I have a major restaurant I service. There are five TRANE gas-package units installed on the roof serving the interior. I am having a great deal of problems with them and am wondering, is anybody else out there experiencing similar happenings?
The units are as follows:
Unit A YCD180B3LAFA Serial R38102585D DOM 9/2000
Unit B YCD150C3LACA Serial R38102642D DOM 9/2000
Unit C YCD150C3LACA Serial R38102541D DOM 9/2000
Unit C has had the evaporator coil replaced earlier this week from multiple pinholes in the copper tubing of the coil. It has also been tripping the internal service disconnect for no obvious reason. Compressors are fine, motors are fine, contacts are clean, connections tight, unit fairly clean, charge is perfect, so on and so forth. No obvious problems.
Unit B has had the condenser coil replaced two weeks ago from leaks resulting from the condenser tubing splitting in several places. It is running perfectly now.
Unit A has been the nightmare. I replaced the condenser coil the same day Unit B had its coil replaced and for the same reason. Weighed in the refrigerant charge per the nameplate rating and checked the operation. No problems whatsoever.
Last Friday, I had to go back and found one of the tubes from the discharge header into the coil circuit had a cracked solder joint and blew the charge for the one circuit. The other circuit had a crack on the bell of the elbow coming off of the compressor discharge outlet. Being late Friday night, I had to repair the cracks by slightly enlarging them and filling and capping with 45% silver solder.
Just today, I find that where that tube I previously repaired ties into the coil circuit at the swage joint of the coil, the swage had cracked around it and blew the charge for this circuit again! Three inches from my repair. It held by the way.
On the other circuit, the discharge elbow got a crack in the copper at the bend of the elbow and blew this charge again also! My previous repair here held also.
I got the torch and 45% out again and made a succesful repair. I think.
I called my boss and informed him of the situation. He got hold of TRANE and got a rep out there to look at what happened. I expect to get a response early next week. I'm sure my boss will keep after TRANE until they talk to us about what is going on. This is ridiculous. Three units at the same location with three coil failures and two other, repeating failures in the span of two weeks!
I have checked the compressors, scrolls, for excessive vibration and can't find anything unusual. They're running as I normally find them, slight vibration but, not excessive. The unit sits still on the rooftop. Can't even feel it standing right next to it and certainly don't see any vibration other than what is normal.
Again, has anybody experienced anything similar to these goings-on? If you have and have made succesful repairs, I would certainly like to know what you had to do. I can't keep going back once a week to fix a brand new coil that keeps cracking or fixing cracking copper tubing. The management there is getting highly upset that their young TRANE equipment is having so many difficulties. And I'm feeling really bad for them. I need some help.