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

...

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

+ 82 hidden pages