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Trane CSRA025FAF0, Installation Operation & Maintenance

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76

CSRA-SVX02A-EN

Service & Maintenance

Important:

 Environmental scientists have found evidence that refrigerant 

emissions contribute to depletion of ozone in the upper atmosphere and can 
increase global warming. Trane encourages every effort to eliminate, if 
possible, or vigorously reduce the emission of CFC, HCFC and HFC 
refrigerant to the atmosphere that can result from installation, operation, 
routine maintenance, or major service on this equipment. Only technicians 
with EPA certification should be allowed to handle CFC, HCFC or HFC 
refrigerants. Compliance or certification to other local or state codes may 
also be required when handling refrigerants. Always act in a responsible 
manner to conserve refrigerants. 

Refer to general service bulletin MSCU-SB-1 (latest edition).

Figure 25 — Suction Line Filter/Drier Installation

Summary of Contents for CSRA025FAF0

Page 1: ...CSRA SVX02A EN Models CSRA025FAF0 CSRA040FAF0 and CSRA060FAF0 Installation Operation Maintenance 25 40 and 60 Ton Air Cooled Cold Generators 2002 American Standard Inc All Rights Reserved...

Page 2: ...Water Piping Requirements 23 Main Electrical Power Requirements 24 Chilled Water Piping 24 Final Water Piping Connections 26 Freeze Protection from Ambient Conditions 26 Electrical Cable 35 Electrica...

Page 3: ...essor Start Up 66 Proper Refrigerant Charge 68 Compressor Crankcase Heaters 72 Low Ambient Damper Adjustment 72 Final System Setup 73 Service Maintenance Compressor Operational Sounds 75 Scroll Compre...

Page 4: ...or component damage will be minimized It is important that periodic maintenance be performed to help assure trouble free operation A maintenance schedule is provided at the end of this manual Should e...

Page 5: ...and other options for any specific unit When ordering replacement parts or requesting service be sure to refer to the specific model number serial number and DL number if applicable stamped on the un...

Page 6: ...6 CSRA SVX02A EN General Information Figure 1a Model Number Description...

Page 7: ...ed in parallel and utilizes a passive oil management system to maintain proper compressor oil level The condenser coils are aluminum fin mechanically bonded to copper tubing Copper fin coils are optio...

Page 8: ...tomer binary contacts to satisfy the applicable request for cooling Refer to the following discussion for an explanation of each module function Human Interface Module HI Standard The Human Interface...

Page 9: ...the operator with their function as they interface with the various modules Refer to the unit s electrical schematic for the specific module connections Lead Lag Standard When Lead Lag is enabled for...

Page 10: ...three minutes of operation the compressors on that circuit will be locked out and a manual reset diagnostic is initiated Saturated Condenser Temperature Sensors Standard Are analog input devices mount...

Page 11: ...output will be at 100 10 VDC When the control is at stage 1 the output 0 to 10 VDC will modulate based on the saturated condensing temperature When the low ambient damper option is installed the dampe...

Page 12: ...Note The unit is wired so the CGM monitors incoming power for proper phase sequencing Observe proper polarity of internal wiring during service procedures Short Cycle Protection Standard If compresso...

Page 13: ...on the prevailing ambient temperature The relationship between this variable time period and the ambient temperature is linear from a maximum of 5 minutes at 0 F to a minimum of 30 seconds at 65 F The...

Page 14: ...ed Emergency Stop is a top priority command that will override all other commands received by the UCM A manual reset diagnostic will occur and an indication showing that the unit is shut down due to E...

Page 15: ...for signs of shipping damage Check for material shortages Refer to Figure 2 Component Layout and Ship with Location If the job site inspection of the unit reveals damage or material shortages file a...

Page 16: ...service clearances for either a single multiple or pit application These clearances are the minimum distances necessary to assure adequate serviceability cataloged unit capacity and peak operating ef...

Page 17: ...d down bolts or isolators Follow the instructions under Unit Isolation for proper isolator placement and installation Check with a roofing contractor for proper waterproofing procedures Figure 3 Typic...

Page 18: ...18 CSRA SVX02A EN Installation Figure 4a C25 Ton Unit Dimensional Data Recommended Clearances...

Page 19: ...CSRA SVX02A EN 19 Installation Figure 4b C40 Ton Unit Dimensional Data Recommended Clearances...

Page 20: ...20 CSRA SVX02A EN Installation Figure 4c C60 Ton Unit Dimensional Data Recommended Clearances...

Page 21: ...oned from Pump End Weight lbs Weight lbs X CSRA010FAF0 10 3800 3820 57 CSRA015FAF0 15 4030 4050 74 CSRA025FAF0 25 6050 6150 83 0 CSRA040FAF0 40 8250 8370 79 0 CSRA060FAF0 60 9300 9615 96 0 Notes 1 Mou...

Page 22: ...t lift the unit to ensure it is properly rigged and balanced make any necessary rigging adjustments 4 Lift the unit and position it into place Leveling the Unit Use the unit base rail as a reference L...

Page 23: ...ns of this manual Verify that the power supply complies with the unit nameplate specifications Check the unit for shipping damage and material shortage file a freight claim and notify Trane office Ver...

Page 24: ...tion pump when choosing not to use pump supplied with chiller Install proper grounding wires to an earth ground Chilled Water Piping Evaporator water inlet and outlet types sizes and locations are sho...

Page 25: ...ed to establish a balanced flow Note Both the entering and leaving water lines have shutoff valves installed to isolate the evaporator for service Strainer A pipe strainer is installed in the water re...

Page 26: ...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 s...

Page 27: ...be utilized Failure to do so may lead to hose collapse and total system failure Flexible Hose Guidelines WARNING Hose Failure Failure to comply with installation instructions that follow may result in...

Page 28: ...r and retighten if necessary on monthly inspec tion intervals Figure 7 Dixon Coupling The following figures illustrate the correct and incorrect methods for installing hose in a horizontal hookup appl...

Page 29: ...imp at the ground The following figures illustrate the correct and incorrect methods for installing hose in a vertical hookup application Figure 10 Correct Vertical Hose Installation Correct vertical...

Page 30: ...igures illustrate the correct and incorrect methods for installing hose in a horizontal and vertical combination application Figure 12 Correct Horizontal Vertical Installation Correct horizontal verti...

Page 31: ...ose 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 Figure 14 Correct Unsupported Horizontal Installation Co...

Page 32: ...tin in writing Freeze Protection from Ambient Conditions Use the procedure described below to ensure that the chilled water system is adequately protected from freeze up in applications where the unit...

Page 33: ...Wrap the heat tape around the pipe or apply it straight along the pipe as necessary to provide the required protection Refer to Figure 15 and Tables 2A and 2B 2 Use friction tape to secure the heat t...

Page 34: ...Heat Tape with Outer Wrap Note Spiralled applications are twisted around pipe 3 turns per linear foot of pipe Application Technique Straight Pipe Size 2 2 1 2 3 4 5 Heat Tape Req per Linear Ft of Pipe...

Page 35: ...one and chemical resistant thermoplastic rubber compound Temperature Rating F 49 to 194 Weight Lbs 100 Ft 64 Conductor Nominal OD in 0 8200 Cable Rating UL Rated at 2000 Volts C UL 600 volts for conti...

Page 36: ...e contents are as follows Four 4 100 sections of 2 0 awg cable and eight 8 15 pig tails Figure 16 Electrical Cable Box Cam lok Connectors Each cable is supplied with a male cam lok on one end and a fe...

Page 37: ...male pig tail has a male cam lok on one end and a barrel lug on the other Each female pig tail has a female cam lok on one and a barrel lug The barrel lug end allows for connection into a power distr...

Page 38: ...ase power supply to the unit 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 Circ...

Page 39: ...listed in Table 4 The electrical service must be protected from over current and short circuit conditions in accordance with NEC requirements Protection devices must be sized according to the electric...

Page 40: ...40 CSRA SVX02A EN Installation Figure 19 Typical Field Installed Power Wiring for Field Installed Pump Refer to the Wiring Diagram Notes at the end of this Section...

Page 41: ...itch Size for each unit Load Definitions LOAD 1 CURRENT OF THE LARGEST MOTOR COMPRESSOR OR FAN MOTOR LOAD 2 SUM OF THE CURRENTS OF ALL REMAINING MOTORS LOAD 4 CONTROL POWER TRANSFORMER AND ANY OTHER L...

Page 42: ...ance with UL Standard 465 Local codes may take precedence 5 All units are across the line starting Compressors will never start simultaneously 6 60 Hz units One field provided 115 60 1 15 amp power su...

Page 43: ...igure 4 for the electrical access locations provided on the unit and Table 5 for AC conductor sizing guidelines and A Use copper conductors unless otherwise specified B Ensure that the AC control wiri...

Page 44: ...lock circuit if a chilled water flow interlock diagnostic is desired for the system Before installing the control wiring refer to Figure 4 for the electrical access into the control panel Refer to the...

Page 45: ...tor sizing guidelines that must be followed when in terconnecting a communication link to the unit C Communication link must not exceed 5 000 feet maximum for each link D Communication link must not p...

Page 46: ...d Ice Building Control Option The CGM provides auxiliary control for a customer specified installed contact closure for ice making When this field installed normally open contact 5K86 is provided the...

Page 47: ...CSRA SVX02A EN 47 Installation Figure 20A Typical Field Control Connections Diagram...

Page 48: ...48 CSRA SVX02A EN Installation Figure 20B Typical GBAS 0 5 Volt Connections Diagram...

Page 49: ...CSRA SVX02A EN 49 Installation Field Connection Diagram Notes for all System Control Options...

Page 50: ...for tightness and point of termination accuracy Verify that the condenser airflow will be unobstructed Check the condenser fan blades Ensure they rotate freely within the fan orifices and are securel...

Page 51: ...n phases can equal as much as a 20 current imbalance with a resulting increase in motor winding temperatures that will decrease motor life If the voltage imbalance is over 2 notify the proper agencies...

Page 52: ...ss each winding is not as important as the amount of variation between the windings The actual resistance measured may vary due to the accuracy of the meter rounding off of the resistance readings and...

Page 53: ...ccurs If illumination occurs only when pushed then phases are correct If red light is illuminated open the field disconnect switch or circuit breaker protection switch and reverse any two power wires...

Page 54: ...btract command is given and a change in the compressor staging has been detected the value of the control algorithm is reset to 0 Chiller Freeze Protection The CGM prevents evaporator fluid from freez...

Page 55: ...loads a Proportional Integral control to setpoint as opposed to control to deadband control strategy is used System reliability is inversely proportional to compressor cycle rates so reliability is th...

Page 56: ...ent temperature sensor 1 Zone Temperature sensor 2 Outside Air Temperature sensor 3 Entering Solution Temperature sensor The reset temperature value Start Temperature to start resetting the Leaving So...

Page 57: ...o 0 LSS ALSS Adjustable Reset 3 16 F End Temperature Range 66 81 Factory Preset 75 Start Temperature Range 66 81 Factory Preset 78 Zone Temperature Zone Reset Cooling Factory Preset 5 Active Leaving S...

Page 58: ...next available compressor which meets the specified criteria will be started If a compressor can not be turned Off due to the minimum On Time the next compressor which meets the specified criteria wil...

Page 59: ...hed lines connecting pairs of fans indicate instances where one contactor controls both fans Sequence of Operation Low Ambient Dampers Low Ambient Dampers are used to extend the operation of these uni...

Page 60: ...ified or licensed service individual who has been properly trained in handling exposed rotating components perform these tasks Failure to follow all safety precautions when exposed to rotating compone...

Page 61: ...glish Note 1 Factor to convert Feet of Water to Lbs per Sq Inch PSI 2 3 Feet of Water 1 PSI Unit Size Water Volume Minimum Flow Rate Maximum Flow Rate gal liter gpm liter s gpm liter s C60 37 8 143 72...

Page 62: ...1A On 1B Off Off Off Off Off 100 Ckt 1 2 Off Off 2A Off 2B Off 1B 2B2 1A Off 1B On Off Off Off Off 100 Ckt 1 2 Off Off 2A Off 2B Off 2A 2B4 1A Off 1B Off Off Off Off Off 100 Ckt 1 2 Off Off 2A On 2B O...

Page 63: ...ed Press the ENTER key to confirm this choice WARNING Rotating Components During installation testing servicing and troubleshooting of this product it may be necessary to check rotating components Hav...

Page 64: ...e power wires at the fan contactors will only affect the individual fan rotation Ensure that the voltage phase sequence at the main terminal block 1TB1 or the factory mounted disconnect switch 1S14 is...

Page 65: ...CSRA SVX02A EN 65 System Start Up Figure 22 Condenser Fan Locations...

Page 66: ...1 2 to 3 4 full when they are Off 5 Check the condenser coils They should be clean and the fins should be straight Straighten any bent coil fins with an appropriate sized fin comb 6 Turn the main powe...

Page 67: ...ed in the previous step has elapsed 12 Turn the 115 volt control circuit switch 1S1 On 13 Press the TEST START key to start the test Remember that the delay designated in step 11 must elapse before th...

Page 68: ...s pressed and the delay designated in this step has elapsed Press the ENTER key to confirm this choice WARNING Rotating Components During installation testing servicing and troubleshooting of this pro...

Page 69: ...he actual liquid line temperature as close to the liquid line service valve as possible To ensure an accurate reading clean the line thoroughly where the temperature sensor will be attached After secu...

Page 70: ...e operating circuit has been com pleted check and record the ambient temperature compressor oil level each circuit compressor suction and discharge pressures each circuit superheat and subcooling each...

Page 71: ...ropriate oil charge for a 9 and 10 Ton scroll compressor is 8 5 pints For a 14 and 15 Ton scroll compressor use 13 8 pints Table 11 Recommended Refrigerant Capacities The listed refrigerant charge is...

Page 72: ...wer has been Off for an extended period allow the crankcase heater to operate a minimum of 8 hours before starting the unit Compressor crankcase heaters can be energized by supplying 115V power to the...

Page 73: ...ing could result in death or serious injury Turn the solution pump control circuit breaker handle to the Off position At the Human Interface Module press the SETUP key The LCD screen will display vari...

Page 74: ...Liquid Super Sub Temp Oil Press Press Press heat cool Oil Press Press Press heat cool Date F Level Psig Psig Psig F F Level Psig Psig Psig F F ok ok low low ok ok low low ok ok low low ok ok low low o...

Page 75: ...erential across the thermal expansion valve that limits its capacity Under these conditions it is not unusual to hear the compressor rattle until the suction pressure climbs and the flow rate increase...

Page 76: ...and HFC refrigerant to the atmosphere that can result from installation operation routine maintenance or major service on this equipment Only technicians with EPA certification should be allowed to h...

Page 77: ...8 29 5 23 9 33 9 C40 4 9 460 17 2 117 18 9 21 7 C60 4 15 460 25 4 178 30 7 35 3 Fuse Replacement Table Condenser Fan Fuse Time Delay 1F1 Thru 1F6 Class RK5 15A Control Power Fuse 1F7 Class K5 6 25 Am...

Page 78: ...orator water carryover fan brake horsepower due to increase static pressure losses airflow reduction At least once each year or more often if the unit is located in a dirty environment clean the evapo...

Page 79: ...of 6 between the sprayer nozzle and the coil spray the solution perpendicular at 90 degrees to the coil face 6 Spray the leaving airflow side of the coil first then spray the opposite side of the coil...

Page 80: ...ion of CFC HCFC and HFC refrigerant to the atmosphere that can result from installation operation routine maintenance or major service on this equipment Only technicians with EPA certification should...

Page 81: ...g bulbs for cleanliness Clean if required Sensing bulbs must make good contact with suction lines and be properly insulated Clean condenser fans Check fan assemblies for proper orifice clearance and f...

Page 82: ...reference you may find it helpful to record the unit data requested below in the blanks provided 1 Complete Unit Model Number 2 Unit Serial Number 3 Unit DL Number design special units only 4 Wiring D...

Page 83: ...ied technicians should perform the installation and servicing of equipment referred to in this bulletin Literature Order Number CSRA SVX02A EN File Number SV CAP Chillersource CSRA SVX02A EN 0502 Supe...

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