and to Table 6 for control settings, and to Figure 17 for control locations.

Unit Safety Controls:

Low Pressure Cutout (LPCO1, LPCO2)

These units are protected by low pressure cutouts that open and stop compressor operation if the operating pressure drops below 38.5 ± 1 psig. The cutout automatically resets when the pressure reaches 44.5 ± 2 psig. The LPCO is a Single Pole Double Throw (SPDT) device and if it opens at low ambient start-up, it will energize Outdoor Fan (ODF) relay, stopping the outdoor fan(s) while the compressor remains energized through the Low Ambient Start Timer (LAST).

High Pressure Cutout (HPCO1, HPCO2)

These units have high pressure cutouts that open and stop compressor operation If the discharge pressure reaches 400 ± 10 psig. The cutout automatically resets when pressure drops to 250 ± 15 psig.

44 CSRA-SVX01A-EN

Page 45

Operation

Figure 17 — Typical Unit Control Panels

CSRA-SVX01A-EN 45

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 prevents the system from recycling until the condition that caused the low (or high) pressure cutout to trip is determined and corrected.

CAUTION Unit Damage!

Do not reset the control circuit until the cause of the safety lockout is Identified and corrected. Failure to do so may result in unit damage.

To reset RR1 and RR2, open and re-close the unit disconnect switch.

Low Temperature Cutout (LTC)

The L TC is designed to protect the evaporator from freeze damage in the event of a water temperature thermostat (WTT) malfunction or restricted water flow. The LTC's remote sensing bulb is in the evaporator, where it monitors leaving water temperature. If, during normal unit operation, the leaving chilled water temperature falls to the trip point, the LTC will open to interrupt compressor operation. (Manual reset is required.)

Motor Overloads

These units have internal compressor and condenser fan motor overloads. These overloads protect the motors from overcurrent and overheating conditions and automatically reset as soon as they cool sufficiently.

Unit Operational Controls:

Water Temperature Thermostat (WTT)

System operation for 10 and 15-ton CGA units is governed by a two-stage water temperature thermostat (WTT). The remote sensing bulb of this device is factory-installed in a bulb well located on the evaporator water inlet; here, it monitors the temperature of the water returning to the evaporator. It has a control range of 5° F per stage, a differential of 5.0° F between stages and a set point range of -30 to + 100 degrees F.

For an explanation on determining the WTT's setpoint and a description of the WTT in operation refer to page 48.

Low Ambient Start Timer (LAST1, LAST2)

When LAST1 or LAST2 energizes, the low pressure control is bypassed for 4 minutes, this allows time for suction pressure to build sufficiently for the low pressure cutout contacts to close.

46 CSRA-SVX01A-EN

Page 47

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. It can also occur because of sudden power outages of short duration. Whenever the contacts of the water temperature thermostat (WTI) open-or when there is a momentary power outage-the anti-short cycle timer will lock out compressor operation for 3 minutes.

Delay Between Compressors (DBC)

The delay between compressors prevents both compressors from starting at the same time by delaying compressor #2 for 30 seconds.

Unit Control System

Sequence of Operation

Refer to the unit wiring schematic pasted to the inside of the control panel cover when reviewing the control sequence described below. Refer to this legend for an explanation of the acronyms used in this sequence.

CWFIR- Chilled Water Flow Interlock Relay

LPCO -Low Pressure Cutout

HPCO -High Pressure Cutout

ASCT -Anti-short Cycle Timer

CC -Compressor Contactor

LTC -Low Temperature Cutout

DBC -Delay Between Compressors

WTT -Water Temperature Thermostat

RR -Reset Relay

CSRA-SVX01A-EN 47

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 heaters, factory supplied evaporator heat tape, and the 24 V control circuit.

3. In order to start the chilled water pump, position handle on pump starter control panel to the “ON” position. Starting the chilled water pump and establishing flow will close the flow switch (FS).

4. When the entering water temperature (EWT) rises 5° F above the WTT's setpoint, its first stage switch closes, allowing power to pass through, the flow switch, the L TC, the ASCT1, the RR1 contacts, the LPCO1, and the HPCO1 to energize the CC1 coil. This starts compressor #1 and the outdoor fan.

15 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 heaters, factory supplied evaporator heat tape, and the 24 V control circuit.

4. When the entering water temperature (EWT) rises 5° above the WTT's setpoint, its first stage switch closes, allowing power to pass through the CWFIR contacts, the ASCT1, the RR1 contacts, the LPCO1, and the HPCO1 to energize the CC1 coil. This starts compressor #1 and outdoor fan #1.

5. If the EWT rises 10° F above the WTT's setpoint, its 2nd stage switch closes, allowing power to pass through the CWFIR contacts, the DBC switch, the ASCT2, the RR2 contacts, the LPCO2, and the HPCO2 to energize the CC2 coil. This starts compressor #2 and outdoor fan #2.

Determining the setpoint for the Water Temperature Thermostat (WTT)

1. Find the difference between the chiller's entering water temperature (EWT) and the leaving water temperature (LWT) while both compressors are running. DT = EWT - LWT

2. Decide what minimum leaving water temperature (LWT min.) is desired. This is the minimum temperature that the leaving water reaches during normal cycling of the WTT.

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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.

Leaving an appropriate safety band between LWT min. and the Low Temperature Cut Out setting is important.

3. The WTT set point is then determined by the following formula: WTT setpoint = LWT min. + DT/2

Note: Actual leaving water temperature will dip lower than the value used in the equation above due to lag in the thermostat's control.

4. The maximum entering water temperature is computed by: EWT max = WTT setpoint + 10

Note: Computing EWT max is important. If the heat source is not warm enough to allow the EWT to rise to EWT max, the second stage of cooling may never activate.

ADDITIONAL INFORMATION

A. Average Chiller Leaving Water Temperature (LWTavg) During Two Stage

Thermostatic Control as the Load Varies LWTavg = WTTsetpoint -DT/2 + 5

B. The Maximum Leaving Water Temperature During Normal Thermostatic

Cycling is computed by: LWTmax = WTTsetpoint -DT/2 + 10

Example:

1. Entering Water Temperature is 55° F based on an actual reading. Leaving Water Temperature is 45° F.

DT = EWT -LWT DT = 55 -45 DT = 10° F

2. Desired Minimum Leaving Water Temperature is 40° F. This temperature is minimum allowable leaving water temperature without requiring ethylene glycol and special controls settings.

3. New Thermostat Setting: WTTsetpoint = LWTmin + DT/2 WTTsetpoint = 40 + 10/2 WTTsetpoint = 45° F

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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. Maximum Leaving Water Temperature:

LWTmax = WTTsetpoint -DT/2 + 10 LWTmax = 45 -10/2 + 10 LWTmax = 50° F

Water Temperature Thermostat Operation

1. At start up, If the entering water temperature (EWT} is less than 5° F above the WTT setpoint, the unit will not run. When the EWT rises to 5° F above the WTT setpoint, its first stage switch closes, energizing compressor #1.

2. If the EWT continues to rise and reaches 10° F above the WTT setpoint, its second stage switch closes, energizing compressor #2.

3. When the cooling demand is met and the EWT drops to 5° F above the WTT setpoint, its second stage switch opens, dropping out compressor #2.

4. If the EWT continues to fall and reaches the WTT setpoint, its first stage switch opens, dropping out compressor #1.

A graphic representation of the above explanation is shown in Figure 18.

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Operation

Figure 18 — WTT Switching Action

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Pressure Gauge Connection

Schematics

Figure 19 — Unit Refrigeration Schematic for 10 Ton (CSRA010FAFO)

HPCO High Pressure Cut Out Switch

Notes: 1. Circuits through the condenser coil are not shown.

SymbolDefinition

LPCO Low Pressure Control Connection

TXV Thermal Expansion Valve

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Schematics

Figure 20 — Unit Refrigeration Schematic for 15 Ton (CSRA015FAFO)

Pressure Gauge Connection

HPCO High Pressure Cut Out Switch

Notes: 1. Circuits through the condenser coil are not shown.

SymbolDefinition

LPCO Low Pressure Control Connection

TXV Thermal Expansion Valve

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Maintenance

Periodic Maintenance

Perform all of the indicated maintenance procedures at the intervals scheduled. 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. This operating log can be a valuable diagnostic tool for service personnel; by noticing trends in operating conditions, the operator can often foresee and prevent problem situations before they become serious.

If the unit does not perform properly during any of these maintenance inspections, consult the “Trouble Analysis” section of this manual for possible causes and recommended repairs.

Weekly Maintenance

Once the unit has been operating for about 30 minutes and the system has stabilized, check operating conditions and complete the checkout procedure described below:

[ ] Check suction and discharge pressures. (Refer to “Checking Operating Conditions”.

[ ] Check the liquid line sight glasses/moisture indicators. (Refer to “Checking Operating Conditions”).

[ ] If operating pressures and sight glass/moisture indicator conditions indicate a refrigerant shortage, measure system superheat and system subcooling. (Refer to “Checking Operating Conditions”).

[ ] If operating conditions indicate an overcharge, slowly (to minimize oil loss) recover refrigerant at the liquid line service valve.

Important Note: Do Not release refrigerant to the atmosphere! Refer to general service bulletin MSCU-SB-1 (latest edition).

CAUTION

Freezing Temperatures!

[ ] Inspect the entire system for unusual conditions and inspect coils for dirt and debris. If coils are dirty, clean them. (Refer to “Coil Cleaning”).

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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 operating log is a valuable diagnostic tool for service personnel.

WARNING

Hazardous Service Procedures!

Refer to unit schematics to check the number of disconnects required to deenergize the unit.

Monthly Maintenance

[ ] Perform all weekly maintenance procedures.

[ ] Measure and record system superheat.

[ ] Measure and record system subcooling.

[ ] Open the unit circuit breaker; then manually rotate the outdoor fans to ensure proper orifice clearance.

[ ] Inspect the fan mounting bolts for tightness.

[ ] Check fan set screws for tightness.

Annual Maintenance

[ ] Perform all weekly and monthly maintenance procedures.

[ ] Have a qualified service technician check the setting and function of each control and inspect the condition of all contactors and replace as necessary.

[ ] If the chiller is not piped to drain facilities, make sure the drain is clear to carry away system water.

[ ] Drain water from evaporator pump and associated piping systems. Inspect all piping components for leakage. damage, etc. Clean out any inIine water strainers.

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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.

[ ] Determine whether or not lubrication of the outdoor fan motor bearings is needed; lubricate bearings with a light-weight oil (e.g., SAE-20 non-detergent or equivalent), if necessary.

Note: CGA outdoor fan motor assemblies are permanently lubricated and usually do not require additional oiling unless the unit is installed in a “dirty” environment. Under such conditions, lubricate the fan motor bearings after every 10,000 hours of operation. Do not over lubricate!

[ ] Clean condenser fans.

Maintenance Procedures

This section describes specific maintenance procedure(s) which must be performed as a part of the normal maintenance program for this unit. Be certain that electrical power to the unit is disconnected before performing these procedures.

WARNING

Hazardous Service Procedures!

Refer to unit schematics to check the number of disconnects required to deenergize the unit.

Coil Cleaning

Clean the condenser refrigerant coil at least once each year (or more frequently if the unit is located in a “dirty” environment) to help maintain proper unit operating efficiency. Specific instructions for cleaning refrigerant coils are outlined below. Follow these instructions as closely as possible to avoid potential damage to the coils.

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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. Failure to follow all safety instructions could result in death or serious injury.

To clean the refrigerant coil, a soft brush and sprayer (i.e., either a garden pump-up type, or a high-pressure sprayer) must be used. In addition, a highquality detergent is required; suggested brands include “SPREX A.C.”, “OAKITE 161”, “OAKITE 166”, and “COILOX”.

Note: If the detergent is strongly alkaline (i.e., has a pH value greater than

8.5) after mixing, an inhibitor must be added.

Cleaning Procedure:

1. Disconnect power to the unit.

WARNING

Hazardous Voltage!

Refer to unit schematics to check the number of disconnects required to deenergize the unit.

2. Remove enough panels and components from the unit to gain access to the condenser coils.

3. Protect all electrical devices such as motors and controls from dust and water.

4. Straighten coil fins with a fin rake, if necessary.

5. Use a soft brush to remove loose dirt and debris from both sides of the coil.

6. Mix the detergent with water according to the manufacturer's instructions. To improve the cleansing ability of the solution, heat it to a maximum of 150° F.

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Maintenance

WARNING

Hazardous Pressures!

Coils contain refrigerant under pressure. When cleaning coils, maintain coil cleaning solution temperature under 1500F to avoid excessive pressure in the coil. Failure to follow these safety precautions could result in coil bursting, which could result in death or serious injury.

7. Place the cleaning solution in the sprayer. Be sure to follow these guidelines if a high-pressure sprayer is used: (1) minimum nozzle spray angle is 15 degrees; (2) spray solution at 90 degrees to the coil face; (3) keep sprayer nozzle at least six inches from the coil; and, (4) sprayer pressure must not exceed 600 psi.

8. Spray the leaving air side of the coil first; then spray the entering air side of the coil. Allow the detergent-and- water solution to stand on the coil for 5 minutes.

9. Rinse both sides of the coil with cool, clean water.

10.Inspect the condenser coil. If it still appears to be dirty, repeat Steps 7 and 8.

11.Remove protective covers installed in step 3.

12.Reinstall all unit components and panels; then restore electrical power to the unit.

Cleaning the Evaporator

The chilled water system is a closed loop. It should not accumulate a large amount of scale or sludge. Inlet strainer should be cleaned periodically. If the chiller is fouled, first try to dislodge foreign material by back-flushing the system several times. If this does not work, take a water sample from the evaporator and analyze it. Determine treatment based on the findings.

CAUTION Evaporator Damage!

Do not use an acidic type cleaning agent. Failure to follow these instructions may result in damage to the internal evaporator components.

Water Treatment

CAUTION Proper Water Treatment!

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Trouble Analysis

Low Ambient Start Timer (LAST) Checkout Procedure

WARNING

Hazardous Voltage!

To determine whether or not a low ambient start timer is defective, follow these steps.

1. Remove power from the CGA unit by opening the supply power circuit breaker.

2. Disable both low pressure cutouts (LPCO1 and LPCO2) by disconnecting the wires from their number 1 terminals. Tape the disconnected wires to prevent shorting.

3. Restore power to the system, energize compressor number one and check how long it runs before cutting out.

4. Remove power from the system and disable compressor number one. Tape any wires removed to prevent shorting.

5. Restore power to the system, energize compressor number two and check how long it runs before cutting out.

6. Remove power from the system and re-connect the wires removed from the low pressure cutouts in step two. Re-connect the wires that disabled compressor number one.

7. Restore power to the unit.

Conclusion: Compare the compressor run times verified in steps 3 and 5 with the rated duration of the low ambient start timers. (The rated duration times are usually stamped on the timers or given in the unit literature). If the compressor run times don't match the duration times of the low ambient start timers, the timers are defective and must be replaced.

Preliminary Troubleshooting Inspection

If operational difficulties are encountered, be sure to perform these preliminary checks before referring to the troubleshooting charts:

[ ] Check the water temperature thermostat (WTT) to ensure that it is set correctly, receiving control power, and “making/breaking” at the proper intervals.

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Trouble Analysis

WARNING

Live Electrical Components!

[ ] Verify that the unit is receiving electrical supply power, and that the fuses in the main control panel are intact.

[ ] Check the evaporator for proper water supply. Check the flow switch for proper operation, and take pressure drop readings across the evaporator.

After completing the preliminary checks described above, be sure to inspect the unit for other obvious causes of trouble such as an excessively dirty condenser coil, leaking water connections, broken or disconnected wires, etc. If everything appears to be in order, but the unit still fails to operate properly, refer to the appropriate troubleshooting chart and contact a qualified service technician.

Troubleshooting Charts

The troubleshooting charts which follow are provided to serve as an aid for identifying the cause of any system malfunctions that may occur. Within each chart are three columns: (1) the Symptom column describes the behavior the unit is exhibiting; (2) the Probable Cause column identifies the most likely sources of the malfunction; and, (3) the Recommended Action column describes the suggested action for correcting the problem.

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.

The following warning applies to many of the recommended actions suggested in the troubleshooting charts.

WARNING

Live Electrical Components!

During troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.

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Troubleshooting

Symptom

A. Compressor neither starts nor hums

Probable Cause Recommended Action

1. No power to unit. Check for the following:

a. Disconnect switch open.

b. Fuse(s) blown.

2. No call for cooling. Check for the following:

a. Defective thermostat.

b. Broken or improper

control wiring.

c. Blown control power fuse.

3. Anti-short cycle Wait at least 3 minutes timer has not for the anti-short cycle times out. timer to time out.

4. Unit locked out by Check for the following: reset relay.

a. Excessive discharge pressure; see “Discharge Pressure Too High”

b. Defective high pressure control.

c. Low Charge; Low pressure switch open.

d. Defective reset relay contact.

5. Compressor contactor Check for the following: will not close.

a. Defective compressor

contactor.

b. Improper wiring.

c. Reset relay open.

d. Low pressure control open.

e. Cooling relay not

energized. Defective relay;

check thermostat circuit.

See probable cause #2

above.

6. Compressor winding See “Compressor Motor stat open. Winding Stat Open”.

a. Check compressor amp

draw.

Symptom

B. Compressor hums, but will not start.

Probable Cause Recommended Action

1. Low voltage at Check for the following: compressor.

a. Single blown fuse.

b. Low line voltage.

c. Defective compressor

contactor.

d. Loose wiring

connections.

2. Defective compressor. Check for the following:

a. Open motor winding.

b. Excessive amp draw on

all phases.

3. Insufficient starting Check for the following: voltage (Single-phase units only) a. Defective start capacity.

b. Defective start relay.

Symptom

C. 2nd stage compressor fails to start.

Probable Cause Recommended Action

1. Time delay contacts Replace time delay relay. fail to close.

2. No call for cooling. Check for the following:

a. Defective thermostat.

b. Broken or improper

control wiring.

3. Unit locked out by See Symptom A, Probable reset relay. Cause #4.

4. Compressor contactor See Symptom A, Probable will not close. Cause #5.

(Continued on next page)

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Troubleshooting

Symptom

D. Compressor short cycles.

Probable Cause Recommended Action

1. Intermittent Contact Check for the following: in control circuit.

a. Defective relay contacts.

b. Loose wiring connections.

Symptom

E. Compressor runs continuously.

Probable Cause Recommended Action

1. Unit undersized for Check for cause of load (cannot maintain excessive load. water temperature).

2. Thermostat setpoint Readjust thermostat. too low.

3. Defective thermostat Replace thermostat. or control wiring. Replace or repair control

wiring.

4. Welded contacts on Repair or replace compressor contactor. contactor.

5. Leaky valves in Replace compressor. compressor (indicated by abnormally low discharge and high suction pressures).

6. Shortage of refrigerant Find and repair refrigerant (indicated by reduced leak. Recharge system. capacity, high super heat, low subcooling and low suction pressure).

Symptom

F. Compressor motor winding stat open.

Probable Cause Recommended Action

1. Excessive load on Check for the following: evaporator (indicated by high supply water a. Excessive water flow. temperature). b. High return water

temperature.

2. Lack of motor cooling Check for the following: indicated by excessive superheat). a. Improper expansion

valve setting.

b. Faulty expansion valve.

c. Restriction in liquid

line.

3. Improper voltage at Check for the following: compressor.

a. Low or imbalanced line

voltage.

b. Loose power wiring.

c. Defective compressor

contactor.

4. Internal parts of Replace compressor. compressor damaged.

Symptom

G. Compressor is noisy.

Probable Cause Recommended Action

1. Internal parts of Replace compressor. compressor damaged or broken (compressor knocks).

2. Liquid flood-back Check and adjust (indicated by superheat. abnormally cold suction line and low superheat.

3. Liquid refrigerant in Check crankcase heater. compressor at start-up (indicated by abnormally cold Check for refrigerant compressor shell). overcharge.

Symptom

H. System short of capacity.

Probable Cause Recommended Action

1. Low refrigerant charge Add refrigerant. (indicated by high superheat and low sub cooling).

(Continued on next page)

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Troubleshooting

2. Clogged filter drier Replace filter drier or (indicated by tempera- filter drier core. ture change in refrigerant line thru drier).

3. Incorrect expansion Re-adjust expansion valve. valve setting.

4. Expansion valve stuck Repair or replace or obstructed (i.e., expansion valve. high superheat and high water temperature).

5. Low evaporator water Check strainers. Adjust flow. water flow.

6. Noncondensibles in Evacuate and recharge system. system.

7. Leaky valves in Replace compressor. compressor (i.e., operation at abnormally high suction and low discharge pressures).

Symptom

I. Suction pressure too low.

Probable Cause Recommended Action

1. Shortage of refrigerant Find and repair leak; (i.e., high superheat, recharge system. low subcooling).

Symptom

J. Suction pressure too high.

Probable Cause Recommended Action

1. Excessive cooling load See Symptom E. (i.e., high supply water temperatures).

2. Expansion valve over- Adjust superheat setting; feeding (i.e. super-heat verify that remote bulb is too low, liquid flooding properly attached to to compressor). suction line.

3. Suction valves broken Replace compressor. (i.e., noisy compressor).

Symptom

K. Discharge pressure too low.

Probable CauseRecommended Action

1. Shortage of refrigerant Find and repair leak; (i.e., low subcooling, recharge system. high superheat, bubbles in sight glass).

2. Broken or leaky Replace compressor. compressor discharge valves.

3. Defective low pressure Replace defective control. switch.

2. Thermostat set too low Readjust thermostat. (i.e., low discharge pressure, low leaving water temperature).

4. Unit running below Provide adequate head minimum operating pressure controls, or an ambient. ambient lockout switch.

Symptom

3. Low water flow. Check for clogged

4. Clogged filter drier. Check for frost on filter

5. Expansion valve power Repair or replace assembly has lost expansion valve charge. power head assembly.

6. Obstructed expansion Clean or replace valve. valve (i.e., high superheat).

CSRA-SVX01A-EN 63

strainers and incorrect

balancing valve settings.

drier. Replace if needed.

L. Discharge pressure too high.

Probable Cause Recommended Action

1. Too little or too warm Clean coil; check fans and condenser air; airflow motors for proper function. restricted.

2. Air or noncondensibles Evacuate and recharge gas in system (i.e., system. exceptionally hot condenser).

(Continued on next page)

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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).

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Trane An American Standard Company www.trane.com

Aftermarket Business Unit 3600 Pammel Creek Road La Crosse, WI 54601

Literature Order Number CSRA-SVX01A-EN

File Number SV-CAP-Chillersource-CSRA-SVX01A-EN-0402

Supersedes New

Stocking Location La Crosse

Trane has a policy of continuous product data and product improvement and reserves the right to change design and specifications without notice. Only qualified technicians should perform the installation and servicing of equipment referred to in this bulletin.

Trane CSRA010FAF0, CSRA015FAF0 Installation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual