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CSRA-SVX01A-EN

Models: CSRA010FAF0, CSRA015FAF0

Installation
Operation
Maintenance

10 and 15 Ton Air-cooled
Cold Generators®

Summary of Contents for CSRA010FAF0

Page 2: ...n 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...

Page 3: ...ce 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 Ope...

Page 4: ...ircuit 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 charge...

Page 5: ...rier 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 o...

Page 6: ...his 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...

Page 7: ...CSRA SVX01A EN 7 General Information Figure 1a Model Number Description...

Page 8: ...8 CSRA SVX01A EN General Information Figure 1 b Unit Nameplate...

Page 9: ...nit 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 o...

Page 10: ...10 CSRA SVX01A EN Figure 2 10 Ton Details Note Both the water inlet and outlet connections are 2 1 2 Victaulic Installation...

Page 11: ...CSRA SVX01A EN 11 Installation Figure 3 15 Ton Details Note Both the water inlet and outlet connections are 2 1 2 Victaulic...

Page 12: ...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 w...

Page 13: ...it 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...

Page 14: ...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 int...

Page 15: ...ntinually 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...

Page 16: ...p 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 Insta...

Page 17: ...e 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 con...

Page 18: ...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 Unsupp...

Page 19: ...t 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 Advis...

Page 20: ...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 Co...

Page 21: ...ooling capac ity 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 p...

Page 22: ...ate 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...

Page 23: ...per Foot of Pipe 1 1 1 1 1 1 1 1 1 1 Protection Down to F 60 41 30 19 12 6 0 9 14 26 All values calculated at 0 MPH wind metallic pipe Fiberglass wrap should not be used with non automatic mod els unl...

Page 24: ...us the sum of the condenser fan FLAs per NEC 440 22 Basic Unit Characteristics Compressor Motor Model Number Unit Electrical Characteristics Allowable Voltage Range Minimum Circuit Ampacity Maximum Fu...

Page 25: ...lectrical Designation Contacts Open Contacts Close Reset 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 Cuto...

Page 26: ...s 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 a...

Page 27: ...hipping 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 Provid...

Page 28: ...quipment failures which result from untreated or improperly treated water or saline or brackish water Make water connections Vent chilled water system at high points in system piping Apply heat tape a...

Page 29: ...oncerning 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 inadverten...

Page 30: ...chilled water evaporator circuit leaving the system air vents open Close vents after filling CAUTION Proper Water Treatment The use of untreated or improperly treated water in an Air Cooled Cold Gener...

Page 31: ...d 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 Elec...

Page 32: ...e would be 463 volts The percentage of imbalance is then 2 2 The 2 2 percent imbalance that exists in the example above exceeds maxi mum allowable imbalance by 2 0 percent This much imbalance between...

Page 33: ...valve on the pipe connected to the inlet piping entering the evapo rator and opening the shut off ball valve on the pipe connected to the out let piping leaving the evaporator The pressure gage mount...

Page 34: ...34 CSRA SVX01A EN Pre Start Procedures Figure 15 10 and 15 Ton Evaporator Water Pressure Drop English...

Page 35: ...T 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 th...

Page 36: ...36 CSRA SVX01A EN Pre Start Procedures Figure 16 Performance Adjustments and Solution Freezing Points Ethylene Glycol in Evaporator...

Page 37: ...ical 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 comp...

Page 38: ...be stable at proper levels Refer to Water System If pressure differ ential drops off clean all evaporator water supply strainers Measure unit suction and discharge pressures by installing pressure gau...

Page 39: ...subcooling for each circuit is 12 to 22 degrees F at ARI conditions 54 entering water 44 leaving water and 95 ambient temperature If sub cooling for either circuit is not in this range check superheat...

Page 40: ...rly 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...

Page 41: ...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...

Page 42: ...e 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 t...

Page 43: ...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 ChillerSou...

Page 44: ...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 Brie...

Page 45: ...CSRA SVX01A EN 45 Operation Figure 17 Typical Unit Control Panels...

Page 46: ...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 mo...

Page 47: ...tary 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...

Page 48: ...d 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...

Page 49: ...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 secon...

Page 50: ...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 com pressor 1 2 If the EWT continues to rise and reaches 10 F...

Page 51: ...CSRA SVX01A EN 51 Operation Figure 18 WTT Switching Action...

Page 52: ...efrigeration Schematic for 10 Ton CSRA010FAFO Notes 1 Circuits through the condenser coil are not shown SymbolDefinition Pressure Gauge Connection LPCO Low Pressure Control Connection HPCO High Pressu...

Page 53: ...efrigeration Schematic for 15 Ton CSRA015FAFO Notes 1 Circuits through the condenser coil are not shown SymbolDefinition Pressure Gauge Connection LPCO Low Pressure Control Connection HPCO High Pressu...

Page 54: ...ete 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 Check ing Opera...

Page 55: ...ed 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 chec...

Page 56: ...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 hazar...

Page 57: ...line 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 Disconnect all electric power including rem...

Page 58: ...ve 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 shou...

Page 59: ...mpressor 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...

Page 60: ...ualified 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 ea...

Page 61: ...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 hum...

Page 62: ...se 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 C...

Page 63: ...assembly has lost expansion valve charge power head assembly 6 Obstructed expansion Clean or replace valve valve i e high superheat Symptom J Suction pressure too high Probable Cause Recommended Acti...

Page 64: ...nt 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...

Page 65: ......

Page 66: ...ied technicians should perform the installation and servicing of equipment referred to in this bulletin Literature Order Number CSRA SVX01A EN File Number SV CAP Chillersource CSRA SVX01A EN 0402 Supe...

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Trane CSRA010FAF0, Installation Operation & Maintenance, Page: 1 / 66

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