Trane RTUD Installation Operation & Maintenance Download

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RLC-SVX14H-GB

Series R™ Helical Rotary Water-Cooled Liquid
and Compressor Chillers
Models RTWD (R134a-R1234ze) and RTUD (R134a)

Installation

Operation

Maintenance

Original instruction

Summary of Contents for RTUD

Page 1: ...RLC SVX14H GB Series R Helical Rotary Water Cooled Liquid and Compressor Chillers Models RTWD R134a R1234ze and RTUD R134a Installation Operation Maintenance Original instruction...

Page 2: ...es 25 Condenser Piping 27 Water Regulating Valve 27 Relief Valves 29 Refrigerant Relief Valve Venting 29 Split system installation 30 RTUD Installation 30 Condenser Above the Compressor Chiller 31 Sys...

Page 3: ...General RTUD 71 Refrigeration Cooling Cycle 73 Oil System Operation RTWD RTUD 76 RTWD Operating map 78 Pre Start Checkout 79 RTWD HSE version 79 Start up 83 Service and Maintenance 84 Overview 84 Main...

Page 4: ...el 4 To avoid any risk it is recommended to place the unit on an area with restricted access Reception On arrival inspect the unit before signing the delivery note Specify any visible damage on the de...

Page 5: ...aintenance which reduces the cost of owning the unit by avoiding serious and costly breakdown Unit Description The RTWD units are helical rotary type water cooled liquid chillers designed for installa...

Page 6: ...Vessel Code 5 PED 6 DLI Digit 15 Unit Application A Std Condenser 35 C Entering Water Temperature RTWD only B High Temperature Condenser 35 C Entering Water Temperature RTWD only C Water to Water Hea...

Page 7: ...ter Current Limit Setpoint 4 20 mA B External Water Current Limit Setpoint 2 10 Vdc Digit 31 Ice Making 0 No Ice Making A Ice Making with Relay B Ice Making without Relay Digit 32 Programmable Relays...

Page 8: ...R134a 1 Nitrogen charge for R134a field charged Z R1234ze Y Nitrogen charge for R1234ze field charged Digit 46 Base Rail Forklifting 0 No Base Rail Forklifting B Base Rail Forklifting Digit 47 Label a...

Page 9: ...40 4 44 2 49 9 55 0 Nominal water connection size Grooved coupling in mm 6 168 3 mm 6 168 3 mm 6 168 3 mm 6 168 3 mm Dimensions 4 Unit Length mm 3490 3490 3490 3490 Unit Width mm 1310 1310 1310 1310 U...

Page 10: ...um l s 5 4 5 4 6 6 7 3 8 1 8 1 9 1 Cond Water Flow rate Maximum l s 19 9 19 9 24 4 26 9 29 8 29 8 33 2 Nominal water connection size Grooved coupling in mm 5 1 139 7 mm 5 1 139 7 mm 5 1 139 7 mm 5 1 1...

Page 11: ...nser Cond Water Flow rate Minimum l s 10 11 12 13 15 4 15 4 18 Cond Water Flow rate Maximum l s 37 40 44 48 56 4 56 4 65 9 Nominal water connection size Grooved coupling in mm DN150 6 168 3 mm DN150 6...

Page 12: ...l water connection size Grooved coupling in mm 6 168 3 6 168 3 6 168 3 Dimensions 4 Unit Length mm 3830 3830 3490 Unit Width mm 1280 1310 1310 Unit Height mm 2010 2010 2010 Weights 5 Shipping Weight k...

Page 13: ...condenser Cond Water Flow rate Minimum l s 5 4 5 4 6 6 7 3 8 1 8 1 9 1 10 0 Cond Water Flow rate Maximum l s 19 9 19 9 24 4 26 9 29 8 29 8 33 2 36 7 Nominal water connection size Grooved coupling in m...

Page 14: ...3 Two pass condenser Cond Water Flow rate Minimum l s 10 9 5 4 5 4 6 6 15 4 18 0 15 4 18 0 Cond Water Flow rate Maximum l s 39 9 19 9 19 9 24 4 56 4 65 9 56 4 65 9 Nominal water connection size Groov...

Page 15: ...3 8 1 3 8 Dimensions 3 Unit Length mm 3320 3320 3320 3320 3320 3320 3320 3400 Unit Width mm 1070 1070 1070 1070 1070 1070 1070 1280 Unit Height mm 1960 1960 1960 1960 1960 1960 1960 1950 Weights 4 Sh...

Page 16: ...1 3 8 1 3 8 1 3 8 1 3 8 1 5 8 1 3 8 1 3 8 1 3 8 1 5 8 1 5 8 1 5 8 Dimensions 3 Unit Length mm 3400 3400 3490 3400 3490 3490 3490 3490 Unit Width mm 1280 1280 1310 1280 1310 1310 1310 1310 Unit Height...

Page 17: ...Flow rate Maximum l s 47 6 47 6 47 6 47 6 56 5 56 5 Nominal water connection size Grooved coupling in mm 6 168 3 mm 6 168 3 mm 6 168 3 mm 6 168 3 mm 6 168 3 mm 6 168 3 mm Dimensions 4 Unit Length mm 3...

Page 18: ...0 5 Cond Water Flow rate Maximum l s 56 5 56 5 75 3 75 3 75 3 Nominal water connection size Grooved coupling in mm 6 168 3 mm 6 168 3 mm 6 168 3 mm 6 168 3 mm 6 168 3 mm Dimensions 4 Unit Length mm 38...

Page 19: ...13 13 15 15 15 Cond Water Flow rate Maximum l s 48 48 48 48 57 57 57 Nominal water connection size Grooved coupling in mm 6 168 3 mm 6 168 3 mm 6 168 3 mm 6 168 3 mm 6 168 3 mm 6 168 3 mm 6 168 3 mm D...

Page 20: ...Power cable gland plate for customer wiring 3 Tracer CH530 or DynaView 4 Suction line 5 Oil separator 6 Condenser water outlet 7 Condenser water inlet 8 Evaporator water outlet 9 Evaporator water inl...

Page 21: ...from the pressure relief to the atmosphere Start the unit under supervision of a qualified service technician Where specified supply and insulate the evaporator and any other portion of the unit as r...

Page 22: ...duit for electrical connections to the unit Isolate all pipe hangers and be sure they are not supported by main structure beams that could introduce vibration into occupied spaces Make sure that the p...

Page 23: ...ide concrete footings at each of the four unit mounting points Mount the unit directly to the concrete pads or footings Level the unit using the base rail as a reference The unit must be level within...

Page 24: ...tor at the return end Be sure to provide additional vents at high points in the piping to bleed air from the chilled water system Install necessary pressure gauges to monitor the entering and leaving...

Page 25: ...tor Damage For all RTWD RTUD units chilled water pumps MUST be controlled by the Trane CH530 to avoid catastrophic damage to the evaporator due to freezing Mount the switch upright on a horizontal por...

Page 26: ...E5AM2 11 E5AMJ 1 11 10 9 8 7 6 5 4 3 2 Select unit evaporator and limits according to General data table Figure 5 3 pass Evaporator Pressure Drop curves 10 0 100 0 1 0 10 0 100 0 Pressure Drop kPa Wat...

Page 27: ...bag in the control panel along with the evaporator drain plug The condenser drains may be connected to suitable drains to permit drainage during unit servicing If they are not the drain plugs must be...

Page 28: ...0 1 0 10 0 100 0 Pressure Drop kPa Water Flow l s Waterside Pressure Drop 50 Hz Units Condenser 1 C1AM2 2 C1AMJ 3 C2AM3 4 C2AM2 5 C2AMJ 6 C3AM2 C3AM3 7 C3AMJ C4AMJ 8 C4AM2 9 C5AM2 10 C5AM1 11 C5AMJ 1...

Page 29: ...25 bar CAUTION Equipment Damage To prevent capacity reduction and relief valve damage do not exceed vent piping code specifications RTWD relief valve discharge setpoints are 21 bar rel Once the relief...

Page 30: ...n releasing nitrogen holding charge ventilate the room Avoid breathing in the nitrogen Application examples No Elevation Difference Figure 8 No Elevation Difference RESTRICTIONS Total distance between...

Page 31: ...CTIONS Total distance between components should not exceed 61 m actual or 91 m equivalent Elevation difference greater than 30 m actual will result in at least a 2 efficiency decrease Inverted Trap He...

Page 32: ...ne the appropriate size for field installed liquid and discharge lines it is first necessary to establish the equivalent length of pipe for each line including the added flow resistance of elbows valv...

Page 33: ...t adds to the overall refrigerant volume of the circuit Note In case of power failure to the expansion valve the amount of liquid refrigerant contained in the refrigerant system must not exceed the ho...

Page 34: ...nits The sensor is required as an important input to the condenser fan control algorithm as well as for the low outdoor air ambient lockout feature The temperature sensor probe is shipped separately i...

Page 35: ...circuit Fan staging provides the correct combination of fixed speed fan relay VFD relay to enable operation of the VFD and speed outputs to provide air flow control commanded by the fan algorithm run...

Page 36: ...e distance of the bottom of the condenser relative to the top of the evaporator Use a positive value for the condenser above the evaporator and a negative value for the condenser below the evaporator...

Page 37: ...n the environment The user must ensure that the other materials used in the environment are compatible This may require additional protection measures If electromagnetic disturbances are detected it s...

Page 38: ...erating conditions TNS IT TNC TT Standard Special Special Standard Differential protection should be suited for industrial machinery with current leak which can be higher than 500 mA several motors an...

Page 39: ...2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 Max Amps A 257 0 233 7 257 0 369 0 233 7 343 4 284 0 259 6 284 0 404 0 259 6 378 1 displacement power factor DPF 0 85 0 95 0 85 0 87 0 95 0 95 0 85 0 95 0 85 0...

Page 40: ...2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 3 0 2 0 2 0 Max Amps A 311 0 284 4 311 0 443 0 284 4 413 6 338 0 309 2 338 0 482 0 309 2 449 1 displacement power factor DPF 0 85 0 95 0 85 0 87 0 95 0 95 0 85 0 95...

Page 41: ...0 2 0 2 0 2 0 2 0 2 0 Max Amps A 88 0 88 0 134 0 108 0 108 0 156 0 123 0 123 0 176 0 138 0 138 0 displacement power factor DPF 0 89 0 89 0 91 0 85 0 85 0 92 0 87 0 87 0 91 0 88 0 88 short circuit with...

Page 42: ...2 0 2 0 2 0 2 0 2 0 Max Amps A 196 0 150 0 150 0 215 0 162 0 162 0 234 0 176 0 176 0 259 0 190 0 displacement power factor DPF 0 89 0 85 0 85 0 89 0 83 0 83 0 88 0 84 0 84 0 86 0 84 short circuit wit...

Page 43: ...iaires 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 Max Amps A 190 0 284 0 210 0 210 0 309 0 230 0 230 0 334 0 257 0 257 0 displacement power factor DPF 0 84 0 85 0 84 0 84 0 86 0 84 0 84 0 86 0 85 0 85 sh...

Page 44: ...ctl auxiliaires 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 Max Amps A 369 0 284 0 284 0 404 0 311 0 311 0 443 0 338 0 338 0 482 0 displacement power factor DPF 0 87 0 85 0 85 0 87 0 85 0 85 0 87 0 85 0...

Page 45: ...mps ctl auxiliaires 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 Max Amps A 230 0 207 7 230 0 207 7 308 7 334 0 257 0 233 7 displacement power factor DPF 0 84 0 95 0 84 0 95 0 95 0 86 0 85 0 95 short circuit withs...

Page 46: ...6 378 1 Amps ctl auxiliaires 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 Max Amps A 257 0 233 7 343 4 284 0 259 6 284 0 259 6 378 1 displacement power factor DPF 0 85 0 95 0 95 0 85 0 95 0 85 0 95 0 95 short cir...

Page 47: ...A 84 2 84 2 131 3 99 3 99 3 154 9 114 9 114 9 171 6 130 5 130 5 188 4 displacement power factor DPF 0 950 0 950 0 950 0 950 0 950 0 950 0 950 0 950 0 950 0 950 0 950 0 950 short circuit withstand rati...

Page 48: ...ps A 137 6 137 6 204 8 144 6 144 6 221 2 158 3 158 3 240 8 172 0 172 0 260 3 displacement power factor DPF 0 950 0 950 0 950 0 950 0 950 0 950 0 950 0 950 0 950 0 950 0 950 0 950 short circuit withsta...

Page 49: ...2 0 2 0 2 0 2 0 2 0 2 0 Max Amps A 189 9 189 9 284 5 207 7 207 7 308 7 233 7 233 7 343 4 259 6 259 6 378 1 displacement power factor DPF 0 950 0 950 0 950 0 950 0 950 0 950 0 950 0 950 0 950 0 950 0...

Page 50: ...ires 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 Max Amps A 284 4 284 4 413 6 309 2 309 2 449 1 362 0 362 0 495 2 393 1 393 1 537 8 displacement power factor DPF 0 950 0 950 0 950 0 950 0 950 0 95...

Page 51: ...131 3 156 0 154 9 176 0 171 6 196 0 188 4 215 0 204 8 234 0 221 2 displacement power factor DPF 0 91 0 95 0 92 0 95 0 91 0 95 0 89 0 95 0 89 0 95 0 88 0 95 short circuit withstand rating kA 35 35 35 3...

Page 52: ...2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 Max Amps A 259 0 240 8 284 0 260 3 309 0 284 5 369 0 343 4 334 0 308 7 404 0 378 1 displacement power factor DPF 0 86 0 95 0 85 0 95 0 86 0 95 0 87 0 95 0 86 0 95 0 87...

Page 53: ...2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 Max Amps A 369 0 343 4 443 0 413 6 404 0 378 1 443 0 413 6 482 0 449 1 495 2 537 8 displacement power factor DPF 0 87 0 95 0 87 0 95 0 87 0 95 0 87 0 95 0 87 0...

Page 54: ...0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 Max Amps A 160 0 160 0 240 0 177 0 177 0 263 0 194 0 194 0 286 0 207 0 207 0 displacement power factor DPF 0 84 0 84 0 89 0 84 0 84 0 88 0 84 0 84 0 88 0 84 0 84...

Page 55: ...l auxiliaires 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 Max Amps A 307 0 220 0 220 0 328 0 245 0 245 0 369 0 270 0 270 0 410 0 displacement power factor DPF 0 88 0 83 0 83 0 87 0 84 0 84 0 88 0 85 0 85...

Page 56: ...2 0 2 0 2 0 Max Amps A 147 7 147 7 228 4 164 8 164 8 250 1 181 8 181 8 271 8 195 8 195 8 displacement power factor DPF 0 95 0 95 0 95 0 95 0 95 0 95 0 95 0 95 0 95 0 95 0 95 short circuit withstand ra...

Page 57: ...2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 Max Amps A 307 4 209 7 209 7 343 1 229 9 229 9 375 6 250 1 250 1 408 2 276 4 displacement power factor DPF 0 95 0 95 0 95 0 95 0 95 0 95 0 95 0 95 0 95 0 95...

Page 58: ...5 324 5 509 0 346 2 346 2 544 6 Amps ctl auxiliaires 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 Max Amps A 276 4 440 7 302 8 302 8 473 3 324 5 324 5 509 0 346 2 346 2 544 6 displacement power factor...

Page 59: ...are shipped with the unit The installer must provide the following components if not ordered with the unit Power supply wiring in conduit for all field wired connections All control interconnecting wi...

Page 60: ...contact 5K9 AUX Connect the proving switch and auxiliary contact to 1A15 J3 1 and 1X4 1 Refer to the field wiring for details The auxiliary contact can be starter contactor auxiliary or any signal whi...

Page 61: ...relay is energized immediately If evaporator water flow is not established in 4 minutes and 15 sec the CH530 de energizes the EWP relay and generates a non latching diagnostic If flow returns e g som...

Page 62: ...cally clearing including diagnostics effecting the entire chiller This classification does not include informational diagnostics Chiller Limit Mode with a 20 minute filter This output is true whenever...

Page 63: ...liary control for a customer specified installed latching trip out When this customer furnished remote contact 5K24 is provided the chiller will run normally when the contact is closed When the contac...

Page 64: ...times Ice building shall be terminated either by opening the contact or based on the entering evaporator water temperature CH530 will not permit the ice building mode to be reentered until the unit h...

Page 65: ...Front Panel DynaView Current Limit Setpoint The TechView Service Tool must be used to set the input signal type from the factory default of 2 10 VDC to that of 4 20 mA current TechView must be also be...

Page 66: ...P provides a menu item for the operator to select a Constant Return Reset Constant Return Reset will reset the leaving water temperature set point so as to provide a constant entering water temperatur...

Page 67: ...etting is replaced by the Software High Pressure Cutout setting The Software HPC is a configuration setting and is defined as an absolute pressure its inherent units is Kpa abs For multiple circuit ch...

Page 68: ...circuits have at least one pressure transducer invalid then output shall 1 0 VDC per the table below but if only one circuit has an invalid pressure transducer the opposite circuit s DP value shall be...

Page 69: ...wisted pair wiring Belden 8760 or equivalent See the table below for wire size selection Table 23 Wire size Maximum Length of Communication Wire 2 5 mm 1525 m 1 5 mm 610 m 1 0 mm 305 m The communicati...

Page 70: ...emp_p Entering Chilled Water Temperature analog temperature SNVT_temp_p Leaving Condenser Water Temperature analog temperature SNVT_temp_p Entering Condenser Water Temperature analog temperature SNVT_...

Page 71: ...r Related interconnecting piping Components of a typical RTUD unit are identified in the following diagram WARNING Contains Refrigerant System contains oil and refrigerant under high pressure Recover...

Page 72: ...nts back view 1 Circuit 1 2 Circuit 2 A Discharge service valve B Compressor junction box C Filter D Liquid level sensor E Oil cooler application dependant F Gas pump behind frame G Baserail for forkl...

Page 73: ...the tubes For RTUD units condensing is accomplished in a remote air cooled condenser unit The refrigerant flows through the tubes in the condenser Air flows over the coils in the condenser removing t...

Page 74: ...e condenser tube bundle Cooling tower water circulating through the condenser tubes absorbs heat from this refrigerant and condenses it For RTUD units airflows across the condenser coils absorbing hea...

Page 75: ...TWD only 15 Condenser Leaving Water Temp Sensor RTWD only 16 Condenser Water Flow Switch RTWD only 17 Evaporator circuit 2 18 Evaporator circuit 1 19 EXV circuit 2 20 EXV circuit 1 21 Liquid Level Sen...

Page 76: ...the oil charge in the separator and oil cooler during off periods The master oil valve is a pressure activated valve Discharge pressure off the rotors that is developed when the compressor is on cause...

Page 77: ...sor Bearing Oil Supply Oil is injected into the bearing housings located at each end of both the male and female rotors Each bearing housing is vented to compressor suction so that oil leaving the bea...

Page 78: ...RLC SVX14H GB 78 RTWD Operating map...

Page 79: ...ectrical panel However for any intervention in the AFD the indicated time on the label of the AFD must be respected CAUTION Compressor Damage Do not operate the unit with the compressor oil discharge...

Page 80: ...n 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 conden...

Page 81: ...e alternator When rotation is clockwise phase sequence is usually called ABC when counterclockwise CBA This direction may be reversed outside the alternator by interchanging any two of the line wires...

Page 82: ...values 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...

Page 83: ...the two sides of the restriction Frost will often form on the line at this point Proper refrigerant charges are shown in the General Data tables Note Important A clear sight glass alone does not mean...

Page 84: ...n the electrical panel of the unit once the AFD is off confirmed by the extinction of the display it is mandatory to wait one minute before working on the electrical panel However for any intervention...

Page 85: ...Refer to Maintenance Procedures Routine oil changing is not necessary on a hermetic system Have a qualified laboratory perform an oil analysis to determine system moisture content and acid level Note...

Page 86: ...g Procedure Mechanical tube cleaning method is used to remove sludge and loose material from smooth bore condenser tubes WARNING Heavy Objects Each of the individual cables chains or slings used to li...

Page 87: ...ght of the waterbox Reference Tables 30 and 31 for waterbox weights 2 Ensure the lift connection device has the correct connection for the waterbox Example thread type course fine English metric Bolt...

Page 88: ...with clean water Note To clean internally enhanced tubes use a bi directional brush or consult a qualified service organization for recommendations Reassembly Once service is complete the waterbox sh...

Page 89: ...29 M12 x 1 75 RTUD 160 170 190 SE Supply 2 or 3 29 M12 x 1 75 RTUD 160 170 190 SE Return 3 29 M12 x 1 75 RTWD 160 180 200 PE HSE Supply 2 or 3 37 M12 x 1 75 RTWD RTUD 200 HE Supply 2 or 3 37 M12 x 1 7...

Page 90: ...general data tables Note Use an oil transfer pump to change the oil regardless of chiller pressure Table 32 POE Oil Properties Description Acceptable levels Moisture content Less than 300 ppm Acid le...

Page 91: ...ering the oil the charging valve connection must be air tight 4 Open the service valve and pump in the required amount of oil Note Adding oil at the oil charging port ensures that the oil filter cavit...

Page 92: ...frigerant charge is essential for proper unit operation unit performance and environmental protection Only trained and licensed service personnel should service the chiller Some symptoms of a refriger...

Page 93: ...ated by a temperature gradient across the filter corresponding to a pressure drop If the temperature downstream of the filter is 2 2 C lower than the upstream temperature the filter should be replaced...

Page 94: ...xx 9 x x x x x xxx 10 x x x x x xxx x over 10 every year every year every year 2 x every year 3 every year every 3 years 40000 h This timetable is applicable to units operating in normal conditions wi...

Page 95: ...iod designated The inspections will be conducted at agreed upon intervals and Trane Service First will submit a written report to the customer after each inspection These reports will indicate any cor...

Page 96: ...gersoll Rand the leader in creating and sustaining safe comfortable and energy efficient environments Trane offers a broad portfolio of advanced controls and HVAC systems comprehensive building servic...

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