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Trane R Series, Installation Operation & Maintenance

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RLC-SVX07A-EN

83

Operating Principles

RTWA Units

This section describes the mechanical operating principles of Series R water-
cooled chillers equipped with microcomputer-based control systems.

The 70-125-ton Model RTWA units are dual compressor, helical-rotary type 
water-cooled liquid chillers. The basic components of an RTWA unit are:

•

Clear Language Display and control modules

•

Helical-rotary compressor

•

Direct expansion evaporator

•

Water-cooled condensers

•

Oil supply system (hydraulic and lubrication) - Interconnecting piping

Components of a typical RTWA unit are identified in 

Figures

 

35

.

RTUA Units

The 70-125 ton RTUA units are dual compressor, helical-rotary type 
compressor chillers. The basic components of an RTUA unit are:

•

Clear Language Display and control modules

•

Helical rotary compressors

•

Direct expansion evaporator 

•

Oil cooler

•

Interconnecting piping between the compressors and evaporator

Components of a typical RTUA are identified in 

Figures

 

36

.

RTCA Units

The 70-125 ton RTCA units are air-cooled condensing units. The basic compo-
nents of an RTCA unit are:

•

Terminal box

•

Air-cooled condenser

•

One (1) fan inverter per circuit - Optional

Components of a typical RTCA are identified in 

Figures

 

36

.

Summary of Contents for R Series

Page 1: ...90 RTUA 90 RTCA 90 RTWA 100 RTUA 100 RTCA 100 RTWA 110 RTUA 110 RTCA 110 RTWA 125 RTUA 125 RTCA 125 Installation Operation Maintenance Series R Rotary Liquid Chillers Water Cooled and Condenserless Packaged Water Cooled Chiller RTWA 70 125 Water Cooled Compressor Chiller RTUA 70 125 Air Cooled Condenser RTCA 70 125 ...

Page 2: ... refrigerants and the equipment that is used in these service procedures In addition some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants Know the applicable laws and follow them WARNING Contains Refrigerant System contains oil and refrigerant under high pressure Recover refrigerant to relieve pressure before opening...

Page 3: ... Pressure Relief Valves 41 Field Installed Water Temperature Sensors 41 Water Sensor Installation Procedure 41 Refrigerant Relief Valve Venting 42 Initial Leak Test 44 Installation Remote Condenser 45 Remote Air Cooled Condenser Interconnecting Refrigerant Piping 45 Installation Electrical 58 Installer Supplied Components 62 Power Supply Wiring 62 Interconnecting Wiring 62 Low Voltage Wiring 67 Op...

Page 4: ... Restart 131 Extended Shutdown Procedure 131 System Restart after Extended Shutdown 131 Periodic Maintenance 133 Weekly Maintenance 133 Monthly Maintenance 133 Annual Maintenance 133 Maintenance 137 Cleaning the Evaporator RTWA and RTUA 137 Cleaning the Condenser 137 Water Treatment 139 Oil Separator Level Check 139 Refrigerant Charging 143 Adding Refrigerant 143 Low Side Repairs 144 High Side Rep...

Page 5: ...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 the damage immediately by phone and by mail Request an immediate joint inspection of the damage with the car rier and the consignee Notify the ...

Page 6: ...rge and electrically tested for proper control operation before shipment The RTWA RTUA series features Trane s exclusive Adaptive Control logic with Clear Language Display It monitors the control variables that govern the operation of the chiller unit Adaptive Control logic can correct these variables when necessary to optimize operational efficiencies avoid chiller shutdown and keep producing chi...

Page 7: ... General Refrig Type HCFC 22 HCFC 22 HCFC 22 HCFC 22 HCFC 22 HCFC 22 HCFC 22 HCFC 22 HCFC 22 HCFC 22 HCFC 22 HCFC 22 Refrig Charge Lb 64 64 85 85 64 64 85 85 72 64 95 85 72 72 95 95 72 72 95 95 72 72 95 95 Kg 29 1 29 1 38 6 38 6 29 1 29 1 38 6 38 6 33 4 29 1 43 6 38 6 32 7 32 7 43 1 43 1 32 7 32 7 43 1 43 1 32 7 32 7 43 1 43 1 Oil Charge3 Qts 10 10 10 10 10 10 10 10 12 10 12 10 12 12 12112 12 12 1...

Page 8: ... 6 8 3 9 5 Max Flow GPM 252 0 288 0 324 0 360 0 396 0 450 0 L Sec 15 9 18 2 20 5 22 7 25 0 28 4 General Refrig Type HCFC 22 HCFC 22 HCFC 22 HCFC 22 HCFC 22 HCFC 22 Oil Charge3 Qts 10 10 10 10 12 10 12 12 12 12 12 12 Ls 11 4 11 4 11 4 11 4 11 4 11 4 11 4 11 4 11 4 11 4 11 4 11 4 Operating Weight2 Lbs 3804 3816 3895 3970 4149 4149 Kg 1725 1731 1766 8 1801 1882 1882 Shipping Wt 2 Lbs 3474 3500 3609 3...

Page 9: ...204 Coil Height In 42 42 42 42 42 42 Number of Rows 2 2 2 2 2 2 Condenser Fans Quantity 1 4 4 4 4 5 4 5 5 5 5 5 5 Diameter In 30 30 30 30 30 30 Total Airflow CFM 71750 71750 77640 83530 87505 91480 Nominal RPM 850 850 850 850 850 850 Tip Speed Ft Min 6675 6675 6675 6675 6675 6675 Motor SP Ea 1 1 1 1 1 1 1 1 1 1 1 1 Min Starting Oper Ambient2 HCFC 22 HCFC 22 HCFC 22 HCFC 22 HCFC 22 HCFC 22 Std Unit...

Page 10: ...erior surface of the Control Panel door A compressor nameplate is located on each compressor The RTCA unit nameplate is applied to the side of the control panel Unit Nameplate The unit nameplate provides the following information Unit model and size descriptor Unit serial number Identifies unit electrical requirements Lists correct operating charges of R 22 and refrigerant oil Lists unit test pres...

Page 11: ...e comprised of numbers and letter which represent features of the equipment Each position or group of positions in the number is used to represent a feature For example Unit Voltage contains the number 4 From the chart it can be seen that a 4 in this position means that the unit voltage is 460 60 3 Figure 1 Nameplates ...

Page 12: ...king 40 to 65 F Daytime 4 Ice Making 0 to 39 F Daytime S Special Digit 13 Condenser Configuration C Standard Length Copper Tubes Std Temp D Long Copper Tubes Std Temp E Standard Efficiency High Temp Copper Tubes F Long Condenser Shell High Temp Copper tubes R Remote Condenser RTUA S Special Digit 14 Agency Listing 0 No Agency Listing 3 C UL Listing Digit 15 Control Interface C Deluxe without Commu...

Page 13: ... 3 4 460 60 3 5 575 60 3 S Special G 200 230 60 3 Dual Voltage Digit 09 Compressor Starter Type 0 Not Applicable Digit 10 11 Design Sequence AO First Sequence Factory Input Digit 12 Evaporator Leaving Temperature 0 Not Applicable Digit 13 Condenser Coil Fin Material A Aluminum 2 Complete Coat 4 Copper Fins S Special Digit 14 Agency Listing 0 No Agency Listing 3 C UL Listing Digit 15 Control Interf...

Page 14: ...xcessive water condensation The RTCA units are designed for outdoor installation Extended storage of the outdoor unit prior to installation requires the following precautionary measures 1 Store the outdoor unit in a secure area 2 At least every three months quarterly check the holding charge to verify that the refrigerant circuits are intact Contact a qualified service organization and the appropr...

Page 15: ... within 1 4 6 4 mm over its length and width The Trane Company is not responsible for equipment problems resulting from an improperly designed or constructed foundation Clearances Provide enough space around the unit to allow the installation and mainte nance personnel unrestricted access to all service points Refer to submittal drawings for the unit dimensions to provide sufficient clearance for ...

Page 16: ...essary 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 Lifting Procedure Attach chains or cables to lifting beam The total lifting weight lifting weight distribution and required lifting beam dimensions are shown in Figures 2 7 and 10 and on the rigging diagram shipped wi...

Page 17: ...RLC SVX07A EN 17 Installation Mechanical Figure 2 Rigging and Lifting for RTWA Units ...

Page 18: ...18 RLC SVX07A EN Installation Mechanical Figure 3 Dimension and Clearances for RTWA Unit Standard Length Condensers 70 100 Tons ...

Page 19: ...RLC SVX07A EN 19 Installation Mechanical Figure 4 Dimension and Clearances for RTWA Unit Long Length Condensers 70 100 Tons ...

Page 20: ...20 RLC SVX07A EN Installation Mechanical Figure 5 Dimension and Clearances for RTWA Unit Standard Length Condensers 110 125 Tons ...

Page 21: ...RLC SVX07A EN 21 Installation Mechanical Figure 6 Dimension and Clearances for RTWA Unit Long Length Condensers 110 125 Tons ...

Page 22: ...22 RLC SVX07A EN Installation Mechanical Figure 7 Rigging and Lifting for RTUA Units ...

Page 23: ...RLC SVX07A EN 23 Installation Mechanical Figure 8 Dimension and Clearances for RTUA Compressor Chiller 70 100 Tons ...

Page 24: ...24 RLC SVX07A EN Installation Mechanical Figure 9 Dimension and Clearances for RTUA Compressor Chiller 100 125 Tons ...

Page 25: ...RLC SVX07A EN 25 Installation Mechanical Figure 10 Rigging and Lifting for RTCA Condenser ...

Page 26: ...26 RLC SVX07A EN Installation Mechanical Figure 11 Dimensions and Clearances for RTCA Condenser ...

Page 27: ...ation Install the optional neoprene isolators at each mounting location Isolators are identified by part number and color 1 Secure the isolators to the mounting surface using the mounting slots in the isolator base plate as shown in Figure 12 13 and 14 Do not fully tighten the isolator mounting bolts at this time 2 Align the mounting holes in the base of the unit with the threaded positioning pins...

Page 28: ...28 RLC SVX07A EN Installation Mechanical Figure 12 Neoprene Isolator Placement for Typical RTWA Package Units 70 125 Ton ...

Page 29: ...RLC SVX07A EN 29 Installation Mechanical Figure 13 Neoprene Isolator Placement for Typical RTUA Package Units 70 125 Ton ...

Page 30: ...30 RLC SVX07A EN Installation Mechanical Figure 14 Neoprene Isolator Placement for Typical RTCA Package Units 70 125 Ton ...

Page 31: ...vent evaporator or condenser damage pipe strainers must be installed in the water supplies to protect components from water born debris Trane is not responsible for equipment only damage caused by water born debris Evaporator Water Piping for RTWA and RTUA Units Only Figure 15 illustrates typical evaporator piping components Components and layout will vary slightly depending on the location of con...

Page 32: ...nes so that the evaporator can be isolated for service A pipe strainer must be installed in the entering water line to prevent water borne debris from entering the evaporator Evaporator Piping Components Piping components include all devices and controls used to provide proper water system operation and unit operating safety These components and their general locations are given below Entering Chi...

Page 33: ...ter flow switch A flow switch for chilled water is strictly discretionary but if not installed a signal must be sent to the chiller to indicate that water flow has been established eg chilled water pump motor starter auxiliary contacts building automation system etc If additional chilled water flow protection is desired use a field installed flow switch or differential pressure switch with the pum...

Page 34: ...m the water system 3 Adjust the switch to open when water flow falls below nominal Evapora tor data is shown in Figure 16 Refer to Tables 1 to 3 General Data for minimum flow recommendations Flow switch contacts are closed on proof of water flow 4 Install a pipe strainer in the entering evaporator water line to protect com ponents from water borne debris ...

Page 35: ... Installation Mechanical Figure 16 RTWA RTUA Evaporator Water Pressure Drop RTWA RTUA Evaporator Water Pressure Drop 0 5 10 15 20 25 30 35 40 0 50 100 150 200 250 300 350 400 450 500 FLOW GPM PRESSURE DROP FT OF H 2 0 ...

Page 36: ...stallation Mechanical Figure 17 RTWA Standard Pressure Water Pressure Drop RTWA Standard Condenser Water Pressure Drop 0 5 10 15 20 25 30 0 50 100 150 200 250 300 350 400 450 500 550 600 FLOW GPM PRESSURE DROP FT OF H 2 O ...

Page 37: ...lation Mechanical Figure 18 RTWA Long Condenser Water Pressure Drop RTWA Long Condenser Water Pressure Drop 0 5 10 15 20 25 30 35 40 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 FLOW GPM PRESSURE DROP FT OF H 2 O ...

Page 38: ...n be caused by excessive pressure drop through the valve and also due to the design of the condenser The condenser waterside is rated at 150 psi CAUTION Equipment Damage To prevent damage to the condenser or regulating valve the condenser water pressure should not exceed 150 psig The optional water regulating valve maintains condensing pressure and temperature by throttling water flow leaving the ...

Page 39: ...the water flow as discharge pressure falls and increase the water flow when discharge pressure rises This valve is not used in cooling tower applications Cooling towers however may require the use of a three way bypass valve to maintain balance between cooling tower water temperature and condensing pressure Figure 19 Typical Well city Water Piping Components for Condenser Water Circuit Figure 20 T...

Page 40: ...ON Equipment Damage To prevent refrigerant loss locate capillary tubing and secure it to avoid damage due to friction or vibration Insure that the valves are closed to the access port before removing the flare cap WARNING Prevent Injury To prevent injury due to instantaneous release of high pressure gas and or contact with refrigerant be sure the discharge valve access port is closed off before re...

Page 41: ...ired This eliminates errors resulting from differently calibrated gauges installed at unmatched elevations Water Pressure Relief Valves Install a water pressure relief valve in the condenser and evaporator leaving chilled water piping See Figures 15 19 and 20 Water vessels with close coupled shutoff valves have a high potential for hydrostatic pressure buildup on a water temperature increase Refer...

Page 42: ...frigerant Relief Valve Venting Condenser Pressure Relief Valve Venting for RTWA units only All RTWA units utilize a refrigerant pressure relief valve for each circuit which must be vented to the outdoor atmosphere The valves are located at the top of the condenser When facing the control panel Circuit 1 relief valve is approximately 5 left of center and Circuit 2 relief valve is approximately 5 ri...

Page 43: ...ubstitutes or refrigerant additives could result in death or serious injury or equipment damage If multiple chillers are installed each unit must have a separate venting for its relief valves Consult local regulations for any special relief line requirements Evaporator Pressure Relief Valve Venting for RTWA and RTUA units only All RTWA and RTUA units utilize a low side refrigerant pressure relief ...

Page 44: ...n death or serious injury or equipment damage If multiple chillers are installed each unit must have a separate venting for its relief valves Consult local regulations for any special relief line requirements Initial Leak Test The RTWA units are shipped with a full charge of refrigerant and oil Before operating the unit install appropriate gauges to verify that the charges are intact If there is n...

Page 45: ...compressors one per circuit oil coolers liquid line service valves sightglasses electronic expansion valves and filter driers The discharge line leaving the oil separator is capped and brazed and the liquid line is terminated with a liquid line service valve The installing contractor need only provide the interconnecting piping between the RTUA and the air cooled condenser Refrigerant piping must ...

Page 46: ... decrease Figure 24 Condenser Above the Compressor Chiller RQGHQVHU RLO 6HUYLFH 9DOYH LOWHU ULHU 6LJKW ODVV 9 7UDS QYHUWHG 7UDS HLJKW TXDO WR 7RS RI RQGHQVHU RESTRICTIONS Total distance between components should not exceed 200 ft actual or 300 ft equivalent Liquid line riser s must not exceed 15 ft from base of air cooled condenser Figure 25 Condenser Below Compressor Chiller RQGHQVHU RLO 6HUYLFH ...

Page 47: ... pressure before removing end caps Do not use a saw to remove end caps as this may allow copper chips to contaminate the system Use a tubing cutter or heat to remove the end caps WARNING Prevent Injury When sweating line connections always provide a sufficient purge of dry nitrogen through the tubing to prevent the formation of oxides scaling cause by high temperature from brazing Use a pressure r...

Page 48: ...ciency decrease 5 Refer to Figures 23 24 and 25 for location of recommended traps 6 Circuit 1 on the condenser must be connected to Circuit 1 on the RTUA unit CAUTION Equipment Damage If circuits are crossed serious equipment damage may occur NOTE The piping shown in Figures 23 24 and 25 are for one circuit only The piping for the other circuit should follow the same guidelines Equivalent Line Len...

Page 49: ...rom the base of the air cooled condenser The liquid line does not have to be pitched Liquid line sizing for these units are shown in Tables 7 to 9 Liquid lines are not typically insulated However if the lines run through an area of high ambient temperature eg boiler room subcooling may drop below required levels In these situations insulate the liquid lines NOTE In case of power failure to the exp...

Page 50: ...1 3 8 1 3 8 1 5 8 250 1 1 8 1 3 8 1 3 8 1 5 8 250 1 3 8 1 3 8 1 3 8 1 5 8 275 1 1 8 1 3 8 1 3 8 1 5 8 275 1 3 8 1 3 8 1 3 8 1 5 8 300 1 3 8 1 3 8 1 3 8 1 5 8 300 1 3 8 1 3 8 1 3 8 1 5 8 50 Ton Circuit 40 60F LWT 60 Ton Circuit 40 60F LWT Total Equiv Length ft Liquid Line Size OD Total Equiv Length ft Liquid Line Size OD Horizontal or Downflow Upflow 1 5 ft Upflow 6 10 ft Upflow 11 15 ft Horizontal...

Page 51: ...75 1 1 8 1 1 8 1 3 8 1 3 8 175 1 1 8 1 1 8 1 3 8 1 3 8 200 1 1 8 1 1 8 1 3 8 1 3 8 200 1 1 8 1 1 8 1 3 8 1 5 8 225 1 1 8 1 1 8 1 3 8 1 3 8 225 1 1 8 1 3 8 1 3 8 1 5 8 250 1 1 8 1 1 8 1 3 8 1 3 8 250 1 1 8 1 3 8 1 3 8 1 5 8 275 1 1 8 1 1 8 1 3 8 1 5 8 275 1 1 8 1 3 8 1 3 8 1 5 8 300 1 1 8 1 1 8 1 3 8 1 5 8 300 1 1 8 1 3 8 1 3 8 1 5 8 50 Ton Circuit 20 39F LWT 60 Ton Circuit 20 39F LWT Total Equiv L...

Page 52: ...75 7 8 7 8 1 1 8 1 1 8 175 7 8 1 1 8 1 1 8 1 3 8 200 7 8 1 1 8 1 1 8 1 1 8 200 1 1 8 1 1 8 1 1 8 1 3 8 225 7 8 1 1 8 1 1 8 1 3 8 225 1 1 8 1 1 8 1 1 8 1 3 8 250 7 8 1 1 8 1 1 8 1 3 8 250 1 1 8 1 1 8 1 1 8 1 3 8 275 1 1 8 1 1 8 1 1 8 1 3 8 275 1 1 8 1 1 8 1 1 8 1 3 8 300 1 1 8 1 1 8 1 1 8 1 3 8 300 1 1 8 1 1 8 1 1 8 1 3 8 50 Ton Circuit 0 19 F LWT 60 Ton Circuit 0 19 F LWT Total Equiv Length ft Liq...

Page 53: ... 8 175 2 1 8 1 5 8 1 5 8 200 2 1 8 1 5 8 1 5 8 200 2 1 8 1 5 8 1 5 8 225 2 1 8 2 1 8 1 5 8 225 2 1 8 2 1 8 1 5 8 250 2 1 8 2 1 8 1 5 8 250 2 1 8 2 1 8 1 5 8 275 2 1 8 2 1 8 1 5 8 275 2 1 8 2 1 8 1 5 8 300 2 1 8 2 1 8 1 5 8 300 2 1 8 2 1 8 1 5 8 50 Ton Circuit 60 Ton Circuit Total Equiv Length ft Leaving Evaporator Water Temperature F Total Equiv Length ft Leaving Evaporator Water Temperature F 40 ...

Page 54: ...nsor must be installed in a location that accurately represents the outdoor ambient temper ature which the condenser will encounter It must not be exposed to direct sunlight or precipitation which could artificially alter the actual outdoor ambient temperature Also it must not be exposed to the recirculating air from the discharge of the condenser The saturated condensing temperature sensors must ...

Page 55: ...mate amount of the refrigerant charge required by the system must be determined by referring to Table 14 and must be verified by running the system and checking the liquid line sightglasses To determine the approximate charge first refer to Table 13 and establish the required charge without the field installed piping Then refer to Table 14 to determine the charge required for the field installed p...

Page 56: ... Discharge Line Actual length of horizontal or downflow lines 2 5 71 78 ft Actual length of upflow lines 15 1 2 5 20 1 2 ft Total equivalent length 1 1 2 x 78 20 1 2 147 75 Approx line size for horizontal downflow lines Table 12 2 1 8 Approx line size for upflow lines Table 13 2 1 8 Equiv length of one long radius elbow at 21 8 Table 7 3 2 5 ft Equiv length of 4 short radius elbows at 2 1 8 Table ...

Page 57: ...ser New line size for horizontal and downflow lines remains Table 8 1 1 8 HORIZONTAL AND DOWNFLOW LIQUID LINES ARE 1 1 8 UPFLOW LIQUID LINES ARE 1 3 8 Figure 26 Example Pipe Size Configuration RQGHQVHU RLO LTXLG 7UDS 4 3CHEMATIC IS NOT TO SCALE ...

Page 58: ... additional information regarding the safe discharge of capacitors see PROD SVB06A EN or PROD SVB06A FR All wiring must comply with local codes and the National Electric Code Typical field wiring diagrams are shown in Section Unit Wiring Minimum circuit ampacities and other unit electrical data are on the unit nameplate and are shown in Table 16 See the unit order specifications for actual electri...

Page 59: ...10 575 60 3 129 175 150 2 57 57 328 328 RTWA 110 Std Cond Temp 200 60 3 407 600 500 2 194 164 1190 990 230 60 3 355 500 400 2 169 143 1044 820 460 60 3 179 250 200 2 85 77 522 410 575 60 3 142 200 175 2 68 57 420 328 RTWA 125 Std Cond Temp 200 60 3 437 600 300 2 194 194 1190 1190 230 60 3 381 500 250 2 169 169 1044 1044 460 60 3 192 250 125 2 85 85 522 522 575 60 3 153 200 100 2 68 68 420 420 1 MC...

Page 60: ...9 250 225 2 84 84 410 410 575 60 3 151 200 175 2 67 67 328 328 RTUA 110 RTWA 110 High Cond Temp 200 60 3 484 700 600 2 233 192 1190 990 230 60 3 421 600 600 2 203 167 1044 820 460 60 3 211 300 250 2 101 84 522 410 575 60 3 169 225 200 2 81 67 420 328 RTUA 125 RTWA 125 High Cond Temp 200 60 3 525 700 600 2 233 233 1190 1190 230 60 3 457 600 600 2 203 203 1044 820 460 60 3 228 300 250 2 101 101 522 ...

Page 61: ...1 2 2 0 75 RTCA 110 200 60 3 49 2 50 50 10 1 4 8 0 75 230 60 3 49 2 50 50 10 1 4 8 0 75 460 60 3 25 6 30 30 10 1 2 5 0 75 575 60 3 22 6 25 25 10 1 2 2 0 75 RTCA 125 200 60 3 49 2 50 50 10 1 4 8 0 75 230 60 3 49 2 50 50 10 1 4 8 0 75 460 60 3 25 6 30 30 10 1 2 5 0 75 575 60 3 22 6 25 25 10 1 2 2 0 75 1 MCA Minimum Circuit Am capacity 125 percent of largest fan motor FLA plus 100 percent of the othe...

Page 62: ...e RTWA and RTUA units The wiring is passed through these conduits and connected to the terminal blocks or optional unit mounted disconnect Refer to Figures 3 thru 6 and Figures 8 and 9 For the RTCA units refer to Figure 11 for the power supply wiring hole location Control Power Supply The RTWA and RTUA units are equipped with a control power transformer It is not necessary to provide control power...

Page 63: ...er mostat building automation system etc 2 UCM Pump Control Contacts Terminals 1U1TB4 8 and 9 This output is a set of contacts that will close and start the chilled water pump when the external Auto Stop contacts are closed When the con tacts are opened 1 to 30 minutes later adjustable through the Clear Lan guage Display the UCM pump contacts open 3 Proof of Chilled Water Flow Interlock Terminals ...

Page 64: ...erating at full capacity As shown in Figure 19 there are three relays Relays 1 has SPDT contacts Relays 2 and 3 have SPST normally open contacts The relays provide three output configurations as shown in Figure 19 and each configuration offers four choices as to how each relay is to respond to a set of diagnostics Table 27 shows the twelve settings available in Programmable Relay Setup Service Set...

Page 65: ... 2 RLY 3 Circuit 1 Alarm Circuit 2 Alarm Maximum Capacity 3 RLY 1 RLY 2 RLY 3 Alarm Circuit 1 Running Circuit 2 Running Table 20 Alarm Running Maximum Capacity Menu Settings Programmable Relay Setup Setting Service Setting Menu Relays Output Configuration Table 19 Diagnostics that the Alarm Relay s is Active MMR CMR diag MAR CAR diag IFW 1 1 YES NO NO 2 1 YES YES NO 3 1 YES YES YES 4 1 YES NO YES ...

Page 66: ... and 6 respectively to monitor the factory installed saturated condensing refrigerant temperature sensor on Circuit 1 115 volt power from the RTUA 1TB4 3 to 11 to RTCA 1TB4 3 to 11 respectively to control the fan contactors The field installed outdoor air temperature sensor on the condenser needs to be wired to RTUA 1TB8 1 and 2 The field installed saturated condensing refrigerant temperature sens...

Page 67: ...ut Circuit 1 The UCM provides for auxiliary control via a customer specified or installed contact closure for individual operation of Circuit 1 If the contact is closed the refrigerant circuit will not operate The refrigerant circuit will run normally when the contact is opened This feature is used to restrict total chiller operation eg during emergency generator operations External circuit lockou...

Page 68: ...ased on the entering evaporator water temperature setting under Active Ice Termination Setting Chiller Report Menu The UCM will not permit the ice building mode to be reentered until the unit has been switched out of ice building mode open 5K20 contacts and then switched back into ice building mode close 5K20 contacts In ice building the current setpoint will be set at 120 For example if the Front...

Page 69: ...RLC SVX07A EN 69 Installation Electrical Figure 28 Interconnecting Wiring from RTUA to RTCA ...

Page 70: ...70 RLC SVX07A EN Installation Electrical Figure 29 Interconnecting Wiring from RTUA to Non RTCA Condensing Unit ...

Page 71: ...ge Display 1 Remote Resistor Potentiometer Input fixed or adjustable Connect the remote resistor and or potentiometer to terminals TB1 4 and TB1 5 of Options Module 1U2 as shown in Figure 30 For units with 40 F to 60 F LCWS range a field furnished 25 Kohm linear taper potentiometer 10 and a fixed 5 6 Kohm 10 1 4 Watt resistor should be used For units with 20 F to 39 F LCWS range a field furnished ...

Page 72: ...E The negative terminal TB1 5 is referenced to the UCM chassis ground To assure correct operation 2 10 VDC or 4 20 mA signals must be Table 21 Input Values Vs External Chilled Water Setpoint Inputs Resulting Chilled Water Setpoint F Resistance Ohms Current ma Voltage Vdc 944330 4 0 2 0 0 0 686092 5 2 2 6 5 0 52946 6 5 3 2 10 0 42434 7 7 3 9 15 0 34889 8 9 4 5 20 0 29212 10 2 5 1 25 0 24785 11 4 5 ...

Page 73: ...x 10 20 Sample values for CLS vs VDC signals are shown in Table 21 5 4 20 mA Current Source Input Set DIP Switch SW1 2 of Options Module 1U2 to ON Connect the current source to terminals T131 7 and TB1 8 of Options Module 1U2 CLS is now based on the following equation CL Setpoint _ mA x 5 20 Sample values for CLS vs mA signals are shown in Table 22 NOTE The negative terminal TB1 8 is referenced to...

Page 74: ... run low voltage wiring 30V or less in conduit with higher voltage circuits Outdoor Air Temperature Sensor This sensor is used for low ambient lockout and chilled water reset by outdoor air It ships with all RTCA units and is optional on the RTUA and RTWA units Remove the sensor from its shipping location in the control panel and install it in the fresh air intake or on the north wall of the build...

Page 75: ... capacitors have discharged Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury Note For additional information regarding the safe discharge of capacitors see PROD SVB06A EN or PROD SVB06A FR CAUTION Use Copper Conductors Only Unit terminals are not designed to accept other types of conductors Failure to use copper conductors may result in ...

Page 76: ...age Display 3 Connect the shield of the communication link wiring to the designated shield terminal at the Tracer unit 4 Connect leads 561 and 562 from the proper terminals of 1U2 TB2 1 and TB2 2 on the UCM to the Tracer There is no polarity requirement for this connection 5 At the UCM the shield should be cut and taped to prevent any contact between the shield and ground NOTE On multiple unit ins...

Page 77: ...allation Procedure The Remote CLD is intended for indoor use and is not weatherproof It can be used with both RTWA or RTUA units It is mounted in a molded rubber plastic box with a molded rubber keypad Although this is not the same as the membrane keyboard of the unit s CLD the key locations and labels are identical Field wiring for the communication link must meet the following require ments 1 Al...

Page 78: ... the panel is a knockout for an electrical outlet box if one is to be used Prior to mounting the panel the actual keypad board needs to be swung open To swing the keypad board our of the way remove the two screws on the right side of the keypad With the screws removed the keypad board can be swung to the left to obtain access to the mounting holes Attach the display box to the mounting surface wit...

Page 79: ...un the shielded twisted pair wire in a conduit that also contains circuits of greater than 30 volts Attach the shield to a grounding lug in the Remote CLD Panel Cut and tape the shield at the Unit Control Panel as shown in Figure 33 NOTE Shielding of the twisted pair can be grounded at either the Unit Control Panel or the Remote CLD Panel as long as both sides are NOT grounded Connect the 24 volt ...

Page 80: ...s used to wire the second third and fourth units to the Remote CLD TB4 is labeled as shown below Terminals 1 3 are for the second unit Terminals 4 6 are for the third unit Terminals 7 9 are for the fourth unit Figure 34 Remote Display Panel Interconnecting Wiring ...

Page 81: ...ing Flush all unit water piping before making final connections to the unit Connect the water piping to the evaporator and condenser if applicable Install pressure gauges and shutoff valves on the water inlet and outlet to the evaporator if applicable Install a water strainer in the entering chilled water line Install a balancing valve and flow switch discretionary in the leaving chilled water lin...

Page 82: ...the panel to the proper terminals on terminal strip 1U1 TB4 If the emergency stop function is used remove the factory installed jumper and install low voltage leads 513 and 514 to terminals 3 and 4 of 1U1 TB1 If indoor zone temperature is to be used install leads 501 and 502 on 6RT4 to the proper terminals on 1U2 TB1 If the ice making option is used install leads 501 and 502 on 5K20 to the proper ...

Page 83: ...on Interconnecting piping Components of a typical RTWA unit are identified in Figures 35 RTUA Units The 70 125 ton RTUA units are dual compressor helical rotary type compressor chillers The basic components of an RTUA unit are Clear Language Display and control modules Helical rotary compressors Direct expansion evaporator Oil cooler Interconnecting piping between the compressors and evaporator Co...

Page 84: ...er Valve Temp Sensor 4 Oil Cooler if digit 17 is a V 14 Electronic Expansion Valve 22 Relief Valve 5 Oil Line Service Valve 15 1 4 Angle Valve 23 Suction Service Valve 6 Oil Temperature Sensor 16 Sat Evaporator Refrigerant 24 Comp Suction Refrigerant 7 Condenser Temp Sensor Temp Sensor 8 Sat Condenser Refrigerant 17 Leaving Water Connection 25 Shutoff Valve Temp Sensor 18 Evaporator Leaving Water ...

Page 85: ...it cools the system water that surrounds the tubes in the evaporator Figure 36 RTUA with RTCA Refrigeration System and Control Components 7 3 1 14 13 12 8 RTCA Condenser Evaporator 5 4 2 6 24 23 22 21 19 9 18 16 15 17 20 11 10 1 Discharge Service Valve 10 Liquid Line Service Valve 19 Temperature Responsive Valve 2 Oil Separator Backseat Port Upstream 20 Entering Water Connection 3 1 4 Angle Valve ...

Page 86: ...ectronic expansion valve and into the tubes of the evaporator As the refrigerant vaporizes it cools the system water that surrounds the tubes in the evaporator Compressor Description The compressors used by the Model RTWA and RTUA Series R Water cooled chiller consists of two distinct components the motor and the rotors Compressor Motor A two pole hermetic squirrel cage induction motor 3600 rpm di...

Page 87: ...d capacity is dictated by the positions of the unloader valves They divert refrigerant gas from the rotors to the compressor suction thus unloading the compressor This varies the compressor capacity to match the load and reduces the KW draw of the compressor motor The two position female unloader will fully open or fully close a port on the rotor housing at the discharge end of the female rotor Th...

Page 88: ...p of the rotors to seal clearance spaces between the rotors and the compressor housing and to lubricate the rotors Female Unloader Valve The position of the female unloader valve determines compressor capacity Its position is dependent on whether the backside of the female unloader valve is exposed to the compressor discharge or suction pressure See Figure 37 The female unloader valve receive a co...

Page 89: ...tial Pressure diagnostic will take the circuit off line if the pressure differential falls below 40 psid for more than two minutes A High Differential Pressure diagnostic will take the circuit off line if the pressure differential increases to 350 psid or greater This diagnostic can also be produced if the pressure differential increases to the range between 320 psid and 349 psid The UCM will allo...

Page 90: ...ng Principles Figure 38 Fan Staging for RTCA 70 to 125 1 5 8 7 1 5 8 7 21752 3 1 B B B 1 5 8 7 1 5 8 7 21752 3 1 1 5 8 7 1 5 8 7 21752 3 1 1 5 8 7 1 5 8 7 21752 3 1 1 5 8 7 1 5 8 7 21752 3 1 DQ 2Q DQ 2II 287 225 5 7 03 B 127 6 ...

Page 91: ... of local setpoints and adjustments Actual controlling setpoints Specific temperatures Specific Pressures Enable Disable status of features and options Selection status of SI units or English units Under Over voltage protection Display of line voltage Alarm Running Maximum Capacity contacts Display Starts and Hours Clear Language Display Keypad Overview Local operator interface with the system is ...

Page 92: ...us key when the desired read out is on the display The operator must be in the Custom Report menu to delete the desired item The Chiller Report Refrigerant Report and Compressor Report are informa tional reports that give current status Each report and its contents are discussed in detail on the following pages When any of the four report keys are pressed the first readout on the display will be t...

Page 93: ...etpoint will remain Passwords Passwords are needed to enter into the Service Setup Menu and the Machine Configuration Menu Both of these menus are accessed through the Service Settings key If access into these menus is necessary follow the list of steps below 1 Press Service Settings 2 Press Next until the readout in the display is Password Required For Further Access Please enter Password 3 To en...

Page 94: ...s pressed if a compressor is running This key has a red background color surrounding it to distinguish it from the others If the chiller is in the Stop mode pressing the Auto key will cause the UCM to go into the Auto Local or Auto Remote mode depending on the Setpoint Source setting The Auto key has a green background color When either the Auto or Stop key is pressed Chiller Operating Mode Chille...

Page 95: ...ICE 0UMPDOWN 3 404 3 52 OCAL 4RACER PERATING ODE 0 4 4 23 AN ONTROL 3ERVICE 3ETTING ENU 3 7R 7 9 855 17 0 7 6 732 17 RQ QH W SDJH 02 23 5 7 1 02 5 48 67 6 732 17 6285 6 737 6285 5 5357 67 786 75 7 036 6 7376 35 66 1 7 35 9 286 72 217 18 2035 66256 21 121 5 8 76 2 287 7 7 121 7 9 7 50 1 7 21 6 732 17 9 3 17 5 1 7 5 7 03 7 9 7 5 6 732 17 9 3 9 1 7 5 7 03 9 3 17 5 1 7 5 7 03 9 3 9 1 7 5 7 03 7 5 75 1...

Page 96: ... IS NOT ENABLED OT APPLICAL ON DOMESTIC UNITS 7 9 855 17 0 7 6 732 17 5 5 287 225 5 7 03 5 785 21 7 03 5 785 1H W 1H W URP 7 5 75 17 5 1 7 5 7 03 RQ SUHYLRXV SDJH 7R KHDGHU RI KLOOHU 5HSRUW ASHES WILL BE DISPLAYED IF THE SENSOR IS OPEN OR SHORTED AND NEITHER UTDOOR IR 2ESET OR OW MBIENT OCKOUT IS ENABLED ASHES WILL BE DISPLAYED IF THE ONE 4EMP 3ENSOR IS OPEN OR SHORTED AND ONE 2ESET IS NOT ENABLED...

Page 97: ...286 72 217 18 7 9 3 5 7 35 6685 36 7 21 5 7 35 6685 36 7 3565 68 7 21 5 7 7 03 7 6 785 7 9 3 5 7 7 03 7 6 785 7 21 7 7 03 7 9 3 5 7 35 6685 36 7 21 5 7 35 6685 36 7 3565 68 7 21 5 7 7 03 7 6 785 7 9 3 5 7 7 03 7 6 785 7 5 7 7 03 5HIULJHUDQW 5HSRUW 1H W 1H W 1H W 1H W 1H W 1H W 1H W ...

Page 98: ...ENSER IMIT 2UN VAPORATOR IMIT 2UN URRENT IMIT 3TOPPING 3ERVICE 0UMPDOWN RPSUHVVRU 5HSRUW 2035 6625 5 3257 02 56 67576 5 35 66 1 7 35 9 286 72 217 18 2035 66256 21 121 5 8 76 2 287 7 7 121 1 92 76 2035 6625 02 02 2035 6625 5 9 5 2035 6625 5 3 6 2035 6625 17 5 1 2 7 03 2035 6625 67 576 2035 6625 5811 1 2856 FTER REVIEW OMPRESSOR OF LAST COMP 4 5 4 4 3 4 3 1H W 1H W 1H W 1H W 1H W 1H W 1H W ...

Page 99: ... 77 1 7 5 3803 2 0 187 6 35 66 72 1 6 77 1 7R 5217 3 1 855 17 0 7 6 737 RQ QH W SDJH 3 52 OCAL 4RACER EFAULT 3ELECT TO F 4 BY UTOUT 3ETPT TO CHANGE IS DISPLAYED REFER TO THE SECTION ON EAVING 7ATER 4EMPERATURE UTOUT AND OW 2EFRIGERANT 4EMPERATURE UTOUT EFAULT ISABLE EFAULT 3ELECT TO EFAULT 3ELECT TO ANUAL OVERRIDE OF HILLED 7ATER 0UMP FF ELAY 54 3 EFAULT IN 3ELECT IN TO IN 5 17 72 67 57 6 732 17 3...

Page 100: ...77 1 7 4 54 PERATOR SETTINGS MENU 3 7 5 5 6 7 7 3 7 3 35 66 72 1 6 77 1 4YPE OF HILLED 7ATER 2ESET 3ELECTED BOVE 2 452 7 4 2 54 2 2 3 7 3 7 3 5 6 7 5 7 2 35 66 72 1 6 77 1 7R 7 3 7 3 67 57 5 6 7 6 737 RQ QH W SDJH EFAULT 3ELECT TO EFAULT ISABLE EFAULT ISABLE EFAULT 3ELECT TO EFAULT ISABLE 3ELECT 2ETURN 7TR ONE UTDOOR IR 490 2ETURN EFAULT 2ANGE TO ONE EFAULT 2ANGE TO UTDOOR EFAULT 2ANGE TO 1H W 1H ...

Page 101: ...TO 490 2ETURN EFAULT 2ANGE TO ONE EFAULT 2ANGE TO UTDOOR EFAULT 2ANGE TO EFAULT ISABLE EFAULT 3ELECT TO URP 7 3 7 3 5 6 7 5 7 2 RQ SUHYLRXV SDJH 7 3 7 3 67 57 5 6 7 6 737 35 66 72 1 6 77 1 7 3 7 3 0 5 6 7 6 737 35 66 72 1 6 77 1 0 1 21752 35 66 72 1 6 77 1 3 1 7 50 1 7 21 6 737 35 66 72 1 6 77 1 1H W 1H W ...

Page 102: ...T ISABLE EFAULT 3ELECTIONS EFAULT SEC 3ELECT TO SEC 6 59 6 77 1 6 1 6 81 76 35 66 1 7 35 9 286 72 217 18 35 66 17 5 72 2 63 3 3 66 25 5 48 5 72 81 2 EPRESS EITHER NTER OR EXT 63 1 3 5 2 17 5 3 66 25 72 81 2 81 5 29 5 92 7 3527 7 21 35 66 72 1 6 77 1 81 7 1 92 7 92 7 9 35 66 72 1 6 77 1 5 67 57 1 7 7 0 6 35 66 72 1 6 77 1 7R 1 3565 67 576 2856 RQ QH W SDJH ISPLAY WILL RETURN TO HILLER PERATING ODE ...

Page 103: ...NG AX APACITY UTPUTS FOR DETAILS EFAULT ISABLE 2EFER TO SECTION ON 0ASSWORDS FOR DETAILS 1 3565 67 576 2856 35 66 72 1 6 77 1 63 81 76 81 76 35 66 72 1 6 77 1 1 8 1 8 35 66 72 1 6 77 1 352 5 00 5 6 783 35 66 72 1 6 77 1 7 51 5 8 7 2 287 35 66 72 1 6 77 1 3 66 25 5 48 5 25 857 5 66 3 6 17 5 3 66 25 7R 0 1 21 85 7 21 0 18 7R 6 59 6 7 83 0 18 RQ QH W SDJH 3ELECT 3ERVICE 3ETUP ENU OR ACHINE ONFIGURATI...

Page 104: ...RP 6HOHFW 6HUYLFH 6HWXS 0HQX RQ SUHYLRXV SDJH 6 59 6 7 83 0 18 35 66 1 7 35 9 286 72 1 6 77 1 3 63 2 785 35 66 72 1 6 77 1 6 5 66 35 66 72 1 6 77 1 9 75 7 03 87287 6 732 17 35 66 72 1 6 77 1 2 5 7 7 03 87287 6 737 35 66 72 1 6 77 1 2 75 7 03 9 1 203 35 66 72 1 6 77 1 21 16 5 0 7 6 732 17 3 35 66 72 1 6 77 1 3 6 81 1 3527 7 21 35 66 72 1 6 77 1 7R 3 6 5 9 56 3527 7 21 RQ QH W SDJH 7R 0 1 21 85 7 21...

Page 105: ...RE RESPONSIVE DECREASE TO MAKE LESS RESPONSIVE EFAULT 3ELECT TO NCREASE TO MAKE MORE RESPONSIVE DECREASE TO MAKE LESS RESPONSIVE EFAULT 3ELECT TO EFAULT 3ELECT TO 3 6 5 9 56 3527 7 21 35 66 72 1 6 77 1 683 5 7 6 732 17 35 66 72 1 6 77 1 9 21752 5 63216 7 35 66 72 1 6 77 1 9 21752 5 63216 7 35 66 72 1 6 77 1 9 75 7 03 175 5 63 6 737 35 66 72 1 6 77 1 1 175 1 6 7 36 35 66 72 1 6 77 1 1 175 1 6 7 36 ...

Page 106: ...1 0 18 RQ SUHYLRXV SDJH 7R 0 1 21 85 7 21 0 18 2035 6625 02 12 35 35 66 72 1 6 77 1 OMPRESSOR ODEL O 0REFIX 2035 6625 7216 7216 35 66 72 1 6 77 1 S THERE A OMPRESSOR 9 3 2035 6625 7216 7216 35 66 72 1 6 77 1 S THERE A OMPRESSOR 9 3 7R 2035 6625 7216 RQ QH W SDJH 7R 0 1 21 85 7 21 0 18 180 5 2 2035 66256 35 66 72 1 6 77 1 1H W 1H W 1H W 2 266 5 17 6 737 35 66 72 1 6 77 1 ...

Page 107: ... FORCED TO ISABLE EFAULT ISABLE EFAULT 3ELECT URP V WKHUH D RPSUHVVRU RQ SUHYLRXV SDJH 7R 0 1 21 85 7 21 0 18 2035 6625 7216 7216 35 66 72 1 6 77 1 S THERE A OMPRESSOR 9 3 2035 6625 7216 7216 35 66 7R 1 6 77 1 8QLW 0RGHO 7 SH 35 66 72 1 6 77 1 5NIT ODEL 24 245 247 9 5 63 1 5 8 7 35 66 72 1 6 77 1 9 5 63 1 5 8 7 35 66 72 1 6 77 1 180 5 2 16 5 8 7 16 35 66 72 1 6 77 1 7R 0 1 21 85 7 21 0 18 7R 180 5...

Page 108: ...O EFAULT 3ELECT TO EFAULT 3ELECT TO 180 5 2 16 5 8 7 16 35 66 72 1 6 77 1 5 8 1586 67 57 1 35 66 72 1 6 77 1 855 17 295 6 77 1 3565 35 66 72 1 6 77 1 S THERE A OMPRESSOR 9 3 855 17 295 6 77 1 356 35 66 72 1 6 77 1 S THERE A OMPRESSOR 9 3 855 17 295 6 77 1 3565 35 66 72 1 6 77 1 S THERE A OMPRESSOR 9 3 1H W 1H W 1H W 1H W 6WDUWHU 7 SH 7 SH 35 66 72 1 6 77 1 1H W 2EDUCED NRUSH 3TARTING 9 3 ...

Page 109: ...2 A 54 24 TON UNITS ARE TO BE RUN WITH 2 REFRIGERANT ONTACT A QUALIFIED SERVICE TECHNICIAN FOR FURTHER DETAILS URP V WKHUH D RPSUHVVRU RQ SUHYLRXV SDJH 7R 0 1 21 85 7 21 0 18 855 17 295 6 77 1 3565 35 66 72 1 6 77 1 AN ONTROL 3ERVICE 3ETTING ENU 3 2 0 81 7 5 2 1 35 66 72 1 6 77 1 2 0 81 7 7 2 63 02725 35 66 72 1 6 77 1 180 5 2 9 9 9 6 7 35 66 72 1 6 77 1 180 5 2 9 9 9 6 7 35 66 72 1 6 77 1 1H W 1H...

Page 110: ...17 18 6 59 3803 2 1 3565 35 66 72 1 6 77 1 S THERE A OMPRESSOR 9 3 6 59 3803 2 1 3565 35 66 72 1 6 77 1 S THERE A OMPRESSOR 9 3 6 59 3803 2 1 3565 35 66 72 1 6 77 1 S THERE A OMPRESSOR 9 3 6 59 3803 2 1 3565 35 66 72 1 6 77 1 9 7 67 5 8 7 35 66 72 1 6 77 1 9 7 67 5 8 7 35 66 72 1 6 77 1 7R 2035 6625 7 67 3565 RQ QH W SDJH 1H W 1H W 1H W 1H W 1H W 1H W 1H W 6HUYLFH 7HVWV ...

Page 111: ...RESSOR 9 3 URP 9 7 67 5 8 7 RQ SUHYLRXV SDJH EFAULT ISABLE EFAULT ISABLE EFAULT ISABLE EFAULT ISABLE EFAULT 5 EFAULT 5 2035 6625 7 67 3565 35 66 72 1 6 77 1 2035 6625 7 67 3565 35 66 72 1 6 77 1 2035 6625 7 67 3565 35 66 72 1 6 77 1 2035 6625 7 67 3565 35 66 72 1 6 77 1 5 8 7 2 287 7 81 2 2 287 35 66 1 6 77 1 1H W 1H W 1H W 1H W 1H W 1H W ...

Page 112: ...h Otherwise this alarm LED is deenergized If more than one diagnostic is present only the highest priority active diagnostic will be explained in detail For example if three diagnostics occur in the following order before the operator returns IFW MMR CMR the display will read A MACHINE SHUTDOWN HAS OCCURRED because the MMR has the highest priority However as the operator moves through the diagnost...

Page 113: ...f the unit If the outdoor temperature subsequently increases to 5 F above the setpoint the UCM will automatically re enable the unit The low ambient lockout feature has a range from 20 F to 60 F Electronic Expansion Valve EXV Test This test can be performed only when the Stop key has been pressed It will confirm proper operation of the electronic expansion valve and the EXV module Once the test ha...

Page 114: ...n the UCM will reset the chilled water temperature setpoint based on either the return water temperature zone air temperature or outdoor air temperature The 1U2 Module is necessary to preform CWR The following are selectable 1 One of four RESET TYPEs from top to bottom in order of reset no CWR RETURN WATER TEMPERATURE RESET OUTDOOR AIR TEMPERATURE RESET The Clear Language Display will not permit m...

Page 115: ...e CWS toward the desired CWS based on the above equations and setup parameters at a rate of 1 F every 5 minutes This applies when the chiller is both running and off Normally the chiller will start at the Differential to Start value above a fully reset CWS or CWS The values for RESET RATIO for each type of reset are Reset Type Reset Ratio Range Increment English Units Increment SI Units Factory De...

Page 116: ...front panel and active chilled water setpoints if necessary If the front panel or Active Chilled Water Setpoints were adjusted the display will show the following when the Enter key is pressed FRONT PANEL CHILLED WATER SETPOINT HAS BEEN INCREMENTED DUE TO CUTOUT SETPOINT CHANGE If the leaving water temperature drops below the cutout setpoint while the compressors are de energized it will produce a...

Page 117: ...ended Ethylene Glycol Solution Freeze Point F 40 35 22 0 32 39 34 20 3 38 33 18 6 37 32 17 8 36 31 15 10 25 35 30 14 12 34 29 12 14 33 28 11 15 21 32 27 9 17 31 26 7 19 30 25 6 20 16 29 24 4 21 28 23 2 23 27 22 0 25 10 26 21 1 26 25 20 3 28 24 19 5 29 23 18 6 30 4 22 17 8 31 21 16 10 33 20 15 11 34 19 14 13 35 3 18 13 15 36 17 12 17 37 16 11 18 38 15 10 19 39 14 9 21 40 11 13 8 23 41 12 7 24 42 11...

Page 118: ...s as shown in Figure 40 Low Refrigerant Temperature Cutout and Low Pressure Cutout Retry If the LRTC or LPC trips despite the low ambient temperature start logic the circuit will be permitted to shutdown and retry one time If the LRTC or LPC trips within the first 20 minutes after initial start but after the low ambient ignore time grace period the compressor stops immedi ately and the Restart Inh...

Page 119: ...ressor within one second if phase reversal is detected CAUTION Reversed Phase Rotation Phase relationships during installation of unit power must be carefully controlled to assure compressor protection against reversed phase rotation See Installation Electrical Oil Failure Protection The 70 to 125 Ton units no longer use the differential pressure switch to monitor for an oil line restriction The l...

Page 120: ...24 02 10001 17 200 60 142 02 11011 27 400 50 52 10 00011 03 400 50 62 10 10001 17 220 50 94 01 11011 27 220 50 108 02 00111 07 50 575 60 57 10 01011 11 50 575 60 67 01 00001 01 460 60 72 01 00111 07 460 60 84 01 10011 19 380 60 87 01 10110 22 380 60 101 02 00001 01 230 60 143 03 00110 06 230 60 167 03 10010 18 200 60 164 03 10001 17 200 60 192 03 11100 28 400 50 69 01 00011 03 400 50 84 01 10011 1...

Page 121: ...Modify Setpoints for Units X Press to change settings The Stop and Auto keys function in the same manner but the following hierarchy between the unit s Stop Auto keys and the Remote CLD Stop Auto keys is as follows 1 Local Stop will always override Local Auto Remote Stop and Remote Auto 2 Local Auto will always override Local Stop Remote Stop and Remote Auto 3 Remote Stop will override Local Auto ...

Page 122: ...f capacitors see PROD SVB06A EN or PROD SVB06A FR Inspect all wiring connections to be sure they are clean and tight Verify that all refrigerant valves as shown in Figure 35 and 36 are OPEN CAUTION Compressor Damage Do not operate the unit with the compressor oil discharge liquid line service valves and the manual shutoff on the refrigerant supply to the auxiliary coolers CLOSED Failure to have th...

Page 123: ...tarter For RTCA units close the fused disconnect switches that supply power to the fans Start the chilled water pump and condenser water pump to begin circula tion of the water Inspect all piping for leakage and make any necessary repairs With water circulating through the system adjust water flow and check water pressure drop through the evaporator and condenser Refer to Figures 16 17 and 18 Adju...

Page 124: ...ured voltages are 221 230 and 227 volts the average would be The percentage of imbalance is then This exceeds the maximum allowable 2 by 0 2 percent Unit Voltage Phasing It is important that proper rotation of the compressors be established before the unit is started Proper motor rotation requires confirmation of the electrical phase sequence of the power supply The motor is internally connected f...

Page 125: ...ompressor motor electrical phasing can be quickly determined and corrected before starting the unit Use a quality instrument such as the Associated Research Model 45 Phase Sequence Indicator 1 Press the Stop key on the Clear Language Display 2 Open the electrical disconnect or circuit protection switch that provides line power to the line power terminal block s in the starter panel or to the unitm...

Page 126: ...tes Establish a balanced chilled water flow through the evaporator The flow rates should fall between the minimum and maximum values given in Table 1 Chilled water flow rates below the minimum values will result in laminar flow which reduces heat transfer and causes either loss of EXV control or repeated nuisance low temperature cutouts Flow rates that are too high can cause tube erosion and damag...

Page 127: ...ller control calls for cooling and all safety interlocks are closed the unit will start The compressor s will load and unload in response to the temperature of the leaving chilled water tem perature Once the system has been operating for approximately 30 minutes and has become stabilized complete the start up procedures as follows Check the evaporator refrigerant pressure and the condenser refrige...

Page 128: ...f operating conditions indicate a refrigerant overcharge remove refriger ant at the liquid line service valve Allow refrigerant to escape slowly to minimize oil loss Do not discharge refrigerant into the atmosphere System Superheat Normal suction superheat for each circuit is approximately 6 F 4 F for RTUA units at full operating load Superheat temperature can be expected to be moving around the 6...

Page 129: ...RLC SVX07A EN 129 Start Up Procedures Figure 41 RTWA Unit Sequence of Operation ...

Page 130: ...130 RLC SVX07A EN Start Up Procedures Figure 42 RTUA Unit Sequence of Operation ...

Page 131: ... Test the unit for refrigerant leakage and repair as necessary 2 Open the electrical disconnect switches for the chilled water pump Lock the switch in the OPEN position CAUTION Pump Damage Lock the chilled water pump and condenser water pump disconnects open to prevent pump damage 3 Close all chilled water supply valves Drain the chilled water from the evaporator and condenser 4 Open the unit main...

Page 132: ...alified 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 4 Close the fused disconnect switches that provides power to the chilled water pump and the condenser water pump 5 Start both the evaporator and condenser water p...

Page 133: ... restric tion in the line can sometimes be identified by a noticeable temperature differential between the two sides of the restriction Frost may often form on the line at this point Proper refrigerant charges are shown on Table 1 CAUTION Equipment Check A clear sight glass alone does not mean that the system properly charged Also check system superheat subcooling and unit operating pressures If o...

Page 134: ...eter mine system moisture content and acid level This analysis is a valuable diagnostic tool Check the pressure drop across the oil filter See Paragraph Oil Filter Change on Page 140 Contact a qualified service organization to leak test the chiller to check operating and safety controls and to inspect electrical components for deficiencies Inspect all piping components for leakage and damage Clean...

Page 135: ...A B Voltage A C B C Compressor Phase A Amps B C Unit Operating Mode Last Diagnostic Evaporator Entering Water Temp F or C Evaporator Leaving Water Temp F or C Outdoor Air Temperature F or C Active Chill Water Setpoint F or C Active Current Limit Setpoint Saturated Evaporator Rfgt Temp F or C Saturated Condenser Rfgt Temp F or C Condenser Refrigerant Pressure psig kPa Evaporator Refrigerant Pressur...

Page 136: ...or Model No Prefix Type Reset Ratio Number of Compressors Type Start Reset Setpt Oil Loss Differential Setpt Type Max Reset Setpt Compressor A Tons Ice Machine Control D E Compressor B Tons Panel Ice Termination Setpt Unit Model Title Service Settings Fan Control D E Under Over Voltage Protection D E Variable Speed Fan Circuit 1 D E Unit Line Voltage Variable Speed Fan Circuit 2 D E Restart Inhibi...

Page 137: ...densing temperatures and use of water with high mineral content Cooling towers collect dust and foreign material which also deposit on the condenser tubes forming sludge To maintain maximum efficiency the condenser must remain as free of these deposits as possible Even a very thin layer on the inside tube surfaces reduces the heat transfer ability of the condenser Indications of scale deposits are...

Page 138: ...l cleaning agents can be either acidic or highly alkaline Handle chemical carefully Proper handling should include goggles or face shield chemical resistant gloves boots apron or suit as required For personal safety refer to the cleaning agent manufacturer s Materials Safety Data Sheet and follow all recommended safe handling practices Failure to follow all safety instructions could result in deat...

Page 139: ... equipment failures which result from untreated or improperly treated water or saline or brackish water Oil Separator Level Check Follow the steps listed below and refer to the notes listed in Figure 44 1 Turn off the unit 2 Attach the hoses and sight glass to the oil separator charging Schrader valve and the compressor discharge service valve as shown in Figure 44 Remove non condensibles 3 After ...

Page 140: ...and follow the steps listed below 1 Shut off the compressor and disconnect all electrical service to the compressor 2 Connect manifold gauge sets to the backseat ports of the suction and dis charge service valves and the Schrader valves on the oil filter cover plate 3 Frontseat the suction and discharge service valves Close the manual oil shutoff valve at the oil supply to the compressor 4 Recover...

Page 141: ...and cover plate gasket 10 Install a new copper gasket under the bolt head that had one at time of removal Replace all other bolts and tighten to 150 ft lbs 11 Energize the three solenoid valves on the compressor by jumpering the proper terminals at the UCM 12 Evacuate to 400 microns from the three ports in Step 2 and perform a rise test 13 De energize the three solenoid valves in Step 11 14 Open t...

Page 142: ...ge set Figure 46 Oil Pressure Drop 35 40 Ton Compressor Oil Filter Replacement Chart 0 2 4 6 8 10 12 14 16 18 20 50 100 150 200 250 300 Condensing Pressure Suction Pressure PSID Oil Filter Pressure Drop PSID Normal Pressur Drop Maximum Pressure Drop 50 60 Ton Compressor Oil Filter Replacement Chart 0 5 10 15 20 25 30 35 40 50 100 150 200 250 300 Condensing Pressure Suction Pressure PSID Oil Filter...

Page 143: ...gerant CAUTION Equipment Damage Water must be flowing through the tube bundles during this entire process Refrigerant pressures below 65 psig can cause freezing and rupturing of the heat exchangers 1 Connect 115 VAC power to the master solenoid the female load solenoid and the male load unload solenoids This must be done to evacuate all of the cavities in the compressor 2 Open all service valves 3...

Page 144: ...pdown enabled the Restart Inhibit will be ignored the EXV will be prepositioned and the selected compressor will start and run for one minute 5 Once the compressor stops close the discharge service valve on the compressor 6 The remaining refrigerant needs to be recovered from the suction service valve and the liquid line Schrader valve Attach the inlet of a recovery sys tem to the backseat port on...

Page 145: ... orator This will transfer the liquid refrigerant 6 Remove the liquid transfer pump Attach the inlet of a recovery system to the manifold gauge set and the outlet to the 1 4 angle valve located between the EXV and the evaporator Remove all of the vapor from the high side of the system 7 Complete all necessary repairs 8 Evacuate the high side through the access port on the liquid line service valve...

Page 146: ... The chilled water flow switch input was open for more than 6 seconds Compressor Overload Setting Cprsr A IFW The CPM NovRam Based overload setting did not agree with the MCSP Dip Switch overload setting for 30 contiguous seconds The affected MCSP shall use the minimum 00000 binary 00 decimal overload setting as a default until the UCM is reset when this diagnostic occurs Compressor Overload Setti...

Page 147: ...ant the display vectoring you to a different display state when you are trying to set either the chilled water setpoint or the leaving water temp cutout setpoint as it will in the case of a diagnostic Discharge Temp Cprsr A CMR a The discharge temp exceeded the trip value 135 or 3 C b The discharge temp PTC or wiring is open c Time to trip from either trip value exceeded or input open shall be 0 5...

Page 148: ...ected on Cprsr A trip at 405 or 7 PSIG High Pressure Cutout Cprsr B CMR A high pressure cutout was detected on Cprsr B trip at 405 or 7 PSIG High Pressure Cutout Cprsr C CMR A high pressure cutout was detected on Cprsr C trip at 405 or 7 PSIG High Pressure Cutout Cprsr D CMR A high pressure cutout was detected on Cprsr 0 trip at 405 or 7 PSIG Loss of Local Display Panel COM IFW The 1U1 has detecte...

Page 149: ...is operating on all Engineering ROM defaults for all setup parameters Check all setup parameters and continue to run chiller Replace the Chiller Module as soon as a replacement is available NOTE It is expected that this diagnostic will be detected on the very first power up of the Chiller Module at the Manufacturer since the NOVRAM will not contain valid data on first power up Memory Error Type II...

Page 150: ... Loss Cprsr A CMR No current was sensed on one or more of the current x former inputs Must hold 20 RLA Must trip 5 RLA Time to trip shall be 1 second minimum 3 seconds maximum Phase Loss Cprsr B CMR Same as Diagnostic for Cprsr A above Phase Loss Cprsr C CMR Same as Diagnostic for Cprsr A above Phase Loss Cprsr D CMR Same as Diagnostic for Cprsr A above Phase Reversal Cprsr A CMR A phase reversal ...

Page 151: ...r B CMR Same as Diagnostic for Cprsr A above Severe Phase Unbalance Cprsr C CMR Same as Diagnostic for Cprsr A above Severe Phase Unbalance Cprsr D CMR Same as Diagnostic for Cprsr A above Slaved EXV E1ec Drive CKT Rfgt Ckt 1 CMR Run the EXV electrical drive circuit test both on demand from the human interface and just before either a circuit or one of a pair of circuits starts Slaved EXV Elec Dri...

Page 152: ...of IPC comm from the 1U6 module U1 Indicating U7 Communications CMR The 1U1 has det a loss of IPC comm from the 1U7 module U3 Indicating U1 Communications MMR The 1U3 has det a loss of IPC comm from the 1U1 module U3 Indicating U4 Communications CMR The 1U3 has det a loss of IPC comm from the 1U4 module U3 Indicating U5 Communications CMR The 1U3 has det a loss of IPC comm from the 1U5 module U3 I...

Page 153: ...et Selected IFW Open or Short a Use end of range value whatever value the open or short gives b Clear diag when the resistance returns to normal range c If Shorted go into the ice making mode if Ice Machine Control is enabled Zone Temp Sensor Zone Reset not Selected None a If Open do normal chiller control b If Shorted go into the ice making mode if Ice Machine Control is enabled Table 28 Diagnost...

Page 154: ...154 RLC SVX07A EN Diagnostics ...

Page 155: ...cular chiller always refer to the nameplates mounted on the unit See Figure 1 Table 29 Legend Drawing Number Description Page RTWA 2307 3332 Schematic Page 1 page 156 2307 3333 Schematic Page 2 page 158 2307 3334 Schematic Page 3 page 160 2307 3335 Schematic Page 4 page 162 2307 3336 Field Wiring Diagram page 164 2307 5119 Component Location Diagram page 166 RTUA 2307 5143 Schematic Page 1 page 16...

Page 156: ...156 RLC SVX07A EN 3332 ...

Page 157: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 158: ...158 RLC SVX07A EN 3333 ...

Page 159: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 160: ...160 RLC SVX07A EN 3334 ...

Page 161: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 162: ...162 RLC SVX07A EN 3335 ...

Page 163: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 164: ...164 RLC SVX07A EN 3336 ...

Page 165: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 166: ...166 RLC SVX07A EN 5119 ...

Page 167: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 168: ...168 RLC SVX07A EN 5143 ...

Page 169: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 170: ...170 RLC SVX07A EN 5144 ...

Page 171: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 172: ...172 RLC SVX07A EN 5145 ...

Page 173: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 174: ...174 RLC SVX07A EN 5146 ...

Page 175: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 176: ...176 RLC SVX07A EN 6008 ...

Page 177: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 178: ...178 RLC SVX07A EN 6009 ...

Page 179: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 180: ...180 RLC SVX07A EN 5147 ...

Page 181: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 182: ...182 RLC SVX07A EN 6526 ...

Page 183: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 184: ...184 RLC SVX07A EN 5150 ...

Page 185: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 186: ...186 RLC SVX07A EN 6010 ...

Page 187: ...RAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY REVISION DATE DATE REV 2D CAD REPLACES FILE NUMBER DRAWING NUMBER SIMILAR TO DRAWN BY ...

Page 188: ...ians should perform the installation and servicing of equipment referred to in this bulletin Literature Order Number RLC SVX07A EN File Number SV RF RLC SVX07A EN 1005 Supersedes RTWA IOM 1A Stocking Location Inland Trane A business of American Standard Companies www trane com For more information contact your local district office or e mail us at comfort trane com ...

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