Trane RAUC-C20, RAUC-C50, RAUC-C30, RAUC-C25, RAUC-C40 User Manual

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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

June 2008

SS-SVX09A-EN

Warnings, Cautions and Notices

Warnings, Cautions and Notices. Note that warnings, cautions and notices appear at

appropriate intervals throughout this manual. Warnings are provide to alert installing contractors to potential hazards that could result in personal injury or death. Cautions are designed to alert personnel to hazardous situations that could result in personal injury, while notices indicate a situation that may result in equipment or property-damage-only accidents.

Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

ATTENTION: Warnings, Cautions and Notices appear at appropriate sections throughout

this literature. Read these carefully.

 WAR NING : Indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

 CAUTION: Indicates a potentially hazardous situation which, if not avoided, could

result in minor or moderate injury. It may also be used to alert against unsafe practices.

NOTICE: Indicates a situation that could result in equipment or property-damage only

accidents.

Important Environmental Concerns!

Scientific research has shown that certain man-made chemicals can affect the earth's naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handling of all refrigerants-including industry replacements for CFCs such as HCFCs and HFCs.

Responsible Refrigerant Practices!

Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified. The Federal Clean Air Act (Section 608) sets forth the requirements 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 additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.

 WARNING

Grounding Required!

Follow proper local and state electrical code on requirements for grounding. Failure to follow code could result in death or serious injury.

Overview of Manual

Note: One copy of this document ships inside the control panel of each unit and is customer

property. It must be retained by the unit's maintenance personnel.

This booklet describes proper installation, operation, and maintenance procedures for air cooled systems. By carefully reviewing the information within this manual and following the instructions, the risk of improper operation and/or component damage will be minimized. It is important that periodic maintenance be performed to help assure trouble free operation. A maintenance schedule is provided at the end of this manual. Should equipment failure occur, contact a qualified service organization with qualified, experienced HVAC technicians to properly diagnose and repair this equipment.

Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Model Number Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Unit Dimensions & Weight Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Unit Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Leveling the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Shipping Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

General Unit Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Refrigerant Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

EVP Chilled Water Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Main Electrical Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Field Installed Control Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . 29

Low Voltage Wiring (AC & DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Refrigerant Line Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Refrigerant Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Suction Line Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Liquid Line Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Evaporator Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Hot Gas Bypass for Commercial 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 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Field Installed Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Disconnect Switch External Handle (Factory Mounted Option) . . . . . . . 45

Main Unit Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Power Wire Sizing and Protection Device . . . . . . . . . . . . . . . . . . . . . . . . . 47

Field Installed Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Controls Using 115 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Controls using 24 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Controls using DC Analog Input/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . 51

Economizer Actuator Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

No System Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Field Connection Diagram Notes for all System Control Options . . . . . . 55

Variable Air Volume Control (Honeywell W7100A) . . . . . . . . . . . . . . . . . 56

Discharge Air Sensor (Honeywell 6RT3) . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Suction Line Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Night Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

EVP Chiller Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Chilled Water Temperature Sensor (Honeywell 6RT2) . . . . . . . . . . . . . . 60

SS-SVX09A-EN 3

Outside Air Thermostat (5S57 Field Provided) . . . . . . . . . . . . . . . . . . . . . 61

Constant Volume Control (Honeywell 973) . . . . . . . . . . . . . . . . . . . . . . . . 63

System Pre-Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

System Evacuation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Discharge Air Controller Checkout (Honeywell W7100A) . . . . . . . . . . . . 71

Discharge Air Sensor Checkout (Honeywell Sensor) . . . . . . . . . . . . . . . . 74

Economizer Actuator Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

EVP Chiller Control Checkout (Honeywell W7100G) . . . . . . . . . . . . . . . . 75

Chilled Water Sensor Checkout (Honeywell Sensor) . . . . . . . . . . . . . . . . 77

Master Energy 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

Low Ambient Damper Adjustment (Factory or Field Installed) . . . . . . . . 87

EVP Chiller Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

“Air Over” Evaporator Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

System Airflow Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Compressor Start-Up (All Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Final System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Service & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Compressor Operational Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Scroll Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Fuse Replacement Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Coil Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

WARRANTY AND LIABILITY CLAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

4 SS-SVX09A-EN

General Information

Model Number Description

All Trane products are identified by a multiple-character model number that precisely identifies a particular type of unit. An explanation of the alphanumeric identification code is provided below. Its use will enable the owner/operator, installing contractors, and service engineers to define the operation, specific components, and other options for any specific unit. When ordering 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.

Sample Model No.: RAUC - C60 E B L 1 3 A, F, G, 1, etc Digit No.: 1 2 3 4 5,6,7 8 9 10 11 12 13+

Digit 1 - Unit Type

R = Remote Condensing Unit

Digit 2 - Condenser

A = Air Cooled

Digit 3 - Air Flow

U = Up Flow

Digit 4 - Development Sequence

C = Third

Digits 5, 6, 7 - Nominal Capacity

C20 = 20 Tons

C25 = 25 Tons

C30 = 30 Tons

C40 = 40 Tons

C50 = 50 Tons

C60 = 60 Tons

Digit 8 - Power Supply

E = 200/60/3 XL

F = 230/60/3 XL

4 = 460/60/3 XL

5 = 575/60/3 XL

9 = 380/50/3 XL

D = 415/50/3 XL

Digit 9 - System Control

B = No System Control

C = Constant Volume Control

E = Supply Air VAV Control P = EVP Control

Digit 10 - Design Sequence

V = Disconnect Redesign

Digit 11 - Ambient Control

0 = Standard

1 = Low Ambient 0

Digit 12 - Agency Approval

0 = None

3 = UL / CSA

Digit 13 - Miscellaneous Options

A = Unit Mounted Disconnect Switch B = Hot Gas Bypass Valves * D = Suction Service Valves F = Pressures Gauges & Gauge Piping * G = Return Air Sensor * H = Condenser Coils with Copper Fins T = Flow Switch (EVP Only) * 1 = Spring Isolators * 2 = Neoprene Isolators * 9 = Packed Stock

* Field Installed Options

Unit Nameplate

One Mylar unit nameplate is located on the outside upper right corner of the control panel door. It includes the unit model number, serial number, electrical characteristics, weight, refrigerant charge, as well as other pertinent unit data. A small metal nameplate with the Model Number, Serial Number, and Unit Weight is located just above the Mylar nameplate, and a third nameplate is located on the inside of the control panel door.

When ordering 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 the “Scroll” compressors are located on the compressor lower housing.

SS-SVX09A-EN 5

General Information

Evaporator Nameplate (EVP Chiller Applications Only)

The nameplate is located on the same side of the refrigerant connections near the top. To view the nameplate, remove the tape over the area and spread the insulation. Retape the insulation after viewing.

Unit Description

All air cooled condensing units are designed for outdoor installations with vertical air discharge. These units may be installed on a flat roof or placed on a concrete slab at ground level.

Before shipment, each unit is leak-tested, evacuated, a Nitrogen holding charge is added, and the controls are tested for proper operation.

The condenser coils are aluminum fin, bonded to copper tubing. Copper-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 “Ship with” items, refer to the Unit Component “Layout” and “Ship with” Locations illustration.

Figure 1. Unit Component Layout and ‘shipwith’ Locations (60 Ton Unit Illustrated)

If low ambient operation is required, low ambient dampers are available as a field or factory installed option.

These units may be order with one of the following options:

No System Controls (Field provided controls required)

Constant Volume Controls

Supply Air Temperature Control (VAV applications)

EVP Chiller Controls

Basic unit components include:

Manifolded Scroll Compressors

Intertwined condenser coils

Condenser fans (number based on unit size)

Discharge service valve (one per circuit)

Liquid line service valve (one per circuit)

6 SS-SVX09A-EN

Installation

Unit Inspection

As soon as the unit arrives at the job site

[ ] Verify that the nameplate data matches the data on the sales order and bill of lading (including electrical data).

[ ] Verify that the power supply complies with the unit nameplate specifications.

[ ] Visually inspect the exterior of the unit, including the roof, for signs of shipping damage.

[ ] Check for material shortages. Refer to the Component Layout and Ship with Location illustration.

If the job site inspection of the unit reveals damage or material shortages, file a claim with the

carrier immediately. Specify the type and extent of the damage on the ‘bill of lading” before signing.

[ ] Visually inspect the internal components for shipping damage as soon as possible after delivery and before it is stored. Do not walk on the sheet metal base pans.

 WARNING

No Step Surface!

Do not walk on the sheet metal drain pan. Walking on the drain pan could cause the supporting metal to collapse. Failure of the drain pan could result in death or serious injury.

Bridging between the unit's main supports may consist of multiple 2 by 12 boards or sheet metal grating.

[ ] If concealed damage 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 carrier and the consignee. 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 appropriate Trane office before installing or repairing a damaged unit.

Unit Clearances

Figure 2 illustrates the minimum operating and service clearances for either a single, multiple, or

pit application. These clearances are the minimum distances necessary to assure adequate serviceability, cataloged unit capacity, and peak operating efficiency.

NOTICE

Providing less than the recommended clearances may result in condenser coil starvation or recirculation of hot condenser air.

Locate the unit as close to the applicable system support equipment as possible to minimize refrigerant piping lengths.

EVP Chiller Considerations

The EVP chiller must be installed indoors unless:

• Outdoor temperatures are always above 32º F.

• System circulating liquid is a non-freezing glycol-type solution selected for prevailing ambient temperatures.

• Chiller is protected from freeze-up by properly installed and applied insulation and heat tape.

SS-SVX09A-EN 7

Installation

NOTICE

To prevent internal chiller damage due to freezing, do not install the BPHE chiller outdoors without adequate freeze protection.

Allow adequate clearance for water and refrigerant piping connections, space to perform service procedures, i.e. read gauges, thermometers, and operate water system valves.

Unit Dimensions & Weight Information

Overall unit dimensional data for each unit is illustrated in Figure 3 to Figure 8.

A Center-of-Gravity illustration and the dimensional data for the unit is shown in Figure 15.

Ta b l e 1 lists the typical operating and point loading weights for the unit.

EVP chiller mounting footprints and overall dimensional data is illustrated in Figure 9 to Figure 14.

Ta b l e 2 lists the typical EVP operating weights and general data.

Foundation

If the unit is installed at ground level, elevate it above the snow line. Provide concrete footings at each support location or a slab foundation for support. Refer to Tabl e 1 for the unit operating and point loading weights when constructing the footing foundation.

Anchor the unit to the footings or slab using hold down bolts or isolators. Isolators should be installed to minimize the transmission of vibrations into the building. Refer to the “Unit Isolation” section for spring or rubber isolator installation instructions.

For rooftop applications, ensure the roof is strong enough to support the unit. Refer to Tabl e 1 for the unit operating weights.

Anchor the unit to the roof with hold-down bolts or isolators. Follow the instructions under “Unit Isolation” for proper isolator placement and installation.

Check with a roofing contractor for proper waterproofing procedures.

The EVP chiller must be installed level and should be mounted on a base that will adequately support the operating weight. Refer to Ta b l e 2 for operating weights.

8 SS-SVX09A-EN

Figure 2. Typical Installation Clearances for Single, Multiple or Pit Applications

Installation

SS-SVX09A-EN 9

Installation

Figure 3. RAUC-C20 Unit Dimensional Data & Recommended Clearances

10 SS-SVX09A-EN

Figure 4. RAUC-C25 Unit Dimensional Data & Recommended Clearances

Installation

SS-SVX09A-EN 11

Installation

Figure 5. RAUC-C30 Unit Dimensional Data & Recommended Clearances

12 SS-SVX09A-EN

Figure 6. RAUC-C40 Unit Dimensional Data & Recommended Clearances

Installation

SS-SVX09A-EN 13

Installation

Figure 7. RAUC-C50 Unit Dimensional Data & Recommended Clearances

14 SS-SVX09A-EN

Figure 8. RAUC-C60 Unit Dimensional Data & Recommended Clearances

Installation

SS-SVX09A-EN 15

Installation

Evaporator mounting brakets

and insulation are provided

with ChillerBPHE Accessory

for field installation - Field

provided vinyl tape is required

to seal insulation edges after

installation.

"6.752"

"8.084"

17.670

6.440

3.331

2.431

1.130 ID

2.431

2.261

17.720

2.261

3.451

FRONT

VIEW

W/INSULATION

SUCTION

LIQUID

ENTERING

WATER

LEAVING

WATER

2X Ø2.00

1.660 Ø ID

RIGHT

VIEW

W/INSULATION

REAR

VIEW

W/INSULATION

SWAGELOK

B-4-P

1/4" NPT

MALE PIPE

PLUG

EQUIVELENT

FIELD

PROVIDED

MOUNTING

BRACKET x 2

9.760

.625

Ø.562 X 2 Each Bracket

Figure 9. BPHE 20 Evaporator Chiller Dimensions

16 SS-SVX09A-EN

Note: All water connections are Victaulic.

Figure 10. BPHE 25 Evaporator Chiller Dimensions

7.994

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

SUCTION

LIQUID

ENTERING

WATER

LEAVING

WATER

2X Ø2.00

2.138 Ø ID

SWAGELOK

B-4-P

1/4" NPT

MALE

PIPE

PLUG

EQUIVELENT

FIELD

PROVIDED

Evaporator mounting brackets

and insulation are provided

with Chiller BPHE Accessory

for field installation - Field

provided vinyl tape is required

to seal insulation edges after

installation.

9.760

.625

FRONT

VIEW

W/INSULATION

RIGHT

VIEW

W/INSULATION

REAR

VIEW

W/INSULATION

MOUNTING

BRACKET x 2

Ø.562 X 2 Each Bracket

Installation

Note: All water connections are Victaulic.

SS-SVX09A-EN 17

Installation

Figure 11. BPHE 30 Evaporator Chiller Dimensions

and insulation are provided

Evaporator mounting brackets

WATER

2.261

ENTERING

with Chiller BPHE Accessory

to seal insulation edges after

for field installation - Field

installation.

provided vinyl tape is required

2X Ø2.00

WATER

LEAVING

.625

9.760

VIEW

REAR

Ø.562 X 2 Each Bracket

MOUNTING

BRACKET x 2

W/INSULATION

6.440

2.261

2.431

10.004

2.261

2.431

SWAGELOK

SUCTION

B-4-P

1/4" NPT

17.670

17.720

MALE

PIPE

23.432

PLUG

FIELD

EQUIVALENT

LIQUID

3.451

10.604

PROVIDED

3.331

.625

FRONT

1.130 ID

VIEW

RIGHT

VIEW

W/INSULATION

2.138 ID

Note: All water connections are Victaulic.

18 SS-SVX09A-EN

Figure 12. BPHE 40 Evaporator Chiller Dimensions

3.960

23.780

2.551

30.292

13.533

2.517

8.500

6.767

13.533

30.292

2.826

4.235

23.230

1.380 ID X 2

7.720

9.096

SUCTION

CIR #1

LIQUID

CIR #1

SUCTION

CIR #2

LIQUID

CIR #2

1.660 Ø ID X 2

ENTERING

WATER

LEAVING

WATER

Ø 3.00 X 2

SWAGELOK

B-4-P

1/4" NPT

MALE

PIPE

PLUG

EQUIVALENT

FIELD

PROVIDED

Evaporator mounting brackets

and insulation are provided

with Chiller BPHE Accessory

for field installation - Field

provided vinyl tape is required

to seal insulation edges after

installation.

FRONT

VIEW

W/INSULATION

RIGHT

VIEW

W/INSULATION

REAR

VIEW

W/INSULATION

MOUNTING

BRACKET x 2

Ø.562 X 2 Each Bracket

11.420

1.020

Installation

Note: All water connections are Victaulic.

SS-SVX09A-EN 19

Installation

Figure 13. BPHE 50 Evaporator Chiller Dimensions

Ø 3.00 X 2

brackets and insulation are

provided with Chiller

BPHE Accessory for field

Evaporator mounting

6.766

vinyl tape is required to

seal insulation edges after

installation.

installation - Field provided

1.020

Ø.562 X 2 Each Bracket

x 2

BRACKET

MOUNTING

13.533

6.767

8.872

2.138 Ø ID X 2

2.517

8.500

13.533

2.827

WATER

ENTERING

CIR

SUCTION

CIR

SUCTION

SWAGELOK

B-4-P

23.230

30.292

1/4"

NPT

MALE

PIPE

LIQUID

WATER

LEAVING

PLUG

CIR

FIELD

EQUIVALENT

4.235

11.42 0

1.020

9.096

PROVIDED

VIEW

REAR

W/INSULATION

VIEW

RIGHT

W/INSULATION

VIEW

FRONT

W/INSULATION

2.517

2.551

23.780

30.292

3.960

1.380 ID X 2

Note: All water connections are Victaulic.

20 SS-SVX09A-EN

Figure 14. BPHE 60 Evaporator Chiller Dimensions

with Chiller BPHE Accessory

and insulation are provided

Ø 3.00 X 2

Evaporator mounting brackets

6.766

WATER

13.533

6.767

ENTERING

for field installation - Field

to seal insulation edges after

provided vinyl tape is required

installation.

WATER

LEAVING

1.020

11.420

Ø.562 X 2 Each Bracket

MOUNTING

BRACKET x 2

VIEW

REAR

W/INSULATION

Installation

2.517

2.826

12.732

2.138 Ø ID X 2

8.500

13.533

2.551

CIR #2

SUCTION

CIR #1

SUCTION

23.230

23.780

30.292

SWAGELOK

MALE

B-4-P

1/4" NPT

30.292

PIPE

PLUG

CIR #2

LIQUID

CIR #1

LIQUID

EQUIVALENT

FIELD

1.020

4.235

14.858

PROVIDED

3.960

1.380 ID X 2

VIEW

RIGHT

W/INSULATION

VIEW

FRONT

W/INSULATION

Note: All water connections are Victaulic.

SS-SVX09A-EN 21

Installation

Table 1. Typical Unit Weights & Point Loading Data

Operating

Unit Size

C20 1522 1720 509 559 398 439 345 404 270 317

C25 1640 1842 555 602 421 467 378 436 286 338

C30 1824 2115 580 640 635 708 291 364 318 403

C40 2769 3102 480 523 457 501 473 528 450 506 466 533 443 511

C50 3148 3540 586 643 562 620 536 601 514 579 485 559 465 538

C60 3480 4050 640 722 618 703 590 684 570 666 540 646 522 629

Note: Mounting locations correlate with those shown in point loading illustration

Weight

AL CU AL CU AL CU AL CU AL CU AL CU AL CU

Location 123456

Unit Weight on Isolator @ Mounting Location

Table 2. Typical EVP Chiller Weights & General Data

Chiller

Size

20 Ton 80 100 1 2.0 2.5

25 Ton 92 116 1 2.4 3.0

30 Ton 105 133 1 2.9 3.7

40 Ton 152 186 2 3.7 4.7

50 Ton 170 211 2 4.3 5.5

60 Ton 242 309 2 7.0 8.9

Notes: 2 - Shipping and Operating weights are approximate 3 - Includes volume of Water Piping Kit. 4 - Refrigerant charge is approximate for chiller evaporator only

Unit Size

C20 1724 38-1/16 968 26-3/8 671

C25 1843 38-1/16 968 26-3/16 666

C30 2107 34-1/16 865 31-1/2 800

C40 3088 44-3/16 1122 43-1/16 1095

C50 3532 54-11/16 1389 43-3/16 1097

C60 4024 55-3/16 1402 43-3/8 1102

Shipping

Weight

Shipping

weight (Max.

Lbs)

Operating

Weight

Number of

Ref. Ckts.

Water Volume in

Gallons

Refrigerant Charge

Location of Center of Gravity

In mm In mm

in Lbs.

22 SS-SVX09A-EN

Rigging

Installation

 WARNING

Heavy Objects!

Do not use cables (chains or slings) except as shown. Each of the cables (chains or slings) used to lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or slings) may not be of the same length. Adjust as necessary 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.

Use spreader bars as shown in the diagram. Refer to the installation manual or nameplate for unit weight. Refer to the installation instructions located inside the central panel for further rigging information.

Figure 15. Rigging and Center-of-Gravity Data

A Rigging illustration and Center-of-Gravity dimensional data table is shown in Figure 15. Refer to the typical unit operating weights table before proceeding.

1. Rig the condensing unit as shown in Figure 15. Attach adequate strength lifting slings to all four lifting brackets in the unit base rail. Do not use cables, chains, or slings except as shown.

2. Install spreader bars, as shown in Figure 15, to protect the unit and to facilitate a uniform lift. The minimum distance between the lifting hook and the top of the unit should be 7 feet.

3. Test-lift the unit to ensure it is properly rigged and balanced, make any necessary rigging adjustments.

4. Lift the unit and position it into place.

SS-SVX09A-EN 23

Installation

Unit Isolation

To minimize unit sound and vibration transmission, one of the following installation methods should be used:

1. Install the unit directly on an isolated (detached) concrete pad or on isolated concrete footings located at each unit load point.

2. Install the optional neoprene or spring isolators at each mounting location. Refer to the “Neoprene isolators” or “Spring isolator” section below.

Neoprene Isolators

Install the neoprene isolators at each unit mounting (load) point, using the following procedure:

1. Elevate the unit (one side at a time) to allow access to the base rail mounting holes.

 WARNING

Heavy Objects!

Use solid type blocks, i.e. 4" X 4" wood blocks or similar material to prevent collapsing. Keep hands and other body limbs clear of elevated base rail while installing isolators. Failure to do so could result in death or serious injury.

2. Align the mounting holes in the base rail of the unit with the holes in the top of the appropriate isolator. Refer to Ta b le 3 for the appropriate isolator for each load point.

3. Install a 1/2" NC bolt (field supplied) through the base rail of the unit into the threaded bolt hole of the isolator. Position the isolator to 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 1/4 inch.

5. Secure the isolator to the mounting surface using the base holes in the isolator.

6. Level the unit carefully. Refer to the “Leveling the Unit” section.

7. After the unit is level, tighten the isolator base mounting bolts to secure them to the mounting surface.

Table 3. Typical Neoprene Isolator Selection & Location

Neoprene Isolator Part Number @ Mounting Location

Unit Size Fin Material

C20

C25

C30

C40

C50

C60

Note: Mounting locations correlate with those shown in point loading illustration

24 SS-SVX09A-EN

Al RDP-3-GRN RDP-3-GRN RDP-3-RED RDP-3-RED

Cu RDP-3-GRY RDP-3-GRN RDP-3-GRN RDP-3-RED

Al RDP-3-GRY RDP-3-GRN RDP-3-GRN RDP-3-RED

Cu RDP-3-GRY RDP-3-GRN RDP-3-GRN RDP-3-RED

Al RDP-3-GRY RDP-3-GRY RDP-3-RED RDP-3-RED

Cu RDP-3-GRY RDP-3-GRY RDP-3-RED RDP-3-GRN

Al RDP-3-GRN RDP-3-GRN RDP-3-GRN RDP-3-GRN RDP-3-GRN RDP-3-GRN

Cu RDP-3-GRN RDP-3-GRN RDP-3-GRY RDP-3-GRN RDP-3-GRY RDP-3-GRN

Al RDP-3-GRY RDP-3-GRY RDP-3-GRY RDP-3-GRN RDP-3-GRN RDP-3-GRN

Cu RDP-3-GRY RDP-3-GRY RDP-3-GRY RDP-3-GRY RDP-3-GRY RDP-3-GRY

Al RDP-3-GRY RDP-3-GRY RDP-3-GRY RDP-3-GRY RDP-3-GRY RDP-3-GRN

Cu RDP-3-GRY RDP-3-GRY RDP-3-GRY RDP-3-GRY RDP-3-GRY RDP-3-GRY

Location 1 Location 2 Location 3 Location 4 Location 5 Location 6

Installation

Spring Isolators

Install the spring isolators at each unit mounting (load) point using the following procedure:

1. Elevate the unit (one side at a time) to allow access to the base rail mounting holes.

 WARNING

Heavy Objects!

Leveling the Unit

2. Align the mounting holes in the base rail of the unit with the positioning pin in the top of the appropriate isolator. Refer to

3. Position the isolator to allow access to the mounting holes in the base of the isolator.

4. Lower the unit onto the isolator. The positioning pin on the isolator must engage into the hole of the base rail. The clearance between the upper and lower isolator housings should be approximately 1/4 to 1/2 inch. 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 (Ta bl e 4) clockwise to increase the clearance and counterclockwise to decrease the clearance. If proper isolator clearance cannot be obtained by turning the leveling bolt, level the isolators themselves. A 1/ 4 inch variance in elevation is acceptable.

6. Secure the isolator to the mounting surface using the base holes in the isolator.

7. After the unit is level, tighten the isolator base mounting bolts to secure them to the mounting surface.

Before tightening the mounting bolts, level the unit carefully. Use the unit base rail as a reference. Level the unit to within 1/4 inch over its entire length. Use shims if non-adjustable isolators (neoprene) are used.

If adjustable isolators (spring) are used, ensure that the proper isolator housing clearance is maintained while leveling the unit. Isolators are identified by color and/or an isolator part number. Shims under the isolators may be required if the unit can not be leveled using the isolator leveling bolt.

Ta bl e 4 for the appropriate isolator for each load point.

SS-SVX09A-EN 25

Installation

Table 4. Typical Spring Isolator Selection & Location

Spring Isolator Part Number @ Mounting Location

Unit

Tons

20 CP-1-27 CP-1-28 CP-1-26 CP-1-27 CP-1-26 CP-1-26 CP-1-25 CP-1-26

25 CP-1-28 CP-1-28 CP-1-27 CP-1-27 CP-1-26 CP-1-27 CP-1-25 CP-1-26

30 CP-1-28 CP-1-31 CP-1-31 CP-1-31 CP-1-25 CP-1-26 CP-1-26 CP-1-26

40 CP-1-27 CP-1-27 CP-1-27 CP-1-27 CP-1-27 CP-1-28 CP-1-27 CP-1-27 CP-1-27 CP-1-28 CP-1-27 CP-1-27

50 CP-1-28 CP-1-31 CP-1-28 CP-1-28 CP-1-28 CP-1-28 CP-1-27 CP-1-28 CP-1-27 CP-1-28 CP-1-27 CP-1-28

60 CP-1-31 CP-1-31 CP-1-28 CP-1-31 CP-1-28 CP-1-31 CP-1-28 CP-1-31 CP-1-28 CP-1-31 CP-1-27 CP-1-28

1. Mounting locations correlate with those shown in point loading illustration.

2. The spring number is marked on the outside of the spring housing, i.e. CP-1-25 is marked 25.

The isolator spring is color coded as follows; CP-1-25=Red, CP-1-26=Purple, CP-1-27=Orange, CP-1-28=Green, Cp-1-31=Gray

3. Refer to the “Spring Isolator” section, step 4, for proper clearance.

Location 1 Location 2 Location 3 Location 4 Location 5 Location 6

Al Cu Al Cu Al Cu Al Cu Al Cu Al Cu

Shipping Fasteners

Compressor Shipping Hardware

Figure 16 illustrates the location of each tiedown bolt and rubber isolator bolt for the compressor

assembly in each circuit. Refer to the illustration and the following discussion to locate and remove the fasteners.

Two Manifolded Compressors

Each manifolded compressor assembly is rigidly bolted to a mounting rail assembly. The rail assembly sets on four (4) rubber isolators. The assembly is held in place by two shipping braces that secure each compressor assembly rail to the unit’s base rail. To remove the shipping hardware, follow the procedures below:

1. Remove the four anchor bolts (2 front and 2 rear), used to secure the shipping brace to the unit’s

2. Remove the three self-tapping screws that secure each shipping brace to the compressor

3. Remove and discard the two 30-1/2" long shipping braces for each assembly.

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.

base rail.

mounting rails.

26 SS-SVX09A-EN

Figure 16. Removing Scroll Compressor Shipping Hardware for 20 through 60 Ton Units

General Unit Requirements

The checklist listed below is a summary of the steps required to successfully install a commercial air cooled condenser. This checklist is intended to acquaint the installing personnel with what is required in the installation process. It does not replace the detailed instruction called out in the applicable sections of this manual.

[ ] Verify that the power supply complies with the unit nameplate specifications.

[ ] Check the unit for shipping damage and material shortage; file a freight claim and notify Trane office.

[ ] Verify that the installation location of the unit will provide the required clearance for proper operation.

[ ] Install appropriate isolators, if required.

Installation

Refrigerant Piping Requirements

[ ] Install properly sized liquid 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.

[ ] Install a properly sized liquid line isolation solenoid valve in each liquid line.

[ ] Install refrigerant rated shutoff valves in the liquid line(s) to isolate the filter drier(s) for service.

[ ] Install a properly sized filter drier in each liquid line.

[ ] Install a properly sized filter in each suction line.

[ ] Install properly sized suction line(s) between the suction 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.

[ ] Install properly sized hot gas bypass line(s) between the hot gas bypass connections on the unit and the evaporator, (i.e., EVP Chiller, if applicable).

[ ] Insulate the suction line.

SS-SVX09A-EN 27

Installation

 WARNING

Hazard of Explosion!

Never use an open flame to detect gas leaks. Explosive conditions may occur. Use a leak test solution or other approved methods for leak testing. Failure to follow recommended safe leak test procedures could result in death or serious injury or equipment or property-only-damage.

[ ] Leak test the system. Refer to the “Refrigerant Piping” section for recommended procedures.

EVP Chilled Water Piping Requirements

[ ] Install properly sized chilled water pipe between the EVP chiller and the supporting equipment. Refer to the “Chilled Water Piping” section for recommended system components and guidelines. Ensure that the recommended components have been installed:

Water pressure gauges (with isolation valves)

Thermometers

Chiller isolation (shutoff) valves in the solution inlet and outlet piping

Strainer in the solution inlet piping

Balancing valve

Flow switch in the solution outlet piping

Chilled solution sensor well and sensor in the solution outlet piping

Freezestat well and freezestat bulb in the chilled solution outlet piping

Chiller drain plug, or drain piping with a shutoff valve

[ ] Flushing the chilled solution piping system, 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 the EVP chiller.

[ ] Connecting the chilled solution piping to the chiller.

[ ] Install heat tape and insulation, if necessary, to protect any exposed solution piping from external freezing conditions.

Main Electrical Power Requirements

 WARNING

Hazardous Voltage!

Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

[ ] Verify the power supply meets the required power requirements of the system.

[ ] Install power wiring in accordance with all applicable codes.

[ ] Install and connect properly sized power supply wiring, with over current protection, to the main power terminal block (1TB1) or to an optional factory mounted nonfused disconnect switch (1S1) in the control panel.

[ ] Install and connect properly sized power supply wiring, with over current protection, to the proper termination point in the air handling unit (If applicable).

[ ] Install and connect properly sized power supply wiring, with over current protection, to the proper termination point for the chilled solution pump (EVP units only).

28 SS-SVX09A-EN

 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. Failure to follow this instruction could 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 injury.

[ ] Install proper grounding wires to an earth ground.

Field Installed Control Wiring Requirements

115 Volt Control Wiring (All Units)

 WARNING

Hazardous Voltage!

Installation

[ ] Verify that the Control transformer (1T1) is wired for the proper operating voltage.

[ ] Connect properly sized wiring to the liquid line solenoid valve(s).

[ ] Connect properly sized wiring to the hot gas bypass solenoid valve(s), if applicable, to operate with the unit. Refer to the unit wiring diagram 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 started, i.e., proof of fan operation device, fan starter auxiliary contacts or pump starter station, pump starter auxiliary contacts, proof of flow device, etc). Refer to the field connection diagram that shipped with the unit for interlocking information.

[ ] Install properly sized power supply wiring, with over current protection, to the proper termination point for the field provided economizer actuator(s), if applicable. Refer to the “Economizer Actuator Circuit” illustrated in the “Field Installed Control Wiring” section.

”No Controls” Units

[ ] A field provided “step” controller must be installed and properly wired. Refer to the field connection diagram for connection information.

“EVP” Chiller Units

 WARNING

Hazardous Voltage!

[ ] Install the EVP chiller remote panel.

[ ] Install and connect properly sized control wiring to the proper termination points between the remote panel and the unit control panel.

SS-SVX09A-EN 29

Installation

 WARNING

Ground Wire!

 WARNING

Grounding Required!

Follow proper local and state electrical code on requirements for grounding. Failure to follow code could result in death or serious injury.

[ ] Install proper grounding wires to an earth ground.

[ ] Install an outside air thermostat in series with the flow switch to stop or prevent the unit from operating below the recommended ambient temperatures.

Figure 17. EVP Chiller Piping

30 SS-SVX09A-EN

Low Voltage Wiring (AC & DC)

 WARNING

Hazardous Voltage!

Variable Air Volume (VAV) Units

[ ] Install a field provided remote system control switch to activate the system.

[ ] Connect properly sized wiring from the field provided economizer, if applicable, to the discharge air controller in the unit control panel.

[ ] Install and connect properly sized wiring from the night setback relay contacts to the proper termination points inside the unit control panel. Verify the appropriate jumpers have been removed.

[ ] Install the suction line thermostat onto the suction line. Connect properly sized wiring between the thermostat and terminal strip 7TB7 in the unit control panel.

[ ] Install the discharge air sensor and wire it to the discharge air controller with shielded cable.

EVP Chiller Units

[ ] Install the appropriate jumpers on the chilled solution temperature controller for hot gas bypass operation (If applicable). Refer to the control wiring diagram that shipped with the unit for jumper details.

[ ] Install and connect the chilled solution temperature sensor to the chilled solution temperature controller with shielded cable.

[ ] Install the proper staging resistor onto the chilled solution temperature controller.

Installation

Constant Volume Units

[ ] Install the zone thermostat, with or without switching subbase.

[ ] Connect properly sized control wiring to the proper termination points between the zone thermostat and the unit control panel.

[ ] Install the discharge air sensor and connect it to the master energy controller (MEC) with shielded cable.

[ ] Connect properly sized wiring from the field provided economizer, if applicable, to the master energy controller (MEC) in the unit control panel.

Refrigerant Line Components

Suction line refrigerant components necessary for field installation in the suction line are a filter (Core Type), access valves (ports), Frostat They are placed in the suction line as illustrated in Figure 18.

The required liquid line refrigerant components include a filter drier (Core Type), access valve(s) or (ports), solenoid valve(s), moisture indicating sight glass, expansion valve(s), and ball shutoff valve(s). They are placed in the liquid line as shown in Figure 18.

Suction And Liquid Line Filter/Filter Drier (Field Supplied)

Install the filter in the suction line upstream of the compressors. It should be installed so the canister is at either a 45 or 90 degree angle to prevent oil accumulation.

Install the filter drier in the liquid line as close as possible to the expansion valves. Locate them upstream of the moisture indicator and solenoid valve.

control for coil frost protection, and ball shutoff valves.

SS-SVX09A-EN 31

Installation

Refer to Tab l e 5 for filter/filter drier recommendations.

Liquid Line Moisture Indicator Sight Glass

To aid in troubleshooting, install a moisture indicator sight glass in the liquid line near the evaporator, down stream of the solenoid valve prior to any branch takeoffs to the expansion valve. The sight glass should not be used to determine adequate refrigerant charge or sub-cooling. Actual temperature measurements are required to determine proper charge and sub-cooling.

Refer to Tab l e 6 for solenoid valve/moisture indicator sight glass recommendations.

Liquid Line Solenoid Valves

Liquid line isolation solenoid valves are required for refrigerant migration control into the evaporator during the “Off” cycle and should be connected as illustrated in the applicable field connection diagram.

Under certain conditions, liquid line solenoid valves may be used to trim the amount of active evaporator as compressors unload. Generally, the trim solenoid valve is unnecessary on comfort cooling VAV systems, and is only required on CV systems when dehumidification is a concern.

Refer to Tab l e 6 for solenoid valve/moisture indicator sight glass recommendations.

Thermostatic Expansion Valve (TEV)

Trane recommends a balance-ported externally equalized valve in order to maintain satisfactory superheat control down to lower valve 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 coil, an expansion valve is required for each coil distributor.

Access Valves (Ports)

The access ports in the liquid line allows the unit to be charged with liquid refrigerant and is used to determine sub-cooling.

The access ports in the suction line allows the operating suction pressure to be checked across the suction line filter. These ports are usually a Schraeder valve with core.

Ball Shutoff Valves

The ball shutoff valve allows for isolation of the Filter/Filter Drier for easier core replacement.

Two ball shutoff valves equal to the OD Tubing size for both the liquid line and suction line are required.

Frostat™ Coil Frost Protection

The Froststat control is the preferred method of coil frost protection. The Frostat control bulb is mechanically attached to the suction line near the evaporator and wired to the unit control panel. Refer to the proper field connection diagram for details.

Table 5. Filter/Filter Drier Recommendations

Capacity

20 Ton RSF-4817-T RPE-48-BD C-485-G RCW-48

25 Ton RSF-4817-T RPE-48-BD C-487-G RCW-48

30 Ton RSF-4817-T RPE-48-BD C-487-G RCW-48

40 Ton RSF-4817-T RPE-48-BD C-485-G RCW-48

50 Ton RSF-4817-T RPE-48-BD C-487-G RCW-48

60 Ton RSF-4817-T RPE-48-BD C-487-G RCW-48

Note: Use specific parts listed or equivalent. (Per Circuit)

Suction Line (Sporlan)

Filter Core (Sporlan)

Liquid Line (Sporlan)

Filter Drier Core (Sporlan)

32 SS-SVX09A-EN

Table 6. Solenoid Valve & Sight Glass w/Moisture Indicator

Capacity

20 Ton E19S250 MKC-2 @ 120V SA-15S

25 Ton E19S270 MKC-2 @ 120V SA-17S

30 Ton E19S270 MKC-2 @ 120V SA-17S

40 Ton E19S250 MKC-2 @ 120V SA-15S

50 Ton E19S270 MKC-2 @ 120V SA-17S

60 Ton E19S270 MKC-2 @ 120V SA-17S

Note: Use specific parts listed or equivalent. (Per Circuit)

Solenoid Valve

(Sporlan)

Solenoid Valve Coil

(Sporlan)

Figure 18. Typical Placement of Split System piping Components

Installation

Sight Glass with

Moisture Indicator

(Sporlan)

Split System Component Number Definitions

(1)Interconnecting Suction Line Tubing

(2)Suction Line Filter

(3)Shutoff Valves - Manual ball valves

(4)Interconnecting Liquid Line Tubing. If risers exceed 10 feet, Trane must review the application

(5)Shutoff valves - Manual ball valves

(6)Access Ports

(7)Liquid Line Filter Drier

(8)Liquid Line Solenoid Valve

(9)Moisture and Liquid Indicator

(10)FrostatTM (Required for coil freeze protection)

(11)Expansion Valve (One Expansion Valve for each Coil Distributor)

(12)Evaporator Coil

SS-SVX09A-EN 33

Installation

Refrigerant Piping

Refrigerant piping must be properly sized and applied. These two factors have a very significant effect on both system performance and reliability.

NOTICE

Use Type “L” refrigerant grade copper tubing only.

Refrigerant Piping should be sized and laid out according to the job plans and specifications. This should be done when the system components are selected.

Suction Line Piping

Proper suction line sizing is required to guarantee that oil is returned to the compressor throughout the operating system. Furthermore, the line must be sized so that the pressure drop does not excessively affect capacity or efficiency. To accomplish both, it may be necessary to have two sizes, one for horizontal run and vertical drops, and another for the vertical lifts. The suction line size preselected in the Table below are independent of the line length for a properly charged RAUC unit operating in a normal air conditioning application.

For more information, refer to the latest edition of Application Guide SS-APG001-EN.

1. Do not use suction line traps.

2. Do not use double risers.

3. Avoid putting liquid lines underground.

4. Route suction lines as short and direct as possible.

5. Slope suction lines toward the evaporator ¼-inch to 1-inch for every 10 feet.

6. Insulate the suction lines.

7. The suction line filter should be as close to the compressor as possible.

Note: If Suction Riser Exceeds 50 Feet, Trane Must Review The Application.

Suction Line Interconnecting Tubing

Capacity OD Horizontal (Per Circuit)

20 Ton 2-1/8" 1- 5/8"

25 Ton 2-1/8" 1-5/8"

30 Ton 2-1/8" 2-1/8"

40 Ton 2-1/8" 1-5/8"

50 Ton 2-1/8" 2-1/8"

60 Ton 2-1/8" 2-1/8"

Note: If risers exceed 50 feet, the application must be reviewed by Trane.

34 SS-SVX09A-EN

OD Vertical

(Per Circuit)

Liquid Line Piping

Installation

Liquid line sizes are based on their ability to provide a minimum of 5 degrees F (2.7ºC) of subcooling at the expansion valve throughout the unit’s operating system. Increasing the liquid line size does not increase the available sub-cooling. The uniform liquid line size, pre-selected in the Table below, are independent of the line length or rise within the permissible guidelines to maintain this minimum required 5 degree F (2.7ºC) sub-cooling at the expansion valve for a properly charged RAUC unit operating in a normal air conditioning application.

The liquid line should have a slight slope in the direction of flow so that it can be routed with the suction line.

The unit has a liquid line check valve that prevents liquid refrigerant from flowing backward through the liquid line, filling the condenser, and overflowing to the compressor during the “Off” cycle. A relief valve is also installed to prevent the build up of high pressure in the liquid line when the unit is off. For 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 condenser. The line that connects the outlet of the 235 psig relief valve to the liquid line service valve must not be removed.

For more information, refer to the latest edition of Application Guide SS-APG001-EN.

1. Avoid putting liquid lines underground.

2. Route liquid lines as short and direct as possible.

3. Slope liquid lines away form the condensing unit 1-inch for every 10 feet.

4. Only insulate liquid lines that pass through heated areas.

5. Wire solenoid valves according to the field connection diagram for proper pump down operation.

6. The liquid line filter drier should be as close to the solenoid valve as possible.

Note: If the liquid line riser exceeds 10 feet, refer to Tube Size and Component Selection,

publication number SS-APG001-EN

Liquid Line Interconnecting Tubing

Capacity OD Horizontal (Per Circuit)

20 Ton 5/8” 5/8”

25 Ton 7/8” 7/8”

30 Ton 7/8” 7/8”

40 Ton 5/8” 5/8”

50 Ton 7/8” 7/8”

60 Ton 7/8” 7/8”

Note: If risers exceed 10 feet, refer to Tube Size and Component Selection, publication number SS-APG001-EN

SS-SVX09A-EN 35

OD Vertical

(Per Circuit)

Installation

Evaporator Piping

1. Install the TXV directly to the unit liquid connection.

2. Locate the TXV bulb midway between the 90 degrees bends on top of the suction line as illustrated in

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 instructions enclosed in the kit as close to the evaporator as possible.

Figure 19. Typical Coil Piping For Dual Circuit Units

Figure 19 and Figure 20.

Figure 20. Typical Coil Piping For Dual Circuit Units

36 SS-SVX09A-EN

Hot Gas Bypass for Commercial Comfort-Cooling Applications

Hot gas bypass is not recommended for use on RAUC units. Frostat™ is the preferred method of protecting the evaporator from freeze-up. It turns off compressors when the coil frosting is sensed. The compressor is allowed to operate when the coil temperature rises a few degrees above the frosting condition. This action reduces the overall energy consumption of the system while reliably maintaining system control.

For more information, refer to the latest edition of Application Guide SS-APG001-EN.

Optional Pressure Gauges

When a unit is ordered with optional pressure gauges, (“F” is included in the miscellaneous digit of the model number), a set of gauges 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 gauges after field installation is shown below.

Installation

Final Refrigerant Pipe Connections

To access the refrigerant pipe connections, remove the louvered side grills.

These condensing units are shipped with a Nitrogen holding charge. Install pressure gauges to the appropriate access valve(s) and take a reading. If no pressure is present, refer to the “Leak Testing Procedure” section. If pressure is present, relieve the pressure before attempting to unsweat the “seal” caps. If refrigerant connections are not capped, but are “spun-end” tubes, use a tubing cutter to remove the end from the pipe.

Note: To prevent damage to the system, do not drill a hole in the seal caps or saw the ends off pipe

stubs. This may introduce copper chips into the system piping.

SS-SVX09A-EN 37

Installation

Brazing Procedures

 WARNING

Hazard of Explosion and Deadly Gases!

Never solder, braze or weld on refrigerant lines or any unit components that are above atmospheric pressure or where refrigerant may be present. Always remove refrigerant by following the guidelines established by the EPA Federal Clean Air Act or other state or local codes as appropriate. After refrigerant removal, use dry nitrogen to bring system back to atmospheric pressure before opening system for repairs. Mixtures of refrigerants and air under pressure may become combustible in the presence of an ignition source leading to an explosion. Excessive heat from soldering, brazing or welding with refrigerant vapors present can form highly toxic gases and extremely corrosive acids. Failure to follow all proper safe refrigerant handling practices could result in death or serious injury.

Proper brazing techniques are essential when installing refrigerant piping. The following factors should be kept in mind when forming sweat connections.

 WARNING

Hazard of Explosion!

Use only dry nitrogen with a pressure regulator for pressurizing unit. Do not use acetylene, oxygen or compressed air or mixtures containing them for pressure testing. Do not use mixtures of a hydrogen containing refrigerant and air above atmospheric pressure for pressure testing as they may become flammable and could result in an explosion. Refrigerant, when used as a trace gas should only be mixed with dry nitrogen for pressurizing units. Failure to follow these recommendations could result in death 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 an inert gas, such as dry nitrogen, through the tubing. Nitrogen displaces air in the tubing and prevents oxidation of the interior surfaces. A nitrogen flow of one to three cubic feet per minute is sufficient to displace the air. Use a pressure regulating valve or flow meter to control the flow.

2. Ensure that the tubing surfaces to be brazed are clean, and that the ends of the tubes have been carefully reamed to remove any burrs.

3. Make sure the inner and outer tubes of the joint are symmetrical and have a close clearance, providing an easy slip fit. If the joint is too loose, the tensile strength of the connection will be significantly reduced. The overlap distance should be equal to the diameter of the inner tube.

4. Wrap the body of each refrigerant line component with a wet cloth to keep it cool during brazing. Move any tube entrance grommets away for the brazing area.

Note: Use 40 to 45% silver brazing alloy (BAg-7 or BAg-28) on dissimilar metals. Use BCup-6

brazing alloy on copper to copper joints.

5. If flux is used, apply it sparingly to the joint. Excessive flux can enter the system which will contaminate the refrigerant system.

6. Apply heat evenly over the length and circumference of the joint to draw the brazing material into the joint by capillary action. Remove the brazing rod and flame from the joint as soon as a complete fillet is formed to avoid possible restriction in the line.

7. Visually inspect the connection after brazing to locate any pin holes or crevices in the joint. The use of a mirror may be required, depending on the joint location.

38 SS-SVX09A-EN

Leak Testing Procedure

 WARNING

Hazard of Explosion!

 WARNING

Hazard of Explosion!

When Leak-testing a refrigerant system, observe all safety precautions.

Installation

 WARNING

Never use oxygen, acetylene or compressed air for leak testing. Always install a pressure regulator, shutoff valves and gauges to control pressure during leak testing. Failure to do so could result in death or serious injury.

Trane condensing units are shipped with a Nitrogen holding charge. If there is no pressure, the unit must be leak tested to determine the location of leak as follows:

Note: These service 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-SB-1 (latest edition).

Use refrigerant gas as a tracer for leak detection and use oil-pumped dry nitrogen to develop the required test pressure. Test the high and low side of the system at pressures dictated by local codes.

1. Close the field supplied liquid line service valve(s) installed near the evaporator and the compressor discharge service valve to isolate the system's high side from the low side. Pressure test the liquid line, discharge line, and condenser coils at pressures dictated by local codes. Do not exceed 10# above the pressure control settings.

2. Connect a refrigerant cylinder to the charging port of the liquid line service valve. Use the refrigerant to raise the high side pressure to 12 to 15 psig.

3. Disconnect the refrigerant cylinder. Connect a dry nitrogen cylinder to the charging port and increase the high side pressure. Do not exceed the condenser maximum working pressure listed on the unit nameplate.

4. Use a halide torch, halogen leak detector or soap bubbles to check for leaks. Check all piping joints, valves, etc...

5. If a leak is located, use proper procedures to remove the refrigerant/nitrogen mixture, break the connection and remake as a new joint. Retest for leaks after making repairs.

6. Repeat the test procedure for the low side of the system, charging through the suction pressure gauge port or through an access provided on the suction line by the installer. Increase the system pressure to 100 psig.

SS-SVX09A-EN 39

Installation

7. If a leak is located, use proper procedures to remove the refrigerant/nitrogen mixture, break the

8. Open the liquid line service valve and the compressor discharge service valve.

Chilled Water Piping

Evaporator water inlet and outlet types, 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 water piping components for chiller applications. Refer to this illustration while following the discussion on the various piping components.

Isolate the water pumps from the system to avoid vibration transmission. To minimize heat gain and prevent condensation, insulate all water piping. Use an appropriate pipe sealant on all threaded connections.

connection and remake as a new joint. Retest for leaks after making repairs.

40 SS-SVX09A-EN

Figure 21. Evaporator Water-Pressure Drop

Installation

Note: Factor to convert “Feet of Water” to “Lbs. per Sq. Inch” (PSI): 2.3 Feet of Water = 1 PSI

SS-SVX09A-EN 41

Installation

Air Vents

Vents must be installed at high points in the piping system to facilitate air purging during the filling process.

Water Pressure Gauges

Install pressure gauge(s) to monitor the entering and leaving chilled water pressure.

NOTICE

To prevent evaporator damage, do not exceed 150 psig evaporator pressure.

Water Shutoff Valves

Provide shutoff valves in the “Supply” and “Return” pipe near the chiller so the gauge(s), thermostats, sensors, strainer, etc., can be isolated during service.

Pipe Unions

Use pipe unions to simplify disassembly for system service. Use vibration eliminators to prevent transmitting vibrations through the water lines.

Thermometers

Install thermometers in the lines to monitor the evaporator entering and leaving water temperatures.

Balancing Valves

Install a balancing cock (valve) in the leaving water line. It will be used to establish a balanced flow.

Note: Both the entering and leaving water lines should have shutoff valves installed to isolate the

evaporator for service.

Strainer

Install a pipe strainer in the water return line to protect the components from entrapped debris.

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: The BPHE chiller does not include a drain plug. Drain piping and shutoff valve must be

installed at the lowest point in the water piping to insure proper draining of the chiller. Insure that the drain is closed before filling system with water.

Chiller Flow Switch

Install a flow switch or other flow sensing device, illustrated in Figure 23, to prevent or stop the compressor operation if the water flow drops off drastically. A flow switch ships with a each unit when a “T” is included in the miscellaneous digit of the model number. Locate the device in the chilled water supply line (water outlet) as shown in Figure 22. Refer to the field wiring and unit schematics for the flow switch electrical interlock connections.

Water Temperature Sensor

The Temperature Sensor and Sensor-well must be installed in the leaving water piping as close to the chiller as possible. Both devices are located inside the remote panel. Thermal paste is also provided inside the remote panel and must be used when installing the sensor into the sensor-well. Refer to Figure 22 for the recommended location. Figure 24 illustrates the Sensor-well dimensions.

42 SS-SVX09A-EN

NOTICE

See unit dimensional drawings for inlet and outlet locations.

3. Evaporator is shown for illustration purposes only. Pipe connections are grooved.

Failure to use thermal paste could result in erratic temperature sensing resulting in equipment damage.

Freezestat

A Bulb-well (located inside the remote panel) must be installed in the leaving water piping as close to the chiller barrel as possible. It should be located upstream of the Temperature Sensor location. The Freezestat, located 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 inside the remote panel and must be used when installing the bulb into the bulb-well. Refer to Figure 22 for the recommended location. Figure 24 illustrates the Bulbwell dimensions.

Figure 22. Typical Piping Recommendations

Installation

SS-SVX09A-EN 43

Installation

Figure 23. Optional Flow Switch Illustration

Figure 24. Freezestat Bulb-well, Temperature Sensor & Well

NOTICE

Failure to use thermal paste could result in erratic temperature sensing resulting in equipment damage.

Final Water Piping Connections

1. All water piping to 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 damage to the internal components of the evaporator.

2. Connect the water pipe to the EVP chiller.

44 SS-SVX09A-EN

3. Install the drain plug, (if no drain is used) or ensure the drain shutoff valve is closed.

4. While filling the chiller system with solution, vent the air from the system at the highest points.

NOTICE

To prevent possible damage to the equipment, do not use untreated or improperly treated water in the system.

Field Installed Power Wiring

An overall dimensional layout for the field installed wiring entrance into the unit is illustrated in

Figure 3 to Figure 8. To insure that the unit’s supply power wiring is properly sized and installed,

follow the guidelines outlined below.

Note: Ensure the water drain shutoff valve is closed.

Verify that the power supply available is compatible with the unit’s nameplate ratings. The available supply power must be within 10% of the rated voltage stamped on the nameplate.

NOTICE

Use only copper conductors to connect the 3-phase power supply to the unit.

Disconnect Switch External Handle (Factory Mounted Option)

Installation

Units ordered with the factory mounted nonfused disconnect switch comes equipped with an externally mounted handle. This allows the operator to disconnect power from the unit without having to open the control panel door. The handle locations and its three positions are shown below;

“ON” - Indicates that the disconnect switch is closed, allowing the main power supply to be applied at the unit.

“OFF” - Indicates that the disconnect switch is open, interrupting the main power supply to the unit controls.

“OPEN COVER/RESET” - Turning the handle to this position releases the handle form the disconnect switch, allowing the control panel door to be opened.

Once the door has been opened, it can be closed with the handle in any one of the three positions outlined above, provided it matches the disconnect switch position.

The handle can be locked in the “OFF” position. While holding the handle in the “OFF” position, push the spring loaded thumb key, attached to the handle, into the base slot. Place the lock shackle between the handle and the thumb key. This will prevent it from springing out of position.

SS-SVX09A-EN 45

Installation

Main Unit Power Wiring

 WARNING

Hazardous Voltage!

Ta b l e 7 lists the field connection wire ranges for both the main power terminal block 1TB1 and the

optional main power disconnect switch 1S1. The unit electrical data is listed in Ta b le 8 . The electrical service must be protected from over current and short circuit conditions in accordance with NEC requirements. Protection devices must be sized according to the electrical data on the nameplate. Refer to the “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. the “Recommended Dual Element fuse size” (RDE).

1. If the unit is not equipped with an optional factory installed nonfused disconnect switch, a field supplied disconnect switch must be installed at or near the unit in accordance with the National Electrical Code (NEC latest edition). Refer to the “Power Wire Sizing & Protection Device Equations” (DSS calculation), for determining the correct size.

2. Complete the unit’s power wiring connections onto either the main terminal block 1TB1, or the factory mounted nonfused disconnect switch 1S1, inside the unit control panel. Refer to the customer connection diagram that shipped with the unit for specific termination points.

3. Provide proper grounding for the unit in accordance with local and national codes.

46 SS-SVX09A-EN

Power Wire Sizing and Protection Device

Equations

Table 7. Customer Connection Wire Range

Installation

To correctly size the main power wiring for the unit, use the appropriate calculation(s) listed below. Read the load definitions that follow and use Calculation #1 for determining the MCA (Minimum Circuit Ampacity), MOP (Maximum Over current Protection), and RDE (Recommended Dual Element fuse size) for each unit. Use Calculation #2 to determine the DSS (Disconnect Switch Size) for each unit.

Load Definitions:

LOAD 1 = CURRENT OF THE LARGEST MOTOR (COMPRESSOR OR FAN MOTOR)

LOAD 2 = SUM OF THE CURRENTS OF ALL REMAINING MOTORS

LOAD 4 = CONTROL POWER TRANSFORMER

= AND ANY OTHER 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 equal a standard fuse size as listed in NEC 240 - 6, select the next lower standard fuse rating.

Note: If selected MOP is less than the MCA, then select the lowest standard maximum fuse size

which is equal to or larger than the MCA, provided the selected fuse size does not exceed 800 amps.

RDE = (1.5 x LOAD 1) + LOAD 2 + LOAD 4

Select a fuse rating equal to the RDE value. If the RDE value does not equal a standard fuse size as listed in NEC 240 - 6 select the next higher standard fuse rating.

Note: If the selected RDE is greater than the selected MOP value, then select the RDE value to equal

the MOP value.

SS-SVX09A-EN 47

Installation

Calculation #2 Disconnect Switch Sizing (DSS)

DSS = 1.15 X (LOAD 1 + LOAD 2 + LOAD 4)

Table 8. Electrical Service Sizing Data

Unit Characteristics Condenser Fan Motor Compressor Motor

Allow-

able

Model

RAUC-C20E 200/60/3XL 180-220 101 125 125 0.90 2 1.0 4.1 20.7 2 41.4 _ 269.0 _ 10.7 _

RAUC-C20F 230/60/3XL 208-254 101 125 125 0.90 2 1.0 4.1 20.7 2 41.4 _ 251.0 _ 10.7 _

RAUC-C204 460/60/3XL 416-508 44 60 50 0.90 2 1.0 1.8 9.0 2 18.1 _ 117.0 _ 10.4 _

RAUC-C205 575/60/3XL 520-635 35 45 40 0.90 2 1.0 1.4 7.2 2 14.4 _ 94.0 _ 10.4 _

RAUC-C209

RAUC-C25E 200/60/3XL 180-220 129 175 150 0.90 3 1.0 4.1 20.7 2 41.4 60.5 269.0 409.0 10.9 16.3

RAUC-C25F 230/60/3XL 208-254 129 175 150 0.90 3 1.0 4.1 20.7 2 41.4 60.5 251.0 376.0 10.9 16.3

RAUC-C254 460/60/3XL 416-508 56 80 70 0.90 3 1.0 1.8 9.0 2 18.1 26.3 117.0 178.0 10.6 15.8

RAUC-C255 575/60/3XL 520-635 45 60 60 0.90 3 1.0 1.4 7.2 2 14.4 21.0 94.0 143.0 10.6 15.8

RAUC-C259

RAUC-C30E 200/60/3XL 180-220 148 200 175 0.90 3 1.0 4.1 20.7 2 _ 60.5 _ 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 575/60/3XL 520-635 52 70 60 0.90 3 1.0 1.4 7.2 2 _ 21.0 _ 143.0 _ 15.5

RAUC-C309

RAUC-C40E 200/60/3XL 180-220 192 225 225 0.90 6 1.0 4.1 20.7 4 41.4 _ 269.0 _ 10.7 _

RAUC-C40F 230/60/3XL 208-254 192 225 225 0.90 6 1.0 4.1 20.7 4 41.4 _ 251.0 _ 10.7 _

RAUC-C404 460/60/3XL 416-508 84 100 90 0.90 6 1.0 1.8 9.0 4 18.1 _ 117.0 _ 10.4 _

RAUC-C405 575/60/3XL 520-635 67 80 80 0.90 6 1.0 1.4 7.2 4 14.4 _ 94.0 _ 10.4 _

RAUC-C409

RAUC-C50E 200/60/3XL 180-220 244 300 175 0.90 6 1.0 4.1 20.7 4 41.4 60.5 269.0 409.0 11.0 16.4

RAUC-C50F 230/60/3XL 208-254 244 300 175 0.90 6 1.0 4.1 20.7 4 41.4 60.5 251.0 376.0 11.0 16.4

RAUC-C504 460/60/3XL 416-508 106 125 125 0.90 6 1.0 1.8 9.0 4 18.1 26.3 117.0 178.0 10.7 15.9

RAUC-C505 575/60/3XL 520-635 85 100 100 0.90 6 1.0 1.4 7.2 4 14.4 21.0 94.0 143.0 10.7 15.9

RAUC-C509

RAUC-C60E 200/60/3XL 180-220 282 300 300 0.90 6 1.0 4.1 20.7 4 _ 60.5 _ 409.0 _ 16.1

RAUC-C60F 230/60/3XL 208-254 282 300 300 0.90 6 1.0 4.1 20.7 4 _ 60.5 _ 376.0 _ 16.1

RAUC-C604 460/60/3XL 416-508 123 125 125 0.90 6 1.0 1.8 9.0 4 _ 26.3 _ 178.0 _ 15.6

RAUC-C605 575/60/3XL 520-635 98 11 110 0.90 6 1.0 1.4 7.2 4 _ 21.0 _ 143.0 _ 15.6

Charac.

380/415/50/

3XL

380/415/50/

3XL

380/415/50/

3XL

380/415/50/

3XL

380/415/50/

3XL

Electrical

Voltage

Range

342-418/

373-456

342-418/

373-456

342-418/

373-456

342-418/

373-456

342-418/

373-456

Circuit

Amp

Over-

Min.

current Protect

-ion

42 50 50 0.75 2 1.0 1.7 9.2 2 17.2 _ 110.0 _ 10.6 _

55 80 70 0.75 3 1.0 1.7 9.2 2 17.2 26.2 110.0 174.0 10.8 16.3

65 90 80 0.75 3 1.0 1.7 9.2 2 _ 26.2 _ 174.0 _ 16.2

80 90 90 0.75 6 1.0 1.7 9.2 4 17.2 _ 110.0 _ 10.6 _

104 125 125 0.75 6 1.0 1.7 9.2 4 17.2 26.2 110.0 174.0 10.9 16.4

Max.

Rec.

Dual

Element

Fuse

Size No

(Ea) No HP

FLA

(Ea)

LRA

(Ea)

RLA (Ea)

Ton

RLA

(Ea)

Ton

LRA

(Ea)

Ton

LRA

(Ea)

Ton

(Ea)

Ton

(Ea)

Ton

48 SS-SVX09A-EN

Installation

Table 8. Electrical Service Sizing Data (continued)

Unit Characteristics Condenser Fan Motor Compressor Motor

Allow-

Model

RAUC-C609

1. Electrical data is for each individual motor.

2. Max Overcurrent Protection device permitted by N.E.C. 440-22 (1993) is 225% of the largest compressor motor RLA plus the remaining motor RLA

and FLA values.

3. Minimum circuit ampacity is 125% of the largest compressor motor RLA plus the remaining motor RLA and FLA values.

4. Recommended dual element fuse size is 150% of the largest compressor motor RLA plus the remaining motor RLA and FLA values.

5. Kw values are taken at conditions of 45ºF saturated suction temperature at the compressor and 95ºF ambient.

6. Local codes may take precedence.

Electrical

Charac.

380/415/50/

3XL

able

Voltage

Range

342-418/

373-456

Min.

Circuit

Amp

Max.

Overcurrent Protect

-ion

122 125 125 0.75 6 1.0 1.7 9.2 4 _ 26.2 _ 174.0 _ 16.4

Rec.

Dual

Element

Fuse

Size No

(Ea) No HP

FLA

(Ea)

LRA

(Ea)

RLA (Ea)

Ton

RLA

(Ea)

Ton

LRA

(Ea)

Ton

LRA

(Ea)

Ton

(Ea)

Ton

(Ea)

Ton

Field Installed Control Wiring

 WARNING

Hazardous Voltage!

Before installing any connecting wiring, refer to Figure 3 to Figure 8 for the electrical access locations provided on the unit. Install appropriately sized control wiring for the 115 volt electrical components as required by the application.

Since the unit-mounted 115V control power transformer (1T1) is provided on all units, it is not necessary to run a separate 115 volt control power source to the unit.

Note: 200/230 Volt units are shipped with transformer 1T1 wired for 200 volt operation. If the unit

is to be operated on a 230 volt power supply, rewire the transformer as shown on the unit schematic.

Controls Using 115 VAC

 WARNING

Hazardous Voltage!

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 control circuit;

system control switch wiring (“No Control” units);

step controller wiring (“No Control” units);

chilled water pump interlock wiring (EVP units);

chilled water flow switch wiring (EVP units);

outside air thermostat wiring (EVP units):

SS-SVX09A-EN 49

Installation

liquid line solenoid valve(s).

Supply Fan Interlock (Control options utilizing an Air Handler)

The normally open evaporator fan interlock auxiliary contacts and the evaporator fan controls; system On/Off switch, fan starter/contactor, and overloads, must be wired as illustrated in the appropriate interlock connection wiring diagram for the specified application.

EVP Interlocks (EVP Flow control 6S58)

The flow switch is a binary output device and must be wired within the interlock circuit. Before installing the control wiring, refer to the remote panel illustration for the electrical access into the panel. Refer to the field connection diagram for the specific connection points inside the remote panel.

 WARNING

Ground Wire!

 WARNING

Grounding Required!

Follow proper local and state electrical code on requirements for grounding. Failure to follow code could result in death or serious injury.

Provide a proper ground for all control circuitry at the ground 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 compressor operation, the fluid flow through the chiller must be maintained. The field provided; ON/OFF switch, pump starter/contactor, auxiliary contacts and overloads (OL’s) must be installed as part of the system’s interlock circuit to disable the compressors in the event the circulating pump shuts down or is turned off.

Note: Due to the location of the 5S1 switch within the circulating pump control circuit, it can be

used as a system ON/OFF switch.

(Outside Air Thermostat 5S57)

A field provided outside air thermostat must be installed within the interlock circuit to prevent the system from operating below it’s workable temperature range. Before installing the control wiring, refer to the remote panel illustration for the electrical access into the panel. Refer to the field connection diagram for the specific connection points inside the remote panel. Refer to the “EVP Chiller Controls” section for temperature requirements.

Hot Gas Bypass (All control options)

If hot gas bypass is required, refer to the “Refrigerant Piping” illustration for supporting equipment tubing connections. Refer to the specific control option field connection diagram terminal connections for the hot gas bypass solenoid coils.

50 SS-SVX09A-EN

Controls using 24 VAC

 WARNING

Hazardous Voltage!

Before installing any connecting wiring, refer to Figure 3 to Figure 8 for the electrical access locations provided on the unit and Ta b l e 9 for AC conductor sizing guidelines, and;

1. Use copper conductors unless otherwise specified.

2. Ensure that the AC control wiring between the controls and the unit’s termination point does not exceed three (3) ohms/conductor for the length of the run.

NOTICE

Resistance in excess of 3 ohms per conductor may cause component failure due to insufficient AC voltage supply.

3. Be sure to check all loads and conductors for grounds, shorts, 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 control switch wiring (VAV units);

night setback relay wiring (VAV units);

economizer actuator circuit wiring (VAV units);

discharge air sensor wiring (VAV units);

chilled water temperature sensor (EVP units);

jumpers for hot gas bypass operation.

Installation

Table 9. AC Conductors

Distance from

Unit to Control

000 - 460 feet 18 gauge

461 - 732 feet 16 gauge

733 - 1000 feet 14 gauge

Recommended

Wire Size

Controls using DC Analog Input/Outputs

 WARNING

Hazardous Voltage!

Before installing any connecting wiring between the unit and components utilizing a DC analog input\output signal, refer to Figure 3 to Figure 8 for the electrical access locations provided on the unit.

SS-SVX09A-EN 51

Installation

These components may include:

Field installed Discharge Duct Sensor (6RT1 CV units);

Field installed Return Duct Sensor (6RT6 CV units);

Field installed Discharge Air Sensor (6RT3 VAV units);

Field installed Chilled Water Sensor (6RT2 EVP units);

1. Wiring for the components utilizing a DC analog input\output signal must be shielded cable (Belden 8760 or equivalent). Ground the shield at one end only.

2. Ta bl e 10 lists the conductor sizing guidelines that must be followed when interconnecting a DC binary output device to the unit.

Note: Resistance in excess of 2.5 ohms per conductor can cause deviations in the accuracy of the

controls.

3. Ensure that 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 signals in or around conduit housing high voltage wires.

Table 10. DC Conductors

Distance from Unit to Control Recommended Wire Size

000 - 499 feet 16 gauge

500 - 1000feet 14 gauge

Economizer Actuator Circuit

Each unit ordered with the Constant Volume or Variable Air Volume control option has the capability of controlling a field installed economizer. The diagram below illustrates a typical economizer actuator circuit.

When connecting the economizer actuator control circuit to the terminal board inside the unit control panel, refer to the actual unit wiring diagram for terminal designation, i.e. W, B, R, & Y. A separate power supply for the actuator(s) must be field provided.

52 SS-SVX09A-EN

Economizer Actuator Circuit Legend

Device Designation Device Designation Parts And Notes

MM Modutral Motor

TR Transformer M.H. 13081B; cover mounted

EC Enthalpy Control M.H. H2051046

MP Minimum Position Potentiometer M.H. S96A1012

EFI Evaporator Fan Interlock Field Provided

7TB88 Low Voltage Terminal Strip

R 1/4 Watt - 5% Carbon

No System Control

Temperature Control Parameters

Each unit ordered with the “No Controls” option, requires a field provided and field wired temperature controller. Single refrigerant circuit units require a 2-step control device, and dual refrigerant circuit units require a 4-step control device.

Each unit is shipped form the factory with internal “Fixed-On” & “Fixed-Off” time delays wired into each step of cooling. The “Fixed-Off” timers are 5 minutes each and they begin timing when the circuit for that step of cooling is deactivated. The “Fixed-On” timers are 3 minutes each and they begin timing when the circuit for that step is activated.

Note: Units ordered with the “No Controls” option can not be used with EVP Chiller applications.

Installation

M.H. M955, (Up to 3 motors may be controlled as shown. Additional motors must be slaved.)

Located in Temperature Controller Panel

1 Motor/Circuit = None Req. 2 Motors/ circuit = 1300 Ohms 3 Motors/Circuit = 910 Ohms

 WARNING

Hazardous Voltage!

Wire the controller in accordance with the field connection diagram illustrated in Figure 25.

SS-SVX09A-EN 53

Installation

Figure 25. Field Connection Diagram or RAUC-C20 - C60 “No System Controls” Applications

Refer to Wiring Notes on p. 55

54 SS-SVX09A-EN

Field Connection Diagram Notes for all System Control Options

Installation

SS-SVX09A-EN 55

Installation

Variable Air Volume Control (Honeywell W7100A)

In a variable air volume system, the desired space temperature is maintained by varying the amount of conditioned air being delivered to the space. As the cooling requirements of the space decreases, less air is delivered to the zone; conversely, as the cooling requirements of the space increases, a greater volume of air is delivered to the zone.

The descriptions of the following basic input devices used with the Honeywell W7100A discharge air controller are to acquaint the operator with their function as they interface with the controller. Refer to the field connection diagram in Figure 27 for the specific component connections at the unit control panel.

For discussion of evaporator fan interlock, hot gas bypass, and economizer connections, refer to the “Controls Using 115 VAC” section. Refer to Figure 26 for the specific component connections.

Discharge Air Sensor (Honeywell 6RT3)

Each unit ordered with variable air volume controls (digit 9 in the model number) is shipped with a Honeywell 6RT3 discharge air sensor.

 WARNING

Hazardous Voltage!

The sensor should be installed 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 information.

The sensor serves two functions;

1. It sends the supply air temperature data to the Discharge Air Controller, in the form of an analog input, to control the economizer (if applicable) and the cycling of the compressors.

2. It serves as a low limit sensor for the system when the supply air temperature reaches too high a delta tee between the actual supply air temperature and the supply air temperature setpoint.

Before installing any connecting wiring, refer to Figure 3 to Figure 8 for the electrical access locations provided on the unit. Wire the sensor in accordance with the field connection diagram in Figure 27. Shielded cable (Belden 8760 or equivalent) must be used when wiring the sensor to the terminal board inside the unit’s control panel.

Connect the shielded cable to the appropriate terminals on the terminal board (7TB7), in the unit’s control panel.

 WARNING

Ground Wire!

 WARNING

Grounding Required!

Follow proper local and state electrical code on requirements for grounding. Failure to follow code could result in death or serious injury.

Ground the shield (at the unit only) using the ground screw in the “customer 24 volt connection area as shown in the field connection diagram.

56 SS-SVX09A-EN

Suction Line Thermostat

Each unit ordered with variable air volume controls (digit 9 in the model number) is shipped with a suction line thermostat (6S63) that must be field installed.

Locate the thermostat close to the expa nsion valve bulb on a slightly flattened portion of the suction line. The thermostat must be securely fastened to the suction line and a field provided thermoconductive grease must be applied to the area to ensure good heat transfer.

 WARNING

Hazardous Voltage!

Before installing any connecting wiring, refer 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 Ta b l e 9 (AC Conductors) for wiring specifications.

Insulate the suction line, where the thermostat is mounted, to isolate it from the surrounding air.

Night Setback

Installation

 WARNING

Hazardous Voltage!

If night setback operation is desired, connect a set of normally open contacts (field provided) to the appropriate terminals on the terminal board (7TB7), in the unit’s control panel. Remove the factory installed jumper at the terminal board when making the final wiring termination. Refer to the field connection diagram in Figure 27 for details.

Figure 26. 6RT3 Discharge Air Sensor Assembly

SS-SVX09A-EN 57

Installation

Figure 27. Field Connection Diagram for RAUC-C20 - 60 “Variable Air Volume” Application

Refer to Wiring Notes on Page p. 55

EVP Chiller Control

Each unit ordered for EVP Chiller applications (digit 9 in the model number), is shipped with the following controls:

EVP Remote Panel w/ W7100G Controller

Freezestat (6S12)

Chiller Water Temperature Sensor (6RT2)

Freezestat Bulb well

Chilled Water Temperature Sensor Well

The installation of the freezestat bulb well, freezestat bulb, and the chilled water 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) controls the system operation by responding to the leaving water temperature. The remote panel must be mounted indoors and within 20 feet of the chiller.

Figure 28 illustrates the remote panel dimensional data, the component locations, the locations for

the shipwith items, grounding lugs, and the field connection terminal board 6TB9. Refer to the field

58 SS-SVX09A-EN

Installation

connection diagram illustrated in Figure 29 for the interconnecting points between the remote panel and the unit’s control panel.

 WARNING

Ground Wire!

 WARNING

Grounding Required!

Follow proper local and state electrical code on requirements for grounding. Failure to follow code could result in death or serious injury.

A ground wire must be installed between the EVP remote panel and the unit control panel.

W7100G Discharge Chilled Water Controller

The discharge chilled water controller (6U11) is shipped from the factory with a combination wire/ resistor type jumper installed across Terminals 6, 7, & 8. The resistive portion of the jumper is across Terminals 7 & 8, which set the number of operating stages, of the control.

As shipped, a 200 ohm resistive jumper is installed across Terminals 7 & 8 on the controller. The 200 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

Hazardous Voltage!

For 40 through 60 Ton units, requiring four (4) stages of operation, a 402 ohm resistive jumper must be installed across Terminals 7 & 8 on the controller. Remove the combination wire/resistor jumper containing the 200 ohm resistor from Terminals 6, 7, & 8. Locate the bag that is secured to the controller, and install the 402 ohm combination jumper across Terminals 6, 7, & 8 on the controller. Refer to the remote panel illustration for the terminal identification.

Note: The resistor portion of the combination jumper must be installed across Terminals 7 & 8 on

the controller.

The descriptions of the following input devices are to acquaint the operator with their function as they interface with the Honeywell W7100G controller.

Note: All wiring must comply with local and national electrical codes (NEC).

SS-SVX09A-EN 59

Installation

Figure 28. EVP Chiller Remote Panel

Chilled Water Temperature Sensor (Honeywell 6RT2)

With the sensor installed in its proper location within the chilled water piping (Figure 18), connect shielded cable (Belden 8760 or equivalent) from the sensor leads to the leads inside the remote panel. Refer to Figure 28 for the electrical access into the remote panel and the field connection diagram illustrated in Figure 29 for the final cable termination points.

 WARNING

Ground Wire!

 WARNING

Grounding Required!

Follow proper local and state electrical code on requirements for grounding. Failure to follow code could result in death or serious injury.

Note: Connect the shield ground to the ground screw inside the remote panel. Do not connect

both ends of the shield to ground.

60 SS-SVX09A-EN

Outside Air Thermostat (5S57 Field Provided)

The setpoint for the outside air thermostat is based upon the working ambient selected when the unit was ordered. A Zero (“0”) in the 11th digit of the model number indicates the system is designed for standard ambient operation of 40ºF and above. A One (“1”) in the 11th digit of the model number indicates the system is designed for low ambient operation of 0ºF and above. Therefore, select a thermostat with the appropriate operating range based on the unit specifications.

 WARNING

Hazardous Voltage!

Refer to the field connection diagram for the specific connection points inside the remote panel.

Installation

SS-SVX09A-EN 61

Installation

Figure 29. Field Connection Diagram for RAUC-C20 - 60 “EVP Chiller” Applications

Refer to Wiring Notes on Page p. 55

62 SS-SVX09A-EN

Constant Volume Control (Honeywell 973)

The descriptions of the following basic input devices used with the Honeywell 973 Master Energy Controller (MEC) are to acquaint the operator with their function as they interface with the controller. Refer to the field connection diagram in Figure 32 for the specific component connections at the unit’s control panel.

Electronic Zone Thermostat (Honeywell T7067)

Each unit ordered with constant volume controls (digit 9 in the model number) is shipped with a Honeywell T7067 electronic zone thermostat. A Honeywell switching subbase (Q667) is also included. The switching subbase allows the operator to select the “System Mode” of operation, i.e., Cool, Heat, Auto, or Off and the “Fan Mode” of operation, i.e., On or Auto.

Note: As long as the status of the system is in an occupied mode, the supply fan will operate

continuously. The fan will only cycle in the “Auto” mode during unoccupied periods.

The zone thermostat should be located in an area with good air circulation to enhance zone temperature averaging. Position the thermostat about 54" above the floor in a frequently occupied area.

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 appliances;

d. Concealed pipes and chimneys;

e. Vibrating surfaces; or

f. Unconditioned areas behind the thermostat (e.g., outside walls).

Mount the thermostat subbase on either a standard 2" X 4" handy box, a comparable European outlet box, or on any nonconductive flat surface. Refer to the illustration in Figure 30 for mounting details.

Note: Specific installation instructions are packaged with each thermostat and subbase. For

subbase and thermostat terminal identification, refer to Figure 31.

Installation

Thermostat Checkout

Once the subbase is mounted, before connecting any wiring, use an ohm meter and complete the continuity checks listed in Ta b l e 11.

Thermostat Wiring

 WARNING

Hazardous Voltage!

Before installing any connecting wiring, refer to Figure 3 to Figure 8 for the electrical access locations provided on the unit. Wire the thermostat in accordance with the field connection diagram in Figure 32.

SS-SVX09A-EN 63

Installation

Figure 30. T7067 Electronic Zone Thermostat & Q667 Switching Subbase

Figure 31. Q667 Switching Subbase & T7067 Thermostat Terminal Identification

64 SS-SVX09A-EN

Installation

Table 11. (Q667) Switching Subbase

Subbase Switch Positions

ON N/A 9 (Subbase) & 10 (Subbase) Closed

AUTO OFF

AUTO HEAT

AUTO AUTO

AUTO COOL

Check Continuity between These

Terminal Pairs

9 (Subbase) & 10 (Subbase) Open

5 (Subbase) & 5 (T’stat) Open

4 (Subbase) & 4(T’Stat) Open

9 (Subbase) & 10 (Subbase) Open

5 (Subbase) & 5 (T’stat) Closed

4 (Subbase) & 4(T’Stat) Open

9 (Subbase) & 10 (Subbase) Closed

5 (Subbase) & 5 (T’stat) Closed

4 (Subbase) & 4(T’Stat) Closed

9 (Subbase) & 10 (Subbase) Closed

5 (Subbase) & 5 (T’stat) Open

4 (Subbase) & 4(T’Stat) Closed

Circuit should

beFan System

Discharge Air Sensor (Honeywell 6RT1)

A discharge air sensor ships with each unit when the constant volume control option is ordered. The sensor should be installed 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 33 for installation and sensor dimensional information.

 WARNING

Hazardous Voltage!

Wire the sensor in accordance with the field connection diagram in Figure 32. As shipped form the factory, a resistor (7R1) is installed on terminal board 1TB8 terminals 5 & 6). Remove this resistor when the sensor is installed. Shielded cable (Belden 8760 or equivalent) must be used when wiring 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 the form of an analog input, to assist in the rate at which the system changes the space temperature. By offsetting the actual zone thermostat setpoint, up or down, the MEC can closer control the zone comfort level.

2. It serves as a low limit for the system when the supply air temperature reaches too high a delta tee between the actual supply air temperature and the zone temperature to help prevent overshooting of the zone thermostat setpoint.

SS-SVX09A-EN 65

Installation

Figure 32. Field Connection Diagram for RAUC- C20 through 60 “Constant volume” Applications

Refer to Wiring Notes on Page p. 55

66 SS-SVX09A-EN

Figure 33. 6RT1 Discharge Air Sensor Assembly

Installation

SS-SVX09A-EN 67

System Pre-Start Procedures

Use the checklist provided below in conjunction with the “General Unit Requirement” checklist” to ensure that the unit is properly installed and ready for operation. Be sure to complete all of the procedures described in this section before starting the unit for the first time.

 WARNING

Hazardous Voltage!

[ ] Turn the field supplied disconnect switch, located upstream of the unit, to the “Off” position.

[ ] Turn the “System” selection switch (at the Remote Panel) to the “Off” position and the “Fan” selection switch (if applicable) to the “Auto” or “Off” position.

[ ] Check all electrical connections for tightness and “point of termination” accuracy.

[ ] Verify that the condenser airflow will be unobstructed.

[ ] Check the condenser fan blades. Ensure they rotate freely within the fan orifices and are securely fastened to the fan motor shaft.

[ ] Disable the compressor (s) by unplugging the reset relay for each circuit. Refer to the unit-wiring diagram that sipped with the unit.

NOTICE

Compressor Damage!

Do not allow liquid refrigerant to enter the suction line. Excessive liquid accumulation 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.

COMPRESSOR SERVICE VALVES MUST BE FULLY OPENED BEFORE START-UP (SUCTION, DISCHARGE, LIQUID LINE, AND OIL LINE).

[ ] Remove the protective plastic coverings that shipped over the compressors.

[ ] Check the compressor oil levels. The oil level in each manifold set of compressor sight glasses should be equally 1/2 to 3/4 full when they are “Off”.

[ ] Pack Stock Units;

Two low pressure switches are installed at the factory. However, only one is wired into the control circuit. This is to facilitate either an EVP chiller application or an air over evaporator application. Before starting the system, verify that the correct pressure switch for the application is connected to the control circuit. Refer to Tab le 1 3 for the pressure control settings and the unit wiring diagram, that shipped with the unit, for the appropriate connections.

[ ] Check the condenser coils. They should be clean and the fins should be straight. Straighten any bent coil fins with an appropriate sized fin comb.

[ ] Inspect the interior of the unit for tools and debris.

EVP Chiller Applications

[ ] Fill the chilled water system.

[ ] Vent the chilled water system at the highest points in the system. Brazed plate heat exchangers should be purged with water through the field provided vent ports to displace any air in the heat exchanger. Shell and tube heat exchanges (chiller barrels) should have the vent plug removed

68 SS-SVX09A-EN

before filling with water to displace any air in the barrel. Close vent ports or replace the vent plug after purging or filling.

[ ] Once the system has been filled, inspect the entire chilled water piping system for leaks. Make any necessary repairs before proceeding.

NOTICE

To avoid possible equipment damage, do not use untreated or improperly treated system water.

[ ] Inspect the interior of the unit for tools and debris in preparation for starting the unit and complete the remainder of the “Pre-start” procedures before starting the unit.

System Evacuation Procedures

Each refrigeration circuit for split system applications must be evacuated before the unit can be started. Use a rotary type vacuum pump capable of pulling a vacuum of 100 microns or less. Verify that the unit disconnect switch and the system control circuit switches are “OFF”.

The oil in the vacuum pump should be changed each time the pump is used with a high quality vacuum pump oil. Before using any oil, check the oil container for discoloration which usually indicates moisture in the oil and/or water droplets. Moisture in the oil adds to what the pump has to remove from the system, making the pump inefficient.

When connecting the vacuum pump to a refrigeration system, it is important to manifold the vacuum pump to both the high and low side of the system (liquid line access valve and suction line access valve). Follow the pump manufacturer’s directions for the proper methods of using the vacuum pump.

The lines used to connect the pump to the system should 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 recommended for system evacuation because they have moisture absorbing characteristics which result in excessive rates of evaporation, causing pressure rise during the standing vacuum test. This makes it impossible to determine if the system has a leak, excessive residual moisture, or a continual or high rate of pressure increase due to the hoses.

An electronic micron vacuum gauge should be installed in the common line ahead of the vacuum pump shutoff valve, as shown in Figure 34. Close Valves B and C, and open Valve A.

Start the vacuum pump, after several minutes, the gauge reading will indicate the maximum vacuum the pump is capable of pulling. Rotary pumps should produce vacuums of 100 microns or less.

System Pre-Start Procedures

NOTICE

Do not, under any circumstances, use a megohm meter or apply power to the windings of a compressor while it is under a vacuum. Electrical shorting between motor windings and/or housing can occur while in a vacuum, causing motor burnout.

Open Valves B and C. Evacuate the system to a pressure of 300 microns or less. As the vacuum is being pulled on the system, there could be a time when it would appear that no further vacuum is being obtained, yet, the pressure is high. It is recommended that during the evacuation process, the vacuum be “Broken”, to facilitate the evacuation process.

To break the vacuum;

Shutoff valves A, B, & C and connect a refrigerant cylinder to the charging port on the manifold. Purge the air from the hose. Raise the standing vacuum pressure in the system to “zero” (0 psig) gauge pressure. Repeat this process two or three times during evacuation.

SS-SVX09A-EN 69

System Pre-Start Procedures

Note: It is unlawful to release refrigerant into the atmosphere. When service procedures require

working with refrigerants, the service technician must comply with all Federal, State, and local laws. Refer to the General Service Bulletin MSCU-SB-1 (latest edition).

Standing Vacuum Test

Once 300 microns or less is obtained, close Valve A and leave valves B and C open. This will allow the vacuum gauge to read the actual system pressure. Let the system equalize for approximately 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 200 microns but levels off to a constant value, excessive moisture is present. If the pressure steadily continues to rise, a leak is indicated. Figure 35 illustrates three possible results of the “standing vacuum test”. If a leak is encounter, repair the system and repeat the evacuation process until the recommended vacuum is obtained. Once the system has been evacuated, break the vacuum with refrigerant, and complete the remaining “Pre-Start Procedures” before starting the unit.

Figure 34. Typical Vacuum Pump Hookup

70 SS-SVX09A-EN

Figure 35. Evacuation Time vs. Pressure Rise

System Pre-Start Procedures

Discharge Air Controller Checkout (Honeywell W7100A)

Note: The following checkout procedure must be performed in its entirety and in the sequence

given.

 WARNING

Hazardous Voltage!

The W7100A (7U11) discharge air controller can be checked out using a highly accurate digital voltohmmete r and the W 7100A acc essory to ol kit (Trane part # 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 evaporator fan and condensing unit “OFF”.

3. Disable the mechanical cooling by removing the field installed evaporator fan auxiliary interlock wire from terminal board 7TB5 terminal 3 inside the unit control panel.

4. At the Discharge Air Controller, in the unit control panel, remove the red dust cover from the test plug socket at the bottom of the W7100A. Insert the “Test Plug”, from the kit, into the test plug socket. The test plug overrides most of the built-in time delays for staging the compressors “On” and “Off”. Refer to the illustration in

SS-SVX09A-EN 71

Figure 36 for terminal and control dial identification.

System Pre-Start Procedures

5. Install a jumper across the P and P1 terminals (remote setpoint input), and another jumper across terminals 6 and 7 (reset input) if reset is enabled.

6. Disconnect the wires from terminals T and T1 (discharge air sensor).

7. Remove the 3,400 ohm resistor (blue leads) from the test kit and connect it across terminals T and T1 to simulate a discharge air temperature of 60ºF.

8. Set the “Setpoint F” dial at 56ºF or below; then set the “Control Band F” dial at 2 to minimize the control response time.

9. At the Discharge Air controller, verify that the controller ground wire is connected to the chassis ground. Refer to the unit wiring diagram that shipped on the unit.

Note: It is not necessary to set the “Reset F” dial since the factory installed jumper across

Terminals 6 and 7 disables this dial.

10. Turn the control circuit switch 1S2, in the unit control panel, and the main power disconnect switch for the condensing unit to the “ON” position.

 WARNING

High Voltage is Present at Terminal Block 1TB1 or Unit Disconnect Switch 1S1.

To prevent injury or death form electrocution, it is the responsibility of the technician to recognize this hazard and use extreme care when performing service procedures with the electrical power energized.i

After approximately 2 minutes (time required to drive the economizer fully open), the LEDs on the W7100 should begin 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 64ºF; within 10 seconds, the LEDs should turn “Off” as the cooling outputs stage “Off”.

13. Immediately readjust the “Setpoint F” dial to 56oF; the LEDs should begin to illuminate again as the cooling outputs stage “On”.

If the unit includes the zone reset option, proceed to the next step; if not, proceed to step 18.

14. Set the “Reset F” dial at 15oF and the “Setpoint F” dial at 41ºF; then remove the jumper across terminals 6 & 7.

To simulate a call for maximum reset, install the 1780 ohm resistor (red leads), from the test kit, across terminals 6 and 7. The cooling LEDs should remain lit.

15. Turn the “Setpoint F” dial to 49ºF; within 1 to 2 minutes, the LEDs should turn “Off” as the cooling outputs stage “Off”.

16. As soon as all of the cooling LEDs are “Off”, remove the 1780 ohm resistor from terminals 6 and 7 and re-install the jumper across these terminals.

17. Adjust the “Setpoint F” dial to 56ºF; within 1 minute, the LEDs should illuminate as the cooling outputs stage “On”.

If the system includes an economizer, complete steps 18 through 23 to verify proper economizer control operation; if not, proceed to step 24.

18. With all of the cooling LEDs “On”, measure the DC voltage across terminals R (-) and W (+). The measured voltage should be 1.7 VDC to 2.1 VDC.

19. Set the “Setpoint F” dial at 64ºF to drive the economizer output to the minimum position.

Within 2 minutes, the LEDs should turn “Off” as the cooling outputs stage “Off”.

72 SS-SVX09A-EN

System Pre-Start Procedures

In approximately 5 minutes; measure the voltage across terminals R (-) & W (+). The measured voltage should drop to approximately 0.2 VDC.

20. Turn the control circuit switch 1S2, in the unit control panel, and the main power disconnect switch to the “OFF” position.

21. Remove the wires from terminals R, B, W, & Y.

22. Measure the resistance across the following pairs of terminals, and compare the actual resistance readings with the values shown below.

W7100 Terminals R-to-W = 226 ohms

W7100 Terminals R-to-B = 432 ohms

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 power disconnect switch to the “OFF” position.

25. Remove the jumper, installed in step 5, from terminals 6 & 7.

26. Remove the 3,400 ohm resistor from terminals T & T1 and reconnect the discharge air sensor leads to terminals T & T1.

27. Remove the “Test Plug” from the W7100 test socket and reinstall the red dust cover.

28. Reconnect the field installed evaporator fan auxiliary interlock wire to terminal board 7TB5 terminal 3.

29. Turn all control switches to the “On” position and restore main power to the system.

Figure 36. W7100A Discharge Air Controller

SS-SVX09A-EN 73

System Pre-Start Procedures

Discharge Air Sensor Checkout (Honeywell Sensor)

 WARNING

Hazardous Voltage!

1. Verify that the main power disconnect switch and the control circuit switch 1S2, in the unit control panel, is “OFF”.

2. At the Discharge Air Controller, in the unit control panel, disconnect the wire connected to Terminal 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 equivalent temperature.

4. Measure the actual temperature at the sensor location. If the measured resistance in step 2 is not within ± 10.0 ohms of the actual temperature, the sensor is out of range; replace it.

Note: Before condemning the sensor, verify that the connecting cable resistance is not excessive.

Refer to the “Field Installed Control Wiring” section.

5. Make all necessary repairs and reconnect the duct sensor lead to terminal T1 on the controller.

6. Restore power to the system and turn all control switches to the “ON” position.

Economizer Actuator Checkout

(w/ “Zone” or “Discharge Air” Temp Controller)

The following 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 used, refer to the specific checkout procedures for that actuator.

 WARNING

Hazardous Voltage!

1. Turn all control switches to the “Off” position to deactivate the Evaporator Fan and the Mechanical Cooling. Verify that the main power disconnect switch for the condensing unit and the control circuit switch 1S2, in the unit control panel, is “OFF”.

2. Verify that the field provided disconnect switch and/or the control circuit switch for the economizer actuator(s) is “OFF”.

3. At the actuator, disconnect the control wires connected to Terminals W, R, B, and Y.

4. Install a jumper across the actuator terminals R-to-W-to-B.

5. Close the field provided disconnect switch and/or the control circuit switch for the economizer actuator(s). If the economizer actuator is working properly, it should drive to mid-position.

6. Open the field provided disconnect switch and/or the control circuit switch for the economizer actuator(s) and remove the jumpers installed in step 4.

7. Reconnect the control wires to the actuator terminals W, R, B, and Y.

8. Restore power to the actuator circuit and turn all control switches to the “ON” position and restore power to the system.

74 SS-SVX09A-EN

Figure 37. Discharge Duct Sensor 6RT2 & 6RT3 “Temperature vs Resistance” Curve

Temperature - OF (OC)

3483 ± 10 Ohms @

F (25O C)

4200 4000 3800 3600 3400 3200 3000

Resistance (Ohms)

20 40 60 80 100 120 140 160 180 200 220

(-6.7oC) (4.4oC) (15.6oC) (26.7oC) (37.8oC) (48.9oC) (60.0oC) (71.1oC) (82.2oC) (93.3oC) (104.4oC)

EVP Chiller Control Checkout (Honeywell W7100G)

Note: The following checkout procedure must be performed in its entirety and in the sequence

given.

System Pre-Start Procedures

 WARNING

Hazardous Voltage!

The W7100G (6U11) chilled water controller can be checked out using a highly accurate digital voltohmmeter, the W7100 accessory tool kit (Trane part # TOL-0101 or Honeywell part # 4074EDJ), and the Honeywell 4074EFV resistor bag assembly.

1. Verify that the main power disconnect switch and the control circuit switch 1S2, in the unit control panel, is “OFF”.

2. At the unit control panel, unplug the reset relay 1K11 and 1K12, (1K12 used on 40 through 60 Ton units only). Refer to the connection diagram that shipped with the unit for the location of the relay(s).

3. At the Chilled Water controller (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 simulate a discharge air temperature of 60ºF.

5. Remove the factory-installed jumper (wire 209A) from the “fast response” Terminals 9 & 10.

6. To simulate a call for maximum reset, remove the jumper from Terminals 6 & 7 and install the 1780 ohm resistor (red leads), from the test kit, across Terminals 6 and 7.

7. Install a jumper across the P1 and P2 Terminals (remote setpoint input).

8. Remove the red dust cover from the test plug socket at the bottom of the W7100G. Insert the “Test Plug”, from the kit, into the test plug socket. The test plug overrides most of the built-in time delays for staging the compressors “On” and “Off”. Refer to the illustration in terminal and control dial identification.

9. Set the “Reset F” dial at 20ºF and the “Setpoint F” dial at 10ºF

Figure 38 for

SS-SVX09A-EN 75

System Pre-Start Procedures

10. “Close” the main power disconnect switch and turn the control circuit switch 1S2, in the unit control panel, “ON”.

 WARNING

High Voltage is Present at Terminal Block 1TB1 or Unit Disconnect Switch 1S1.

11. At the Chilled Water Controller, use a digital voltmeter to verify there is 24 volts AC across terminals TR & TR.

12. After approximately 15 seconds, the LEDs on the W7100G should begin to illuminate as the cooling outputs stage “On”.

13. Set the “Setpoint F” dial at 60ºF; within 15 seconds, the LEDs should turn “Off” as the cooling outputs stage “Off”.

14. Remove the 1780 ohm resistor from Terminals 6 & 7 and reinstall the wire jumper removed in step 6.

15. Set the “Setpoint F” dial at 50ºF; within 15 seconds, the LEDs should turn “On” as the cooling outputs stage “On”.

16. Turn the control circuit switch 1S2, in the unit control panel, to the “OFF” position.

17. Remove the 3,400 ohm resistor from Terminals T & T1 and reconnect the chilled water temperature sensor leads to Terminals T & T1.

18. Remove the “Test Plug” from the W7100G test socket and reinstall the red dust cover.

19. Plug the reset relay(s) 1K11 and 1k12 (if applicable) back into their receptacle.

20. Turn the control switch 1S2 to the “On” position to restore power to the control system.

76 SS-SVX09A-EN

Figure 38. W7100G Chilled Water Controller

System Pre-Start Procedures

Chilled Water Sensor Checkout (Honeywell Sensor)

 WARNING

Hazardous Voltage!

1. Verify that the main power disconnect switch and the control circuit switch 1S2, in the unit control panel, is “OFF”.

2. At the temperature controller, disconnect the wire connected to terminal 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 equivalent temperature.

4. Measure the actual temperature at the sensor location. If the measured resistance in step 2 is not within ± 10.0 ohms of the actual temperature, the sensor is out of range; replace it.

Note: Before condemning the sensor, verify that the connecting cable resistance is not excessive.

Refer to the “Field Installed Control Wiring” section.

5. Make all necessary repairs and reconnect the duct sensor lead to terminal T1 on the controller.

6. Turn all control switches to the “ON” position and restore power to the system.

SS-SVX09A-EN 77

System Pre-Start Procedures

Master Energy Control Checkout

 WARNING

Hazardous Voltage!

1. Open the system control switches 5S1 and 5S2 to disable the Evaporator Fan and Heating system.

2. Verify that the main power disconnect switch and the control circuit switch 1S2, in the unit control panel, is “OFF”.

3. At the Master Energy Controller (7U11), in the unit control panel, remove at least one wire from each of the “Heat Relay” normally open contacts and one from each of the “Cool Relay” normally open contacts. Insulate the wires with tape to prevent shorting or grounding during control checkout.

4. Close the main power disconnect switch and turn the control circuit switch 1S2, in the unit control panel, “ON”.

 WARNING

High Voltage is Present at Terminal Block 1TB1 or Unit Disconnect Switch 1S1.

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). Refer to the illustration in Figure 36 for terminal identification.

Note: The wires that are still connected to one side of the “Cool Relay” contacts, are active with

115 volts applied. Ohming the contacts when only one wire is connected will not cause any damage to the ohmmeter. However, do not try to ohm any set of contacts with wires connected to both terminals of that contact.

6. To verify the “Heating” output relays are operating;

a. place a jumper between Terminals 2 (+20) & 5 (H).

b. place the ohmmeter leads across each set of normally open “Heat Relay” contacts. The

ohmmeter should read “Resistance” which indicates that the heating output relays have “pulled in”.

7. To verify the “Cooling” output relays are operating;

a. Remove the jumper from Terminals 2 (+20) & 5 (H) and reinstall it between Terminals 2 (+20)

& 4 (C).

b. place the ohmmeter leads across each set of normally open “Cool Relay” contacts. The

ohmmeter should read “Resistance” which indicates that the cooling output relays have “pulled in”.

8. With all of the “Cooling Output” relays pulled in (step 7), measure the DC voltage across Terminals R (-) and W (+). The measured voltage should be approximately 1.7 to 2.1 VDC.

9. Remove the jumper installed between Terminals 2 (+20) & 4 (C).

78 SS-SVX09A-EN

10. Measure the voltage again across Terminals R (-) and W (+). The measured voltage should now be approximately 0.2 VDC.

11. Turn the control circuit switch 1S2, in the unit control panel, to the “OFF” position.

12. Remove the wires from Terminals R, B, W, & Y.

13. Measure the resistance across the following pairs of terminals and compare the actual resistance readings with the values shown below:

(1) MEC Terminals R-to-W = 226 ohms

(2) MEC Terminals R-to-B = 432 ohms

(3) MEC Terminals R-to-Y = 226 ohms

14. Reconnect the economizer leads W, R, B and Y to the appropriate terminals on the controller.

15. Turn switches 1S2, 5S1, & 5S2 to the “ON” position to restore power to the control system.

Zone Thermostat Checkout (Honeywell T7067)

1. Open the system control switches 5S1 and 5S2 to disable the Evaporator Fan and Heating system.

2. Close the main power disconnect switch and turn the control circuit switch 1S2, in the unit control panel, “ON”.

 WARNING

High Voltage is Present at Terminal Block 1TB1 or Unit Disconnect Switch 1S1.

System Pre-Start Procedures

3. At the Zone Thermostat (6U37), use a digital voltmeter to verify that there is 20 volts DC power between thermostat Terminals 1 & 2. Refer to the illustration in identification. Refer to Ta bl e 12 for the thermostat “voltage output” ramps.

4. To check the “Cooling” output signal, place the voltmeter leads between thermostat Terminals 1 & 4. Refer to

a. move the cooling (blue) setpoint lever from right to left. As the cooling setpoint is lowered,

the voltage signal should increase and the “Cooling” LED brighten.

b. move the cooling (blue) setpoint lever from left to right. As the cooling setpoint rises, the

voltage signal should decrease and the “Cooling” LED dim.

5. To check the “Heating” output signal, place the voltmeter leads between thermostat Terminals 1 & 5. Refer to

a. move the heating (red) setpoint lever from left to right. As the heating setpoint rises, the

voltage signal should increase and the “Heating” LED brighten.

b. move the heating (red) setpoint lever form right to left. As the heating setpoint lowers, the

voltage signal should decrease and the “Heating” LED dim.

Figure 30 and;

Figure 31 for terminal

SS-SVX09A-EN 79

System Pre-Start Procedures

Table 12. Zone Thermostat (6U37) “Voltage Output” ramps

1U11

Function

HEAT 1 4.63 VDC 4.0 VDC

HEAT 2 5.88 VDC 5.25 VDC

HEAT 3 7.13 VDC 6.50 VDC

HEAT 4 8.38 VDC 7.75 VDC

COOL 1 4.58 - 5.42 VDC 3.44 - 4.56 VDC

COOL 2 5.43 - 6.34 VDC 4.69 - 5.81 VDC

COOL 3 6.63 - 7.63 VDC 5.90 - 7.10 VDC

COOL 4 7.84 - 8.92 VDC 7.11 - 8.39 VDC

Economizer 2.75 - 4.00 VDC

* "Pull-In" and "Drop-Out" valves are ± 0.25 VDC ** If Applicable

Nominal Operating Points and Throtting Ranges

Pull-In

Voltage*

Drop-Out

Voltage

Throtting

Range

Measured

between

these 1U11

Terminals

Terminal 5 ( h e a t i n g )

Terminal 1 (common)

Terminal 4 ( c o o l i n g )

Terminal 1 (common)

Discharge Air Sensor Checkout (Honeywell 6RT1)

 WARNING

Hazardous Voltage!

1. Turn the control circuit switch 1S2, in the unit control panel, to the “OFF” position.

2. At the Master Energy Controller, disconnect the wire connected to Terminal T1. Use a digital ohmmeter to measure the resistance between Terminal T and the wire removed from Terminal T1.

3. Use the conversion chart in Figure 37 to convert the measured resistance to an equivalent temperature.

4. Measure the actual temperature at the sensor location. If the measured resistance 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.

Refer to the “Field Installed Control Wiring” section.

5. Make all necessary repairs and reconnect the duct sensor lead to terminal T1 on the controller.

6. Turn switches 1S2, 5S1, & 5S2 to the “ON” position to restore power to the control system.

80 SS-SVX09A-EN

System Pre-Start Procedures

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 - Degree F (C)

Resistance (Ohms)

(16oC) (18oC) (21oC) (24oC) (27oC) (29oC) (32oC) (35oC)

3000 Ohms @

F (25O C)

Figure 39. 6RT1 Discharge Duct Sensor “Temperature vs Resistance” Curve

SS-SVX09A-EN 81

Figure 40. W973 Master Energy Controller (MEC)

System Pre-Start Procedures

Voltage Imbalance

Excessive three phase voltage imbalance between phases will cause motors to overheat and eventually fail. The maximum allowable voltage imbalance is 2%. Measure and record the voltage between phases 1, 2, and 3 and calculate the amount of imbalance as follows:

% Voltage Imbalance = 100 X [(AV - VD)/(AV)] where;

AV (Average Voltage) = (Volt 1 + Volt 2 + Volt 3)/3

V1, V2, V3 = Line Voltage Readings

VD = Line Voltage reading that deviates the farthest from the average voltage.

Example: If the voltage readings of the supply power measured 221, 230, and 227, the average volts would be:

(221 + 230 + 227)/3 = 226 Avg.

VD (reading farthest from average) = 221

The percentage of Imbalance equals:

100 X [(226 - 221)/226)] = 2.2%

The 2.2% imbalance in this example exceeds the maximum allowable imbalance of 2.0%. This much imbalance between phases can equal as much as a 20% current imbalance with a resulting increase in motor winding temperatures that will decrease motor life. If the voltage imbalance is over 2%, notify the proper agencies to correct the voltage problem before operating this equipment.

Electrical Phasing

Proper electrical phasing can 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 supplied disconnect switch that provides power to terminal block 1TB1 to the “Off” position.

[ ] Connect the phase sequence indicator leads to the terminal block or to the “Line” side of the optional factory mounted disconnect switch as follows;

Black (phase A) to L1

Red (phase B) to L2

Yellow (phase C) to L3

[ ] Close the main power disconnect switch or circuit protector switch that provides the supply power to the condensing unit.

 WARNING

High Voltage is Present at Terminal Block 1TB1 or Unit Disconnect Switch 1S1.

[ ] Observe the ABC and CBA phase indicator lights on the face of the sequencer. The ABC indicator light will glow if the phase is ABC. If the CBA indicator light glows, open the disconnect switch or circuit protection switch and reverse any two power wires.

[ ] Restore the main electrical power and recheck the phasing. If the phasing is correct.

[ ] Open the main power disconnect switch or circuit protection switch and remove the phase sequence indicator.

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Sequence of Operation

VAV W7100A Discharge Air Controller (7U11)

The discharge air controller used in Variable Air Volume applications is a Honeywell W7100A. This microprocessor controller is designed to maintain an average discharge air (D/A) temperature by:

1. monitoring the discharge air temperature sensor; and

2. modulating economizer dampers and sequencing stages of mechanical cooling “On” or “Off”, as required.

The W7100A receives analog input from the discharge air sensor mounted in the supply duct every 2 to 3 seconds by pulsing DC current across the sensor, then “reading” the voltage potential across this thermistor.

If the comparison between the setpoint and the actual discharge air temperature indicates that cooling is required, the W7100A attempts to satisfy the load by modulating the economizer open (if applicable).

Economizer Cycle

The economizer is only allowed to function if the ambient conditions are below the setpoint of the enthalpy switch.

If the ambient air conditions are above the enthalpy setpoint, the W7100A will open the Fresh Air dampers to the minimum setpoint position.

To take full advantage of the “free cooling” provided by the economizer, the W7100A “resets” the discharge air setpoint. The amount of “reset” between the actual discharge air setpoint and the economizer control point is equal to 1/2 of the W7100’s control band setpoint.

Example: With a typical control band setting of 6oF, the amount of discharge air “reset” is 3ºF (1/ 2 of the control band setpoint). Therefore, if the discharge air setpoint is 55ºF, the economizer control point is 52ºF (i.e., 55ºF - 3ºF).

A second economizer “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 temperature strays further from the control point, the response time becomes faster; and, as the discharge air temperature approaches the control point, the response time becomes slower.

When the discharge air temperature is within the “Deadband” (± 1.5ºF of the economizer control point); the W7100A maintains the economizer’s present position.

When the economizer can not handle the cooling requirement or when the outdoor ambient conditions are unsuitable for “economizing”, the W7100A activates the unit’s mechanical cooling section.

Note: As long as ambient conditions are suitable for economizing, the economizer works in

conjunction with the mechanical cooling operation.

The control algorithm used by the W7100A to add stages of cooling is illustrated in Figure 41. When the discharge air temperature drifts above the setpoint, “Region 1”, a stage of mechanical cooling is added based on time and the amount of deviation from setpoint. If the discharge air temperature remains above the setpoint, the W7100A energizes additional stages of mechanical cooling.

If the operating cooling stage is capable of satisfying the cooling requirement, as the discharge air temperature falls below the setpoint for a sufficient period of time, the W7100A turns the stages of mechanical cooling “Off”, “Region 3”.

The W7100A determines the length of the time before stages of mechanical cooling are turned “On” and “Off”. When the system is operating within the control band, the delay is longest at setpoint, and decreases to a minimum of 4 minutes when the discharge air temperature exceeds the upper or lower limit of the control band. Refer to the illustration in Figure 41.

SS-SVX09A-EN 83

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Figure 41. W7100A Staging Sequence

Chilled Water Temperature Controller (6U11)

The chilled water temperature controller used with EVP chiller applications is a Honeywell W7100G. This microprocessor controller is designed to maintain an average leaving water temperature using an integrating control band concept that matches the required operating capacity to the chiller load. The integral action, unlike “proportional only” type controllers, minimizes the amount of offset from the control setpoint.

The control band setting is centered on the leaving water setpoint. It is adjustable from 0ºF to 10ºF [0ºC to 6ºC] and is used to stabilize system operation.

The control algorithm used by the W7100G to add stages of cooling is illustrated in Figure 42. As the water temperature rises above the upper control band limit, a stage of mechanical cooling is added, provided the minimum “Off” time has been satisfied (Point A). The minimum “fast response” time and the time delay between staging for the W7100G is set for 60 seconds.

If the water temperature remains above the upper control band limit (Point B), the next available stage of cooling will be energized when the minimum time delay between stages has elapsed.

As the water temperature decreases 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 stages being cycled “Off”, the controller will maintain it’s current position, i.e., no staging of cooling “On” or “Off”, as long as the temperature remains inside the control band.

When the temperature increases above the upper control band limit (Point D), mechanical cooling stages will be sequenced “On” in the same manner as before. As a rule, any time the water temperature is above the upper control band limit, a stage of cooling will be “added” and anytime the water temperature decreases below the lower control band limit, a stage of cooling will be “Subtracted”.

Thermostatic Expansion Valve

The reliability and performance of the refrigeration system is heavily dependent upon proper expansion valve adjustment. Therefore, the importance of maintaining the proper superheat cannot be over emphasized. Accurate measurements of superheat will provide the following information.

1. How well the expansion valve is controlling the refrigerant flow.

2. The efficiency of the evaporator coil.

3. The amount of protection the compressor is receiving against flooding or overheating.

The recommended range for superheat is 10 to 16 degrees at the evaporator. Systems operating with less than 10 degrees of superheat:

84 SS-SVX09A-EN

System Start-Up

a. Could cause serious compressor damage due to refrigerant floodback.

b. Removes working surface from the evaporator normally used for heat transfer.

Systems operating with superheat in excess of 16 degrees:

c. Could cause excessive compressor cycling on internal winding thermostat which leads to

compressor motor failure.

d. Lowers the efficiency of the evaporator by reducing the heat transfer capability.

The outdoor ambient temperature must be between 65ºF and 105ºF and the relative humidity of the air entering the evaporator must be above 40 percent. When the temperatures are outside of these ranges, measuring the operating pressures can be meaningless.

Figure 42. W7100G Staging Sequence

Condenser Fans

Condenser fan cycling is accomplished through interlocking the fan contactors with liquid line pressure switches (4S11 and 4S12). When the low ambient damper option is applied, ambient thermostats (1S36 & 1S37) are used to provide additional fan cycling control on “No System Control”, Constant Volume, and Variable Air Volume applications. Figure 43 illustrates the condenser fan locations with their respective fan and relay designator.

When a cooling command has been initiated (circuit #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), condenser fan relay 1K5 is energized starting fan 2B1. The normally open interlock contacts 1K5 closes, energizing fan contactor 1K6, starting fan 2B2. When the normally open interlock contacts 1K6 close, they seal 1K6 contactor in the “On” position until the cooling demand has been satisfied. Condenser fan 2B3 on 25, 30, 50 & 60 Ton units is not allowed to start until compressor relay 1K13 has energized and the low ambient thermostat (1S36, if applicable) has closed.

If a second step cooling command is initiated, (circuit #2), condenser fans 2B4, 2B5, and 2B6 are held “Off” by the liquid line pressure switch (4S12) and normally open interlock contacts 1K8 & 1K9. Once the pressure switch has closed (275 psig), condenser fan relay 1K8 is energized starting fan 2B4. The normally open interlock contacts 1K8 closes, energizing fan contactor 1K9, starting fan 2B5. When the normally open interlock contacts 1K9 close, they seal 1K9 contactor in the “On” position until the cooling demand has been satisfied. Condenser fan 2B6 on 50 and 60 Ton units is not allowed to start until compressor relay 1K14 has energized and the low ambient thermostat (1S37, if applicable) has closed.

SS-SVX09A-EN 85

System Start-Up

Figure 43. Condenser Fan Locations

Low Ambient Dampers

Low Ambient Dampers are available as a factory installed option or can be field-installed. Dampers are used to extend the operation of these units from the standard operational temperatures to a minimum of 0ºF without hot gas bypass or 10ºF with hot gas bypass. (These values apply when wind speed across the condenser coil is less than 5 m.p.h.). If typical wind speeds are higher than 5 m.p.h., a wind screen around the unit may be required. By restricting the airflow across the condenser coils, saturated condensing temperatures can be maintained as the ambient temperatures change.

The low ambient damper actuator controls damper modulation for each refrigerant circuit in response to saturated condensing temperature.

Compressor Crankcase Heaters

Each 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 elevated compressor oil temperature during the “Off” cycle to reduce oil foaming during compressor starts.

When the compressor starts, the sudden reduction in crankcase pressure causes the liquid refrigerant to boil rapidly causing the oil to foam. This condition could damage compressor bearings due to reduced lubrication and could cause compressor mechanical failures.

When power has been “Off” for an extended period, allow the crankcase heater to operate a minimum of 8 hours before starting the unit.

Pump Down

Each circuit will go into a pump down cycle when the last compressor on that circuit is turned "Off". During pump down, the solenoid valves are closed, the reset circuit is bypassed and the compressor will continue to run until the 30 psig pressure switch opens.

86 SS-SVX09A-EN

Low Ambient Thermostats

In addition to the low ambient dampers on 25, 30, 50 & 60 Ton units, a low ambient thermostat is installed to further restrict the airflow across the condenser by cycling the 2B3 condenser fan on 25 & 30 Ton units plus 2B6 on 50 & 60 Ton units. The thermostat opens when the ambient temperature reaches 30ºF and closes at approximately 33ºF.

Hot Gas Bypass Operation

The HGBP valve regulates evaporator pressure by opening as suction pressure decreases, to maintain a desired minimum evaporating pressure regardless of a decrease in evaporator external loading.

When the evaporator (suction) pressure is above the valve’s setpoint, it remains closed. As suction pressure falls below the valve’s setpoint, the valve begins to open. The valve will continue to open at a rate proportional to the suction pressure drop, thus maintaining evaporator pressure.

Hot gas bypass valves are adjustable and should be set to begin opening at approximately 58 psig suction pressure and reach the full open position at 51 psig for DX coil applications. For EVP chiller applications, the regulator should be adjusted to begin opening at approximately 69 psig suction pressure and reach full open position at 61 psig.

Low Ambient Damper Adjustment (Factory or Field Installed)

When a unit is ordered with the low ambient option (i.e., Digit 11 is a “1” in the model number), a damper is factory installed over the lead condenser fan for each refrigeration circuit. Refer to the appropriate unit illustrated in Figure 43 for the damper locations.

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

Instructions provided with each low ambient damper kit.)

The controller has a factory default setpoint of 105 F. This setpoint can be adjusted by installing a field supplied resistor on 2TB34 in the low ambient control panel located in the back of the main control panel. (See the low ambient wiring diagram, that shipped with the unit or with the field kit, for resistance values and installation location.)

System Start-Up

 WARNING

Live Electrical Components!

During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.

Inspect the damper blades for proper alignment and operation. Dampers should be in the closed position during the “Off” cycle. If adjustment is required;

1. Remove the sensor leads from the input terminals 6 and 7 for circuit #1 and/or 11 and 12 for circuit #2. (Controller output signal will go to 0.0 VDC and the damper will drive to the closed position.)

2. Loosen the damper shaft “Locking” set screws on the actuator

3. Firmly hold the damper blades in the closed position

4. Retighten the “Locking” set screws.

To check damper operation, jumper between the sensor input terminals 6 and 7 and/or 11 and 12 (if applicable). Controller output signal will go to 10 VDC and the damper will drive to the full open position.

SS-SVX09A-EN 87

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Pressure Drop (Ft of Water)

Flow (GPM)

20 30 40 50 60 70 80 90100100 200 300

10101

Flow (L/S)

EVP Chiller Applications

Start the chilled water circulating pump by closing the field provided pump disconnect switch and turn the pump control circuit switch 5S1 “On”.

Check the flow device to ensure it opens and close properly.

With water circulating through the system, check the EVP chiller pressure 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 of 5oF above the chilled water freezing temperature.

Figure 44. Evaporator Pressure Drops

88 SS-SVX09A-EN

“Air Over” Evaporator Application

Verifying Proper Supply Fan Rotation

1. Ensure that the “System” selection switch at the remote panel is in the “Off” position and the “Fan” selection switch for the appropriate controls application is in the “Auto” position. (VAV units do not utilize a “Fan” selection input.)

2. Turn the main power disconnect switch or circuit protector switch for the unit to the “On” position.

3. Turn the 115 volt control circuit switch 1S2 to the “On” position.

 WARNING

Rotating Components!

Verifying proper components rotation exposes you to rotating components. Have a qualified or licensed service individual who has been properly trained in handling exposed rotating components, perform this task. Failure to follow all safety precautions when exposed to rotating components could result in death or serious injury.

4. Turn the field provided disconnect switch for the supply fan to the “On” position and “bump” the field supplied control circuit switch “On”, (i.e., “On” then immediately “Off”).

5. While the fan is coasting down, check the rotation. If the fan is rotating backwards, turn the field provided disconnect switch for the air handler to the “Off” position and interchange any two of the main power wires at the fan motor starter or contactor.

6. After all adjustments have been made, restart the supply fan and proceed through the following procedures.

System Start-Up

System Airflow Measurement

Much of the systems performance and reliability is closely associated with, and dependent upon having the proper airflow supplied both to the space that is being conditioned and across the evaporator coil.

With the supply fan rotating in the proper direction, measure the amperage at the supply fan contactor. If the amperage exceeds the motor nameplate value, the static pressure is less than design and the airflow is too high. If the amperage is below the motor nameplate value, static pressure may be too high and CFM may be too low. To determine the actual CFM (± 5%);

a. Measure the actual fan RPM

b. Calculate the Theoretical BHP

i. (Actual Motor Amps X Motor HP)/Motor Nameplate Amps

c. Plot this data onto the appropriate Fan Performance Curve or Performance Table that

shipped with the Air Handling equipment. Where the two points intersect, read the CFM line.

Use this data to assist in calculating a new fan drive if the CFM is not at design specifications.

An alternate method with less accuracy is to measure the static pressure drop across the evaporator coil. This can be accomplished by;

1. Drilling a small hole through the unit casing on each side of the coil.

NOTICE

Coil damage can occur if care is not taken when drilling holes in this area.

2. Measure the difference between the pressures at both locations.

SS-SVX09A-EN 89

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3. Plot this value onto the appropriate component pressure drop curve that shipped with the Air Handling equipment. Use the data to assist in calculating a new fan drive if the CFM is not at design specifications.

4. Plug the holes after the proper CFM has been established.

Turn the 115 volt control circuit switch 1S2 to the “OFF” position and open the field provided or optional factory mounted disconnect switch.

After all adjustments have been made, proceed through the following procedures.

Compressor Start-Up (All Systems)

 CAUTION

Compressor Damage!

Do not allow liquid refrigerant to enter the suction line. Excessive liquid accumulation in the liquid lines may result in compressor damage.

1. Before closing the field provided or optional factory mounted disconnect switch at the unit, ensure that the compressor discharge service valve and the liquid line service valve for each circuit is back seated.

COMPRESSOR SERVICE VALVES MUST BE FULLY OPENED BEFORE START-UP (SUCTION, DISCHARGE, LIQUID LINE, AND OIL LINE).

2. If the system has been previously charged before starting, disable the compressor(s) by unplugging the reset relay for each circuit. Refer to the unit-wiring diagram that sipped with the unit. Turn the main power disconnect to the “On” position and allow the crankcase heater to operate a minimum of 8 hours 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 suction and discharge gauge ports for each circuit.

4. Charge liquid refrigerant into the liquid line of each refrigerant circuit with the required amount of R-22. Refrigerant should be charged into the system by weight. Use an accurate scale or a charging cylinder to monitor the amount of refrigerant entering the system. Refer to for the required amount of refrigerant for the condensing unit.

If the pressure within the system equalizes with the pressure in the charging cylinder before charging is completed, complete the process by charging into the suction (low) side of the system after the system has been started.

Ta b l e 1 5 gives the minimum starting temperatures for both “Standard” & “Low” Ambient

units.

Do not attempt to charge the system with the low ambient dampers and/or hot gas bypass operating (if applicable). Disable the low ambient dampers in the “Open” position (refer to the “Low Ambient Damper Adjustment” section) and de-energize the hot gas bypass solenoid valves before proceeding.

5. On units with dual circuits, start only one circuit at a time. To disable the compressors, unplug the appropriate lockout relay inside the unit control panel. Refer to sequencing and Figure 45 for their location.

6. Close the “High Side” valve on the manifold gauge set.

7. Set the “System” selection switch to the “Cool” position

Ta bl e 16 for the compressor

Ta bl e 14

90 SS-SVX09A-EN

System Start-Up

 WARNING

Live Electrical Components!

8. Turn the main power disconnect switch or circuit protector switch, to the unit, “On”.

 WARNING

Rotating Components!

9. Turn the 115-volt control circuit switch 1S2 to the “On” position.

a. Once each compressor or compressor pair has started, verify that the rotation is correct. If

a scroll compressor is rotating backwards, it will not pump and a loud rattling sound can be observed.

b. Check the condenser fans for proper rotation. The direction of rotation is clockwise when

viewed from the top of the unit.

All Motors are Rotating Backwards;

i. Turn the field supplied disconnect switch or circuit protector switch 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 wires at the unit terminal block

1TB1 or the optional factory mounted non-fused disconnect switch (1S1) in the unit control panel.

Note: Interchanging “Load” side power wires at the contactors will only affect the individual fan

rotation. Ensure that the voltage phase sequence at the main terminal block 1TB1 is ABC as outlined in the “Electrical Phasing” section.

Some Motors are Rotating Backwards;

iii. Turn the field supplied disconnect switch or circuit protector switch that provides power

to the condensing unit to the “Off” position. Lock the disconnect switch in the open position while working at the unit.

iv. If the electrical phasing is correct, interchange any two of the motor leads at the contactor

for each motor that is rotating backwards. Before condemning a compressor, interchange any two leads (at the compressor Terminal block) to check the internal phasing. Refer to the illustration in Figure 46 for the compressor terminal/phase identification. If the compressor runs backward for an extended period (15 to 30 minutes), the motor winding can overheat and cause the motor winding thermostat to open.

10. With the compressors operating, slowly open the “Low Side” valve on the manifold gauge set. The remainder of the refrigerant will be drawn into the system.

NOTICE

To prevent compressor damage due to no refrigerant flow, do not utilize the compressors to pump the system down below 7 PSIG under any circumstances.

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11. After the compressors and condenser fans for the operating circuit have been operating for approximately 30 minutes, observe the operating pressures. Use the appropriate pressure curve in indicate a refrigerant shortage, measure the system superheat and system subcooling.

Note: Do Not release refrigerant to the atmosphere! If adding or removing refrigerant is required,

Figure 47 to determine the proper operating pressures. If the operating pressures

the service technician must comply with all Federal, State and local laws. Refer to general service bulletin MSCU-SB-1 (latest edition).

Subcooling

With the unit operating at “Full Circuit Capacity”, acceptable subcooling ranges between 14ºF to 22ºF.

Measuring Subcooling

a. At the liquid line service valve, measure the liquid line pressure. Using a Refrigerant 22

pressure/temperature chart, convert the pressure reading into the corresponding saturated temperature.

b. Measure the actual liquid line temperature as close to the liquid line service valve as

possible. To ensure an accurate reading, clean the line thoroughly where the temperature sensor will be attached. 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. Determine the system subcooling by subtracting the actual liquid line temperature

(measured in b) from the saturated liquid temperature (converted in a).

Measuring Superheat

d. Measure the suction pressure at the outlet of the evaporator as close to the expansion valve

bulb location as possible.

e. Measured the suction line temperature as close to the expansion valve bulb, as possible.

f. Using a Refrigerant/Temperature chart, convert the pressure reading to a corresponding

saturated vapor temperature.

Note: On many Trane fan/coil units, an access valve is provided close to the expansion valve bulb

location. This valve must be added on climate changers and other evaporators.

g. Subtract the saturated vapor temperature (converted in c), from the actual suction line

temperature (measured in b). The difference between the two temperatures is known as “superheat”.

12. Verify that the oil level in each compressor is correct. The oil level may be down to the bottom of the sight glass but should never be above the sight glass.

13. Once the checks and adjustments for the operating circuit has been completed, check and record the:

ambient temperature;

compressor oil level (each circuit);

compressor suction and discharge pressures (each circuit);

superheat and subcooling (each circuit);

Record this data on an “operator’s maintenance log” shown in Ta b l e 18 . Repeat these procedures for the second refrigeration circuit, if applicable.

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14. Turn the 115-volt control circuit switch 1S2 to the “OFF” position and open the field provided or optional factory mounted disconnect switch.

15. After shutting the system off, check the compressor oil appearance. Discoloration of the oil indicates that an abnormal condition has occurred. If the oil is dark and smells burnt, it has overheated because of: compressor is operating at extremely high condensing temperatures; high superheat; a compressor mechanical failure; or, occurrence of a motor burnout.

If the oil is black and contains metal flakes, a mechanical failure has occurred. This symptom is often accompanied by a high compressor amperage draw.

If a motor burnout is suspected, use an acid test kit to check the condition of the oil. Test results will indicate an acid level exceeding 0.05 mg KOH/g if a burnout occurred.

Compressor Oil

The scroll compressor uses Trane OIL-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 scroll compressors have a 100-watt heater installed. 14 and 15 ton scroll compressors have two 80-watt heaters installed per compressor.

Table 13. Pressure Control Switch Settings

Pressure Switch Make Break

Hi Pressure 350 psi 405 psi

Lo Pressure

Condenser Fan Cycling switch 275 psi 155 psi

(EVP only w/HGB - wo/HGB) std.

Lo Ambient Thermostat 33 F 30 F

Compressor Winding T-Stat 181F 221 F

Note: Pack Stock units will have both low pressure switches shipped and the user should use the above valves that apply

EVPB

All others

60 psi 45 psi

40 psi 30 psi

Table 14. Recommended Refrigerant Capacities

Total Interconnecting Line Length

Capacity

Approximate Total System Refrigerant Charge (Lbs. Per Circuit)

20 Ton495664

25 Ton587387

30 Ton718599

40 Ton465361

50 Ton567085

60 Ton688297

50 100 150

Table 15. Minimum starting Ambient Temperature

Minimum Starting Ambient (1)

Standard Units Low Ambient Units

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Table 15. Minimum starting Ambient Temperature

Unit Size

20-60 45° 40° 10° 0°

Note: Minimum starting ambients in degrees F and is based on the unit operating at minimum step of unloading and 5 mph

wind across condenser.

With

HGBP

With

HGBP

Table 16. Compressor Sequence

Unit Size Control Step Circuit 1 Circuit 2

Note: A, B, C and D indicate which compressor in the unit is operating. (%) indicates the amount of the circuit in operation

during a given step. refer to the compressor location illustration for the unit.

1A50%

2 A, B 100%

1B40%

2 A, B 100%

1A50%

2 A, B 100%

1A50%

2 A 50% C (50%)

3 A 50% C, D (100%)

4 A, B 100% C, D (100%)

1A61%

2 A 61% C (61%)

3 A 61% C, D (100%)

4 A, B 100% C, D (100%)

1A50%

2 A 50% C (50%)

3 A 50% C, D (100%)

4 A, B 100% C, D (100%)

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Figure 45. Typical Compressor Locations

System Start-Up

Figure 46. Typical Compressor Terminal Block

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Figure 47. 20 Ton Pressure Curve

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Figure 48. 25 Ton Pressure Curve

System Start-Up

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Figure 49. 30Ton Pressure Curve

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Figure 50. 40 Ton Pressure Curve per Circuit

System Start-Up

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System Start-Up

Figure 51. 50 Ton Pressure Curve per Circuit

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Trane RAUC-C20, RAUC-C50, RAUC-C30, RAUC-C25, RAUC-C40 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General Information

Installation

System Pre-Start Procedures

System Start-Up