Trane RAUC-C20 Installation Operation & Maintenance Download Page 1

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June 2008

SS-SVX09A-EN

Installation
Operation
Maintenance

Remote Split System Units

Air Cooled Condensing Units and EVP Chillers

Models
“V” and Later Design Sequence
RAUC-C20

RAUC-C40

RAUC-C25

RAUC-C50

RAUC-C30

RAUC-C60

Summary of Contents for RAUC-C20

Page 1: ...SS SVX09A EN Installation Operation Maintenance Remote Split System Units Air Cooled Condensing Units and EVP Chillers Models V and Later Design Sequence RAUC C20 RAUC C40 RAUC C25 RAUC C50 RAUC C30...

Page 2: ...equirements for handling reclaiming recovering and recycling of certain refrigerants and the equipment that is used in these service procedures In addition some states or municipalities may have addit...

Page 3: ...ial Comfort Cooling Applications 37 Optional Pressure Gauges 37 Final Refrigerant Pipe Connections 37 Brazing Procedures 38 Leak Testing Procedure 39 Chilled Water Piping 40 Final Water Piping Connect...

Page 4: ...Control Checkout 78 Zone Thermostat Checkout Honeywell T7067 79 Discharge Air Sensor Checkout Honeywell 6RT1 80 Voltage Imbalance 82 Electrical Phasing 82 System Start Up 83 Sequence of Operation 83 L...

Page 5: ...replacement parts or requesting service be sure to refer to the specific model number serial number and DL number if applicable stamped on the unit nameplate Compressor Nameplate The nameplate for th...

Page 6: ...pper fin coils are optional Louvered condenser grilles for coil protection are standard Direct drive vertical discharge condenser fans are provided with built in current and overload protection For Sh...

Page 7: ...mage is discovered notify the carrier s terminal of damage immediately by phone and by mail Concealed damage must be reported within 15 days Request an immediate joint inspection of the damage by the...

Page 8: ...alled at ground level elevate it above the snow line Provide concrete footings at each support location or a slab foundation for support Refer to Table 1 for the unit operating and point loading weigh...

Page 9: ...SS SVX09A EN 9 Installation Figure 2 Typical Installation Clearances for Single Multiple or Pit Applications...

Page 10: ...10 SS SVX09A EN Installation Figure 3 RAUC C20 Unit Dimensional Data Recommended Clearances...

Page 11: ...SS SVX09A EN 11 Installation Figure 4 RAUC C25 Unit Dimensional Data Recommended Clearances...

Page 12: ...12 SS SVX09A EN Installation Figure 5 RAUC C30 Unit Dimensional Data Recommended Clearances...

Page 13: ...SS SVX09A EN 13 Installation Figure 6 RAUC C40 Unit Dimensional Data Recommended Clearances...

Page 14: ...14 SS SVX09A EN Installation Figure 7 RAUC C50 Unit Dimensional Data Recommended Clearances...

Page 15: ...SS SVX09A EN 15 Installation Figure 8 RAUC C60 Unit Dimensional Data Recommended Clearances...

Page 16: ...Field provided vinyl tape is required to seal insulation edges after installation 6 752 8 084 17 670 6 440 3 331 2 431 23 432 1 130 ID 2 431 2 261 17 720 2 261 3 451 FRONT VIEW W INSULATION SUCTION L...

Page 17: ...NG WATER LEAVING WATER 2X 2 00 2 138 ID SWAGELOK B 4 P 1 4 NPT MALE PIPE PLUG OR EQUIVELENT FIELD PROVIDED Evaporator mounting brackets and insulation are provided with Chiller BPHE Accessory for fiel...

Page 18: ...LIQUID SWAGELOK B 4 P 1 4 NPT MALE PIPE PLUG OR EQUIVALENT FIELD PROVIDED ENTERING WATER LEAVING WATER 2X 2 00 Evaporator mounting brackets and insulation are provided with Chiller BPHE Accessory for...

Page 19: ...SUCTION CIR 2 LIQUID CIR 2 1 660 ID X 2 ENTERING WATER LEAVING WATER 3 00 X 2 SWAGELOK B 4 P 1 4 NPT MALE PIPE PLUG OR EQUIVALENT FIELD PROVIDED Evaporator mounting brackets and insulation are provide...

Page 20: ...SUCTION CIR 2 LIQUID CIR 2 2 138 ID X 2 ENTERING WATER LEAVING WATER 3 00 X 2 SWAGELOK B 4 P 1 4 NPT MALE PIPE PLUG OR EQUIVALENT FIELD PROVIDED Evaporator mounting brackets and insulation are provide...

Page 21: ...N CIR 2 LIQUID CIR 2 2 138 ID X 2 ENTERING WATER LEAVING WATER 3 00 X 2 12 732 SWAGELOK B 4 P 1 4 NPT MALE PIPE PLUG OR EQUIVALENT FIELD PROVIDED Evaporator mounting brackets and insulation are provid...

Page 22: ...in point loading illustration Table 2 Typical EVP Chiller Weights General Data Chiller Size Shipping Weight2 Operating Weight Number of Ref Ckts Water Volume in Gallons3 Refrigerant Charge in Lbs 4 20...

Page 23: ...tructions located inside the central panel for further rigging information A Rigging illustration and Center of Gravity dimensional data table is shown in Figure 15 Refer to the typical unit operating...

Page 24: ...allow access to the mounting holes in the base of the isolator then tighten securely 4 Lower the unit and isolator onto the mounting surface The maximum isolator deflection should be approximately 1...

Page 25: ...h A clearance greater than 1 2 inch indicates that shims are required to level the unit Refer to the Leveling the Unit section 5 Make minor clearance adjustments by turning the isolator leveling bolt...

Page 26: ...bly 4 Do not remove the shipping plate located on top of the compressors 5 Ensure that the compressor rail assembly is free to move on the rubber isolators Unit Tons Spring Isolator Part Number Mounti...

Page 27: ...line s between the liquid line connections on the unit and the evaporator i e DX evaporator or an EVP Chiller Refer to the Refrigerant Piping section for recommended line components and guidelines Ins...

Page 28: ...ystem if applicable Note If using an acidic commercial flushing solution to prevent damage to the internal evaporator components flush all chilled solution piping before making the final connection to...

Page 29: ...m that shipped with the unit Install the interlock circuitry wiring for the air handling unit or the chilled solution pump to permit compressor operation after the fan or chilled solution pump has sta...

Page 30: ...result in death or serious injuries WARNING Grounding Required Follow proper local and state electrical code on requirements for grounding Failure to follow code could result in death or serious inju...

Page 31: ...d solution temperature controller with shielded cable Install the proper staging resistor onto the chilled solution temperature controller Constant Volume Units Install the zone thermostat with or wit...

Page 32: ...loading conditions and to compensate for pressure drops between the expansion valve and superheat control point evaporator refrigerant outlet In order to get proper refrigerant distribution into the c...

Page 33: ...rostatTM Required for coil freeze protection 11 Expansion Valve One Expansion Valve for each Coil Distributor 12 Evaporator Coil Table 6 Solenoid Valve Sight Glass w Moisture Indicator Capacity Soleno...

Page 34: ...for the vertical lifts The suction line size pre selected in the Table below are independent of the line length for a properly charged RAUC unit operating in a normal air conditioning application For...

Page 35: ...or proper operation of the relief valve the liquid line service valve should not be in the back seated position but cracked open so the relief valve and the fan pressure switch is open to the condense...

Page 36: ...suction line as illustrated in Figure 19 and Figure 20 3 Secure the bulb to the suction line with two clamps provided by the manufacturer and insulate the bulb 4 Install the Frostat according to the i...

Page 37: ...ges and the necessary mounting hardware ship in the location illustrated in the Unit Component Layout and Shipwith Location The mounting location and tubing configuration for the optional pressure gau...

Page 38: ...th or serious injury or equipment or property only damage 1 When copper is heated in the presence of air Copper oxide forms To prevent copper oxide from forming inside the tubing during brazing sweep...

Page 39: ...procedures require working with refrigerant Do NOT release refrigerant to the atmosphere The service technician must comply with all federal state and local laws Refer to general service bulletin MSCU...

Page 40: ...es sizes and locations are shown in Figure 9 to Figure 14 Refer to the operating GPM parameters listed in Figure 21 when determining flow and piping requirements Figure 22 illustrates the typical wate...

Page 41: ...SS SVX09A EN 41 Installation Note Factor to convert Feet of Water to Lbs per Sq Inch PSI 2 3 Feet of Water 1 PSI Figure 21 Evaporator Water Pressure Drop...

Page 42: ...s Chiller Drain The chiller drain should be piped to a suitable drain facility to facilitate evaporator draining during service or shutdown procedures Provide a shutoff valve in the drain line Note Th...

Page 43: ...ocated within the remote panel is equipped with a remote Sensing Bulb and 20 feet of capillary tube The Remote Sensing Bulb must be installed by the installing personnel Thermal paste is also provided...

Page 44: ...the system should be flushed thoroughly before making the final connections NOTICE If an acidic commercial flushing solution is used construct a temporary bypass around the EVP chiller to prevent dam...

Page 45: ...witch External Handle Factory Mounted Option Units ordered with the factory mounted nonfused disconnect switch comes equipped with an externally mounted handle This allows the operator to disconnect p...

Page 46: ...e Power Wire Sizing Protection Device Equations for determining a the appropriate electrical service wire size based on Minimum Circuit Ampacity MCA b the Maximum Over current Protection MOP device c...

Page 47: ...THER LOAD RATED AT 1 AMP OR MORE Calculation 1 MCA MOP and RDE MCA 1 25 x LOAD 1 LOAD 2 LOAD 4 MOP 2 25 x LOAD 1 LOAD 2 LOAD 4 Select a fuse rating equal to the MOP value If the MOP value does not equ...

Page 48: ...5 _ 409 0 _ 15 9 RAUC C30F 230 60 3XL 208 254 148 200 175 0 90 3 1 0 4 1 20 7 2 _ 60 5 _ 376 0 _ 15 9 RAUC C304 460 60 3XL 416 508 65 90 80 0 90 3 1 0 1 8 9 0 2 _ 26 3 _ 178 0 _ 15 5 RAUC C305 575 60...

Page 49: ...Install appropriately sized 115 volt control wiring for the electrical components as required by the application These components may include hot gas bypass solenoid wiring supply fan interlock and c...

Page 50: ...ound connection screws provided within both the remote panel and the unit s control panel EVP Circulating Pump Interlock Pump operation and sequence is the responsibility of the installer During compr...

Page 51: ...orts and miswiring 4 Do not run the AC low voltage wiring in the same conduit with the high voltage power wiring Typical Low voltage components may include zone thermostat wiring AC DC wiring system c...

Page 52: ...the wiring between the binary controls and the unit s termination point does not exceed two and a half 2 5 ohms conductor for the length of the run 4 Do not run the electrical wires transporting DC s...

Page 53: ...EVP Chiller applications WARNING Hazardous Voltage Disconnect all electric power including remote disconnects before servicing Follow proper lockout tagout procedures to ensure the power can not be i...

Page 54: ...54 SS SVX09A EN Installation Refer to Wiring Notes on p 55 Figure 25 Field Connection Diagram or RAUC C20 C60 No System Controls Applications...

Page 55: ...SS SVX09A EN 55 Installation Field Connection Diagram Notes for all System Control Options...

Page 56: ...in a turbulent free area of the discharge air duct at a location that will provide accurate supply air sensing Refer to the illustration in Figure 26 for installation and sensor dimensional informati...

Page 57: ...to Figure 3 to Figure 8 for the electrical access locations provided on the unit Wire the suction line thermostat in accordance with the field connection diagram in Figure 27 Refer to Table 9 AC Condu...

Page 58: ...ter temperature sensor was discussed in the Chilled Water Piping section Refer to that section for their installation locations and dimensional data The chiller control located in the remote panel con...

Page 59: ...0 ohm resistive jumper is required for two 2 stage operation on 20 through 30 Ton units If the unit is a 20 25 or 30 Ton unit locate the bag that is secured to the controller and discard it WARNING Ha...

Page 60: ...or the final cable termination points WARNING Ground Wire All field installed wiring must be completed by qualified personnel All field installed wiring must comply with NEC and applicable local codes...

Page 61: ...er indicates the system is designed for low ambient operation of 0 F and above Therefore select a thermostat with the appropriate operating range based on the unit specifications WARNING Hazardous Vol...

Page 62: ...62 SS SVX09A EN Installation Refer to Wiring Notes on Page p 55 Figure 29 Field Connection Diagram for RAUC C20 60 EVP Chiller Applications...

Page 63: ...rea Do not mount the thermostat where its sensing element may be affected by a Drafts or dead spots behind doors or in corners b Hot or cold air from ducts c Radiant heat from the sun or from applianc...

Page 64: ...64 SS SVX09A EN Installation Figure 30 T7067 Electronic Zone Thermostat Q667 Switching Subbase Figure 31 Q667 Switching Subbase T7067 Thermostat Terminal Identification...

Page 65: ...ring the sensor to the terminal board inside the unit s control panel When the sensor is installed it serves two functions 1 It sends the supply air temperature to the master energy controller MEC in...

Page 66: ...66 SS SVX09A EN Installation Refer to Wiring Notes on Page p 55 Figure 32 Field Connection Diagram for RAUC C20 through 60 Constant volume Applications...

Page 67: ...SS SVX09A EN 67 Installation Figure 33 6RT1 Discharge Air Sensor Assembly...

Page 68: ...umulation in the liquid lines could result in compressor damage Verify that all compressor service valves discharge service valves and liquid line service valves is back seated on each circuit COMPRES...

Page 69: ...uld be copper and of the largest diameter that can practically be used Using larger line sizes with minimum flow resistance can significantly reduce evacuation time Rubber or synthetic hoses are not r...

Page 70: ...mately 15 minutes This is referred to as a standing vacuum test where time versus pressure rise The maximum allowable rise over a 15 minute period is 200 microns If the pressure rise is greater than 2...

Page 71: ...TOL 0101 or Honeywell part 4074EDJ 1 Turn all control switches to the OFF position to deactivate the Evaporator Fan and the Mechanical Cooling 2 Turn the main power disconnect switch for the evaporat...

Page 72: ...egin to illuminate as the cooling outputs stage On 11 At the Discharge Air Controller use a digital voltmeter to verify there is 24 volts AC across terminals TR TR 12 Set the Setpoint F dial at 64 F w...

Page 73: ...W7100 Terminals R to Y 226 ohms 23 Reconnect the economizer leads R B W Y to the appropriate terminals on the controller 24 Turn the control circuit switch 1S2 in the unit control panel and the main p...

Page 74: ...owing procedures should be used to verify that the field provided economizer actuator s function properly These procedures are based on using a typical Honeywell actuator If another type actuator is u...

Page 75: ...oller 6U11 inside the remote panel disconnect the sensor 6RT2 leads form Terminals T T1 4 Remove the 3 400 ohm resistor blue leads from the test kit and connect it across Terminals T and T1 to simulat...

Page 76: ...illuminate as the cooling outputs stage On 13 Set the Setpoint F dial at 60 F within 15 seconds the LEDs should turn Off as the cooling outputs stage Off 14 Remove the 1780 ohm resistor from Terminal...

Page 77: ...l T1 Use a digital ohmmeter to measure the resistance across terminal T and the wire removed from terminal T1 3 Use the conversion chart in Figure 37 to convert the measured resistance to an equivalen...

Page 78: ...hen performing service procedures with the electrical power energized 5 At the Master Energy Controller use a digital voltmeter to verify that there is 20 volts DC power between terminals 1 N 2 20 Ref...

Page 79: ...trocution it is the responsibility of the technician to recognize this hazard and use extreme care when performing service procedures with the electrical power energized 3 At the Zone Thermostat 6U37...

Page 80: ...ance in step 2 is not within 10 0 ohms of the actual temperature the 6RT1 is out of range replace it Note Before condemning the sensor verify that the connecting cable resistance is not excessive Refe...

Page 81: ...vs Resistance Curve Figure 40 W973 Master Energy Controller MEC 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 55 60 65 70 75 80 85 90 95 100 105 Temperature Degr...

Page 82: ...be quickly determined and corrected before starting the unit by using an instrument such as an Associated Research Model 45 Phase Sequence Indicator and following the steps below Turn the field suppl...

Page 83: ...omizer algorithm within the W7100A is the response time of the controller The greater the amount of deviation between the discharge air temperature and the economizer control point i e as the temperat...

Page 84: ...reases below the lower control band the last stage that was turned On will be cycled Off Point C when the minimum On time for that stage has elapsed As the load on the water increases due to cooling s...

Page 85: ...rcuit 1 first step condenser fans 2B1 2B2 and 2B3 are held Off by the liquid line pressure switch 4S11 and normally open interlock contacts 1K5 1K6 Once the pressure switch has closed 275 psig condens...

Page 86: ...h compressor is equipped with a crankcase heater and is controlled by a 600 volt auxiliary switch on the compressor contactor The proper operation of the crankcase heater is important to maintain an e...

Page 87: ...ions For field installation mount the dampers over the condenser fans at the locations shown in Figure 43 and connect the actuator controller and sensor for each circuit Refer to the Installation Inst...

Page 88: ...re drop and adjust the flow if necessary Refer to the appropriate EVP chiller size in Figure 44 for the operating pressure drop Freezestat Setting At the remote panel set the freezestat at a minimum o...

Page 89: ...r or contactor 6 After all adjustments have been made restart the supply fan and proceed through the following procedures System Airflow Measurement Much of the systems performance and reliability is...

Page 90: ...before continuing NOTICE Compressor Damage could occur if the crankcase heater is not allowed to operate the minimum 8 hours before starting the compressor s 3 Attach a set of service gauges onto the...

Page 91: ...tch that provides power to the condensing unit to the Off position Lock the disconnect switch in the open position while working at the unit ii Interchange any two of the field connected main power wi...

Page 92: ...After securing the sensor to the line insulate the sensor and line to isolate it from the ambient air Note Glass thermometers do not have sufficient contact area to give an accurate reading c Determin...

Page 93: ...42 without substitution The appropriate 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 Compressor Crankcase Heaters 9 and 10 ton scr...

Page 94: ...Circuit 1 Circuit 2 20 1 A 50 2 A B 100 25 1 B 40 2 A B 100 30 1 A 50 2 A B 100 40 1 A 50 2 A 50 C 50 3 A 50 C D 100 4 A B 100 C D 100 50 1 A 61 2 A 61 C 61 3 A 61 C D 100 4 A B 100 C D 100 60 1 A 50...

Page 95: ...SS SVX09A EN 95 System Start Up Figure 45 Typical Compressor Locations Figure 46 Typical Compressor Terminal Block...

Page 96: ...96 SS SVX09A EN System Start Up Figure 47 20 Ton Pressure Curve...

Page 97: ...SS SVX09A EN 97 System Start Up Figure 48 25 Ton Pressure Curve...

Page 98: ...98 SS SVX09A EN System Start Up Figure 49 30Ton Pressure Curve...

Page 99: ...SS SVX09A EN 99 System Start Up Figure 50 40 Ton Pressure Curve per Circuit...

Page 100: ...100 SS SVX09A EN System Start Up Figure 51 50 Ton Pressure Curve per Circuit...

Page 101: ...SS SVX09A EN 101 System Start Up Figure 52 60 Ton Pressure Curve per Circuit...

Page 102: ...cuit switch 1S2 On The system will start automatically once a request for cooling has been given Verify that all exterior panels and the control panel doors are secured in place Table 17 Recommended O...

Page 103: ...ss Psig Liquid Press Psig Super heat F Subcool f Compr Oil level Suct Press Psig Disch Press Psig Liquid Press Psig Super heat F Subcool f ok Low ok Low ok Low ok Low ok Low ok Low ok Low ok Low ok Lo...

Page 104: ...e flow rate increases Scroll Compressor Replacement Table 19 lists the specific compressor electrical data and the circuit breaker operating ranges The compressor manifold system was purposely designe...

Page 105: ...9 41 4 269 0 50 4 58 0 230 9 41 4 251 0 50 4 58 0 460 9 18 1 117 0 22 0 25 3 575 9 14 4 94 0 17 5 20 2 380 415 9 17 2 110 0 20 9 24 1 200 14 60 5 404 0 73 7 84 7 230 14 60 5 376 0 73 7 84 7 460 14 26...

Page 106: ...plicable to ensure that all moving parts are securely mounted Clean the blades as necessary Verify that all damper linkages move freely lubricate with white grease if necessary Check Supply Fan motor...

Page 107: ...y burned or pitted replace the contactor Do not clean the contacts Check the compressor oil level Compressors Off Coil Cleaning Regular coil maintenance including annual cleaning enhances the unit s o...

Page 108: ...estore the unit to it s operational status and check system operation System operation Close the main power disconnect switch for the condensing unit and all system support equipment Turn all system c...

Page 109: ...shall not be obligated to pay for the cost of lost refrigerant No liability whatever shall attach to the Company until said products have been paid for and then said liability shall be limited to the...

Page 110: ...l Nameplate 6 Evaporator water inlet and outlet types 40 EVP Chiller Applications 68 88 EVP Chiller Considerations 7 EVP Chiller Control 58 EVP Circulating Pump Interlock 50 EVP Interlocks 50 Excessiv...

Page 111: ...lection Location 24 Typical Placement of Split System piping Components 33 Typical Spring Isolator Selec tion Location 26 Typical Unit Weights Point Loading Data 22 Typical Vacuum Pump Hookup 70 U Un...

Page 112: ...e or e mail us at comfort trane com Literature Order Number SS SVX09A EN Date June 2008 Supersedes RAUC IOM 14 June 2007 Trane has a policy of continuous product and product data improvement and reser...

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