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13.1

REFRIGERANT CHARGE

13.1.1 Refrigerant replacement procedure with unit stopped and in vacuum (refrigerant charge in

the liquid phase)

Open the shut off valve as far as possible so that it closes the service coupling. Connect the refrigerant cylinder to the

service coupling without tightening the coupling. Half close the liquid shut off valve. If the circuit has been dehydrated and

is in vacuum, charge the liquid by turning the cylinder upside down. Weigh and charge the appropriate quantity. Open the

valve completely. Start up the unit and leave it running at full charge for some minutes. Check that the indicator is clear

with no bubbles. Make sure that the transparency condition without bubbles is due to the liquid and not to the vapour.

Correct functioning of the unit allows for overheating of 4 - 7° C and sub cooling of 4 - 8°C. Values of overheating which

are too high may be caused by a lack of refrigerant, whereas high sub cooling values may mean an excess of charge. After

intervention on the charge, it is appropriate to check that the unit runs within the declared values: with unit steadily running

on a full charge, measure the temperature of the suction line downstream of the thermostatic valve bulb; read the balance

pressure to the evaporator on the low pressure manometer and the corresponding saturation temperature.

Overheating is equal to the difference between the temperatures measured in this way. Then measure the temperature of

the liquid line coming out of the condenser and read the balance pressure to the condenser on the high -pressure

manometer and the corresponding saturation temperature. The sub cooling is the difference between these temperatures.

Danger

While refrigerant is being added do not exclude any control system and let the water circulate in the evaporator to

avoid the formation of ice

Refrigerant charge in the liquid phase

Refrigerant circuit diagram connection to vacuum pump

High pressure

port

Low pressure

port

High pressure

gauge

Vacuum meter

Vacuum pump

Oil trap

Low

pressure

gauge

Liquid sight glass

HR port

LP port

HP gauge

Scale

LP gauge

Содержание RAUS 160-400

Страница 1: ...densing units Air cooled chillers and heat pumps condensing units with scroll compressors RAUS 160 400 Cooling capacity 56 3 140 kW RAUX 150 350 Cooling capacity 52 4 122 1 kW Heating capacity 55 8 130 9 kW July 2021 CG SVX053A GB Original instructions ...

Страница 2: ...OW TO SIZE REFRIGERANT LINES 12 8 LIQUID RECEIVER 21 9 REMOTE TERMINALS CONTROL AND EXPANSION VALVE 24 10 ELECTRICAL PANEL 25 11 OPERATOR RESPONSABILITIES 26 12 START UP PRELIMINARY PROCEDURES 26 13 CHECK LIST MANDATORY OPERATION CONTROL BEFORE START UP 27 14 MAINTENANCE 31 15 RECOMMENDED SPARE PARTS 34 16 TROUBLESHOOTING 35 17 IMPROPER USES 38 ...

Страница 3: ...ance of the above mentioned rules and of all the indications written on this manual will cause the immediate loss of warranty getting free TRANE from any responsibility for the unit and any damages to persons or things 1 3 RECEIVING THE UNIT On receiving the unit it is up to the customer to check that there is no obvious damage or pieces missing If this is so an immediate complaint must be made to...

Страница 4: ...s of a hinge do not touch the air condensation batteries without having first put on protective gloves do not remove the protections to the moving parts while the unit is running before restarting the unit make sure that the moving part protections are in the correct position 2 6 PREVENTION AGAINST RESIDUAL ELECTRICAL RISKS connect the unit to the mains in accordance with the provisions of this ma...

Страница 5: ...s been carried out for units which are located outside do not carry out interventions in dangerous atmospheric conditions such as rain snow fog etc The following precautions should also be taken at all times never dispose of fluids contained in the refrigerant circuit into the environment when replacing the electronic card always use appropriate equipment extractor anti static bracelet etc if a co...

Страница 6: ...ponents 3 2 OPERATING LIMITS RAUS RAUX unit operation is permitted within the limits indicated in the diagram provided in 3 3 CAUTION The operation outside the limits specified may cause the activation of the protections and disrupt the operation of the unit and in extreme cases damage the unit In case of doubt consult the factory These operating limits apply to unit operating at full load 3 3 OPE...

Страница 7: ...Page 7 OAT Outdoor Air Temperature C ET Evaporating Temperature C RAUX 150 350 CHILLER MODE ...

Страница 8: ...Page 8 OAT Outdoor Air Temperature C CT Condensing Temperature C RAUX 150 350 HEAT PUMP MODE ...

Страница 9: ... supporting structures fit shock absorbers in every fastening point Rubber shock absorbers are recommended for units installed on the ground spring shock absorbers for units installed on roofs Open spaces around the unit must be provided for in order to allow for the passage of necessary airflow and in order to allow normal maintenance to be carried out as shown on general catalogues IMPORTANT Mak...

Страница 10: ...des of the units Respect the safety distances as shown on the units dimensional drawings In case of presence of dominant winds in the installation area it is strictly necessary to avoid for units with horizontal flow fans that such winds blow in front of the unit fans discharge side In case of unit with vertical flow fans it is strictly necessary to avoid installations where the dominant winds cou...

Страница 11: ...IEC 60364 All wiring must comply with local code 6 1 POWER CONNECTIONS Protect the unit electric box power supply circuit with protection devices not included in the supplied equipment Connect the line terminals with a three core cable of a section which is appropriate to the machine absorption The switch and the fuses like all the power connections must comply with the regulations in force 6 2 IM...

Страница 12: ...tical feature in sizing the refrigerant lines The refrigerant speed inside the pipes and the pressure drop depend on the diameter Although it is advisable to limit as much as possible the pressure drop to reduce the loss of cooling capacity is important to ensure a velocity in the pipe to allow the oil carryover Generally the dimensioning of the suction line is made in order to maintain a speed hi...

Страница 13: ...ge line loss of load forces the compressor to work at a pressure that is higher than the actual condensation with effects equal to those previously analyzed In the following table the pressure drops effects on the cooling capacity are shown expressed in terms of temperature drops C on the suction and discharge lines Losses of load C Power output Power input 0 100 100 1 C suction 95 7 103 5 1 C dis...

Страница 14: ...ated in the column heading If different pressure drops are needed the cooling capacity shall be corrected with the following formula Where Pf cooling capacity P cooling capacity shown in table 1 Le equivalent length of the table 1 Leff actual equivalent length ΔT required pressure drop ΔTtab pressure drop shown in table 1 The equivalent length can be calculated as follows A fictitious length for e...

Страница 15: ...e the proper diameter in accordance to the requested cooling capacity and the evaluated pressure drops Once the choice is taken a check shall be made by calculating the real pressure drop using the following formula with symbols having the same meaning as in formula 1 In order to verify if the selected diameter could be correct the following maximum pressure drops shall be considered according to ...

Страница 16: ... capacity is lower than the cooling capacity supplied by the unit 30 kW the pipe diameter will be undersized The Δext 35 mm will then be chosen In order to verify if the choice is correct the total pressure drop must be calculated again by using the formula 2 Consequently having chosen Δext 35 mm only the P value will change as follows P 54 37x1 11 60 35 kW And then As shown the new total pressure...

Страница 17: ...30 40 50 Correction factor 1 08 0 91 0 82 Table 3 a Correction factors for different liquid temperature Table 4 Minimum capacity kW ensuring the oil flowing in vertical sections of the discharge line R410a In this case also the cooling capacity shown in table 4 refers to a saturated evaporating temperature equal to 5 C for different temperature values the capacity must be adjusted according to the...

Страница 18: ... a single line dimensioned in accordance to the maximum cooling capacity Between the two vertical sections a sump is realized The sump is sized in order to guarantee that at minimum loads it will be filled with oil closing the entrance to the line B The sump however must not contain excessive amounts of oil but it must have a minimum volumetric capacity When the cooling capacity grows the greater ...

Страница 19: ...d using check valves and making oil taps if the condenser is mounted at a higher level than the compressor On the liquid line it is important to avoid that non liquid refrigerant reaches the thermostatic valve This purpose is achieved by giving to the fluid a high subcooling in the condenser but a proper sized liquid receiver shall be installed upstream from the line in the case of high lengths ov...

Страница 20: ...e Temperature C 20 0 25 50 75 100 125 Expansion mm mt 0 0 4 0 7 1 1 1 5 1 9 2 3 These special couplings or U shaped or L shaped sections used to compensate the pipe expansion can be sized according to the following sketch Since this type of components may cause significant pressure drops their use must be carefully evaluated Supports shall be installed to support the pipes weight and shall be spac...

Страница 21: ...ork as condenser or as evaporator in accordance to the cycle The liquid receivers are installed on the refrigerant circuit and allow to store the charge difference between the two cycles The placement of the liquid receiver shall be evaluated depending on the capacity of the heat exchangers of the plant and those installed on board of the unit For example Capacity of the heat exchanger on board 10...

Страница 22: ...NSION VALVE C COMPRESSOR VS SIGHT GLASS PA HP PRESSURE KA HP TRANSDUCER PS SERVICE VALVE F FILTER MA HP GAUGE R SHUT OFF VALVE VA SAFETY VALVE Rliq LIQUID RECEIVER BCE EVAP COND COIL VL SOLENOID VALVE V FAN KB LP TRANSDUCER PB LP PRESSURE MB LP GAUGE CONNECTION BY THE CUSTOMER REFRIGERANT 410a RAUS 160 400 ...

Страница 23: ... BCE EVAP COND COIL V2 V3 CIRCUIT VALVE V FAN KB LP TRANSDUCER PB LP PRESSURE SWITCH VA LIQUID SAFETY VALVE OPTION MB LP GAUGE AA ACCUMULATOR VIC CYCLE INVERSION VALVE TSC COMPRESSOR DISCHARGE VEE ELECTRONIC EXPANSION Tair EXTERNAL AIR TEMPERATURE REFRIGERANT 410a Liquid receiver in heat pump mode Liquid receiver in chiller mode CONNECTION BY THE CUSTOMER CONNECTION BY THE CUSTOMER GAS LINE LIQUID...

Страница 24: ...receiver shall be placed in a location that ensure the proper filling during the operation in chiller mode and the proper emptiness during heat pump mode IMPORTANT The choice of the liquid receiver capacity and its placing is the responsibility of the designer of the plant 9 REMOTE TERMINALS CONTROL AND EXPANSION VALVE The units can be connected to hydronics or direct expansion terminals In both c...

Страница 25: ...ously the operation of the electrical resistors is ensured as long as the unit is power supplied The unit is equipped with an alarm relay which changes state every time an alarm occurs in one of the cooling circuits Connect the terminals as per the wiring diagram on the unit terminal X a visual or audible alarm or any external supervision system BMS to monitor its operation is allowed See the wiri...

Страница 26: ...With the general switch open check that the electrical connections are tightly clamped Check for any possible refrigerant leaks Check that the electrical data on the label correspond to those of the mains supply Check that the thermal charge available is appropriate for starting 12 2 REFRIGERANT SEALS CONTROL RAUS and RAUX units are shipped void of refrigerant pressed with nitrogen and with pipes ...

Страница 27: ...T OR THE HYDRAULIC CIRCUIT OR THE ELECTRICAL PANEL OR CHANGES TO THE UNIT OPERATING PARAMETERS MADE BY A THIRD PERSON WITHOUT A WRITTEN AUTHORIZATION ISSUED BY TRANE THE UNIT SHALL BE CONFORM TO TRANE WIRING DIAGRAMS AND TECHNICAL DOCUMENTATION IN CASE OF RELEVANT DIFFERENCE BETWEEN THE UNIT AND TRANE STANDARD CONFIGURATION PLEASE CONTACT TRANE WARNING PLEASE BE AWARE THAT RELEVANT DAMAGES CAUSED ...

Страница 28: ... BEFORE THE START UP 16 AN ELECTRONIC SUPERVISOR OR ANY ADDITIONAL CONTROLLER HAS BEEN INSTALLED 17 THE CONNECTION WIRES ARE SHIELDED 18 REMOTE CONTROL DEVICES OR INTERFACES ARE CONNECTED TO THE ELECTRICAL PANEL IN CONFORMITY WITH TRANE WIRING DIAGRAMS 19 ELECTRONIC DEVICES ARE INTACT AND DON T DISPLAY ANY DAMAGE 20 THE ELECTRICAL ABSORPTION IS STANDARD REFRIGERANT CIRCUIT COMPLIANCE YES NO 21 ALL...

Страница 29: ...lues may mean an excess of charge After intervention on the charge it is appropriate to check that the unit runs within the declared values with unit steadily running on a full charge measure the temperature of the suction line downstream of the thermostatic valve bulb read the balance pressure to the evaporator on the low pressure manometer and the corresponding saturation temperature Overheating...

Страница 30: ...sumption and possible damage to the compressor The symptoms of a low refrigerant charge are Low evaporation pressure High value of superheating Low value of sub cooling In this case add refrigerant R410A The system is provided with a charging port between the expansion valve and the evaporator Charge refrigerant until conditions return to work normal Remember to replace the cap closing the valve a...

Страница 31: ...eriodically on an annual basis Compressor Electrical Connections It is very important that all the compressors are wired correctly for proper rotation These compressors will not tolerate reverse rotation Verify correct rotation phasing using a rotation meter If wired incorrectly the compressor will make excessive noise will not pump and will draw about half the normal current It will also become v...

Страница 32: ...leansers or detergents is strongly discouraged due to the all aluminum construction straight water should prove sufficient if not please contact Trane Any breach in the tubes can result in refrigerant leaks IMPORTANT Only in extreme cases should any type of chemical cleaner or detergent be used on microchannel coils If it becomes absolutely necessary because water alone did not clean the coil spec...

Страница 33: ... X Check through the sight glass coolant flow Full Indicator X Check the pressure drop of the filter drier X Carry out the analysis of the vibrations of the compressor X Carry out the analysis of the acidity of the oil of the compressor 5 X Condensing section Cleaning the condenser coils Note 4 X Check that the fans are tightened X Notes 1 The monthly activities include all those weekly 2 The annu...

Страница 34: ...per type fans and engines 1 per type 2 YEAR COMPONENTS QUANTITY fuses all filter dryers all solenoid valves all electronic expansion valves all pressure switches all gas gauges all contactors and relays all thermal protectors all carter electric heaters all check valve 1 per type 4 way valve 1 per type safety valve 1 per type sight glass 1 per type fans and engines 1 per type electrical components...

Страница 35: ...arge in the circuit Make sure that working conditions are within the limits of operation Loss of coolant see section G C The compressor starts up and stops repeatedly x x s Intervention of the minimum See point E x x s Compressor contactor defective Check and replace if necessary x x u Calibration values of the set point or differential Modify them as reported in the tables x x s Lack of coolant S...

Страница 36: ...and the continuity of the coil x x s Lack of output voltage from the control fan speed Check the contacts replace if necessary x x s Thermal protection inside the fan Check the condition of the fan and the air temperature during operation of the unit x x s Fan motor faulty Check and replace x x s Loose electrical connections Check and replace G Lack of gas x x s Loss in the refrigerant circuit Che...

Страница 37: ...frigerant charge See point G x x s The liquid filter is clogged Replace N Abnormal noise detected in the system x x s Compressor noisy Check and replace if necessary x x s The panel vibrate Fasten properly O The defrosting cycle is never activated x s 4 way reversing valve defective Check the power supply and the coil of the valve and replace the valve x s The defrost thermostat is worn out or has...

Страница 38: ...aximum safety in its proximity as well as to resist to the aggressive environmental conditions The fans are protected by grilles Residual risks are indicated with warning labels SAFETY SYMBOLS DANGER DANGER DANGER DANGER General danger Temperature Moving parts Cutoff voltage ...

Страница 39: ...portfolio of heating ventilating and air conditioning systems and controls services parts and supply For more information please visit trane eu or tranetechnologies com Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice 2021 Trane CG SVX053A GB_0721 New ...

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