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

...
4.5 (6)

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

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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.

WARNING: 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.

© 2008 Trane All rights reserved

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Table of Contents

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

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

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

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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

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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 0o F

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.

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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

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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.

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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.

Table 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.

Table 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 Table 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 Table 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 Table 2 for operating weights.

8

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Installation

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

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9

Installation

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

10

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Installation

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

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11

Installation

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

12

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Installation

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

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13

Installation

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

14

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

Installation

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

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15

Installation

Figure 9. BPHE 20 Evaporator Chiller Dimensions

brakets provided Accessory Field required after mounting - is edges are ChillerBPHE installation tape insulation Evaporator insulation vinyl .installation and with field provided seal for to SWAGELOK NPT PIPE EQUIVELENT FIELD PROVIDED P MALE PLUG - 1/4" 4 OR -B

 

BracketEach 2X562 .Ø

625.

MOUNTING 2x BRACKET

 

760.9

REAR VIEW W/INSULATION

 

625.

 

752"."6

 

261.2

261.2

 

440.6

 

431.2

 

IDØ

4312.

660.1

 

720.17

ENTERINGWATER

SUCTION

432.23 670.17

LEAVING WATER LIQUID

451.3

331.3

 

 

 

 

 

W/INSULATION

 

 

 

 

 

 

 

 

 

084"."8

 

RIGHT

VIEW

 

 

 

 

 

 

 

 

 

 

00Ø2.

 

 

 

 

 

 

2X

 

 

 

 

 

 

FRONT

VIEW

W/INSULATION

 

ID130 .1

 

 

 

Note: All water connections are Victaulic.

16

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Installation

Figure 10. BPHE 25 Evaporator Chiller Dimensions

SWAGELOK

Evaporator mounting brackets

with Chiller BPHE Accessory 1/4" NPT

and insulation are provided B-4-P

for field installation - Field MALE

provided vinyl tape is required PIPE

to seal insulation edges after PLUG

installation. OR EQUIVELENT FIELD PROVIDED

7.994

2.261

6.440

2.261

ENTERING WATER

17.720

EAVINGL WATER

3.451

2.431

 

 

SUCTION

 

LIQUID

 

 

2.138ØID

2.431

17.670

23.432

 

3.331

 

 

 

Ø.562X2EachBracket

.625

 

MOUNTING

BRACKETx2

 

 

 

9.760

REAR VIEW W/INSULATION

.625

 

 

 

8.084

RIGHT

VIEW

W/INSULATION

2XØ2.00

 

 

 

 

FRONT

VIEW

W/INSULATION

1.130ID

 

 

 

Note: All water connections are Victaulic.

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Installation

Figure 11. BPHE 30 Evaporator Chiller Dimensions

forto Evaporatorinsulationand Chillerwithfield vinylprovidedseal .installation areBPHEinstallationtapeinsulation mounting-isedges bracketsprovidedAccessoryFieldrequiredafter

261.2

ENTERING WATER

261.2

720.17

 

004.10

261.2

SWAGELOK P NPT MALE PIPE - 1/4" 4-B

2X 00.Ø2

LEAVINGWATER

PLUGOREQUIVALENTFIELD

 

625.

 

760.9

451.3

625.

604.10

PROVIDED

562.Ø 2X BracketEach

MOUNTING 2x

BRACKET

REARVIEWW/INSULATION

RIGHTVIEWW/INSULATION

440.6

 

 

SUCTION

 

LIQUID

FRONT VIEW W/INSULATION

431.2 ID

431.2

670.17

432.23

331.3

ID130 .1

138.2

 

 

 

 

 

Note: All water connections are Victaulic.

18

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Installation

Figure 12. BPHE 40 Evaporator Chiller Dimensions

Ø 3.00 X 2

Evaporatormountingbrackets andinsulationareprovided withChillerBPHEAccessory forfieldinstallation-Field providedvinyltapeisrequired tosealinsulationedgesafter installation.

Ø.562X2EachBracket

MOUNTING BRACKETx2

 

1.020

13.533

6.767 6.767

ENTERING WATER

 

LEAVING WATER

11.420

 

2.826

23.230

30.292

4.235

1.020

7.720

9.096

2.517

1.660ØIDX2

 

 

13.533

8.500

SUCTION

CIR#2

SUCTION

CIR#1

2.517

 

2.551

 

SWAGELOK B-4-P

1/4"NPT MALE PIPE PLUG OR

EQUIVALENT FIELD PROVIDED

 

 

LIQUID

CIR#2

 

 

LIQUID

CIR#1

 

23.780

30.292

3.960

1.380IDX2

REAR VIEW W/INSULATION

RIGHT VIEW W/INSULATION

FRONT VIEW W/INSULATION

Note: All water connections are Victaulic.

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Installation

Figure 13. BPHE 50 Evaporator Chiller Dimensions

 

 

2X00 .3Ø

mounting areinsulation Chiller fieldfor providedField torequired afteredges and with Accessory - is insulation . Evaporator brackets provided BPHE installation tape installation vinyl seal

 

533.13

766.6 767

ENTERING WATER

 

 

 

.6

 

 

 

 

827.2

230.23

292

 

 

 

 

.30

 

872.8

 

 

517.2

2XID Ø138 .2

 

SWAGELOK P -4-B

1/4" NPT

 

533.13

500.8

SUCTION CIR #2

 

 

SUCTION CIR #1

 

517.2

 

551.2

780.23

292

 

 

 

 

.30

 

020.1

LEAVING WATER

420.11

235.4

020.1

 

096.9

MALE PIPE PLUG OR EQUIVALENT FIELD PROVIDED

 

LIQUID CIR #2

 

LIQUID CIR #1

 

960

2X

.3

ID

 

380.1

Note: All water connections are Victaulic.

562.Ø 2X BracketEach

x MOUNTINGBRACKET2

REARVIEWW/INSULATION

RIGHTVIEWW/INSULATION

FRONTVIEWW/INSULATION

20

SS-SVX09A-EN

Installation

Figure 14. BPHE 60 Evaporator Chiller Dimensions

13.533

6.766

6.767

Ø3.00X2

Evaporatormountingbrackets andinsulationareprovided

withChillerBPHEAccessory forfieldinstallation-Field providedvinyltapeisrequired

 

ENTERING

WATER

 

2.826

23.230

edgesafter

 

 

 

 

Ø.562X2EachBracket

tosealinsulation

installation.

 

1.020

MOUNTING

BRACKETx2

 

LEAVING WATER

 

11.420

REAR VIEW

W/INSULATION

 

30.292

4.235

1.020

 

 

12.732

2.517

2.138ØIDX2

 

 

13.533 8.500

SUCTION

CIR#2

2.517

SUCTION

CIR#1

 

2.551

 

23.780

 

 

14.858

SWAGELOK B-4-P 1/4"NPT MALE PIPE PLUG OR EQUIVALENT FIELD PROVIDED

 

LIQUID

CIR#2

 

LIQUID

CIR#1

 

30.292

3.960

1.380IDX2

Note: All water connections are Victaulic.

RIGHT VIEW W/INSULATION

FRONT VIEW W/INSULATION

SS-SVX09A-EN

21

Installation

 

 

 

Table 1.

Typical Unit Weights & Point Loading Data

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Operating

 

 

 

 

 

Unit Weight on Isolator @ Mounting Location

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Unit

Weight

 

Location 1

2

 

 

3

4

 

 

5

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Size

AL

CU

 

AL

CU

AL

 

CU

AL

 

CU

AL

 

CU

AL

 

CU

AL

 

CU

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

Table 2. Typical EVP Chiller Weights & General Data

Chiller

Shipping

Operating

Number of

Water Volume in

Refrigerant Charge

 

Size

Weight2

Weight

Ref. Ckts.

Gallons3

in Lbs.4

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Shipping

 

 

Location of Center of Gravity

 

 

 

 

 

 

 

 

 

 

 

 

X

 

 

Z

 

 

weight (Max.

 

 

 

 

 

 

 

 

 

 

 

Unit Size

Lbs)

 

In

mm

 

In

mm

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

22

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Installation

Rigging

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.

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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 Table 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

Location 1

Location 2

Location 3

Location 4

Location 5

Location 6

 

 

 

 

 

 

 

 

C20

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

 

 

 

 

 

 

 

 

 

 

 

 

 

C25

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

 

 

 

 

 

 

 

 

 

 

 

 

 

C30

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

 

 

 

 

 

 

 

 

 

 

 

 

 

C40

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

 

 

 

 

 

 

 

 

 

C50

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

 

 

 

 

 

 

 

 

 

C60

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

 

 

 

 

 

 

 

 

 

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

24

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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!

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 positioning pin in the top of the appropriate isolator. Refer to Table 4 for the appropriate isolator for each load point.

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 (Table 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.

Leveling the Unit

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.

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25

Installation

Table 4. Typical Spring Isolator Selection & Location

 

 

 

 

Spring Isolator Part Number @ Mounting Location

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Unit

Location 1

Location 2

Location 3

Location 4

Location 5

Location 6

 

 

 

 

 

 

 

 

 

 

 

 

Tons

Al

Cu

Al

Cu

Al

Cu

Al

Cu

Al

Cu

Al

Cu

 

 

 

 

 

 

 

 

 

 

 

 

 

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.

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 base rail.

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

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.

26

SS-SVX09A-EN

Installation

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.

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

Installation

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!

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 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!

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.

[ ] 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.

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29

Installation

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.

[ ] 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

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