Trane CSRA010FAF0 Owner's manual

CSRA-SVX01A-EN
Models: CSRA010FAF0, CSRA015FAF0
Installation
Operation
Maintenance
10 and 15 Ton Air-cooled
Cold Generators®
© 2002 American Standard Inc. All Rights Reserved

2CSRA-SVX01A-EN
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

CSRA-SVX01A-EN 3
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

4CSRA-SVX01A-EN
General
Information
Literature History
CSRA-SVX01A-EN (April 2002)
Original issue of manual. Describes the Installation, Operation and Mainte-
nance 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 proce-
dures 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 out-
door installation with a vertical air discharge. Each refrigerant circuit is pro-
vided 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 Genera-
tor. Piping is provided to the inlet of the pump, pump to inlet of the Cold Gen-
erator, and the Cold Generator outlet. All necessary pressure gages, water
temperature gages, flow switches, and valves are mounted and ready for
operation.
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. It may also be
used to alert against unsafe practices.
CAUTION –Indicates a situation that may result in equipment or
property-damage-only accidents.

CSRA-SVX01A-EN 5
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 sup-
ply 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 litera-
ture before installing and operating the unit. Refer to Figures 2 and 3 for cir-
cuit 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 fol-
lowing 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.

6CSRA-SVX01A-EN
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 per-
tinent 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 compres-
sor access panel. This nameplate (shown in Figure 1b) specifies unit model
number, serial number, electrical characteristics, heat tape power require-
ments 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.

CSRA-SVX01A-EN 7
General
Information
Figure 1a — Model Number Description

8CSRA-SVX01A-EN
General
Information
Figure 1 b — Unit Nameplate

CSRA-SVX01A-EN 9
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 eas-
ily 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 addi-
tional 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.
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 property-
only 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.
Table 1: Unit Weights
Model No. Tons Shipping
Weight (lbs) Operational Weight (lbs)
CSRA010FAF0 10 T 3800 3820
CSRA015FAF0 15 T 4030 4050

10 CSRA-SVX01A-EN
Figure 2 — 10 Ton Details
Note: Both the water inlet and outlet connections are 2 1/2” Victaulic
Installation

CSRA-SVX01A-EN 11
Installation
Figure 3 — 15 Ton Details
Note: Both the water inlet and outlet connections are 2 1/2” Victaulic

12 CSRA-SVX01A-EN
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.
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 con-
nections 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.

CSRA-SVX01A-EN 13
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 con-
nections 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 evapora-
tor 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 flexi-
ble hose provided as part of a ChillerSource rental. It is critical that this pro-
cedure 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.

14 CSRA-SVX01A-EN
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 cou-
plings separating from the hose.
•Install elbows for a smooth hose transition on all vertical hose instal-
lations, see Figure 4.
•Never pressurize hose above 150 psi.
Figure 4 — Correct Vertical Hose Installation

CSRA-SVX01A-EN 15
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 install-
ing hose in a horizontal hookup application.
Figure 6 — Correct Horizontal Hose Installation
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 connec-
tion. 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.
90° Elbow

16 CSRA-SVX01A-EN
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.
Vertical Hose Installation
The following figures illustrate the correct and incorrect methods for install-
ing 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 cou-
pling connection. This elbow also directs the hose to the ground at an appro-
priate angle to minimize the crimping of the hose at the ground or supporting
surface.

CSRA-SVX01A-EN 17
Installation
Figure 9 — Incorrect Vertical Hose Installation
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. It also causes the hose to crimp at the ground.
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
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.
Coupling
Couplings
Couplings

18 CSRA-SVX01A-EN
Installation
Figure 11 — Incorrect Horizontal/Vertical Installation
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.
Couplings

CSRA-SVX01A-EN 19
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:
•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.

20 CSRA-SVX01A-EN
Installation
Evaporator Drain
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.
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.
Important: When installing water pipes, be certain to route them away from
the compressor access panels to allow for compressor servicing or replace-
ment.
10 Ton