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