Trane RAUC-IOM-15 Installation & Maintenance Instructions Manual

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Installation RAUC-IOM-15 Operation Maintenance

Library Service Literature Product Section Unitary

Product Split System Air Conditioning (80 - 120 Tons) Model RAUC Literature Type Installation/Operation/Maintenance Sequence 15 Date March 2006 File No. SV-UN-S/S-RAUC-IOM-15 03/06 Supersedes December 2001

Remote Split System Units

Air Cooled Condensing Units and EVP Chillers

Models

"L" and Later Design Sequence RAUC-C80 RAUC-D10 RAUC-D12

Note: The installation of this equipment must comply with all National, State, and Local Codes.

Since the manufacturer has a policy of continuous product improvement, it reserves the right to change specifications and design without notice.

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About The Manual

Literature Change History

RAUC-IOM-15 (March 2006)

Manual reissued due to minor corrections: Provides Installation, Operation, and Maintenance instructions for “L” and later design sequence on RAUC 80 through 120 Ton air cooled condensing units and the EVP chiller Models used with these units.

RAUC-IOM-15 (December 2001)

First issue of manual; provides Installation, Operation, and Maintenance instructions for “L” and later design sequence on RAUC 80 through 120 Ton air cooled condensing units and the EVP chiller Models used with these units.

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.

Note: The procedures discussed in this manual should only be performed by qualified, experienced HVAC technicians. Do Not release refrigerant to the atmosphere! If adding or removing refrigerant is required, the service technician must comply with all federal, state, and local laws.

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Table of Contents

Section One

About The Manual

Literature Change History................................................2

Overview of Manual .........................................................2

Section Two

General Information

Model Number Description ..............................................4

Unit Nameplate ................................................................4

Compressor Nameplate ...................................................4

Evaporator Barrel Nameplate ..........................................4

Hazard Identification ........................................................4

Unit Description................................................................4

Unit Component “Layout” and “Shipwith” Locations........5

Section Three

Installation

Unit Inspection .................................................................6

Unit Clearances ............................................................... 6

Unit Dimensions & Weight Information............................6

Foundation .......................................................................6

Rigging ...........................................................................16

Unit Isolation ..................................................................16

Leveling the Unit ............................................................17

Shipping Fasteners ........................................................17

General Unit Requirements ...........................................19

Refrigerant Piping Requirements...............................19

EVP Chilled Water Piping Requirements...................19

Main Electrical Power Requirements .........................19

Field Installed Control Wiring Requirements .............20

Low Voltage Wiring (AC & DC) ..................................20

Refrigerant Line Components........................................21

Refrigerant Piping.......................................................23

Suction Lines ..............................................................23

Liquid Lines ................................................................23

Evaporator Piping.......................................................24

Hot Gas Bypass Lines................................................24

Optional Pressure Gauges.........................................24

Final Refrigerant Pipe Connections ...........................25

Brazing Procedures .......................................................25

Leak Testing Procedure .................................................26

Chilled Water Piping ......................................................27

Final Water Piping Connections.................................28

Field Installed Power Wiring ..........................................28

Main Unit Power Wiring..............................................28

Power Wire Sizing and Protection Device

Equations....................................................................29

Field Installed Control Wiring.........................................31

Controls Using 115 VAC .............................................31

Controls using 24 VAC ...............................................31

Controls using DC Analog Input/Outputs...................32

Economizer Actuator Circuit .......................................32

No System Control .....................................................33

Variable Air Volume Control .......................................36

Discharge Air Sensor..................................................36

Suction Line Thermostat ............................................36

Night Setback .............................................................36

EVP Chiller Control ....................................................39

Chilled Water Temperature Sensor ............................39

Outside Air Thermostat...............................................39

Section Four

System Pre-Start Procedures

System Evacuation Procedures.....................................42

Discharge Air Controller Checkout ................................44

Discharge Air Sensor Checkout.....................................45

Economizer Actuator Checkout .....................................46

EVP Chiller Control Checkout........................................46

Chilled Water Sensor Checkout.....................................47

Voltage Imbalance .........................................................48

Electrical Phasing ..........................................................48

Section Five

System Start-Up

Sequence of Operation ..................................................49

Sequence of Operation ..................................................50

Sequence of Operation ..................................................51

Low Ambient Damper Adjustment .................................52

EVP Chiller Applications ................................................ 52

“Air Over” Evaporator Application..................................52

System Airflow Measurement ........................................53

Compressor Start-Up .....................................................53

Final System Setup........................................................59

Section Six

Service & Maintenance

Compressor Operational Sounds ..................................61

Scroll Compressor Replacement...................................61

Fuse Replacement Data ................................................62

Monthly Maintenance.....................................................62

Coil Cleaning..................................................................63

System operation ...........................................................63

Index ..................................................................................64

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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.

Sample Mo del N o .: RAUC - C80 4 A B 1 1 2 H , B, 3, et c D i git No.: 1 2 3 4 5,6, 7 8 9 10 11 12 13 14+

Digit 1 - Unit Type Digit 8 - Power Supply Digit 12 - Agency Approval

R = Remote Condensing Unit E = 200/60/3 XL 0 = None

F = 230/ 60/3 XL 3 = UL/ CS A

Digit 2 - Condenser

A = Ai r Cooled 5 = 575/ 60/ 3 XL

Digit 3 - Air Flow Digit 9 - System Control

U = Up Fl ow B = No System Control

Digit 4 - Development Sequence

C = Thir d 3 = Flow S wit c h ( EVP O nly)

D i gits 5, 6, 7 - Nominal Cap aci ty

C80 = 80 Tons D = S uc tion Service Valves D10 = 100 Tons D12 = 120 Tons 0 = S tandard H = Copper Fins

4 = 460/ 60/ 3 XL

E = Supply Air VAV Control P = EVP Control 1 = Spri ng I solator s

Digit 10 - Design Sequence

L = Disconnect Redesign B = Hot Gas By pass Valves

Digit 11 - Ambient Control

1 = 0 F

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.

Digit 13 - Number of Circuits

2 = Dual Circ uit

D igit s 14, etc. - Miscellaneous Options

9 = Packed Stock

F = Pr essures G auges & G auge P iping

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.

Evaporator Barrel Nameplate

(EVP Chiller Applications Only)

The nameplate is located on the top of the evaporator near the supply-end tube sheet. The word “Nameplate” is stenciled on the insulation. To view the nameplate, remove the tape over the area and spread the insulation. Retape the insulation after viewing.

Hazard Identification

Warnings are provided through-

this manual to indicate to installing contractors, opera-

out tors, and service personnel of potentially hazardous situa-

tions which, if not avoided, COULD result in death or serious injury.

Cautions are provided throughout

this manual to indicate to installing contractors, operators, and service personnel of potentially hazardous situations which, if not avoided, MAY result in minor or moderate injury.

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 Ni- trogen 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.

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General Information (Continued)

Direct-drive, vertical discharge condenser fans are provided with built-in current and overload protection.

For “Shipwith” items, refer to the Unit Component “Layout” and “Shipwith” Locations illustration.

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)

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)

Unit Component “Layout” and “Shipwith” Locations

(120 Ton Unit Illustrated)

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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 name-

plate 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 Shipwith Location illustration.

If the job site inspection of the unit reveals damage or material shortages, 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.

FOR ACCESS TO COMPONENTS, THE BASE SHEET

file a claim with the carrier immediately.

NO STEP SURFACE!

METAL SURFACE MUST BE REINFORCED.

EVP Chiller Considerations

The EVP chiller must be installed indoors unless:

Outdoor temperatures are always above 32 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.

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

Allow adequate clearance at one end of the chiller to pull the evaporator tubes and 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 3-2A.

A Center-of-Gravity illustration and the dimensional data for the unit is shown in Figure 3-3.

Table 3-1A lists the typical operating and point loading weights for the unit.

Bridging between the unit's main supports may con-

sist of multiple 2 by 12 boards or sheet metal grating.

Failure to comply can cause severe personal injury

or death from falling.

[ ] 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 re-

pairing a damaged unit.

Unit Clearances

Figure 3-1 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.

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

EVP chiller barrel mounting footprints and overall dimensional data is illustrated in Figure 3-2B.

Table 3-1B 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 3-1A 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 3-1A 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.

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

The EVP chiller barrel must be installed level and should be mounted on a base that will adequately support the operating weight. Refer to Table 3-1B for operating weights.

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Installation (Continued)

Figure 3-1

Typical Installation Clearances for Single, Multiple or Pit Applications

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Figure 3-2A

RAUC-C80 Unit Dimensional Data & Recommended Clearances

Page 9

Figure 3-2A (Continued)

RAUC-D10 Unit Dimensional Data & Recommended Clearances

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Figure 3-2A (Continued)

RAUC-D12 Unit Dimensional Data & Recommended Clearances

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Figure 3-2B

EVPB-C80 Evaporator Chiller Dimensions

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Figure 3-2B (Continued)

EVPB-D10 Evaporator Chiller Dimensions

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Figure 3-2B (Continued)

EVPB-D12 Evaporator Chiller Dimensions

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Figure 3-2B (Continued)

EVPB-C80 through D12 Chill Water Pipe Stubout Dimensions

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Installation (Continued)

Table 3-1A

Typical Unit Weights & Point Loading Data

Unit Fin Operating Unit Weight on Isolator @ M ounting Loca tion

Size Material Weight Location 1 2345678

C80 AL 5500 855 557 835 544 830 541 810 528

CU 6099 926 629 909 618 906 616 890 605

D10 AL 6472 1010 656 983 639 979 636 951 618

CU 7272 1104 752 1083 738 1080 736 1058 721

D12 AL 7000 1100 694 1075 678 1071 676 1046 660

CU 8199 1241 838 1225 827 1222 825 1206 815

Note:

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

Table 3-1B

Typical EVP Chiller Weights & General Data

Chiller Shipping Operating No. of R e f. Capacity Refrigerant Tube Pull

Size Weight Weight Circuits (Gallons) Charge (Lbs.)* (inches)**

80 Ton 875 1,205 2 43.1 26.5 95 100 Ton 960 1,230 2 35.0 33.4 95 120 Ton 1,150 1,535 2 47.9 40.4 95

* - Refrigerant change is approximate and for the evaporator chiller only. ** - Tube Pull given is the length of the evaporator.

Figure 3-3

Rigging and Center-of-Gravity Data

Location of Center of

Shipping Gravity = Unit Weight X Z Size (Max. Lb s) In mm In mm

C80 5995 79.1 2009 34.5 876.3 D10 7160 104.2 2647 34.6 878.8 D12 8052 104.7 2659 34.4 873.8

LIFTING AND MOVING INSTRUCTIONS!

DO NOT USE CABLES (CHAINS OR SLINGS) EXCEPT AS SHOWN. OTHER LIFTING ARRANGEMENTS MAY CAUSE EQUIPMENT DAMAGE OR SERIOUS PERSONAL INJURY.

EACH OF THE CABLES (CHAINS OR SLINGS) USED TO LIFT UNIT MUST BE CAPABLE OF SUPPORTING THE ENTIRE WEIGHT OF THE UNIT.

LIFTING CHAINS (CABLES OR SLINGS) MAY NOT BE THE SAME LENGTH. ADJUST AS NECESSARY FOR EVEN LEVEL LIFT.

USE SPREADER BARS AS SHOWN IN DIAGRAM. REFER TO INSTALLATION MANUAL OR NAMEPLATE FOR UNIT WEIGHT. REFER TO INSTALLATION INSTRUCTIONS LOCATED INSIDE CONTROL PANEL FOR FURTHER RIGGING INFORMATION.

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Installation (Continued)

Rigging

A Rigging illustration and Center-of-Gravity dimensional data table is shown in Figure 3-3. Refer to the typical unit operating weights table before proceeding.

1. Rig the condensing unit as shown in Figure 3-3. 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 3-3, 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.

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 spring isolators at each mounting location. Refer to the following “Spring Isolator” section.

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.

Note: 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 to prevent personal 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 Figure 3-4 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. Refer to Figure 3-4. 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 (Figure 3-4) 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.

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Installation (Continued)

Figure 3-4

Typical Spring Isolator Selection & Location

Fin Spring Isolator Part Number @ M ounting Loca tion

Unit Figure Mat’l. Location 1 2345678

RAUC-C80 3 AL CP-1-32 CP-1-28 CP-1-32 CP-1-28 CP-1-32 CP-1-28 CP-1-32 CP-1-28

CU CP-2-27 CP-1-28 CP-1-32 CP-1-28 CP-1-32 CP-1-28 CP-1-32 CP-1-28

RAUC-D10 3 AL CP-2-27 CP-1-31 CP-2-27 CP-1-31 CP-2-27 CP-1-31 CP-2-27 CP-1-28

CU CP-2-28 CP-1-31 CP-2-28 CP-1-31 CP-2-28 CP-1-31 CP-2-28 CP-1-31

RAUC-D12 3 AL CP-2-28 CP-1-31 CP-2-28 CP-1-31 CP-2-28 CP-1-31 CP-2-27 CP-1-31

CU CP-2-28 CP-1-32 CP-2-28 CP-1-32 CP-2-28 CP-1-32 CP-2-28 CP-1-32

Note:

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-1-27 is marked 27. If the isolator is color coded, there is a painted mark on each spring as follows; CP-2-27 = one orange mark CP-1-31 = two yellow marks CP-1-28/CP-2-28 = one green markCP-1-32 = one white mark

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

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.

Shipping Fasteners

Compressor Shipping Hardware

Figure 3-5 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.

Three Manifolded Compressors

Each manifolded compressor assembly is rigidly bolted to a mounting rail assembly. The rail assembly sets on six (6) rubber isolators. The assembly is held in place by four (4) shipping “Tiedown” bolts. To remove the shipping hardware, follow the procedures below:

1. At each “Tiedown” location (2 front and 2 rear), remove and discard the tiedown bolt and the slotted shipping

Page 18

Installation (Continued)

spacer located between the compressor rails and the unit base rail as illustrated in the “Tiedown Bolt” detail.

2. Remove the bolt in each rubber isolator and the slotted shipping spacer located between the compressor rails and the unit base rail as illustrated in the “Isolator Bolt” detail. Reinstall each isolator bolt into the rubber isolator and screw it two to three turns into the base rail.

3. Ensure that the compressor rail assembly is free to move on the rubber isolators.

Four Manifolded Compressors

Each manifolded compressor assembly is rigidly bolted to a mounting rail assembly. The rail assembly sets on eight (8) rubber isolators. The assembly is held in place by six (6)

Figure 3-5A

Removing C80 Scroll Compressor Shipping Hardware

shipping “Tiedown” bolts. To remove the shipping hardware, follow the procedures below:

1. At each “Tiedown” location (3 front and 3 rear), remove and discard the tiedown bolt and the slotted shipping spacer located between the compressor rails and the unit base rail as illustrated in the “Tiedown Bolt” detail.

2. Remove the bolt in each rubber isolator and the slotted shipping spacer located between the compressor rails and the unit base rail as illustrated in the “Isolator Bolt”

Reinstall each isolator bolt into the rubber isolator

detail. and screw it two to three turns into the base rail.

3. Ensure that the compressor rail assembly is free to move on the rubber isolators.

Figure 3-5B

Removing D10 & D12 Scroll Compressor Shipping Hardware

Page 19

Installation (Continued)

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 name-

plate specifications.

[ ] Check the unit for shipping damage and material short-

age; 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 Barrel). 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 Barrel). Refer to the “Re-

frigerant Piping” section for recommended line compo-

nents and guidelines. [ ] Install properly sized hot gas bypass line(s) between the

hot gas bypass connections on the unit and the evapora-

tor, (i.e., EVP Chiller Barrel, if applicable). [ ] Insulate the suction line. [ ] 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 on the chiller

outlet stubout pipe 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 barrel.

[ ] Connecting the chilled solution piping to the chiller barrel. [ ] Install heat tape and insulation, if necessary, to protect

any exposed solution piping from external freezing conditions.

Main Electrical Power Requirements

[ ] Verify the power supply meets the required power re-

quirements 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).

[ ] Install proper grounding wires to an earth ground.

Page 20

Installation (Continued)

Field Installed Control Wiring Requirements

115 Volt Control Wiring (All Units)

[ ] 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 sole-

noid 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 contact, 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 cur-

rent 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.

[ ] 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.

Low Voltage Wiring (AC & DC)

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 dis-

charge 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.

“EVP” Chiller Units

[ ] 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.

[ ] Install and connect the chilled solution temperature sen-

sor to the chilled solution temperature controller with shielded cable.

[ ] Install the proper staging resistor onto the chilled solution

temperature controller.

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Installation (Continued)

Refrigerant Line Components

Suction line refrigerant components necessary for field installation in the suction line are a filter (Core Type), access valves (ports), FrostatTM control for coil frost protection, and ball shutoff valves. They are placed in the Suction line as illustrated in Figure 3-7.

The required 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 3-7.

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.

Refer to the Filter/Filter Drier Table for 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 the Solenoid Valve/Moisture Indicator Sight Glass Table for 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 the Solenoid Valve/Moisture Indicator Sight Glass Table for 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 sucton 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.

FrostatTM 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.

Filter / Filter Drier Recommendations

Capacity Suction Line

(Sporlan)

80 Ton RSF-5621-T RPE-48-BD C-967-G RCW-48 100 Ton RSF-5621-T RPE-48-BD C-969-G RCW-48 120 Ton RSF-9625-T RPE-48-BD C-969-G RCW-48

Use specific parts listed or equivalent. (Per Circuit)

Filter Core

(Sporlan)

Liquid

Line

(Sporlan)

Filter Drier Core

(Sporlan)

Solenoid Valve &

Sight Glass w/Moisture Indicator

Capacity Solenoid

Valve

(Sporlan)

80 Ton E25S270 MKC-2 @ 120V SA-17S 100 Ton E25S290 MKC-2 @ 120V SA-19S 120 Ton E34S290 MKC-2 @ 120V SA-19S

Use specific parts listed or equivalent. (Per Circuit)

Solenoid Valve

Coil (Sporlan)

Sight Glass with

Moisture Indicator

(Sporlan)

Page 22

Figure 3-7

Typical Refrigerant Piping Components

Installation (Continued)

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 applica-

tion (5) Shutoff valves - Manual ball valves (6) Access Ports

(7) Liquid Line Filter Drier (8) Solenoid Valve (9) Moisture and Liquid Indicator (10) Frostat (11) Expansion Valve (One Expansion Valve for each Coil

Distributor)

(12) Evaporator Coil

(Required for coil freeze protection)

Page 23

Installation (Continued)

Refrigerant Piping

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

Note: 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 systems. 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 pre-selected 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 com-

pressor as possible.

Note: If Suction Riser Exceeds 50 Feet, Trane Must

Review The Application.

Liquid Line Piping

Liquid line sizes are based on their ability to provide a minimum of 5 degrees F (2.7 valve throughout the unit’s operating envelope. 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 with in 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, Trane Must Review The Application

C) of sub-cooling at the expansion

Suction Line Interconnecting Tubing

Capacity

80 Ton 2-5/8" 2-1/8" 100 Ton 2-5/8" 2-5/8" 120 Ton 3-1/8" 2-5/8"

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

OD Horizontal

(Per Circuit)

OD Vertical

(Per Circuit)

Liquid Line Interconnecting Tubing

Capacity

80 Ton 7/8" 7/8" 100 Ton 1-1/8" 1-1/8" 120 Ton 1-1/8" 1-1/8"

Note: If risers exceed 10 feet, the application must be reviewed by Trane.

OD Horizontal

(Per Circuit)

OD Vertical

(Per Circuit)

Page 24

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 Figure 3-7A.

3. Secure the bulb to the suction line with two clamps provided by the manufacturer and insulate the bulb.

4. Install the Frostat closed in the kit as close to the evaporator as possible.

according to the instructions en-

Figure 3-7A

Typical Coil Piping For Dual Circuit Units

Installation (Continued)

Hot Gas Bypass for Commercial ComfortCooling Applications

Hot gas bypass is not recommended for use on RAUC units. Frostat 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.

is the preferred method of protecting the

Optional Pressure Gauges

When a unit is ordered with optional pressure gauges, (“F” 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.

1. Assemble the valve depressor, flare nuts, 1/4" copper tubing, 90 degree flare elbows, gauge & gauge bracket together as shown in Detail “A” & “B”.

Note: Wrap all appropriate pipe threads with teflon tape before assembly.

Page 25

Installation (Continued)

2. Remove the valve stem cap and place the valve depressor (with tubing connected) onto the valve stem and tighten.

Note: Do not install the valve depressor without the tubing being connected. If gauges need to be replaced, remove valve depressor from valve stem, first, to prevent loss of refrigerant charge.

3. Using the gauge bracket as a template for the self tapping screws, mount the gauge bracket approximately 1/ 2" to 3/4" from the outer edge of the base rail, relative to the compressors for that circuit, as illustrated.

4. Apply 6" strips of edge protector to both side flanges of the gauge bracket, to prevent the bracket from cutting into the power wires.

Final Refrigerant Pipe Connections

To access the refrigerant pipe connections, remove the louvered side grills. Refer to Figure 3-2.

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.

Brazing Procedures

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

1. When copper is heated in the presence of air, Copper oxide forms. To prevent copper oxide from forming inside

Page 26

Installation (Continued)

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.

USE NITROGEN ONLY TO PURGE THE SYSTEM

WHILE SWEATING CONNECTIONS.

Failure to follow proper procedures can result in per-

sonal injury or death due to a possible formation of

an explosive mixture of R-22 and air and/or inhala-

tion of phosgene gas.

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.

Leak Testing Procedure

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

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.

7. 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.

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

Note: 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.

Page 27

Installation (Continued)

Chilled Water Piping

Evaporator water inlet and outlet types, sizes and locations are shown in Figure 3-2B. Refer to the operating GPM pa-

rameters listed in Table 3-3 when determining flow and piping requirements. Figure 3-8 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.

Table 3-3

GPM vs Pressure Drop

Chiller Pressure Drop **

GPM* Chiller Size

80 Ton 100 Ton 120 Ton

100 4.5 120 6.5 3.2 140 8.7 4.3 3.2 160 11.2 5.6 4.1 180 14.1 7.0 5.2 200 17.2 8.5 6.3 240 24.8 12.2 9.0 280 16.3 12.0 320 21.0 15.8 360 26.0 19.7

400 24.0 * - Gal lons Per Minut e ** - All Pressure Drops are in Feet of Water = Beyond the working limits of the barrel

Air Vents

A vent port is located on top of the chiller near the return end. Additional 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.

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

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 EVP chiller ships without the drain plug installed. If drain piping is not installed, remove the drain plug from the EVP control panel and install it in the drain port before filling the system with water.

Chiller Flow Switch

Install a flow switch or other flow sensing device, illustrated in Figure 3-9, 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 3-8. 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 using the threaded connection provided on the chiller barrel leaving water pipe. Both devices are shipped inside the unit’s shipwith location. Thermal paste must be used when installing the sensor into the sensor-well. Refer to Figure 32B for the sensor location and dimensional data.

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.

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

Page 28

Installation (Continued)

Figure 3-8

Typical Piping Recommendations

Figure 3-9

Optional Flow Switch Illustration

Final Water Piping Connections

1. All water piping to the system should be flushed thoroughly before making the final connections.

Note: If an acidic commercial flushing solution is used, construct a temporary bypass around the EVP chiller barrel to prevent damage to the internal components of the evaporator.

2. Connect the water pipe to the EVP chiller.

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.

Note: 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 3-2. To insure that the unit’s supply power wiring is properly sized and installed, follow the guidelines outlined below.

Figure 3-10

Temperature Sensor & Well

Note: All field installed wiring must conform to NEC guidelines as well as State and Local codes.

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

USE COPPER CONDUCTORS ONLY!

UNIT TERMINALS ARE NOT DESIGNED TO ACCEPT

OTHER TYPES OF CONDUCTORS.

Failure to do so may cause damage to the equip-

ment.

Main Unit Power Wiring

Table 3-4 lists the field connection wire ranges for the main power terminal block 1TB1. The unit electrical data is listed in Table 3-5. 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).

Page 29

Installation (Continued)

1. 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. Location for the electrical service entrance is illustrated in

3. Provide proper grounding for the unit in accordance with

Table 3-4

Customer Connection Wire Range

Power Wire Sizing and Protection Device Equations

Figure 3-2. Complete the unit’s power wiring connections onto the main terminal block 1TB1 inside the unit control panel. Refer to the customer connection diagram that shipped with the unit for specific termination points.

local and national codes.

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.

Calculation #2

Disconnect Switch Sizing (DSS)

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

Page 30

41.4 60.5 269.0 409.0 10.99 16.48

2/4 41.4 60.5 251.0 376.0 10.99 16.48

18.1 26.3 117.0 178.0 10.99 16.48

14.4 21.0 94.0 143.0 10.99 16.48

41.4 60.5 269.0 409.0 11.09 16.64

4/4 41.4 60.5 251.0 376.0 11.09 16.64

18.1 26.3 117.0 178.0 11.09 16.64

14.4 21.0 94.0 143.0 11.09 16.64

60.5 409.0 16.43

4/4 60.5 376.0 16.43

26.3 178.0 16.43

21.0 143.0 16.43

Compressor Motor

RLA RLA LRA LRA Kw Kw

No. (Ea) (Ea) (Ea) (Ea) (Ea) (Ea)

10/15 10 Ton 15 Ton10 Ton 15 Ton 10 Ton 15 Ton

motor RLA and FLA values.

F ambient.

lus the remainin

ressor and 95

ressor moto r RL A

erature at the com

est com

Unit Characteristics Condenser Fan Motor

Protecton Fuse Size (Ea) No HP (Ea) (Ea)

F saturated suction tem

Allowable Minimum Maximum Recommende d

Electrical Voltage Circuit Overcurreent Dual Element KW FLA LRA

200/60/3XL 180-220 373 400 400 0.90 8 1.0 4.1 20.7

460/60/3XL 416-508 162 175 175 0.90 8 1.0 1.8 9.0

575/60/3XL 520-635 129 150 150 0.90 8 1.0 1.4 7.2

200/60/3XL 180-220 472 500 500 0.90 12 1.0 4.1 20.7

460/60/3XL 416-508 206 225 225 0.90 12 1.0 1.8 9.0

575/60/3XL 520-635 164 175 175 0.90 12 1.0 1.4 7.2

200/60/3XL 180-220 548 600 600 0.90 12 1.0 4.1 20.7

460/60/3XL 416-508 239 250 250 0.90 12 1.0 1.8 9.0

575/60/3XL 520-635 190 200 200 0.90 12 1.0 1.4 7.2

Model Characteristics Range Ampacit

Table 3-5

Electrical Service Sizing Data

RAUC-C80 230/60/3XL 208-254 373 400 400 0.90 8 1.0 4.1 20.7

RAUC-D10 230/60/3XL 208-254 472 500 500 0.90 12 1.0 4.1 20.7

Notes :

1. Electrical data is for each individual motor.

2. Maximum 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 lar

6. Local codes may take precedence.

RAUC-D12 230/60/3XL 208-254 548 600 600 0.90 12 1.0 4.1 20.7

5. Kw values are taken at conditions of 45

Page 31

Installation (Continued)

Field Installed Control Wiring

Before installing any connecting wiring, refer to Figure 3-2 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.

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.

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

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): 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.

loads (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.

Controls using 24 VAC

Before installing any connecting wiring, refer to Figure 3-2 for the electrical access locations provided on the unit and Table 3-6 for AC conductor sizing guidelines, and;

a. Use copper conductors unless otherwise specified. b. 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.

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

c. Be sure to check all loads and conductors for

grounds, shorts, and miswiring.

d. Do not run the AC low voltage wiring in the same

conduit with the high voltage power wiring.

Typical Low voltage components include:

constant volume thermostat (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.

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 oper ation, the fluid flow through the chiller must be maintained. The field provided; ON/OFF switch, pump starter/contactor, auxiliary contacts and over-

Table 3-6

AC Conductors

Distance from Unit Recommended

to Control Wire Size

000 - 460 feet 18 gauge 461 - 732 feet 16 gauge

733 - 1000 feet 14 gauge

Page 32

Installation (Continued)

Controls using DC Analog Input/Outputs

Before installing any connecting wiring between the unit and components utilizing a DC analog input\output signal, refer to Figure 3-2 for the electrical access locations provided on the unit.

These components may include:

Field installed Discharge Air Sensor (8RT3 VAV units); Field installed Chilled Water Sensor (8RT2 EVP units);

a. 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.

b. Table 3-7 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.

c. 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.

d. Do not run the electrical wires transporting DC

signals in or around conduit housing high voltage wires.

Table 3-7

DC Conductors

Distance from Unit Recommended

to Control Wire Size

000 - 499 feet 16 gauge

500 - 1000 feet 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.

Economizer Actuator Circuit Legend

Device Device Designation Description Parts And Notes

MM Modutrol M.H. M955, ( Up to 3 motors may

Motor be controlled as shown.Additional

TR Transformer M.H. 13081B; cover mounted EC Enthalpy Control M.H. H2051046 MP Minimum Position M.H. S96A1012

Potentiometer

EFI Evaporator Fan Field Provided

Interlock

7TB8 Low Voltage Located in Temperature

Terminal Strip Controller Planel

R 1/4 Watt - 5% 1 Motor/Circuit = None Req.

Carbon 2 Motors/Circuit = 1300 Ohms

motors must be slaved.)

3 Motors/Circuit = 910 Ohms

Page 33

Installation (Continued)

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 “FixedOn” & “Fixed-Off” time delays wired into each step of cool-

ing. 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.

Wire the controller in accordance with the field connection diagram illustrated in Figure 3-11.

Figure 3-11A

Field Connection Diagram for RAUC-C80 “No System Controls” Application

Refer to Wiring Notes on page 35

Diagram continued on next page

Page 34

Installation (Continued)

Figure 3-11B

Field Connection Diagram for RAUC-D10 & D12 “No System Controls” Application

Refer to Wiring Notes on page 35

Page 35

Installation (Continued)

Field Connection Diagram Notes for all System Control Options

Page 36

Installation (Continued)

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 3-13 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 3-12 for the specific component connections.

Discharge Air Sensor

(Honeywell 8RT3)

Each unit ordered with variable air volume controls (digit 9 in the model number) is shipped with a Honeywell 8RT3 discharge air sensor.

Locate the thermostat close to the expansion 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.

Before installing any connecting wiring, refer to Figure 3-2 for the electrical access locations provided on the unit. Wire the suction line thermostat in accordance with the field connection diagram in Figure 3-13. Refer to Table 3-6 (AC Conductors) for wiring specifications.

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

Night Setback

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 3-13 for details.

Figure 3-12

8RT3 Discharge Air Sensor Assembly

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 3-12 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 3-2 for the electrical access locations provided on the unit. Wire the sensor in accordance with the field connection diagram in Figure 3-13. 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. 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.

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.

Page 37

Installation (Continued)

Figure 3-13A

Field Connection Diagram for RAUC-C80 “Variable Air Volume” Applications

Refer to Wiring Notes on Page 35 Diagram continued on next page

Page 38

Installation (Continued)

Figure 3-13B

Field Connection Diagram for RAUC-D10 & D12 “Variable Air Volume” Applications

Refer to Wiring Notes on Page 35

Page 39

Installation (Continued)

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 (8S12) Chiller Water Temperature Sensor (8RT2) 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 barrel.

Figure 3-14 illustrates the remote panel dimensional data, the component locations, the locations for the shipwith items, grounding lugs, and the field connection terminal board 8TB9. Refer to the field connection diagram illustrated in Figure 3-15 for the interconnecting points between the remote panel and the unit’s control panel.

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 (8U11) 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 604 ohm resistive jumper is installed across Terminals 7 & 8 on the controller. The 604 ohm resistive jumper is required for six (6) stage operation on 80 through 120 Ton units.

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).

Figure 3-14

EVP Chiller Remote Panel

Chilled Water T emperature Sensor

(Honeywell 8RT2)

With the sensor installed in its proper location within the chilled water piping (Figure 3-7), connect shielded cable (Belden 8760 or equivalent) from the sensor leads to the leads inside the remote panel. Refer to Figure 3-14 for the electrical access into the remote panel and the field connection diagram illustrated in Figure 3-15 for the final cable termination points.

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

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.

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

Page 40

Installation (Continued)

Figure 3-14A

Field Connection Diagram for RAUC-C80 “EVP Chiller” Applications

Refer to Wiring Notes on page 35 Diagram continued on next page

Page 41

Installation (Continued)

Figure 3-14B

Field Connection Diagram for RAUC-D10 & D12 “EVP Chiller” Applications

Refer to Wiring Notes on page 35

Page 42

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.

[ ] Turn the field supplied disconnect switch, located up-

stream of the unit, to the “Off” position.

HAZARDOUS VOLTAGE!

DISCONNECT ALL ELECTRIC POWER INCLUDING

REMOTE DISCONNECTS BEFORE SERVICING.

Failure to disconnect power before servicing can

cause severe personal injury or death.

[ ] 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.

[ ] Verify that all compressor service valves, discharge ser-

vice valves, and liquid line service valves are back seated on each circuit.

[ ] 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.

COMPRESSOR SERVICE VALVES!

COMPRESSOR SERVICE VALVES MUST BE FULLY

OPENED BEFORE START-UP (SUCTION, DIS-

CHARGE, LIQUID LINE, AND OIL LINE).

Failure to fully open valves prior to start-up may

cause compressor failure due to lack of refrigerant

and/or oil flow.

[ ] 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. Vent the air out of the chiller barrel by removing the vent pipe plug, located on the top of the chiller barrel. Replace the vent plug when the chiller barrel is full of water.

[ ] Once the system has been filled, inspect the entire

chilled water piping system for leaks. Make any necessary repairs before proceeding.

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

An electronic micron vacuum gauge should be installed in the common line ahead of the vacuum pump shutoff valve, as shown in Figure 4-1. Close Valves B and C, and open V alve 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.

Note: 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

Page 43

System Pre-Start Procedures (Continued)

pressure in the system to “zero” (0 psig) gauge pressure. Repeat this process two or three times during evacuation.

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 4-2 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 4-1

Typical Vacuum Pump Hookup

Figure 4-2

Evacuation Time-vs-Pressure Rise

1600

Continuously i ncreasi ng pres sure indic ates t he presence of leaks,

1400

1200

1000

800

PRESSURE IN MICRON

600

400

Initial evacuati on pressure

mois ture or both.

State of equilibrium indicates the

true amount of moisture left in

the system. It indicates that no

leaks are present , but further

evacuat i on i s requi red.

State of equilibrium indicates the

true amount of moisture left in

the system. It indicates that no

leaks are present and the

system is properly evacuated.

200

-10 0 10 20 30 40 50 60 70 80 90

TI ME IN MIN UTES

Page 44

System Pre-Start Procedures (Continued)

Discharge Air Controller Checkout

(Honeywell W7100A)

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

The W7100A (7U11) discharge air controller can be checked out using a highly accurate digital volt-ohmmeter and the W7100A accessory tool kit (Trane part # TOL-0101 or Honeywell part # 4074EDJ).

1. Turn all control switches to the “OFF” positon 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 auxillary 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 Figure 4-3 for terminal and control dial identification.

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 60 F.

8. Set the “Setpoint F” dial at 56 F 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.

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 64 F; within 10 seconds, the LEDs should turn “Off” as the cooling outputs stage “Off”.

13. Immediately readjust the “Setpoint F” dial to 56 F; 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 15 F and the “Setpoint F” dial at 41 F; 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 49 F; 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 56 F; 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 64 F to drive the economizer output to the minimum position.

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

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.

HAZARDOUS VOLTAGE!

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 ser-

vice procedures with the electrical power energized.

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

Page 45

System Pre-Start Procedures (Continued)

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 auxillary 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 4-3

W7100A Discharge Air Controller

Discharge Air Sensor Checkout

(Honeywell Sensor)

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 Table 4-1 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.

Page 46

Table 4-1

)

“Temperature vs Resistance” Curve for EVP & VAV sensors

4200

4000

3800

3600

System Pre-Start Procedures (Continued)

3400

Resistance (Ohms

3483 ± 10 Ohms @

F (25O C)

3200

3000

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)

Temperature -

Economizer Actuator Checkout

Used with “Zone” or “Discharge Air” Temperature 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.

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.

F (OC)

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.

EVP Chiller Control Checkout

(Honeywell W7100G)

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

The W7100G (6U11) chilled water controller can be checked out using a highly accurate digital volt-ohmmeter, 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).

HAZARDOUS VOLTAGE

ROTATING PARTS!

UNIT STARTS AUTOMATICALLY

Make sure all personnel are standing clear of the unit before proceeding. The system components will start

when the power is applied.

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 60

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

Page 47

System Pre-Start Procedures (Continued)

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 Figure 4-4 for terminal and control dial identification.

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

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

HAZARDOUS VOLTAGE!

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 ser-

vice procedures with the electrical power energized.

Figure 4-4

W7100G Chilled Water Controller

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 60

F; 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.

Chilled Water Sensor Checkout

(Honeywell Sensor)

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 Table 4-1 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.

Page 48

System Pre-Start Procedures (Continued)

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 where;

AV (Average Voltage) =

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 = 226 Avg.

VD (reading farthest from average) = 221 The percentage of Imbalance equals:

100 X

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.

226 - 221 = 2.2%

226

Volt 1 + Volt 2 + Volt 3

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 termi-

nal 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 protec-

tor switch that provides the supply power to the condensing unit.

HAZARDOUS VOLTAGE!

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 ser-

vice procedures with the electrical power energized.

[ ] 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 phas-

ing. If the phasing is correct.

[ ] Open the main power disconnect switch or circuit protec-

tion switch and remove the phase sequence indicator.

Page 49

System Start-Up

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.

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 5-1. 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 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 6

amount of discharge air “reset” is 3 control band setpoint). Therefore, if the discharge air setpoint is 55oF, the economizer control point is 52oF

(i.e., 55

F - 3oF).

F (1/2 of the

F, the

Figure 5-1

W7100A Staging Sequence

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 5-1.

Page 50

System Start-Up (Continued)

Sequence of Operation

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 0 used to stabilize system operation.

The control algorithm used by the W7100G to add stages of cooling is illustrated in Figure 5-2. 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”.

F to 10oF [0oC to 6oC] and is

Sequence of Operation

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:

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:

a. Could cause excessive compressor cycling on

internal winding thermostat which leads to compressor motor failure.

b. Lowers the efficiency of the evaporator by reducing

the heat transfer capability.

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

F and the relative humidity of the air entering the

Figure 5-2

W7100G Staging Sequence

Page 51

System Start-Up (Continued)

Sequence of Operation

Condenser Fans

Condenser fan cycling is accomplished through interlocking the fan contactors with liquid line pressure switches (4S7 and 4S8). Figure 5-3 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 4B1, 4B2, 4B3, 4B4, 4B5 & 4B6 are held “Off” by the liquid line pressure switch (4S7) and normally open interlock contacts 1K5 & 1K9. Once the pressure switch has closed (275 psig), condenser fan relay 1K7 (& 1K10 if applicable) is energized starting fans 4B1 & 4B4 (& 4B3 if applicable). The normally open interlock contacts 1K7 closes, energizing fan contactor 1K9, starting fan 4B2 (& 4B6 if applicable). 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 4B5 is not allowed to start until compressor contactor 1K5 has energized.

If a second step cooling command is initiated, (circuit #2), condenser fans 5B1, 5B2, 5B3, 5B4, 5B5 & 5B6 are held “Off” by the liquid line pressure switch (4S8) and normally open interlock contacts 1K6 & 1K13. Once the pressure switch has closed (275 psig), condenser fan relay 1K11 (& 1K14 if applicable) is energized starting fans 5B1 & 5B4 (& 5B3 if applicable). The normally open interlock contacts 1K11 closes, energizing fan contactor 1K13, starting fan 5B2 (& 5B6 if applicable). When the normally open interlock contacts 1K13 close, they seal 1K13 contactor in the “On” position until the cooling demand has been satisfied. Condenser fan 5B5 is not allowed to start until compressor relay 1K6 has energized.

Figure 5-3

Condenser Fan Locations

Sequence of Operation

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

F with hot gas bypass. (These values apply when

or 10 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.

Sequence Of Operation

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.

Sequence of Operation

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.

Sequence of Operation

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.

Page 52

System Start-Up (Continued)

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 5-3 for the damper locations.

For field installation, mount the dampers over the condenser fans at the locations shown in Figure 5-3 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 105oF. 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.)

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.)

Table 5-1

EVP GPM vs Pressure Drop

Chiller Pressure Drop **

GPM* Chiller Size

80 Ton 100 Ton 120 Ton

100 4.5 120 6.5 3.2 140 8.7 4.3 3.2 160 11.2 5.6 4.1 180 14.1 7.0 5.2 200 17.2 8.5 6.3 240 24.8 12.2 9.0 280 16.3 12.0 320 21.0 15.8 360 26.0 19.7

400 24.0 * - Gal lons Per Minute ** - All Pressure Drops are in Feet of Water = Beyond the working limits of the barrel

“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. 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.

EVP Chiller Applications

Start the chilled water circulating pump by closing the field provided pump disconnect switch and turn the pump control circuit switch 6S1 “On”.

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

With water circulating through the system, check the EVP chiller barrel pressure drop and adjust the flow (if necessary). Refer to the appropriate EVP chiller barrel size in Table 5-1 for the operating pressure drop.

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.

HAZARDOUS VOLTAGE

ROTATING PARTS!

UNIT STARTS AUTOMATICALLY

Make sure all personnel are standing clear of the unit before proceeding. The system components will start

when the power is applied.

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.

Page 53

System Airflow Measurement

System Start-Up (Continued)

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

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;

a. Drilling a small hole through the unit casing on each

side of the coil.

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

b. Measure the difference between the pressures at

both locations.

c. 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.

d. 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 SERVICE VALVES!

COMPRESSOR SERVICE VALVES MUST BE FULLY

OPENED BEFORE START-UP (SUCTION, DIS-

CHARGE, LIQUID LINE, AND OIL LINE).

Failure to fully open valves prior to start-up may

cause compressor failure due to lack of refrigerant

and/or oil flow.

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.

Note: 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 Table 5-3 for the required amount of refrigerant for the system.

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.

Table 5-4 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 Table 5-5 for the compressor sequencing and Figure 5-4 for their location.

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

Compressor Start-Up

(All Systems)

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.

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

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

Page 54

HAZARDOUS VOLTAGE

ROTATING PARTS!

System Start-Up (Continued)

Note: 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.

UNIT STARTS AUTOMATICALLY

Make sure all personnel are standing clear of the unit before proceeding. The system components will start

when the power is applied.

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;

1. 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.

2. 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.

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 Table 5-6 to determine the proper operating pressures. If the operating pressures indicate a refrigerant shortage, measure the system superheat and system sub-cooling.

Note: Do Not release refrigerant to the atmosphere! If adding or removing refrigerant is required, the service technician must comply with all Federal, State and local laws. Refer to general service bulletin MSCU-SB-1 (latest edition).

Sub-Cooling

The outdoor ambient temperature must be between 65 and 105

F 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.

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

Measuring Sub-Cooling

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.

Some Motors are Rotating Backwards;

2. 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 5-5 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.

Note: Glass thermometers do not have sufficient contact area to give an accurate reading.

c. Determine the system sub-cooling by subtracting the

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

Measuring Superheat

a. Measure the suction pressure at the outlet of the

evaporator as close to the expansion valve bulb location as possible.

b. Measured the suction line temperature as close to

the expansion valve bulb, as possible.

c. 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.

Page 55

System Start-Up (Continued)

d. 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 sub-cooling (each circuit);

Record this data on an “operator’s maintenance log” shown in Table 5-8. Repeat these procedures for the second refrigeration circuit, if applicable.

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:

1. Compressor is operating at an extremely high condensing temperature;

2. High superheat;

3. A compressor mechanical failure or motor burnout

has occurred. 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.

Table 5-2

Pressure Control Settings

Pressure Switch Make Break

Hi Pr essure 350 psi 405 p si Lo Pressure EVPB 60 psi 45 psi All other s 40 psi 30 psi Condenser Fan Cycling Swit c h 275 psi 155 psi (EVP O nly w/HG B - wo/HGB)

Std.

Low Ambient Ther mostat 33

F30

Compressor Windi ng T-Stat 181

Note:

Pack Stock units will have both

F221

low pressure switches shipped and the user should use th e above valv es th at apply.

Table 5-3

Recommended Refrigerant Capacities

Capacity Total Interconnecting Line Length

50 100 150

Approximate Total System Refrigerant Charge

(Lbs. Per Circuit)

80 Ton 92 107 150 100 Ton 108 131 155 120 Ton 134 157 183

Table 5-4

Minimum Starting Ambient Temperature

Minimum Starting Ambient (1)

Standard Units Low Ambie nt Units Unit With No With No Size HGBP HGBP HGBP HGBP

80-120 45° 40° 10° 0°

Note :

1. Minimum starting ambients in degrees F and is based on the unit operating at minimum step of unloading and 5 mph wind across condenser.

Compressor Oil

The scroll compressor uses

Trane OIL-42 without substi-

tution. 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 80watt heaters installed per compressor.

Page 56

System Start-Up (Continued)

Table 5-5

Compressor Sequence

Circuit # 1 % Load ed Circuit # 2 % Lo ad ed % Lo ad ed

U nit Contro l 1A 1B 1C 1D CKT #1 2A 2B 2C 2D CKT #2 U nit

Si z e Step (1K2) ( 1K5) (1K1) (1K19 ) (1K3) ( 1K6) (1K4) (1K 20)

1 Off Off On N/A 38% Of f Off Of f N/A 0% 19% 2 Off Off On 38% Of f Off On 38% 38%

80 Ton 3 On On Off 63% Off Off On 38% 50%

4 On On Off 63% On On Off 63% 63% 5 On On On 100% On On Off 63% 81% 6 On On On 100% On On On 100% 100% 1 Off Off On On 40% Off Off Off Off 0% 20% 2 Off Off On On 40% Off Off On On 40% 40%

100 T on 3 Of f On On On 70% O ff Of f On On 40% 55%

4 Off On On On 70% Off On On On 70% 70% 5 On On On On 100% Of f On On On 70% 85% 6 On On On On 100% On On On On 100% 100% 1 Off Off On On 50% Off Off Of f Off 0% 25% 2 Off Off On On 50% Off Off On On 50% 50%

120 T on 3 Of f On On On 75% O ff Of f On On 50% 63%

4 Off On On On 75% Off On On On 75% 75% 5 On On On On 100% Of f On On On 75% 88% 6 On On On On 100% On On On On 100% 100%

Figure 5-4

Typical Compressor Locations

Page 57

Figure 5-5

Typical Scroll Compressor Terminal Block

System Start-Up (Continued)

Page 58

Table 5-8

80 Ton Pressure Curve for each Circuit

COOLING CYCLE PRES SURE CURVE

(Based on Indoor Airflow of 400 CFM / Ton)

400

System Start-up (Continued)

FULL LOAD

380 360 340 320 300 280 260 240

DISCHARGE PRESSURE, PSIG

220 200 180

55 60 65 70 75 80 85 90 95 100 105

To Check Operating Pressures

1. S t art the unit and allow t he pres sures t o stabiliz e.

2. Measure the out door ai r dry bul b temperature (F) entering the condens er coil.

3. Measure the discharge and suct i on pressure (ps i g) next to the compressor.

SUCT ION PRES SURE, P SIG

100 Ton Pressure Curve for each Circuit

COOLING CYCLE PRES SURE CURVE

(Based on Indoor Airflow of 400 CFM / Ton)

400 380

115 F OD Am bi ent

105 F OD Am bi ent

95 F OD Am bi ent

85 F OD Am bi ent

75 F OD Am bi ent

65 F OD Am bi ent

4. P l ot the outdoor dry bul b t em perature and the operating suct i on pressure (ps i g) ont o the chart .

5. A t the point of intersec tion, read t o t he l eft for the discharge pressure. The measured di scharge

press ure should be wit hi n ± 7 ps i g of the graph.

FULL LOAD

115 F OD Am bi ent

360 340 320 300 280 260 240

DISCHARGE PRESSURE, PSIG

220 200 180

55 60 65 70 75 80 85 90 95 100 105

To Check Operating Pressures

1. S t art the unit and allow t he pres sures t o stabiliz e.

2. Measure the out door ai r dry bul b temperature (F) entering the condens er coil.

3. Measure the discharge and suct i on pressure (ps i g) next to the compressor.

105 F OD Am bi ent

95 F OD Am bi ent

85 F OD Am bi ent

75 F OD Am bi ent

65 F OD Am bi ent

SUCT ION PRES SURE, P SIG

4. P l ot the outdoor dry bul b t em perature and the operating suct i on pressure (ps i g) ont o the chart .

5. A t the point of intersec tion, read t o t he l eft for the discharge pressure. The measured di scharge

press ure should be wit hi n ± 7 ps i g of the graph.

Page 59

Table 5-8 (Continued)

120 Ton Pressure Curve for each Circuit

COOLING CYCLE PRES SURE CURVE

(Based on Indoor Airflow of 400 CFM / Ton)

400 380 360 340

System Start-up (Continued)

FULL LOAD

115 F OD Am bi ent

105 F OD Am bi ent

320 300 280 260 240

DISCHARGE PRESSURE, PSIG

220 200 180

55 60 65 70 75 80 85 90 95 100 105

To Check Operating Pressures

1. S t art the unit and allow t he pres sures t o stabiliz e.

2. Measure the out door ai r dry bul b temperature (F) entering the condens er coil.

3. Measure the discharge and suct i on pressure (ps i g) next to the compressor.

SUCT ION PRES SURE, P SIG

4. P l ot the outdoor dry bul b t em perature and the operating suct i on pressure (ps i g) ont o the chart .

5. A t the point of intersec tion, read t o t he l eft for the discharge pressure. The measured di scharge

press ure should be wit hi n ± 7 ps i g of the graph.

Final System Setup

After completing the Pre-start and Start-up procedures outlined in the previous sections, perform these final checks before leaving the unit:

[ ] Turn the 115 volt control circuit switch 1S2 “Off”.

95 F OD Am bi ent

85 F OD Am bi ent

75 F OD Am bi ent

65 F OD Am bi ent

[ ] Verify that the “System” control switch for the supply fan

or the chilled water pump is “On”.

[ ] Set the correct “Operating Temperature” for the system at

the system controller. Refer to Table 5-9 for the recommended control setpoints for the appropriate control option.

[ ] Program the Night Setback (NSB) panel (if applicable) for

proper unoccupied operation. Refer to the programming instructions for the specific panel.

[ ] Verify that the “System” selection switch and the “Fan

Mode” selection switch at the Remote panel is set correctly.

[ ] Turn the 115 volt control circuit switch 1S2 “On”. The sys-

tem will start automatically once a request for cooling has been given.

[ ] Verify that all exterior panels and the control panel doors

are secured in place.

Page 60

System Start-Up (Continued)

Table 5-9

Recommended Operating Setpoints

Control Control Setting Recom m e nde d Setting

Discharge Air Supply Air Set at design discharge (supply) Controller Setpoint air temperature; (VAV unit s only) min imum setting = 55o F

Reset Set at maximum amount of allowable Setpoint reset for supply air setpoint. Control Band Set at 6o F Minimum

Setpoint Chiller Control Leaving Fluid Set at design leaving chilled water (EVP unit s only) Setpoint temperature.

Design D T Set at design full load water Setpoint D T through evaporator. Number of Stages Factory setting - 6 steps Setpoint Freeze Protection 35° F (Contact Trane for alternate

Setpoint settings) Load Limit Cut-In = 64° F Setpoint Cut-Out = 56° F Low Pressure Cut-In = 60 PSIG Lockout Cut-Out = 45 PSIG

"No Controls" Units - See System Engineer-

Table 5-10

Sample Maintenance Log

Refrigerant Circuit #1 Refrigerant Circuit #2

Current

Ambient Compr . Suct. Disch. Liquid Super- Sub- Compr. Suct. Disch. Liquid Super- Sub-

Temp. Oil Press. Press. Press. heat cool. Oil Press. Press. Press. heat cool.

Date (F) Level (Psig) (Psig) (Psig) (F) (F) Level (Psig) (Psig) (Psig) (F) (F)

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

Note:

Check and record the data requested above each month during the cooling season with the unit running.

Page 61

Service & Maintenance

Compressor Operational Sounds

Because of the scroll compressor design, it emits a higher frequency tone (sound) than a reciprocating compressor. It is designed to accommodate liquids, both oil and refrigerant, without causing compressor damage. The following discussion describes some of the operational sounds that differentiate it from those typically associated with a reciprocating compressor. These sounds do not affect the operation or reliability of the compressor.

At Shutdown:

When a Scroll compressor shuts down, the gas within the scroll expands and causes momentary reverse rotation until the discharge check valve closes. This results in a “flutter” type sound.

At Low Ambient Start-Up

When the compressor starts up under low ambient conditions, the initial flow rate of the compressor is low due to the low condensing pressure. This causes a low differential across the thermal expansion valve that limits its capacity. Under these conditions, it is not unusual to hear the compressor rattle until the suction pressure climbs and the flow rate increases.

Scroll Compressor Replacement

Table 6-1 lists the specific compressor electrical data and the circuit breaker operating ranges.

Table 6-1

Compressor Circuit Breaker Data

Voltage Comp RLA LRA Must Mus t

Tons Hold Trip

200 9 41.4 269.0 50.4 58.0 230 9 41.4 251.0 50.4 58.0 460 9 18.1 117.0 22.0 25.3 575 9 14.4 94.0 17.5 20.2

380/415 9 17.2 110.0 20.9 24.1

200 14 60.5 404.0 73.7 84.7 230 14 60.5 376.0 73.7 84.7 460 14 26.3 178.0 32.0 36.8 575 14 21.0 143.0 25.6 29.4

380/415 14 26.2 174.0 31.9 36.7

Figure 6-1

Suction Line Filter/Drier Installation

The compressor manifold system was purposely designed to provide proper oil return to each compressors. The refrigerant manifolded system must not be modified in any way.

Note: Altering the manifold piping may cause oil return problems and compressor failure.

Should a compressor replacement become necessary and a suction line filter drier is to be installed, install it a minimum of 18 inches upstream of the oil separator tee. Refer to the illustration in Figure 6-1.

Anytime a compressor is replaced, the oil for each compressor within the manifolded set must be replaced.

The scroll compressor uses Trane OIL-42 without substi- tution. 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.

Note: Refrigerant oil is detrimental to some roofing materials. Care must be taken to protect the roof from oil leaks or spills.

Page 62

Fuse Replacement Data

Table 6-2 lists the replacement fuses for the control circuit, compressors, and condenser fans.

Table 6-2

Fuse Replacement Data

Service & Maintenance (Continued)

Monthly Maintenance

Before completing the following checks, turn all system control circuit switches to the “Off” position.

“Open” the main power disconnect switches for the condensing unit and all system support equipment. “lock” the disconnect switches in the “Off” position before removing any access panels.

HAZARDOUS VOLTAGE!

DISCONNECT ALL ELECTRIC POWER INCLUDING

REMOTE DISCONNECTS BEFORE SERVICING.

Failure to disconnect power before servicing can

cause severe personal injury or death.

Air Handling Equipment

[ ] Inspect the return air filters. Clean or replace them if nec-

essary.

[ ] Check the evaporator drain pan and condensate piping

to ensure that there are no blockages.

[ ] Inspect the evaporator coils for dirt. If the coils appear

dirty, clean them according to the instructions described in the “Coil Cleaning” section.

[ ] Lubricate the supply fan bearings. Refer to the equip-

ment manufacturer for their recommended greases.

Note: Over lubrication can be just as harmful as not enough grease.

Use a hand grease gun to lubricate these bearings; add grease until a light bead appears all around the seal. Do not over lubricate!

After greasing the bearings, check the setscrews to ensure that the shaft is held securely to the bearings and Fan wheels. Make sure that all bearing supports are tight.

[ ] Check the supply fan belt(s). If the belts are frayed or

worn, replace them. [ ] Verify that all wire terminal connections are tight. [ ] Generally inspect the unit for unusual conditions (e.g.,

loose access panels, leaking piping connections, etc.) [ ] Make sure that all retaining screws are reinstalled in the

unit access panels once these checks are complete.

Condensing Unit

[ ] Manually rotate the condenser fans to ensure free move-

ment and check motor bearings for wear. Verify that all of

the fan mounting hardware is tight.

[ ] Inspect the economizer damper hinges and pins (if appli-

cable) to ensure that all moving parts are securely mounted. Clean the blades as necessary.

[ ] Verify that all damper linkages move freely; lubricate with

white grease, if necessary.

[ ] Check Supply Fan motor bearings; repair or replace the

motor as necessary.

[ ] Check the fan shaft bearings for wear. Replace the bear-

ings as necessary.

[ ] Verify that all wire terminal connections are tight. [ ] Inspect the condenser coils for dirt and foreign debris. If

the coils appear dirty, clean them according to the in-

structions described in the “Coil Cleaning” section. [ ] Inspect the compressor and condenser fan motor contac-

tors. If the contacts appear severely burned or pitted, re-

place the contactor. Do not clean the contacts. [ ] Check the compressor oil level. (Compressors “Off”)

Page 63

Service & Maintenance (Continued)

Coil Cleaning

Regular coil maintenance, including annual cleaning, enhances the unit’s operating efficiency by minimizing:

compressor head pressure and amperage draw; evaporator water carryover; fan brake horsepower, due to increase static pressure

losses;

airflow reduction.

At least once each year, or more often if the unit is located in a “dirty” environment, clean the evaporator and condenser coils using the instructions outlined below. Be sure to follow these instructions as closely as possible to avoid damaging the coils.

To clean refrigerant coils, use a soft brush and a sprayer (either a garden pump-up type or a high-pressure sprayer). A high-quality detergent is also required; suggested brands include “SPREX A.C.”, “OAKITE 161”, “OAKITE 166” and “COILOX”. If the detergent selected is strongly alkaline (ph value exceeds 8.5), add an inhibitor.

1. Remove enough panels from the unit to gain access to the coil.

2. Protect all electrical devices such as motors and controllers from any over spray.

3. Straighten any bent coil fins with a fin comb.

4. Mix the detergent with water according to the manufacturer’s instructions. If desired, heat the solution to 150 F maximum to improve its cleansing capability.

CONTAINS REFRIGERANT!

SYSTEM CONTAINS OIL AND REFRIGERANT

Do not heat the detergent-and-water solution above

150

F. Hot liquids sprayed on the exterior of the coil

will raise the coil’s internal pressure and may cause

Failure to follow proper procedures can result in per-

sonal illness or injury or severe equipment damage.

Note: Refrigerant oil is detrimental to some roofing materials. Care must be taken to protect the roof from oil leaks or spills.

it to burst.

6. Spray the leaving-airflow side of the coil first; then spray the opposite side of the coil. Allow the cleaning solution to stand on the coil for five minutes.

7. Rinse both sides of the coil with cool, clean water.

8. Inspect both sides of the coil; if it still appears to be dirty, repeat Steps 6 and 7.

9. Reinstall all of the components and panels removed in Step 1 and any protective covers installed in step 2.

10. Restore the unit to it’s operational status and check system operation.

System operation

[ ] Close the main power disconnect switch for the condens-

ing unit and all system support equipment. Turn all system control circuit switches to the “On” position.

HAZARDOUS VOLTAGE

ROTATING PARTS!

UNIT STARTS AUTOMATICALLY

Make sure all personnel are standing clear of the unit before proceeding. The system components will start

when the power is applied.

[ ] With the unit running, 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” similar to the one illustrated in the “Final Setup” section of this manual. If the operating pressures indicate a refrigerant shortage, measure the system Superheat and system Subcooling. For guidelines, refer to the “system Start-Up” section.

Note: Do Not release refrigerant to the atmosphere! If adding or removing refrigerant is required, the service technician must comply with all federal, state and local laws. Refer to general service bulletin MSCU-SB-1 (latest edition).

5. Pour the cleaning solution into the sprayer. If a high-pressure sprayer is used:

a. do not allow sprayer pressure to exceed 600 psi. b. the minimum nozzle spray angle is 15 degrees. c. maintain a minimum clearance of 6" between the

sprayer nozzle and the coil.

d. spray the solution perpendicular (at 90 degrees) to

the coil face.

Page 64

Index

Symbols

100 Ton Pressure Curve for each Circuit ..........................58

See

Table 5-8

120 Ton Pressure Curve ....................................................59

See

Table 5-8

80 Ton Pressure Curve for each Circuit ............................58

See

Table 5-8

AC Conductors ..................................................................31

See

Table 3-6

Air Handling Equipment.....................................................62

Air Vents.............................................................................26

Airflow Measurement.........................................................53

Align the mounting holes ...................................................16

balancing cock ...................................................................26

C80 Scroll Compressor Shipping Hardware .....................18

See

Figure 3-5A

Cautions...............................................................................4

Chilled Water Controller ........................................................

See

Figure 4-5

chiller drain ........................................................................26

clearance adjustments.......................................................16

coil maintenance................................................................63

COILOX .............................................................................63

See

Coil Cleaning

Compressor Circuit Breaker Data .....................................61

compressor discharge service valve .................................42

Compressor Locations.......................................................51

See

Figure 5-3

Compressor Oil..................................................................55

Compressor Sequence......................................................56

See

Table 5-6

Compressor Shipping Hardware .......................................18

See

Figure 3-5

concealed damage ..............................................................6

concrete footings ...............................................................16

concrete pad ...................................................................... 16

Condenser Fan Locations .................................................51

See

Figure 5-3

Condensing Unit ................................................................62

Copper oxide .....................................................................25

Customer Connection Wire Range ...................................29

See

Table 3-4

D10 & D12 Scroll Compressor Shipping Hardware ..........18

See

Figure 3-5B

DC Conductors ..................................................................32

See

Table 3-7

Discharge Air Sensor Assembly ........................................36

See

Figure 3-12

Economizer Actuator Circuit Legend.................................32

Economizer Cycle..............................................................49

Electrical Service Sizing Data ...........................................30

See

Table 3-5

electronic micron vacuum gauge ......................................42

Evacuate the system .........................................................42

Evacuation Time-vs-Pressure Rise ...................................43

See

Figure 4-2

evaporator fan interlock.....................................................31

Evaporator water inlet and outlet types.............................26

EVP Chiller Considerations .................................................6

EVP GPM vs Pressure Drop .............................................52

See

Table 5-1

Excessive flux ....................................................................25

Expansion Valve ................................................................ 21

factory mounted disconnect switch ...................................28

Field Connection Diagram for EVP Chiller.................40, 41

Field Connection Diagram for “No System

Controls” .....................................................................33, 34

Field Connection Diagram for Variable Air

Volume........................................................................37, 38

See

Figure 3-17

filter driers ..........................................................................21

Filter driers and valves ......................................................21

“Fixed-On” & “Fixed-Off” time delays ................................33

flow switch .................................................................. 26, 31

flushing water piping.......................................................... 27

Fuse Replacement Data....................................................64

See

Table 6-2

General Unit Requirement.................................................42

GPM vs Pressure Drop......................................................26

See

Table 3-3

halide torch ........................................................................25

halogen leak detector ........................................................25

Honeywell W7100 Discharge Air Controller......................36

Horizontal Lines .................................................................21

Hot Gas Bypass.................................................................31

Hot Gas Bypass Operation................................................51

Inspection ............................................................................6

Installation Clearances ........................................................7

See

Figure 3-1

Leak-testing a refrigerant system......................................25

Liquid Line & Drier Refrigerant Requirements ..................55

See

Table 5-4

Low Ambient Dampers ......................................................51

low ambient option.............................................................52

Page 65

Maintenance Log ...............................................................60

See

Table 5-9

Maximum allowable pressure drop ............................21, 22

maximum allowable voltage imbalance.............................48

Maximum Liquid velocity ...................................................21

Maximum suction gas velocity...........................................22

Maximum velocity .............................................................. 21

Minimum Starting Ambient Temperature ...........................56

See

Table 5-6

Minimum suction gas velocity at minimumload.................22

Minimum velocities at Minimum Load ........................21, 22

Minimum Vertical Line Velocities ....................................... 22

See

Table 3-3

Model 45 Phase Sequence Indicator ................................48

Moisture Indicators ............................................................21

shutoff valves.....................................................................26

silver brazing alloy .............................................................25

sizing refrigerant piping .....................................................21

Solenoid Valves .................................................................21

sound and vibration transmission......................................16

SPREX A.C........................................................................63

See

Coil Cleaning

Spring Isolator Selection....................................................17

See

Figure 3-5

spring isolators ..................................................................16

“standing vacuum test” ......................................................43

Sub-cooling........................................................................54

Suction Line Filter/Drier Installation ..................................61

See

Figure 6-1

Suction Line Refrigerant Requirements ............................55

See

Table 5-5

suction line thermostat.......................................................36

Superheat ..........................................................................54

Supply Fan Rotation .......................................................... 52

night setback operation .....................................................36

Nitrogen .........................................................................4, 25

nitrogen flow ......................................................................25

OAKITE 161.......................................................................63

See

Coil Cleaning

OAKITE 166.......................................................................63

See

Coil Cleaning

OIL-42 without substitution................................................61

Operating Setpoints...........................................................60

See

Table 5-8

Optional Flow Switch .........................................................27

See

Figure 3-9

Outside Air Thermostat ......................................................31

Pack Stock Units................................................................56

pipe strainer .......................................................................26

pipe unions ........................................................................26

Power Wire Sizing and Protection Device ........................29

Pressure Control Settings .................................................55

See

Table 5-2

pressure gauge..................................................................26

pressure regulating valve ..................................................25

pulling a vacuum of 100 microns.......................................42

Recommended Refrigerant Capacities .............................55

See

Table 5-3

Refrigerant Capacities .......................................................55

See

Table 5-3

Rigging and Center-of-Gravity ..........................................15

See

Figure 3-3

scroll compressor design...................................................61

Secure the isolator.............................................................16

Sensor and Sensor-well ....................................................26

“Temperature vs Resistance” Curve for EVP &

VAV sensors.......................................................................46

See

Table 4-1

Type “L” refrigerant tubing.................................................21

Typical Clearances .............................................................. 7

See

Figure 3-1

Typical Compressor Terminal Block ..................................56

See

Figure 5-4

typical economizer actuator...............................................32

Typical EVP Chiller Weights & General Data....................15

See

Table 3-1B

Typical Piping recommendations ......................................27

See

Figure 3-8

Typical Refrigerant Piping Components............................23

See

Figure 3-7

Typical Unit Weights & Point Loading Data.......................15

See

Table 3-1

vacuum be “Broken” ..........................................................42

Vacuum Pump Hookup......................................................43

See

Figure 4-1

vacuum pump oil ............................................................... 42

Vertical Lines .....................................................................21

vibration eliminators...........................................................26

W7100A Discarge Air Controller........................................45

See

Figure 4-3

W7100A Discharge Air Controller ......................................49

W7100A Staging Sequence...............................................49

See

Figure 5-1

W7900 Chilled Water Controller........................................47

See

Figure 4-4

W7900 Controller Diagnostics...........................................50

See

Figure 5-2

Warnings..............................................................................4

Page 66

WARRANTY AND LIABILITY CLAUSE

COMMERCIAL EQUIPMENT

RATED 20 TONS AND LARGER AND RELATED ACCESSORIES

PRODUCTS COVERED - This warranty* is extended by American Standard Inc. and applies only to commercial equipment rated 20 Tons and larger and related accessories.

The Company warrants for a period of 12 months from initial start-up or 18 months from date of shipment, whichever is less, that the Company products covered by this order (1) are free from defects in material and workmanship and (2) have the capacities and ratings set forth in the Companys catalogs and bulletins, provided that no warranty is made against corrosion, erosion or deterioration. The Companys obligations and liabilities under this warranty are limited to furnishing f.o.b. factory or warehouse at Company designated shipping point, freight allowed to Buyers city (or port of export for shipment outside the conterminous United States) replacement equipment (or at the option of the Company parts therefore) for all Company products not conforming to this warranty and which have been returned to the manufacturer. The Company shall not be obligated to pay for the cost of lost refrigerant. No liability whatever shall attach to the Company until said products have been paid for and then said liability shall be limited to the purchase price of the equipment shown to be defective.

The Company makes certain further warranty protection available on an optional extra-cost basis. Any further warranty must be in writing, signed by an officer of the Company.

THE WARRANTY AND LIABILITY SET FORTH HEREIN ARE IN LIEU OF ALL OTHER WARRANTIES AND LIABILITIES, WHETHER IN CONTRACT OR IN NEGLIGENCE, EXPRESS OR IMPLIED, IN LAW OR IN FACT, INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE, IN NO EVENT SHALL WARRANTOR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Manager - Product Service American Standard Inc. Clarksville, Tn 37040-1008

PW-215-2688 *Optional Extended Warranties are available for

compressors and heat exchangers of Combination Gas-Electric Air Conditioning Units.

The warranty and liability set forth herein are in lieu of all other warranties and liabilities, whether in contract or in negligence, express or implied, in law or in fact, including implied warranties of merchantability and fitness for particular use. In no event shall the Company be liable for any incidental or consequential damages.

Page 67

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