Trane RTAA-130, RTAA-340, RTAA-140, RTAA-185, RTAA-270 Installation, Operation And Maintenance Manual

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Air-Cooled Series R

Rotary Liquid Chillers

Installation RTAA-IOM-3 Operation Maintenance

Library Service Literature Product Section Refrigeration Product Rotary liquid Chillers – Air-Cooled Model RTAA Literature Type Installation, Operation, Maintenance Sequence 3 Date December 1991 File No. SV-RF-RLC-RTAA-IOM-3-1291 Supersedes

“CO” and Later Design Sequence Packaged Air-Cooled Chiller,

RTAA 130-400 Remote Evaporator Air-Cooled Chiller,

RTAA 130-200

Models RTAA-130 RTAA-170 RTAA-240 RTAA-340

RTAA-140 RTAA-185 RTAA-270 RTAA-370 RTAA-155 RTAA-200 RTAA-300 RTAA-400

Part No. X39560468-01

Since The Trane Company has a policy of continuous product improvement, it reserves the right to change specifications and design without notice. The installation and servicing of the equipment referred in this booklet should be done by qualified, experienced technicians.

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©American Standard Inc. 1991

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Table of Contents

World environmental scientists have concluded, based on the best currently available evidence, that ozone in our upper atmosphere is being reduced due to release of CFC fully halogenated compounds.

Prior to installation, operation, service or maintenance on this equipment, refer to “Refrigerant Emission Control” in the Periodic Maintenance Section.

9 General Information

9 Literature Change History 9 Unit Identification 9 Unit Inspection 9 Inspection Checklist 9 Loose Parts Inventory 10Unit Description 10Commonly Used Acronyms 20Warnings and Cautions 20Installation Responsibilities 21Nameplates 21— Outdoor Unit Nameplate 21— Compressor Nameplate 21— Remote Evaporator Nameplate 23Storage 25 Installation - Mechanical, Packaged

Unit with Remote Evaporator 25General 25Pre-installation 25Location Requirements 25— Noise Considerations 25— Foundation 25— Clearances 31— Additional Location

Requirements for Remote

Evaporator Only 31— Drainage 32Rigging 32Lifting Procedures 36Unit Isolation and Leveling 36Evaporator Water Piping 41— Evaporator Piping 42— Evaporator Piping Components 42— Entering Chilled Water Piping 42— Leaving Chilled Water Piping 42— Evaporator Drain 42— Evaporator Flow Switch 44— Water Treatment 44— Water Pressure Gauges 44— Water Pressure Relief Valves 44— Freeze Protection 45— Domestic Water Heater Piping 45— Domestic Water Heater Piping

Components 45— Entering Water Piping 45— Leaving Water Piping 45— Water Pressure Relief Valves 45— Freeze Protection

47Installation - Mechanical,

Remote Evaporator Interconnecting Refrigerant Piping

47General 51Line Sizing 51— Equivalent Line Length 51— Liquid Line Sizing 53—Suction Line Sizing 54Piping Installation Procedures 54Refrigerant Sensors 56Leak Test and Evacuation 56Refrigerant and Additional Oil

Charge

56— Refrigerant Charge

Determination

56— Oil Charge Determination

57Installation - Electrical

57General Recommendations 68Installer-Supplied Components 68— Remote Evaporator Only 68Power Supply Wiring 68— General 68— Control Power Supply 68— Heat Tape Power Supply

(Packaged Units Only) 68— Water Pump Power Supply 68— Auxiliary Heat Tape Power

Supply 69Interconnecting Wiring 69— Chilled Water Pump Interlock

and External Auto/Stop 69— Chilled Water Pump Interlock 69— External Auto/Stop Wiring 70— Alarm/Running/Maximum

Capacity Outputs 71— Alarm/Running/Maximum

Capacity Indicator Wiring 71Low Voltage Wiring 71— Emergency Stop (Normal Trip) 71— External Circuit Lockout -

Circuit #1 71— External Circuit Lockout -

Circuit #2 71— Ice Making Option 72— External Chilled Water Setpoint

(CWS) Remote Resistor/

Potentiometer, Voltage Source

2-10 VDC or Current Source

4-20 mA 73— External Current Limit Setpoint

(CLS) Remote Resistor/

Potentiometer, Voltage Source

2-10 VDC or Current Source

4-20 mA 74— Optional Bidirectional

Communication Link (BCL) 74— General 74— Communication Link

Connection Procedure 75Installation Check List

RTAA-IOM-3

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77 Operating Principles -

Mechanical

77 General 77 Refrigeration (Cooling) Cycle 77 — Cycle Description 77 — Compressor Description 77 — Compressor Motor 77 — Compressor Rotors 77 — Compressor Loading Sequence 82 Oil System Operation 82 — Overview 82 — Domestic Water Heater 83 — Oil Separator 83 — Compressor Bearing Oil Supply 83 — Compressor Rotor Oil Supply 84 — Slide Valve Movement 84 — Oil Filter 84 —Condenser Fans

87 Operating Principles -Adaptive

Control™ Microprocessor Logic

87 General 87 Digital Display 93 — Menus 99 — Chiller Switch 100 Menu Function Descriptions and

Selection 100 — Selecting Variables and Options 100 — Menu 0 - Operating Display 100 — Menu 1 - Service #1 Display 101 — Menu 2 - Service #2 Display 101 — Menu 3 - Auxiliary Options 102 — Menu 4 - Factory Display #1 104 — Menu 5 - Factory Display #2 105 Operational Features 105 — Entering Evaporator Water

Temperature 105 — Current Limit Setpoint 105 — Low Ambient Lockout 105 — Electronic Expansion Valve

(EXV) Test 105 — Current Overload Protection 105 — Leaving Chilled Water

Temperature Control 106 — Chilled Water Reset (CWR) 107 — Leaving Water Temperature

Cutout 107 — Low Refrigerant Temperature

Cutout 107 — Low Ambient Temperature Start 107 — Low Refrigerant Temperature

Cutout Retry 108 — Auto Lead/Lag 108 — Phase Imbalance Protection 108 —Reverse Rotation Protection 108 DIP Switch Settings 108 Compressor Overload DIP

Switches 108 IPC Address 108 — 2-10 VDC/4-20 mA Input for

(CWS) and (CLS) 109 Diagnostics and Troubleshooting 109 —Mechanical Control Settings

121 Pre-Start Check-out

121 General 122 Unit Voltage Power Supply 122 Unit Voltage Imbalance 123 Unit Voltage Phasing 124 Water System Flow Rates 124 Water System Pressure Drop 124 UCM Set-up

125 Start-up Procedures

125 General 125 System Superheat 125 System Subcooling

129 Unit Shutdown Procedures

129 Temporary Shutdown and Restart 129 Extended Shutdown Procedure 130 System Restart After Extended

Shutdown

131 Periodic Maintenance

131 General 133 Refrigerant Emission Control 133 Weekly Maintenance 134 Monthly Maintenance 134 Annual Maintenance

135 Maintenance

135 General 135 Coil Cleaning 135 Chemically Cleaning the

Evaporator

135 Domestic Water Heater –

Tube Cleaning 136 Water Treatment 136 Oil Separator Level Check

RT AA-IOM-3

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List of Illustrations

11 Figure 1

Typical RT AA Packaged Unit 130 to 200 Tons (Front/side Exterior View)

12 Figure 2

Typical RT AA Packaged Unit 130 to 200 Tons (Rear/side Exterior View)

13 Figure 3

Typical RT AA Packaged Unit 240 to 400 Tons (Front/side Exterior View)

14 Figure 4

Typical RTAA Unit (Rear Exterior View)

15 Figure 5

Typical RT AA Unit with Remote Evaporator Option (Rear Exterior View)

18 Figure 6

Remote Evaporator

21 Figure 7

Nameplates

22 Figure 8

Model Number Coding System

26 Figure 9

Dimensions and Clearances for RTAA Packaged Unit

- 130 to 200 T ons

27 Figure 10

Dimensions and Clearances for RTAA Packaged Unit

- 240 to 300 T ons

28 Figure 11

Dimensions and Clearances for RTAA Packaged Unit

- 340 to 400 T ons

29 Figure 12

Dimensions and Clearances for RTAA Outdoor Unit with Remote Evaporator Option

30 Figure 13

Dimensions and Weights for Remote Evaporator

33 Figure 14

Rigging and Lifting Weights for RTAA Packaged Unit

- 130 to 200 Tons Including Domestic Water Heater

34 Figure 15

Rigging and Lifting Weights for RTAA Packaged Unit

- 240 to 300 T ons

34 Figure 16

Rigging and Lifting Weights for RTAA Packaged Unit

- 340 to 400 T ons

35 Figure 17

Rigging and Lifting Weights for RTAA Outdoor Unit with Remote Evaporator Option

37 Figure 18

Spring Isolator Placement for Typical RTAA Packaged Unit

- 130 to 200 Tons

38 Figure 19

Spring Isolator Placement for Typical RTAA Packaged Unit

-240 to 400 Tons

39 Figure 20

Spring Isolator Placement for Typical RTAA Outdoor Unit with Remote Evaporator Option

40 Figure 21

Spring Isolator Placement for Typical RTAA Unit with Heat Recovery Domestic Water Heater

41 Figure 22

Suggested Piping for Typical RTAA Evaporator

43 Figure 23

RTAA 130 thru 400 Evaporator Water Pressure Drop

46 Figure 24

Typical Domestic Water Heater Piping

46 Figure 25

RTAA 130 thru 400 Domestic Water Heater Water Pressure Drop

47 Figure 26

Remote Evaporator Installation No Elevation Difference

48 Figure 27

Remote Evaporator Installation Condenser and Compressor above Evaporator

49 Figure 28

Restricted Installation -Evaporator is More Than 1’8" Above Base of Outdoor Unit.

49 Figure 29

Restricted Installation -Suction Line is on a Higher Plane than the Outdoor Unit.

50 Figure 30

Refrigerant Circuit Identification

52 Figure 31

Remote Evaporator Piping Example

55 Figure 32

Customer Interconnect Wiring for RTAA Outdoor Unit with Remote Evaporator -130 to 200 Tons

57 Figure 33

Warning Label

58 Figure 34

Typical Field Wiring for RTAA Packaged Unit - 130 to 200 T ons

61 Figure 35

Typical Field Wiring for RTAA Packaged Unit - 240 to 400 T ons

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64 Figure 36

Typical Field Wiring for Outdoor Unit with Remote Evaporator Option

70 Figure 37

Alarm/Running/Maximum Capacity Contact Outputs

72 Figure 38

Resistor and Potentiometer Arrangement for External Chilled Water Setpoint

73 Figure 39

Resistor and Potentiometer Arrangement for External Current Limit Setpoint

78 Figure 40

Refrigeration System and Control Components - Single Circuit

80 Figure 41

Refrigeration System and Control Components - Duplex Circuit

81 Figure 42

Typical RTAA Compressor

82 Figure 43

RTAA Compressor Oil System Schematic

83 Figure 44

Oil Separator

85 Figure 45

Fan Configurations - RTAA 130 to 200 Ton 15 F Minimum Ambient

86 Figure 46

Fan Configurations - RTAA 130 to 400 Ton 0 F Minimum Ambient

88 Figure 47

RTAA Control Panel

- 130 to 200 Tons

89 Figure 48

RTAA Control Panel

- 240 to 300 Tons

90 Figure 49

RTAA Control Panel

- 340 to 400 Tons

91 Figure 50

RTAA Control Panel 130 to 200 Tons with Remote Evaporator Option

92 Figure 51

Operator Interface Controls

93 Figure 52

Menu Formats

98 Figure 53

Condition/Diagnostic Codes

107 Figure 54

Low Refrigerant Temperature Cutout Ignore Time

123 Figure 55

Associated Research Model 45 Phase Sequence Indicator

126 Figure 56

Unit Sequence of Operation

- 240 to 400 T ons

128 Figure 57

Unit Sequence of Operation

-130 to 200 Tons

132 Figure 58

Operator’s Log 135 Figure 59

Chemical Cleaning Configuration 137 Figure 60

System Oil Level Specification

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List of Tables

16 Table 1

General RTAA Mechanical Specifications

17 Table 2

RTAA Refrigerant Circuit Designations and Capacities

51 Table 3

RTAA Circuit Capacities

51 Table 4

Liquid Line Size for Horizontal and/ or Downflow Lines

51 Table 5

Equivalent Lengths of Non-Ferrous Valves and Fittings

53 Table 6

Suction Line Size for Horizontal and/or Upflow Lines

53 Table 7

Suction Line Size for Horizontal and/or Downflow Lines

56 Table 8

System Refrigerant Charge

56 Table 9

Field-installed Piping Charge

67 Table 10

Electrical Data

70 Table 11

Alarm/Running/Maximum Capacity Relay Output Configurations

70 Table 12

Alarm/Running/Maximum Capacity Menu Settings

72 Table 13

Input Values vs Extended Chilled Water Setpoint Inputs (Ohms)

73 Table 14

Input Values vs External Current Unit Setpoint

102 Table 15

Leaving Fluid Temperature Setpoints

104 Table 16

Compressor Overload DIP Switch Settings

105 Table 17

Compressor(s) Current Limit Setpoint vs. Chiller Current Limit Setpoint (CLS)

110 Table 18

Diagnostic and Troubleshooting Chart

RT AA-IOM-3

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RT AA-IOM-3

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General Information

Literature Change History

RTAA-IOM-3 (October 1991) Original manual. Covers installation,

operation, and maintenance of “CO” design sequence RTAA-130 thru RTAA-400 units.

Unit Identification

When the unit arrives, compare all nameplate data with ordering and shipping information.

Unit Inspection

When the unit is delivered, verify that it is the correct unit and that it is property equipped. Compare the information which appears on the unit nameplate with the ordering and submittal information. Refer to “Nameplates”.

Note: If the Remote Evaporator Option is ordered, the remote evaporator will be shipped in a separate crate. The serial number on the evaporator nameplate must match the serial number on the outdoor unit nameplate.

Caution: If the serial numbers on the remote evaporator and the outdoor unit do not match, do not proceed with the installation. Notify the appropriate Trane Sales Office.

Inspect all exterior components for visible damage. Report any apparent damage or material shortage to the carrier and make a “unit damage” notation on the carrier’s delivery receipt. Specify the extent and type of damage found and notify the appropriate Trane Sales Office.

Do not proceed with installation of a damaged unit without sales off ice approval.

Inspection Checklist

To protect against loss due to damage incurred in transit, complete the following checklist upon receipt of the unit.

[ ] Inspect the individual pieces of the

shipment before accepting the unit. Check for obvious damage to the unit or packing material.

[ ] Inspect the unit for concealed

damage as soon as possible after delivery and before it is stored. Concealed damage must be reported within 15 days.

[ ] If concealed damage is discovered,

stop unpacking the shipment. 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 carrier’s terminal of the

damage immediately, by phone and by mail. Request an immediate, joint inspection of the damage with the carrier and the consignee.

[ ] Notify the Trane sales representative

and arrange for repair . Do not repair the unit, however , until damage is inspected by the carrier’s representative.

Loose Parts Inventory

Check all the accessories and loose parts which are shipped with the unit against shipping list. Included in these items will be water vessel drain plugs, rigging and electrical diagrams, and service literature, which are placed inside the control panel and/or starter panel for shipment.

RT AA-IOM-3

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Unit Description

The 130 thru 400-ton Model RTAA units are helical-rotary type, air-cooled liquid chillers designed for installation outdoors Depending upon rated capacity, the unit will have two, three or four compressors. The compressor circuits are completely assembled, hermetic packages that are factorypiped, wired, leak-tested, dehydrated, and tested for proper control operation before shipment.

Note: Packaged units are factory charged with refrigerant and oil. Remote evaporator units are shipped with a holding charge of nitrogen and a partial charge of oil.

Figures 1 thru 4 show typical RTAA packaged units and their components. Figures 5 and 6 show a typical RTAA Remote Evaporator outdoor unit and evaporator . Tables 1 and 2 contain general RTAA mechanical specifications. Chilled water inlet and outlet openings are covered for shipment. Each compressor has a separate compressor motor starter.

The RTAA series features Trane’s exclusive Adaptive Control which monitors the control variables that govern the operation of the chiller unit. Adaptive Control logic can correct these variables, when necessary, to optimize operational efficiencies, avoid chiller shutdown, and keep producing chilled water. An optional remote display is available to monitor unit operation from a remote location.

These units feature two independent refrigerant circuits. Compressor unloaders are solenoid actuated and oil pressure operated. Each refrigerant circuit is provided with filter drier, sight glass, electronic expansion valve, and charging valves.

The shell-and-tube type evaporator is manufactured in accordance with ASME standards. Each evaporator is fully insulated and is equipped with water drain and vent connections. Packaged units have heat tape protection to -200 F. Remote evaporators do not have heat tape.

™

logic,

Commonly Used Acronyms

Acronyms used in this manual are defined below.

OAT = Outdoor Air Temperature BAS = Building Automation System BCL = Bidirectional Communications

CAR = Circuit Shutdown, Auto Reset CLS = Current Limit Setpoint CMR = Circuit Shutdown, Manual

CWR = Chilled Water Reset CWS = Chilled Water Setpoint DDT = Design Delta-Temperature

ENT = Entering Chilled Water EXV = Electronic Expansion Valve

FLA = Full Load Amps HGBP = Hot Gas Bypass HVAC = Heating, Ventilating and Air

IFW = Informational - Warning I/O IPC = Inter-Processor LRA = Locked Rotor Amps Leaving MAR = Machine Shutdown, Auto MMR = Machine Shutdown, Manual NEC = National Electric Code

PCWS =Front Panel Chilled Water PFCC = Power Factor Correction PSID = Pounds-per-Square-inch

PSIG = Pounds-per-Square-inch RAS = Reset Action Setpoint

RLA = Rated Load Amps RCWS =Reset Chilled Water Setpoint

RRS = Reset Reference Setpoint SV = Slide Valve

T racer

SCI = Serial Communications UCLS = Unit Current Limit Setpoint

UCM = Unit Control Module UCWS= Unit Chilled Water Setpoint

Link

Reset

Setpoint (i.e., the difference between entering and leaving chilled water temperatures)

Temperature

Conditioning Input and Output Wiring Communications Chilled Water Temperature Reset Reset

Setpoint Capacitors Differential (pressure

differential) (gauge pressure)

(CWR) (CWR)

=Type of Trane Building

Automation System Interface

(Microprocessor-based)

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Figure 1 Typical RTAA Packaged Unit 130 - 200 T o n (Front/Side Exterior View)

Condenser

Coils

Starter and Power Panel

Nameplate

Line Voltage Connection Access

Connection Access

for Control Voltage

and Interlocks

Control Panel

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Figure 2 Typical RTAA Packaged Unit 130 - 200 T on (Rear/Side Exterior View)

Chilled Water Outlet

Chilled Water Inlet

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Figure 3 Typical RTAA Packaged Unit 240-400 Tons

Control Panel

Evaporator

Outlet

Inlet

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Figure 4 Typical RTAA Unit (Rear Exterior View)

Condenser Fans/Motors

Condenser

Liquid Line Filter

Condenser

Electronic Expansion Valves

Liquid Line Filter

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Figure 5 Typical RTAA Unit (with Remote Evaporator Option) (Rear Exterior View)

Condenser Circuit #1

Condenser Fans/Motors Circuit #1

Condenser Fans/Motors Circuit #2

Condenser Circuit #2

Circuit #1 Field Refrigerant Piping Connections

Circuit #2 Field Refrigerant Piping Connections

RT AA-IOM-3

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Table 1 General RTAA Mechanical Specifications

Compressor

130 140 155 170 185 200

Quantity 2 2 2 2 2 2 Nominal Size(1)(Tons) 70/70 70/70 85/70 100/70 100/85 100/100

Evaporator

Water Storage (Gallons) 49 46 73 69 62 61

(Liters) 184 175 277 261 234 231

Min. Flow (GPM) 156 156 186 186 222 222

(L/Sec) 9.8 9.8 11.7 11.7 14.0 14.0

Max. Flow (GPM) 504 504 612 612 720 720

(L/Sec) 31.8 31.8 38.6 38.6 45.4 45.4

Condenser

Oty of Coils 4 4 4 4 4 4 Coil Length (In) 214/214 214/214 240/214 240/214 240/240 240/240

Coil Height (In) 42 42 42 42 42 42

Number of Rows 3 3 3 3 3 3

Condenser Fans

Quantity 5/5 5/5 6/5 7/5 7/6 7/7 Diameter (In) 30 30 30 30 30 30 T otal Airflow (CFM) 105,860 105,860 114,610 120,160 128,910 134,460 Nominal RPM 1140 1140 1140 1140 1140 1140 Tip Speed (Ft/Min) 8954 8954 8954 8954 8954 8954 Motor HP (Ea) 1.5 1.5 1.5 1.5 1.5 1.5

Min Starting/Oper. Ambient (2)

Std Unit (Deg. F) 15 15 15 15 15 15 Low Amb. (Deg. F) 0 0 0 0 0 0

General Unit

Refrigerant HCFC-22 HCFC-22 HCFC-22 HCFC-22 HCFC-22 HCFC-22 No. of Independent

Refrigerant Circuits 2 2 2 2 2 2

% Min. Load (3) 10 10 10 10 10 10

Refrig. Charge(1)(Lb) 130/130 130/130 165/130 170/130 170/165 170/170

(Kg) 59/59 59/59 75/59 77/59 77/75 77/77

Oil Charge (Gal) 7/7 7/7 8/7 8/7 8/8 8/8

(1,4,5) (L) 27127 27/27 31/27 31/27 31/31 31/31

Size

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Table 1 (Continued from previous page) General RTAA Mechanical Specifications

Compressor

240 270 300 340 370 400

Quantity (1) 2/1 1-1/1 2/1 2/2 1-1/2 2/2 Nominal Size (1)(Tons) 70/100 100-70/100 100/100 70/100100-70/100 100/100

Evaporator

Water Storage (Gallons) 151 143 135 124 116 108

(Liters) 572 523 511 470 439 407

Min. Flow (GPM) 288 288 288 408 408 408

(L/Sec) 18.2 18.2 18.2 25.7 25.7 25.7

Max. Flow (GPM) 1080 1080 1080 1440 1440 1440

(L/Sec) 68.1 68.1 68.1 90.8 90.8 90.8

Condenser

Qty. of Coils 4/4 2-2/4 4/4 4/4 2-2/4 4/4 Coil Length (In) 214/120 240-214/120 240/120 214/240240-214/240 240/240 Coil Height (In) 42 42 42 42 42 42

Number of Rows 3 3 3 3 3 3 Condenser Fans Quantity (1) 10/7 12/7 14/7 10/14 12/14 14/14

Diameter (In) 30 30 30 30 1 30 30

Total Airflow (CFM) 173,090 187,390 201,690 240,320 254,620 268,920

Nominal RPM 1140 1140 1140 1140 1140 1140

T ip Speed (Ft/Min) 8954 8954 8954 8954 8954 8954

Motor HP (Ea) 1.5 1.5 1.5 1.5 1.5 1.5 Min Starting/Oper. Ambient (2) 0 0 0 0 0 0

(Deg. F)

General Unit

Refrigerant HCFC-22 HCFC-22 HCFC-22 HCFC-22 HCFC-22 HCFC-22

No. of Independent

Refrigerant Circuits 2 2 2 2 2 2 % Min. Load (3) 10 10 10 10 10 10 Refrig Charge(1)(Lb) 276/180 318/180 360/180 276/360 318/360 360/360

(Kg) 125/82 144/82 163/82 125/163 144/163 163/163

Oil Charge) (Gal) 15/8 16/8 17/8 15/17 16/17 17117

(1.4,5) (L) 57/31 61/31 65/31 57/65 61/65 65/65

Notes: (1) Data containing information on two circuits shown as follows: ckt1/ckt2 (2) Minimum start-up/operating ambient based on a 5 mph wind across the condenser. (3) Percent minimum load is for total machine, not each individual circuit. (4) Trane Part# OIL-15 (5) Add 6 gal./circuit for domestic water heater.

Size

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Figure 6 Remote Evaporator

Refrigerant Liquid Line Circuit #1

Refrigerant Suction Line Circuit #1

Terminal Box

Refrigerant Suction Line Circuit #2

Filter/Dryer

Entering Chilled Water Temp. Sensors

Sight Glass

Electronic Expansion Valve

Leaving Chilled Water Temperature Sensor

Evaporator Refrigerant Temperature Sensors

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Table 2 RTAA Refrigerant Circuit Designations and Capacities

RTAA Model Circuit/Tons Compressor/Tons 130 1 70 A 70

270 B70

140 1 70 A 70

270 B70

155 1 85 A 85

270 B70

170 1 100 A 100

270 B70

185 1 100 A 100

285 B85

200 1 100 A 101

2 100 B 100

RTAA Model Circuit/Tons Compressor/Tons 240 1 140 A 70

B70

2 100 C 100

270 1 170 A 100

B70

2 100 C 100

300 1 200 A 100

B 100

2 100 C 100

340 1 140 A 70

B70

2 200 C 100

D 100

370 1 170 A 100

B70

2 200 C 100

D 100

400 1 200 A 100

B 100

2 200 C 100

D 100

Package Unit 130-200

COND 1

COND 2

EVAP 1 EVAP 2

Remote Evaporator Unit 130-200

COND 1 A

COND 2 B

Electronic Expansion Valves

240-300

COND 2

EVAP 2 EVAP 1

COND 1

340-400

COND 2

EVAP 2 EVAP 1

COND 1

EVAP 1 EVAP 2

P N L

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Warnings and Cautions

Warnings and Cautions appear in boldface type at appropriate points in

this manual. Warnings are provided to alert

personnel to potential hazards that can result in personal injury or death; they do not replace the manufacturer’s recommendations.

Cautions alert personnel to conditions that could result in equipment damage.

Your personal safety and reliable operation of this machine depend upon strict observance of these precautions. The Trane Company assumes no liability for installation or service procedures performed by unqualified personnel,

Installation Responsibilities

Generally, the contractor must do the following when installing an RTAA unit:

[ ] Install unit on a flat foundation, level

(within 1/4" [6.4 mm]), and strong enough to support unit loading.

[ ] Install unit per the instructions

contained in the Installation Mechanical and Installation Electrical sections of this manual.

[ ] Install any optional sensors and

make electrical connections at the UCM.

Note: The standard leaving chilled water sensor is factory installed in the evaporator leaving water outlet.

[ ] Where specified, provide and install

valves in water piping upstream and downstream of evaporator water connections to isolate the evaporator for maintenance, and to balance/trim system.

[ ] If desired, supply and install flow

switches in the chilled water piping; interlock each switch with proper pump starter to ensure unit can only operate if water flow is established. Chilled water flow protection is provided by the UCM without the need for a chilled water flow switch. A flow switch for chilled water is strictly discretionary.

[] For Remote Evaporator units only,

furnish and install refrigerant piping, refrigerant and oil, per the instructions outlined in this manual.

[ ] Furnish and install pressure gauges

in inlet and outlet piping of the evaporator.

[ ] Furnish and install a drain valve to

the bottom of the evaporator.

[ ] Supply and install a vent cock to the

top of the evaporator.

[ ] Where specified, furnish and install

strainers ahead of all pumps and

automatic modulating valves. [ ] Provide and install field wiring. [ ] Start unit under supervision of a

qualified service technician. [ ] Install heat tape and insulate the

chilled water lines and any other

portions of the system, as required,

to prevent sweating under normal

operating conditions or freezing

during low ambient temperature

conditions.

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Nameplates

The RTAA outdoor unit nameplates are applied to the exterior and interior surface of the Control Panel door (Figure 1). A compressor nameplate is located on each compressor. On remote evaporators, the nameplate is located on the Terminal Box.

Outdoor Unit Nameplate

The outdoor unit nameplate provides the following information:

– Unit model and size description. – Unit serial number . – Identifies unit electrical requirements.

Figure 7 Nameplates

– Lists correct operating charges of

R-22 and refrigerant oil. – Lists unit test pressures. – Identifies installation, operation and

maintenance and service data

literature – Lists drawing numbers for unit wiring

diagrams.

Compressor Nameplate

The “compressor’ nameplate provides following information:

– Compressor model number. – Compressor serial number.

– Compressor electrical characteristics. – Utilization Range. – Recommended refrigerant.

Remote Evaporator Nameplate

The “evaporator” nameplate provides the following information:

– RTAA outdoor unit to which the

remote evaporator is designed to be connected.

– Evaporator serial number. This

number and the serial number of the outdoor RT AA unit to which it is connected will be identical.

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Model Number Coding System

The model numbers for the outdoor unit and the compressors are comprised of numbers and letter which represent features of the equipment. Shown on the chart in Figure 8 are samples of typical unit and compressor model numbers, followed by the coding system for each.

Each position, or group of positions, in the number is used to represent a feature. For example, in Figure 8, position 08 of the unit model number , Unit Voltage, contains the letter “G”.

From the chart, it can be seen that a “G” in this position means that the unit voltage is 200-230/60/3 dual voltage.

Figure 8 Model Number Coding System

RTA A 200 G X B0 1 A 0 D 0 B D E G

01 2 123 4 567 8 9 01 2 3 4 5 6 7 8 9 0 (Digit position for above)

Where digits are assigned the following meanings:

Digit Character No. Value Description

1, 2, 3 Unit Type/Function

RTA Rotary (Series “R”)

Air Cooled Chiller

4 Development Sequence

A “A” Dev. Sequence

5, 6, 7 Unit Nominal Tons

130 130 Tons 140 140 Tons 155 155 Tons 170 170 Tons 185 185 Tons 200 200 Tons 240 240 Tons 270 270 Tons 300 300 Tons 340 340 Tons 370 370 Tons 400 400 Tons

8 Unit Voltage

D 380/60/3 G 200-230/60/3 Dual

Voltage 1 346/50/3 K 380-415/50/3 4 460/60/3 5 575/60/3 S Special Customer Option

9 Compressor Starter Type

Y Y-Delta

(Closed Transition) X X-Line

(Across the line) S Special Customer Option

10, 11 Design Sequence

BO Second design.

Increment when parts

are affected for

service purposes.

12 Evaporator Leaving Temp.

1 Standard 40-60 F 2 Low 20-40 F 3 Ice making 20-60 F S Special Customer Option

13 Condenser Coil Fin

Material A Aluminum B Aluminum with

corrosion protection S Special Customer Option

Digit Character No. Value Description

14 Agency Listing

0 No agency listing 1 U.L. listed - Standard

where applicable 2 C.S.A. listed 3 *U.L./C.S.A. listed S Special Customer Option

15 Control Interface

A Standard Control

No communication

module B Standard Control

With communication

module C Deluxe Control

No communication

module D Deluxe Control With communication module Deluxe control option consists of the following: A - Cycle counter and

hour meter B - Under/over voltage

protection C - Remote alarm contacts

and compressor run

indication D - % volts

16 Chilled Water Reset

0 None 1 Return water temperature 2 Outside air temperature 3 Zone temperature S Special Customer Option

17+ Add on Options

A Architectural louvered

panels B Control power transformer C Heat recovery D Low ambient lockout

sensor E Suction service valves F Power disconnect G Low ambient operation H *Unit sound attenuator I Remote evaporator S Special Customer Option

Note:

1. Digits 17 and on may be multiple, independent add on options.

2. * Denotes that this option assignment has been made but is not available now

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Storage

Extended storage of the outdoor unit prior to installation requires the following precautionary measures:

1. Store the outdoor unit in a secure area.

2. At least every three months (quarterly), check the pressure in the refrigerant circuits to verify that the refrigerant charge is intact. If it is not, contact a qualified service organization and the appropriate Trane sales off ice.

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Installation - Mechanical Packaged Unit and Units with Remote Evaporator Option

General

The following instructions are, for the most part, applicable to both packaged units and units with the remote evaporator option. Specific exceptions are noted.

The most significant difference in the installation of the two systems is the requirement for interconnecting piping with the remote evaporator option. For this reason, these installation procedures are covered separately in the following section, Installation Mechanical, Remote Evaporator Interconnecting Piping.

Pre-installation

Report any damage incurred during handling or installation to the T rane sales office immediately. An Installation Check Sheet is provided.

Location Requirements

Noise Considerations

Locate the outdoor unit away from sound sensitive areas. If required, install rubber vibration isolators in all water piping and use flexible electrical conduit. Refer to “Unit Isolation”. Consult an acoustical engineer for critical applications. Also refer to Trane Engineering Bulletins for application information on RTAA chillers.

Foundation

Provide rigid, non-warping mounting pads or a concrete foundation of sufficient strength and mass to support the outdoor unit operating weight (i.e., including completed piping, and full operating charges of refrigerant, oil and water). Refer to Figures 18 thru 21 for unit operating weights. Once in place, the outdoor unit must be level within 1/ 4" (6.4 mm) over its length and width. The Trane Company is not responsible for equipment problems resulting from an improperly designed or constructed foundation.

Clearances

Provide enough space around the outdoor unit to allow the installation and maintenance personnel unrestricted access to all service points. Refer to submittal drawings for the unit dimensions. A minimum of four feet is recommended for compressor service. Provide sufficient clearance for the opening of control panel doors. Refer to Figures 9 thru 12 for minimum clearances. which require additional clearances will take precedence over these recommendations.

Note: If the outdoor unit configuration requires a variance to the clearance dimensions, contact your Trane Sales Office Representative. Also refer to Trane Engineering Bulletins for application information on RTAA chillers.

In all cases, local codes

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Figure 9 Dimensions and Clearances for RT AA Packaged Unit – 130 to 200 Ton

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Figure 10 Dimensions and Clearances for RT AA Packaged Unit – 240 - 300 Ton

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Figure 11 Dimensions and Clearances for RT AA Packaged Unit – 340 to 400 Ton

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Figure 12 Dimensions and Clearances for RT AA Outdoor Unit with Remote Evaporator Option

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Figure 13 Dimensions and Weights for Remote Evaporator Option

NOTES:

1. TOLERANCE ± 1/8” UNLESS OTHERWISE SPECIFIED.

2. ALLOW 8’-8” ON EITHER END FOR TUBE REMOVAL.

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Additional Location Requirements for Remote Evaporator Only

The remote evaporator must be installed indoors, unless:

– ambient temperatures are always

above 32 F.

– the system circulating liquid is a non-

freezing glycol-type solution, selected for the prevailing ambient temperatures.

– the evaporator is protected from

freezing by properly installed and applied insulation and heat tape.

Caution: To prevent internal damage due to freezing, do not install the outdoor unit without adequate freeze protection.

The remote evaporator should be mounted on a base of suitable strength to support the operating weight. Remote evaporator weights and mounting locations are shown in Figure 13.

The remote evaporator must be level when installed. Be sure to allow

adequate clearance for water and refrigerant piping connections, performance of service procedures, reading of gauges and thermometers, and operation of valves. Space must be allowed at one end of the evaporator to pull tubes, if required.

Drainage

Provide a large capacity drain for water vessel drain-down during shutdown or repair . The evaporator is provided with a drain connection. Refer to “Evaporator Drain”. All local and national codes apply. The vent on the top of the evaporator is provided to prevent a vacuum by allowing air into the evaporator for complete drainage.

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Rigging

The Model RTAA chiller should be moved by lifting. Refer to Figures 14 thru 17 for typical unit lifting and operating weights. Refer to the rigging diagram that ships with each unit for specific “per unit” weight data.

WARNING: To prevent injury or death and unit damage, capacity of lifting equipment must exceed unit lifting weight by an adequate safety factor.

Lifting Procedure

Caution: To prevent damage do not use a forklift to lift the unit.

[ ] Install clevis connectors through the

four , six or eight lifting plates provided on the unit (Figures 14 thru 17).

WARNING: To prevent injury or death and unit damage, use the lifting method shown in Figures 14 and 17.

[ ] Attach lifting chains or cables to

clevis connectors. Each cable alone must be strong enough to lift the chiller.

[ ] Attach cables to lifting beam. Total

lifting weight, lifting weight distribution and required lifting beam dimensions are shown in Figures 14 thru 17 and on the rigging diagram shipped with each unit. Lifting beam crossbars must be positioned so lifting cables do not contact the sides of the unit.

Caution: To prevent unit damage, position lifting beam so that cables do not contact the unit.

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Figure 14 Rigging and Lifting Weights for RTAA Packaged Unit

130-200 Tons without Domestic Water Heater

NOTES:

1. LIFTING CHAINS (CABLES) WILL NOT BE THE SAME LENGTH. ADJUST TO KEEP UNIT LEVEL WHILE LIFTING.

2. DO NOT FORK LIFT UNIT.

3. WEIGHTS ARE TYPICAL FOR UNITS WITH R-22 CHARGE.

4. DEDUCT 740 FROM TOTAL WEIGHT FOR UNITS WITHOUT ARCHITECTURAL LOUVER PANELS.

RTAA-SA-2001C

130-200 Tons with Domestic Water Heater

NOTES:

1. LIFTING CHAINS (CABLES) WILL NOT BE THE SAME LENGTH. ADJUST TO KEEP UNIT LEVEL WHILE LIFTING.

2. DO NOT FORK LIFT UNIT.

3. WEIGHTS ARE TYPICAL FOR UNITS WITH R-22 CHARGE.

4. DEDUCT 740 FROM TOTAL WEIGHT FOR UNITS WITHOUT ARCHITECTURAL LOUVERED PANELS.

RTAA-SA-2007A

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Figure 15 Rigging and Lifting Weights for RT AA Packaged Unit – 240-300 Tons

NOTES:

1. LIFTING CHAINS (CABLES) WILL NOT BE THE SAME LENGTH. ADJUST TO KEEP UNIT LEVEL WHILE LIFTING.

2. DO NOT FORK LIFT UNIT.

3. WEIGHTS ARE TYPICAL FOR UNITS WITH R-22 CHARGE.

4. DEDUCT 1166 FROM TOTAL WEIGHT FOR UNITS WITHOUT ARCHITECTURAL LOUVER PANELS.

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Figure 16 Rigging and Lifting Weights for RTAA Packaged Unit – 340-400 T o ns

NOTES:

1. LIFTING CHAINS (CABLES) WILL NOT BE THE SAME LENGTH. ADJUST TO KEEP UNIT LEVEL WHILE LIFTING.

2. DO NOT FORK LIFT UNIT.

3. WEIGHTS ARE TYPICAL FOR UNITS WITH R-22 CHARGE.

4. DEDUCT 1480 FROM TOTAL WEIGHT FOR UNITS WITHOUT ARCHITECTURAL LOUVERED PANELS.

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Figure 17 Rigging and Lifting Weights for RTAA Outdoor Unit with Remote Evaporator Option

NOTES:

1. LIFTING CHAINS (CABLES) WILL NOT BE THE SAME LENGTH. ADJUST TO KEEP UNIT LEVEL WHILE LIFTING.

2. DO NOT FORK LIFT UNIT .

3. WEIGHTS ARE TYPICAL FOR UNITS WITH R-22 CHARGE.

4. DEDUCT 740 FROM TOTAL WEIGHT FOR UNITS WITHOUT ARCHITECTURAL LOUVER PANELS.

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Unit Isolation and Leveling

For additional reduction of sound and vibration, use one of the two mounting methods outlined below:

1. Construct an isolated concrete pad for the unit or provide concrete footings at each of the eight unit mounting points. Mount the unit directly to the concrete pads or footings. Level the unit using the base rail as a reference. The unit must be level within 1/4" over the entire length. Use shims as necessary to level the unit.

2. Install the optional spring isolators at each of the eight/ten unit mounting points. Refer to Figures 18 thru 21 for isolator placement locations and loading information.

a. Secure the isolators to the

mounting surface, using the mounting slots in the isolator base plate. Do not fully tighten the isolator mounting bolts at this time.

b. Positioning pins are located on the

top of each isolator , as shown in Figures 18 thru 21. Lower the unit on to the isolators so that the pins register with the unit mounting holes.

c. The weight of the unit will force

the upper housing of each isolator down. This may cause the upper housing to contact the lower housing. As shown in Figures 18 thru 21, the clearances between upper and lower housings must be 1/4 to 1/2 inch. If the clearance on any isolator is greater than 1/2 inch, it will be necessary to use shims or grout to achieve the required clearance.

d. Minor adjustments can be made

to the clearance by turning the leveling bolt; clockwise to increase the clearance and counterclockwise to decrease the clearance. All eight isolators must be supporting the entire weight of the unit while these adjustments are being made.

Note: If proper clearances cannot be achieved using the leveling bolts, use shims or grouting under the isolators, as required. Isolators must not straddle small gaps in the shims or grout.

e. Before tightening the mounting

bolts, level the unit using the unit base rail as a reference. The unit must be level within 1/4" over the entire length. Use the leveling bolts and/or additional shims or grout to level the unit.

Evaporator Water Piping

Thoroughly flush all water piping to the unit before making the final piping connections to the unit.

Caution: If using an acidic commercial flushing solution, construct a temporary bypass around the unit to prevent damage to internal components of the evaporator .

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

When completing the NPT-type water connections, apply a suitable pipe sealant, or Teflon tape, to prevent water leakage. To minimize heat gain and to prevent condensation, insulate all piping.

Caution: Avoid overtightening and possible damage of water connections. The lubricating properties of T eflon tape make the possibility of overtightening more likely.

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Figure 18 Spring Isolator Placement for T ypical R TAA Packaged Unit – 130 to 200 Tons without Domestic Water Heater

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Figure 19 Spring Isolator Placement for T ypical RT AA Packaged Unit – 240-400 Tons

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Figure 20 Spring Isolator Placement for Typical RT AA Outdoor Unit with Remote Evaporator Option

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Figure 21 Spring Isolator Placement for T ypical RT AA Unit with Heat Recovery Domestic Water Heater

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Evaporator Piping

Figure 22 illustrates typical evaporator piping components. Components and layout will vary slightly, depending on the location of connections and the water source.

Caution: The chilled water connections to the evaporator are to be “victaulic” type connections. Do not attempt to weld these connections, as the heat generated from welding can cause internal damage to the evaporator.

The chilled water connections are on the left side of the unit. If it is necessary for the chilled water piping to enter the unit from the right side, elbows can be used to route the piping 1800 over the top of the evaporator, as shown in Figure 22, for RT AA 130-200 units only.

A vent is provided on the top of the evaporator at the return end. Be sure to provide additional vents at high points in the piping to bleed air from the chilled water system. Install necessary pressure gauges to monitor the entering and leaving chilled water pressures.

Caution: To prevent damage to chilled water components, do not allow evaporator pressure (maximum working pressure) to exceed 215 psig.

Provide shutoff valves in lines to the gauges to isolate them from the system when they are not in use. Use rubber vibration eliminators to prevent vibration transmission through the water lines.

If desired, install thermometers in the lines to monitor entering and leaving water temperatures. Install a balancing valve in the leaving water line to control water flow balance. Install shutoff valves on both the entering and leaving water lines so that the evaporator can be isolated for service.

A pipe strainer should be installed in the entering water line to prevent waterborne debris from entering the evaporator.

Figure 22 Suggested Piping for Typical RTAA Evaporator

Vents

Drain

Union

Vibration Eliminator

Valved

Pressure

Gauge

Flow Switch (Optional)

Union

Gate Valve

Balancing Valve

Vibration Eliminator

Water Strainer

Gate Valve

RTAA 130-200 with Opposite-Side Connections

(View from end opposite control panel)

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Evaporator Piping Components

“Piping components” include all devices and controls used to provide proper water system operation and unit operating safety. These components and their general locations are given below.

Entering Chilled Water Piping

[ ] Air vents (to bleed air from system). [ ] Water pressure gauges with shutoff

valves. [ ] Vibration eliminators. [ ] Shutoff (isolation) valves.

Thermometers (if desired). [ ] Clean-out tees. [ ] Pipe strainer.

Caution: To prevent tube damage install strainer in evaporator water inlet piping.

Leaving Chilled Water Piping

[ ] Air vents (to bleed air from system). [ ] Water pressure gauges with shutoff

valves. Vibration eliminators. [ ] Shutoff (isolation) valves. [ ] Thermometers. [ ] Clean-out tees. [ ] Balancing valve. [ ] Flow Switch (If desired)

Caution: To prevent evaporator damage, do not exceed 215 psig (14.6 bar) evaporator water pressure.

Evaporator Drain

A 3/4" drain connection is located under the outlet end of the evaporator. This may be connected to a suitable drain to permit evaporator drainage during unit servicing. A shutoff valve must be installed on the drain line.

Evaporator Flow Switch

Chilled water flow protection is provided by the UCM without the need for a chilled water flow switch. A flow switch for chilled water is strictly discretionary but if not installed, a signal still must be sent to the chiller to indicate that water flow has been established, e.g. chilled water pump motor starter auxiliary contacts.

If additional chilled water flow protection is desired, use a fieldinstalled flow switch or differential pressure switch with the pump interlock to sense system water flow. Install and wire the flow switch in series with the chilled water pump motor starter auxiliaries (refer to “Electrical Wiring”).

Specific connection and schematic wiring diagrams are shipped with the unit. Some piping and control schemes, particularly those using a single water pump for both chilled and hot water, must be analyzed to determine how and or if a flow sensing device will provide desired operation.

Follow the manufacturer’s recommendations for selection and installation procedures. General guidelines for flow switch installation are outlined below

1. Mount the switch upright, with a minimum of 5 pipe diameters of straight horizontal run on each side. Do not install close to elbows, orifices or valves.

Note: The arrow on the switch must point in the direction of flow.

2. To prevent switch fluttering, remove all air from the water system.

Note: The UCM provides a 6-second time delay after a “loss-of-flow” diagnostic before shutting the unit down. Contact a qualified service representative if nuisance machine shutdowns persist.

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3. Adjust the switch to open when water flow falls below nominal. Evaporator data is shown in Figure

23. Refer to Table 1 for minimum flow recommendations. Flow switch contacts are closed on proof of water flow.

Figure 23 RT AA 130 thru 400 Evaporator Water Pressure Drop

4. Install a pipe strainer in the entering evaporator water line to protect components from waterborne debris.

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Water Treatment

Using untreated or improperly treated water in these units may result in inefficient operation and possible tube damage. Consult a qualified water treatment specialist to determine whether treatment is needed. The following disclamatory label is provided on each RTAA unit:

Customer Note

The use of improperly treated or untreated water in this equipment may result in scaling, erosion, corrosion, algae or slime. The services of a qualified water treatment specialist should be engaged to determine what treatment, if any, is advisable. The Trane Company warranty specifically excludes liability for corrosion, erosion or deterioration of Trane equipment. Trane assumes no responsibilities for the results of the use of untreated or improperly treated water, or saline or brackish water.

Caution: Do not use untreated or improperly treated water. Equipment damage may occur.

Water Pressure Gauges

Install field-supplied pressure gauges (with manifolds, whenever practical) as shown in Figure 22. Locate pressure gauges or taps in a straight run of pipe; avoid placement near elbows, etc. Be sure to install the gauges at the same elevation on each shell if the shells have opposite-end water connections.

To read manifolded pressure gauges, open one valve and close the other (depending upon the reading desired). This eliminates errors resulting from differently calibrated gauges installed at unmatched elevations.

Caution: To prevent shell damage, install pressure relief valves in the evaporator water system.

Freeze Protection

If the unit will remain operational at subfreezing ambient temperatures, the chilled water system must be protected from freezing, following the steps listed below

1. Heat tape is factory-installed on the packaged unit evaporator and will protect it from freezing in ambient temperatures down to -20 F.

2. Install heat tape on all water piping, pumps, and other components that may be damaged if exposed to freezing temperatures. Heat tape must be designed for low ambient temperature applications. Heat tape selection should be based on the lowest expected ambient temperature.

3. Add a non-freezing, low temperature, corrosion inhibiting, heat transfer fluid to the chilled water system. The solution must be strong enough to provide protection against ice formation at the lowest anticipated ambient temperature. Refer to Table 1 for evaporator water storage capacities.

Note: Use of glycol type antifreeze reduces the cooling capacity of the unit and must be considered in the design of the system specifications.

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Water Pressure Relief Valves

Install a water pressure relief valve in the evaporator inlet piping between the evaporator and the inlet shutoff valve, as shown in Figure 22. Water vessels with close-coupled shutoff valves have a high potential for hydrostatic pressure buildup on a water temperature increase. Refer to applicable codes for relief valve installation guidelines.

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Domestic Water Heater Piping

Figure 24 illustrates typical domestic water heater piping components. Components and layout will vary slightly, depending on the location of connections and the water source. See unit submittals to insure identification of water inlet and outlet connections.

Be sure to provide additional vents at high points in the piping to bleed air from the water system.

Caution: To prevent damage to components, do not allow domestic water heater pressure (maximum working pressure) to exceed 150 psig.

Use rubber vibration eliminators to prevent vibration transmission through the water lines.

Install a balancing valve in the leaving water line to control water flow balance. Install shutoff valves on both the entering and leaving water lines so that the domestic water heater can be isolated for service.

The vent and drain can be used to temporarily install gauges and determine pressure drop at the heater. Water flow rates, as a function of pressure drop, are charted in Figure 25, or pressure drop can be calculated using the following formula:

Pressure Drop (Ft. H20) = 2.31 (Drain psig -Vent psig)

A pipe strainer should be installed in the entering water line to prevent waterborne debris from entering the domestic water heater.

Domestic Water Heater Piping Components

“Piping components” include all devices and controls used to provide proper water system operation and unit operating safety. These components and their general locations are given below.

Entering Water Piping

[ ] Drain [ ] Vibration eliminators. [ ] Shutoff (isolation) valves. [ ] Pipe strainer.

Caution: To prevent tube damage install strainer in the water inlet piping.

Leaving Chilled Water Piping

[ ] Air vents (to bleed air from system) [ ] Vibration eliminators. [ ] Shutoff (isolation) valves. [ ] Balancing valve.

Caution: To prevent damage, do not exceed 215 psig (14.6 bar) domestic water heater water pressure.

Water Pressure Relief Valves

Install a water pressure relief valve in the outlet piping between the domestic water heater and the outlet shutoff valve, as shown in Figure 24. Water vessels with close-coupled shutoff valves have a high potential for hydrostatic pressure buildup on a water temperature increase. Refer to applicable codes for relief valve installation guidelines.

Caution: To prevent shell damage, install pressure relief valves in the evaporator water system.

Freeze Protection

If water in the domestic water heater will be subjected to subfreezing ambient temperatures, the water system must be protected from freezing, following the steps listed below:

1. Heat tape is factory-installed on the domestic water heater and will protect it from freezing in ambient temperatures down to -20 F Insure that electrical power is provided for the heat tape.

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Figure 24 Typical Domestic Water Heater Piping

Figure 25 Typical Domestic Water Heater Piping

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Installation - Mechanical Remote Evaporator Interconnecting Refrigerant Piping.

Figure 26 Remote Evaporator Installation – No Elevation Difference

General

The RT AA outdoor unit with the Remote Evaporator option is shipped as two pieces: the outdoor unit (condensing) and the evaporator. The outdoor unit includes a suction accumulator line on each circuit and has the field connections for the refrigerant at the end opposite the control panel.

The evaporator is shipped complete with factory-mounted refrigeration specialties (electronic expansion valves, sight-glasses and removable core filter-dryers). All evaporator refrigerant line connections are at one end of the evaporator. The installing contractor need only provide and install the refrigerant piping between the evaporator and the outdoor unit.

System Configuration

The system may be configured in either of the two primary arrangements as shown in Figures 26 and 27. The configuration and its associated elevation, along with the total distance between the remote evaporator and the compressor/condenser section, play a critical role in determining suction and liquid line sizes. This will also affect field refrigerant and oil charges. Consequently, there are physical limits which must not be violated if the system is to operate as designed. Please note the following restrictions:

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Figure 27 Remote Evaporator Installation – Condenser and Compressor above Evaporator

A. The line sizes established in this installation manual are to be used only for 40-50 F leaving water temperature and full-load ice-making applications.

B. The evaporator can be mounted only on the SAME PLANE OR LOWER PLANE than the outdoor unit. Figure 28 illustrates what not to do. The elevation difference is to not exceed 100 feet.

C. Piping between evaporator and outdoor unit is to not exceed 200 (linear) feet or an equivalent length (includes equivalent length pressure drop of fittings) of 300 feet.

D. The suction line must never cross or be above a plane that is 1’8" above the bottom of the outdoor unit. Figure 29 illustrates what not to do.

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E. Horizontal portions of the suction lines must be downward sloping to the compressors. Suction lines must be insulated.

F. Install an inverted trap in the liquid line when the evaporator is on a lower plane than the outdoor unit. The apex of the trap should be at a height above the top of the condenser coils. See Figure 27.

G. Install a suction line trap at the evaporator when the evaporator is on a lower plane than the outdoor unit. See Figure 27.

Figure 28 Restricted Installation – Evaporator is on a Higher Plane than the Outdoor Unit

H. The evaporator MUST be matched with its respective outdoor unit. The nameplate on the evaporator will have a serial number that is matched to the outdoor unit’s serial number. See Figure 7.

Also the circuits on the outdoor unit must match the circuits on the evaporator (I.E. circuit #1 on the outdoor units must be connected with circuit #1 on the evaporator).

Caution: If the circuits are crossed, serious equipment damage may occur.

See Figure 30 for circuit number identification.

Figure 29 – Restricted Installation Suction Line is More Than 1’8" Above Base of Outdoor Unit

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Figure 30 Refrigerant Circuit Identification

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Line Sizing

Equivalent Line Length

To determine the appropriate size for field installed liquid and suction lines, it is first necessary to establish the equivalent length of pipe for each line. An initial approximation can be made by assuming that the equivalent length of pipe is 1.5 times the actual length of pipe. These assumed lengths can then be used with the appropriate tables in the Liquid Line Sizing section and the Suction Line Sizing sections which follow.

It is also necessary to know the capacity (tons) of each circuit. Circuit capacities for each RTAA unit are listed in Table 3.

Table 3 RTAA Circuit Capacities

Model Circuit 1 Circuit 2

130 70 70 140 70 70 155 85 70 170 100 70 185 100 85 200 100 100

From Table 4, for horizontal and/or downflow liquid lines, and assuming an 85 ton circuit, 175 feet of equivalent line requires a liquid line with an OD of 1 5/8 in.

There are 6 long-radius elbows in this example. Using Table 5 and the pipe OD of 1 5/8 in., these fittings represent

15.6 feet (6 elbows @ 2.6 feet each).

The following are examples of how to determine line sizes.

Therefore our new equivalent line length is 132.6 feet (117 +15.6).

Referring back to Table 4, an 85 ton

Liquid Line Sizing

This example uses the unit installation shown in Figure 31 and assumes an 85 ton circuit. The actual length of field installed piping is 117 feet (80 + 8 + 8 +

21). Using the factor of 1.5, the equivalent line length is 175 feet.

circuit with 132.6 feet of equivalent pipe length (use the dimension closest to the calculated dimension) can use a pipe O.D. of 1% in. rather than 1 5/8 in. From Table 5 we see that the 6 elbows of 1 3/8 in. have an equivalent pipe length of 13.2 feet (6 elbows @ 2.2 feet each). This further reduces the equivalent pipe length to 130.2 feet (117 + 13.2), and, as shown in Table 4, still allows the use of 1 3/8 in. O.D. pipe.

Table 4 Liquid Line Size for Horizontal and/or Downflow Lines

Circuit Size: Liquid Line Size (OD”)

Total Equiv. Length (Ft) 100 Ton 85 T o n 70 Ton

25' 1 1/8 1 1/8 1 1/8 50' 1 3/8 1 1/8 1 1/8

75' 1 3/8 1 3/8 1 3/8 100' 1 3/8 1 3/8 1 3/8 125' 1 3/8 1 3/8 1 3/8 150' 1 5/8 1 3/8 1 3/8 175' 1 5/8 1 5/8 1 5/8 200' 1 5/8 1 5/8 1 5/8 225' 1 5/8 1 5/8 1 5/8 250' 1 5/8 1 5/8 1 5/8 275' 1 5/8 1 5/8 1 5/8

300': 1 5/8 1 5/8 1 5/8

Table 5 Equivalent Lengths of Non-Ferrous valves and Fittings

Line Size Globe Angle Short Long

Inches OD Valve Valve Radius ELL Radius ELL

1 1/8 87 29 2.7 1.9 1 3/8 102 33 3.2 2.2

1 5 /8 115 34 3.8 2.6

2 1/8 141 39 5.2 3.4 2 5/8 159 44 6.5 4.2 3 1/8 185 53 8.0 5.1 3 5/8 216 66 10.0 6.3 4 1/8 248 76 12.0 7.3

Reproduced by permission of Air conditioning and Refrigeration Institute.

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Figure 31 Remote Evaporator Piping Example

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Suction Line Sizing

This example uses the unit installation shown in Figure 31 and assumes a 100 ton circuit. As in the liquid line sizing example, the equivalent pipe length must first be determined. It must also be determined what portion of the pipe is “horizontal and/or downflowing” and what portion is “horizontal and/or upflowing.”

In Figure 31, the actual length of field installed piping is 100 feet (20 + 5 + 75). Using the factor of 1.5, the equivalent line length is 150 feet. The suction line has an elevation of 20 feet and consists of horizontal and vertical (upflowing) sections, which must be sized separately.

The two vertical sections are separated by a small horizontal section. The total distance is 25 feet (20 +5). The first approximation of equivalent pipe length is 37.5 feet (1.5 times 25). Referring to Table 6 for a horizontal and/or upflow suction line on a 100 ton circuit with 37.5 feet of line, the pipe O.D. should be 3 1/8 in.

There are four long-radius elbows in this section of piping. Using Table 5 and the pipe OD of 3 1/8 in., these fittings represent 20.4 feet (4 elbows @

5.1 feet each). Therefore our new equivalent line length is 45.4 feet (25 +

20.4). Table 6 indicates that 45.4 equivalent feet still permits the use of 3 1/8 in. O.D. pipe.

In sizing the horizontal and/or downflow portion of the suction line, it is necessary to account for the total equivalent length of the line.

Note: In this example, the horizontal line is pitched downward in the direction of flow

Using T able 7 and 150 feet of equivalent pipe length for a 100 ton circuit, a pipe O.D. of 4 1/8 in. is specified. There are no fittings in the 75 foot horizontal run, so no equivalent fitting lengths need to be determined.

Add the 75 feet of horizontal and/or downflow line to the 45.4 feet of horizontal and/or upflow line, resulting in 120.5 of equivalent pipe length. Table 7 at 125 feet (use the dimension closest to the calculated dimension) indicates the use of 4 1/8 in. O.D. pipe. Therefore, the 4 1/8 in line will have to be reduced for the vertical sections of the line and expanded again for the horizontal sections.

Table 6 Suction Line Size for Horizontal and/or Upflow Lines

Total Vertical Equiv. Length (Ft) 100 T on 85 Ton 70 Ton

Circuit Size: Suction Line Size (OD”)

50': 3 1/8 3 1/8 2 1/8 75': 3 1/8 3 1/8 2 1/8

100': 3 1/8 3 1/8 2 1/8

Table 7 Suction Line Size for Horizontal and/or Downflow Lines

Circuit Size:

Total Equiv. Length (Ft) Suction Line Size (OD”)

(Including vertical section, if any) 100 Ton 85 Ton 70 Ton

50': 3 1/8 3 1/8 2 5/8

75': 3 1/8 3 1/8 2 5/8 100': 3 1/8 3 1/8 3 1/8 125': 4 1/8 3 1/8 3 1/8 150': 4 1/8 3 1/8 3 1/8 175': 4 1/8 4 1/8 3 1/8 200': 4 1/8 4 1/8 3 1/8 225': 4 1/8 4 1/8 3 1/8 250': 4 1/8 4 1/8 3 1/8 275': 4 1/8 4 1/8 3 1/8 300': 4 1/8 4 1/8 3 1/8

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Piping Installation Procedures

The outdoor unit and the evaporator are shipped with a 25 psig holding pressure of dry nitrogen. Do not relieve this pressure until field installation of the refrigerant piping is to be accomplished. This will require the removal of the temporary pipe caps.

Note: Use Type L refrigerant-grade copper tubing only.

The refrigerant lines must be isolated to prevent line vibration from being transferred to the building. Do not secure the lines rigidly to the building at any point.

All horizontal suction lines should be pitched downward, in the direction of flow, at a slope of 1/2 in. per 10 feet of run, This allows for larger line size, which will improve unit efficiency.

Do not use a saw to remove end caps, as this may allow copper chips to contaminate the system. Use a tubing cutter or heat to remove the end caps.

When sweating copper joints, flow dry nitrogen through the system. This prevents scale formation and the possible formation of an explosive mixture of R-22 and air . This will also prevent the formation of toxic phosgene gas, which occurs when refrigerant is exposed to open flame.

WARNING: To prevent Injury or death, due to explosion and/or inhalation of phosgene gas, purge the system thoroughly while sweating connections. Use a pressure regulator in the line between the unit and the high pressure nitrogen cylinder to avoid over-pressurization and possible explosion.

Refrigerant Sensors

The suction line refrigerant sensors must be installed by the contractor installing the refrigerant piping. The sensors are pre-wired and each is “wire-tied” to its respective liquid line. Fittings and adapters for mounting of the sensors are located in the remote evaporator terminal box. See Figure 32 for mounting instructions.

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Figure 32 Customer Interconnect Wiring for RTAA Outdoor unit with Remote Evaporator – 130 to 200 T o ns

2306-9133A

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Leak Test and Evacuation

After installation of the refrigerant piping, thoroughly test the system for leaks. Pressure test the system at pressures required by local codes.

Immediately before evacuation, install the liquid line filter cores. These will be shipped with the evaporator.

Note: Do not install these before the circuit is ready for evacuation, as the cores will absorb moisture from the atmosphere.

For field evacuation, use a rotary-type vacuum pump capable of pulling a vacuum of 100 microns or less. Follow the pump manufacturer’s instructions for proper use of the pump. The line used to connect the pump to the system should be copper and be the largest diameter that can be practically used. A larger line size with minimum flow resistance can significantly reduce evacuation time.

Use the ports on the compressor suction service valves and the liquid line shutoff valves for access to the system for evacuation. Insure that the compressor suction service valve, the liquid line shutoff valve, the oil line shutoff valve and any field installed valves are open in the proper position before evacuating.

Insulate the entire suction line and the suction accumulator line. Where the line is exposed to the weather, wrap it with weatherproof tape and seal with weatherproof compound.

Refrigerant and Additional Oil Charge

Refrigerant Charge Determination

The approximate amount of refrigerant charge required by the system must be determined by referring to Table 8 and must be verified by running the system and checking the liquid line sightglasses.

Table 8 System Refrigerant Charge

Circuit Size Lbs. of R-22

70 130 85 165

100 170

To determine the appropriate charge, first refer to Table 8 to establish the required charge required without the field-installed piping. Next, determine the charge required for the fieldinstalled piping by referring to Table 9.

Table 9 Field-installed Piping Charge

Pipe O.D. Suction Liquid

(inches) Line Line

1 3/8 1.2 63.0 1 5/8 1.7 89.2 2 1/8 2.9 155.2 2 5/8 4.5 239.4 3 1/8 6.4 — 4 1/8 11.3 —

Note: The amounts of refrigerant listed in Table 9 are based on 100 feet of pipe. Actual requirements will be in direct proportion to the actual length of piping.

Note: Table 9 assumes:

Liquid Temperature = 100 F Suction Temperature = 35 F Suction Superheat Temperature = 8 F

The approximate amount of refrigerant is therefore the sum of the values determined from Tables 8 and 9.

Example:

Determine the approximate amount of charge required for an RT AA 200 ton unit with a remote evaporator that is located 75 feet away (i.e. the actual length of field installed pipe is 75 feet for each suction line and liquid line). Assume that the suction lines have been previously determined to be 4 1/8 in., O.D. and the liquid lines are 1 3/8 in. O.D.

A 200 ton unit has two 100 ton circuits. From Table 8 above, a 100 ton circuit requires 170 lbs. of R-22. In addition, the 4 1/8 in. 0. D. suction line for the 100 ton circuit will require 11.3 lbs. per 100 feet of the 75 feet of line will therefore require 8.5 lbs. (11.3 times 75/100).

Similarly from Table 9, the 1 3/8 in. O.D. liquid line will require 47.3 lbs. of R-22 (63 times 75/100). The total R-22 charge for the 100 ton circuit will be 225.8 lbs. (170 + 8.5 + 47.3). And because the RTAA 200 has two 100 ton circuits, the total system charge will be twice as much, or 461.6 lbs.

Oil Charge Determination

The unit is factory charged with the amount of oil required by the system, without the field-installed piping. The amount of additional oil required is dependent upon the amount of refrigerant that is added to the system for the field-installed piping.

Use the following formula to calculate the amount of oil to be added:

Pints of Oil (T rane Oil-15) = lbs. of refrigerant added for field-installed piping/18.375

From the example above, in which the weight of the additional refrigerant added for the field-installed piping was

55.8 lbs. (47.3 + 8.5), the amount of oil to be added equals 3 pints (55.8/18.375) per circuit.

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Installation – Electrical

General Recommendations

WARNING: The Warning Label shown in Figure 33 is displayed on the equipment and shown on wiring diagrams and schematics. Strict adherence to these warnings must be observed.

All wiring must comply with local codes and the National Electric Code. Typical field wiring diagrams are shown in Figures 34 thru 36. Minimum circuit ampacities and other unit electrical data are on the unit nameplate and are shown in Table 10. See the unit order specifications for actual electrical data. Specific electrical schematics and connection diagrams are shipped with the unit.

Figure 33 Warning Label

Caution: To avoid corrosion and overheating at terminal connections, use copper conductors only.

Do not allow conduit to interfere with other components, structural members or equipment.

Control voltage (115V) wiring in conduit must be separate from conduit carrying low voltage (<30V) wiring.

Caution: To prevent control malfunctions, do not run low voltage wiring (<30V) in conduit with conductors carrying more than 30 volts.

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Figure 34 Typical Field Wiring for RT AA Packaged Unit – 130 to 200 T ons

(Continued on Next Page)

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(Continued from Previous Page)

See Notes on Next Page

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Figure 34 (Continued from Last Page) T ypical Field Wiring for RT AA Packaged Unit – 130 to 200 T ons

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Figure 35 Typical Field Wiring for RTAA Packaged Unit – 240-400 Tons

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Figure 35 (Continued from Previous Page) T ypical Field Wiring for RT AA Packaged Unit – 240-400 Tons

See Notes on Previous Page

(Continued on Next Page)

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(Continued from Previous Page)

See Notes on Page 61

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Figure 36 T ypical Field Wiring for RTAA With Remote Evaporator Option

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(Continued from Previous Page)

See Notes on Page 61

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Figure 36 (Continued from Previous Page) T ypical Field Wiring for RTAA With Remote Evaporator Option

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Table 10 Electrical Data

Unit Wiring Motor Data

Rated MCA (3) Rec Time Comp. (Ea) Qty. Qty.

Unit Size Voltage Ckt1/Ckt2(1) MOP(2) Delay or RDE4) Qty. RLA(5) LRA(8) (11) (12) kW FLA kW(7)

RTAA 130 200 383/389 600/600 500/500 2 280/280 1689/1689 10 11 1.3 6.5 0.8

230 383/389 600/600 500/500 2 280/280 1689/1689 10 11 1.3 6.5 0.8 460 306 400 350 2 122/122 633/633 10 11 1.3 2.8 0.8 575 246 300 300 2 98/98 512/512 10 11 1.3 2.3 0.8

RTAA 140 200 383/389 600/600 500/500 2 280/280 1689/1689 10 11 1.3 6.5 0.8

230 383/389 600/600 500/500 2 280/280 1689/1689 10 11 1.3 6.5 0.8 460 306 400 350 2 122/122 633/633 10 11 1.3 2.8 0.8 575 246 300 300 2 98/98 512/512 10 11 1.3 2.3 0.8

RTAA 155 200 422/389 700/600 500/500 2 306/280 2044/1689 11 12 1.3 6.5 0.8

230 422/389 700/600 500/500 2 306/280 2044/1689 11 12 1.3 6.5 0.8 460 322 450 400 2 133/122 766/633 11 12 1.3 2.8 0.8 575 260 350 300 2 107/98 611/512 11 12 1.3 2.3 0.8

RTAA 170 200 515/389 800/600 700/500 2 375/280 2391/1689 12 13 1.3 6.5 0.8

230 515/389 800/600 700/500 2 375/280 2391/1689 12 13 1.3 6.5 0.8 460 363 500 450 2 163/122 896/633 12 13 1.3 2.8 0.8 575 292 400 350 2 131/987 25/512 12 13 1.3 2.3 0.8

RTAA 185 200 515/428 800/700 700/600 2 375/306 2391/2044 13 14 1.3 6.5 0.8

230 515/428 800/700 700/600 2 375/306 2391/2044 13 14 1.3 6.5 0.8 460 376 500 450 2 163/133 896/766 13 14 1.3 2.8 0.8 575 303 400 350 2 131/107 725/611 13 14 1.3 2.3 0.8

RTAA 200 200 514/514 800/800 700/700 2 375/375 2391/2391 14 14 1.3 6.5 0.8

230 514/514 800/800 7001700 2 375/375 2391/2391 14 14 1.3 6.5 0.8 460 406 500 450 2 163/163 896/896 14 14 1.3 2.8 0.8 575 327 450 400 2 131/131 725/725 14 14 1.3 2.3 0.8

RTAA 240 460 303/224 400/350 350/300 3 122-122/163 633-633/896 N/A 17 1.3 2.8 1.0

575 244/180 300/300 300/225 3 98-98/131 512-512/725 N/A 17 1.3 2.3 1.0

RTAA 270 460 360/224 500/350 450/300 3 163-122/163 896-633/896 N/A 19 1.3 2.8 1.0

575 290/180 400/300 350/225 3 131-98/131 725-512/725 N/A 19 1.3 2.3 1.0

RTAA 300 460 406/224 500/350 450/300 3 163-163/163 896-896/896 N/A 21 1.3 2.8 1.0

575 327/180 450/300 400/225 3 131-131/131 725-725/725 N/A 21 1.3 2.3 1.0

RTAA 340 460 303/406 400/500 350/450 4 122-122/163-163 633-633/896-896 N/A 24 1.3 2.8 1.0

575 244/327 300/450 300/400 4 98-98/131-131 512-512/725-725 N/A 24 1.3 2.3 1.0

RTAA 370 460 360/406 500/500 450/450 4 163-122/163-163 896-633/896-896 N/A 26 1.3 2.8 1.0

575 290/327 400/450 350/400 4 131-98/131-131 725-512/725-725 N/A 26 1.3 2.3 1.0

RTAA 400 460 406/406 500/500. 450/450 4 163-163/163-163 896-896/896-896 N/A 28 1.3 2.8 1.0

575 327/327 450/450 400/400 4 131-131/131-131 725-725/725-725 N/A 28 1.3 2.3 1.0

Notes:

(1) Low voltage units (200 & 230 volt) require separate power connections for each circuit. (2) MOP - Maximum Overcurrent Protection - may be either fused (UL/CSA) or with circuit breakers (CSA only).

MOP = 225 percent of the largest compressor RLA plus 100 percent of the second compressor RLA plus the sum of the condenser fans FLAs per NEC 440-22.

(3) MCA - Minimum Circuit Ampacity - 125 percent of largest compressor RLA plus 100 percent of second compressor plus the sum of the

condenser fans FLAs per NEC 440-33.

(4) RECOMMENDED TIME DELAY OR DUAL ELEMENT (RDE) FUSE SIZE: 150 percent of the largest compressor RLA plus 100 percent of the

second compressor RLA and the sum of the condenser tan FLAs. (5) RLA - Rated Load Amps - rated in accordance with UL Standard 465. (6) Local codes may take precedence. (7) Control kW includes operational controls only. Does not include heat tapes. (8) LRA - Locked Rotor Amps - based on full winding start units. (9) VOLTAGE UTILIZATION RANGE:

Rated Voltage Utilization Range

200 180-220 230 208-254 460 414-506 575 516.633

(10) A 11 5/60/1, 15 amp. customer provided power connection is required to operate the unit controls. A separate 115(60/1, 15 amp. customer

provided power connection is also needed to power the evaporator heat tape (RT AA 130-200 = 420 watts, RTAA 240-400 = 840 wafts @

120 volts) and optional Domestic Water Heater (420 watts @ 120 volts.). If the optional control power is used, the customer needs only to

provide a power connection for the heat tapes.

(11) 15 F minimum starting/operating ambient. (12) 0 F minimum starting/operating ambient

Fans (Ea)

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Installer-Supplied Components

Caution: Customer wiring interface connections are shown in the electrical schematics and connection diagrams that are shipped with the unit.

The installer must provide the following components if not ordered with the unit:

[ ] Power supply wiring (in conduit) for

all field-wired connections.

[ ] All control (interconnecting) wiring

(in conduit) for field supplied

devices. [ ] Fused-disconnect switches. [ ] Power factor correction capacitors.

Remote Evaporator Only:

Control wiring between the outdoor unit and the evaporator terminal box.

Power Supply Wiring

General

All power supply wiring must be sized and selected accordingly by the project engineer in accordance with NEC Table

31016.

WARNING: To prevent injury or death, disconnect electrical power source before completing wiring connections to the unit.

All wiring must comply with local codes and the National Electrical Code. The installing (or electrical) contractor must provide and install the system interconnecting wiring, as well as-the power supply wiring. It must be properly sized and equipped with the appropriate fused disconnect switches. The type and installation location(s) of the fused disconnects must comply with all applicable codes.

Caution: Use only copper conductors for terminal connections to avoid corrosion or overheating.

Remove the plate on the lower right side of the power connection panel and cut holes for the appropriately-sized wiring conduits. The wiring is passed through these conduits and connected to the terminal blocks or optional unitmounted disconnect. Refer to Figure 1 and Figures 34 thru 36.

To provide proper phasing of 3-phase input, make connections as shown in Figures 34 thru 36 and as stated on the yellow WARNING label in the starter panel. For additional information on proper phasing, refer to “Unit Voltage Phasing Proper equipment ground must be provided to each ground connection in the panel (one on 460/ 575 volt units and two on 200/230 volt units).

CAUTION: IT IS IMPERATIVE THAT L1-L2-L3 IN THE STARTER BE CONNECTED IN THE A-B-C PHASE SEQUENCE TO PREVENT EQUIPMENT DAMAGE DUE TO REVERSE ROTATION.

Control Power Supply

If the unit is equipped with the optional control power transformer, it is not necessary to provide control power voltage to the unit.

Caution: 200/230 volt units are factory connected as 200 volt units. For 230 volt units, the leads must be moved to the appropriate terminals on the transformer (1T1). See Unit Wiring Diagrams.

If the transformer is not provided, connect control power (115V , 750VA, 15 amp maximum fuse size) to terminals 1TB3-1 and 1TB3-2, on 130-200 units. Use 1TB3-1 and 1TB4-1 on 240-400 units.

Heat T ape Power Supply (Packaged Units Only)

Note: Units with the Remote

Evaporator option do not have heat tape.

The evaporator shell and optional Domestic Water Heater are insulated from ambient air and protected from freezing temperatures by a thermostatically-controlled heat tape. Whenever the water temperature drops to approximately 37 F, the thermostat energizes the heat tape. The heat tape will provide protection from ambient temperatures down to -20 F.

Provide an independent power source (115V, 15 amp), with a fuseddisconnect. The heat tape is factory wired back to the unit control panel. Customer connections are made on terminal strip 1TB3-11 and 1TB3-12 on 130-200 units or 1TB3-10 and 1TB4-1 0 on 240-400 units.

Water Pump Power Supply

Provide power supply wiring with fused disconnect for the chilled water pump(s).

Auxiliary Heat Tape Power Supply

Provide power wiring and properly sized fused-disconnect for any electrical heat tape installed on the system water piping.

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Interconnecting Wiring

Chilled Water Pump Interlock and External Auto/Stop for Model RTAA Air-Cooled Series R CenTraVac

Caution: The following must be adhered to or equipment damage may occur.

The Model RTAA Series R chiller requires a minimum of two fieldsupplied control inputs:

Chilled water pump interlock (TB3-1, -

•

2 on the 1U1 board).

External Auto/Stop (T133-3, -4 on the

•

1U1 board)

When there is a command to shut down the chilled water system, the chilled water pump is required to operate for a minimum of one minute after the External AUTO/STOP gives the shutdown command.

Normally, when the compressors are terminating a cycle (via chiller Stop/ Reset switch, loss of load, Low Ambient Run Inhibit or External Auto/ Stop), the controller will initiate the “Run:Unload” mode. This operating mode energizes the unload solenoid for 20 seconds, to unload the compressor so that it will be unloaded for the next start-up. Then the master oil solenoid is de-energized and closure of the master oil solenoid is verified. The entire process may take up to 40 seconds.

If the chilled water pump interlock is used without the external Auto/Stop input, the chiller will shut down immediately upon the command for shut down, without initiating the “Run:Unload” mode. This is considered a “non-friendly” shut down and a “Machine Auto Reset” diagnostic will be displayed on the LICK

Caution: The method in the previous paragraph is not to be used as a normal means of cycling the chiller off, e.g. time clock, building automation system, etc.

The proper method for cycling the chiller off is to open a set of contact between TB3-3, -4 on the 1U1 board (External Auto/Stop). Then, following a one minute delay, the chilled water pump is cycled off. Chilled water flow indication should be provided between TB3-1, -2 on the 1U1 board, e.g. water pump motor starter auxiliaries and/or flow switch.

The wiring for this recommendation is shown in the furnished electrical schematics and connection diagrams. Relay 5DL1 is a normally-open, instantaneous close, timed open (1 min.) time delay relay. An alternative solution is to provide proper programming in a building automation system.

Chilled Water Pump Interlock

The installer must provide leads 520 and 521 from the chilled water pump (5B1) starter auxiliary (5K1) to the proper terminals of terminal strip 1U1 TB3 on the UCM, as shown in Figures 34 thru 36. Circuit requirement is 115 VAC, with minimum contact rating @ 115 V AC of 6.9 VA inrush, 1.3 VA sealed. Refer to the field diagrams which are shipped with the unit.

The auxiliary contact of the chilled water pump may be wired in series with an optional flow switch, as shown. The standard UCM provides internal protection for the unit against loss of chilled water flow. Also refer to “Evaporator Flow Switch.”

External Auto/Stop Wiring

If the unit requires the Auto/Stop function, the installer must provide leads 522 and 523 from the remote contacts (5K5, 5K21) to the proper terminals of the terminal strip 1U1 TB3 on the UCM, as shown in Figures 34 thru 36.

The chiller will run normally when the contacts are closed. When either contact opens, the compressor(s), if operating, will go to the RUN:UNLOAD operating mode and cycle off. Unit operation will be inhibited. Re-closure of the contacts will permit the unit to automatically return to normal operation.

Circuit requirements are 2-wire, 115 VAC, with minimum contact rating @ 115 V AC of 6.9 VA inrush, 1.3 VA sealed. Refer to the field diagrams which are shipped with the unit.

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Alarm/Running/Maximum Capacity Outputs

Terminals 1 to 8 on terminal strip TB4 of the 1U1 board provide a variety of contact outputs. These are dependent upon the setting of Menu Item 4E and its relationship to diagnostics, compressors operating and the system operating at full capacity.

Table 11 Alarm/Running/Maximum Capacity Relay Output Configurations

Relay Output Configuration 1: RLY 1 = Alarm

RLY 2 = Compressor Running RLY 3 = Maximum Capacity

2: RLY 1 = Circuit I Alarm

RL Y 2 = Circuit 2 Alarm RLY 3 = Maximum Capacity

3: RLY 1 = Alarm

RL Y 2 = Circuit 1 Running RL Y 3 = Circuit 2 Running

As shown in Figure 37, there are three relays. Relays 1 and 2 have SPDT contacts. Relay 3 has SPST normally open contacts. The relays can provide three different output configurations, as shown in Table 11, and each configuration offers four choices as to how the alarm relay is to respond to a set of diagnostics.

Table 12 shows the twelve settings available in Menu Item 4E and the diagnostics which are issued for each set of conditions.

Figure 37 Alarm/Running/Maximum Capacity Contact Outputs

Table 12 Alarm/Running/Maximum Capacity Menu Settings

Diagnostics that the

Relays Output Alarm Relay(s) is Active

Menu Item 4E Configuration MMR/ MAR/

Setting (Table 11) CMR diag. CAR diag. IFW diag.

1 1 YES NO NO 2 1 YES YES NO 3 1 YES YES YES 4 1 YES NO YES 5 2 YES NO NO 6 2 YES YES NO 7 2 YES YES YES 8 2 YES NO YES

9 3 YES NO NO 10 3 YES YES NO 11 3 YES YES YES 12 3 YES NO YES

Notes: MMR = Machine Manual Reset CMR = Circuit Manual Reset MAR = Machine Auto Reset CAR = Circuit Auto Reset IFW = Informational Warnings

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Alarm/Running/Maximum Capacity Indicator Wiring

If the optional remote Alarm/Running/ Maximum Capacity contacts are used, provide electrical power, 115 VAC (contact load not to exceed 1150 V A inrush, 115 VA sealed), with fuseddisconnect to a customer-furnished remote device. Also provide proper remote device ground connection.

To install the available remote running and alarm indication, the installer must provide leads 525 thru 532 from the panel to the proper terminals of terminal strip 1U1TB4 on the UCM, as shown in Figures 31 thru 32. Refer to the field diagrams which are shipped with the unit.

Low Voltage Wiring

The remote devices described below require low voltage wiring. All wiring to and from these remote input devices to the UCM must be made with shielded, twisted pair conductors. Be sure to ground the shielding only at the UCM. See Figures 34 thru 36 for the recommended conductor sizes.

Caution: To prevent control malfunctions, do not run low voltage wiring (<30 V) in conduit with conductors carrying more than 30 volts.

Emergency Stop (Normal Trip)

The UCM provides auxiliary control for a customer specified/installed latching tripout. When this customer-furnished remote contact (5K18) is provided, the chiller will run normally when the contact is closed. When the contact opens, the unit will trip off on a manually resettable diagnostic. This condition requires manual reset at the chiller switch on the front of the UCM.

To connect, first remove the jumper located between terminals 3 and 4 of 1U1,TB1 on the UCM. Connect low voltage leads 513 and 514 to those terminals. Terminal strip locations are shown in Figures 34 thru 36. Refer to the field diagrams which are shipped with the unit.

Silver or gold-plated contacts are recommended. These customerfurnished contacts must be compatible with 12 VDC, 45 mA resistive load.

External Circuit Lockout – Circuit #1

The UCM provides auxiliary control of a customer specified or installed contact closure, for individual operation of Circuit #1. If the contact is open, the refrigerant circuit will not operate. Upon closure, the refrigerant circuit will run normally. This feature is used to restrict total chiller operation, e.g. during emergency generator operations.

External circuit lockout will only function if menu item 3b is enabled.

These customer-supplied contact closures must be compatible with 12 VDC, 45 mA resistive load. Silver or gold plated contacts are recommended.

RTAA 130-200

To install, cut, strip and wire-nut existing wire loop #W59 on the P43 connector of the 1U4 module to low voltage leads 45A and 45B. Connections are shown in the field diagrams which are shipped with the unit.

RTAA 240-400

To install, cut, strip and wire-nut existing wire loop #W53 on the P43 connector of the 1U4 module to low voltage leads 568 and 569. Connections are shown in the field diagrams which are shipped with the unit.

External Circuit Lockout – Circuit #2

The UCM provides auxiliary control of a customer specified or installed contact closure, for individual operation of Circuit #2. If the contact is open, the refrigerant circuit will not operate. Upon closure, the refrigerant circuit will run normally. This feature is used to restrict total chiller operation, e.g. during emergency generator operations.

These customer-supplied contact closures must be compatible with 12 VDC, 45 mA resistive load. Silver or gold plated contacts are recommended.

External circuit lockout will only function if menu item 3b is enabled.

RTAA 130-200

To install, cut, strip and wire-nut existing wire loop #W60 on the P53 connector of the 1U5 module to low voltage leads 46A and 46B. Connections are shown in the field diagrams which are shipped with the unit.

RTAA 240-400

To install, cut, strip and wire-nut existing wire loop #W55 on the P63 connector of the 1U6 module to low voltage leads 566 and 567. Connections are shown in the field diagrams which are shipped with the unit.

Ice Making Option

Menu Item 32 must be Enabled. The UCM provides auxiliary control for a customer specified/installed contact closure for ice making. When contact (5K20) is provided, the chiller will run normally when the contact is open. Upon contact closure, the UCM will initiate an ice-building mode, in which the unit runs fully loaded at all times. Ice-building shall be terminated either by opening the contact or based on the entering evaporator water temperature (Menu Item 33 = Setpoint). The UCM will not permit the ice-building mode to be reentered until the unit has been switched out of ice-building mode (open 5K20 contacts) and then switched back into ice-building mode (close 5K20 contacts.)

In ice-building, both the 1.5 F/min. pulldown rate limit and freeze avoidance will be ignored and the current unit setpoint will be set at 120%. For example, if the Front Panel or External Current Limit setpoint is set to 80%, in ice-building the Active Current Limit is 120%.

If, while in ice-building mode, the unit gets down to the freezestat setting (water or refrigerant), the unit will shut down on a manually resettable diagnostic, just as in normal operation.

Connect leads 501 and 502 from 5K20 to the proper terminals of 1U2,TB1 on the UCM, as shown in Figures 34 thru

36. Refer to the field diagrams which are shipped with the unit.

Silver or gold-plated contacts are recommended. These customer furnished contacts must be compatible with 12 VDC, 45 mA resistive load.

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External Chilled Water Setpoint (CWS): Remote Resistor/Potentiometer, V oltage Source 2-10 VDC, or Current Source 4-20 mA

This option allows the external setting of the Chilled Water Setpoint, independent of the Front Panel Chilled Water Setpoint, by one of three means:

1. A remote resistor/potentiometer input (fixed or adjustable)

Figure 38 Resistor and Potentiometer Arrangement for External Chilled Water Setpoint

2. An isolated voltage input 2-10 VDC

3. An isolated current loop input 4-20 mA

Methods 2 and 3 are usually used in interfacing with a Generic BAS or a process controller to the chiller.

To enable external setpoint operation, Item 30 of Menu 3, “External Chilled Water Setpoint d/E”, should be set to “E” using the Front Panel Operator Interface.

1. Remote Resistor/Potentiometer Input (fixed or adjustable)

Connect the remote resistor and/or potentiometer to terminals TB1 -3 and TB1 -5 of Options Module 1U2, as shown in Figure 38.

For units with 40 F to 60 F LCWS range, a field-furnished 25 Kohm linear taper potentiometer (±10%) and a fixed 5.6 Kohm (±10%) 1/4 watt resistor should be used.

For units with 20 F to 39 F LCWS range, a field-furnished 25 Kohm linear taper potentiometer (±1 0%) and a fixed 15 Kohm (±1 0%) 1/4 watt resistor should be used.

If the potentiometer is to be remotely mounted, it and the resistor must be connected to the UCM prior to mounting. Then, with the UCM display in Menu 0 and the display advanced to “Active Chilled Water Setpoint”, the UCM can be used to calibrate the positions of the potentiometer to correspond with the desired settings for the leaving water temperature. External resistor input values for various chilled water setpoints are shown in Table 13.

Table 13 Input Values Vs. External Chilled Water Setpoint

Inputs

Resistance (Ohms) Current (mA) Voltage (Vdc) Water Setpoint (F)

94433 4.0 2.0 0.0 68609 5.2 2.6 5.0 52946 6.5 3.2 10.0 42434 7.7 3.9 15.0 34889 8.9 4.5 20.0 29212 10.2 5.1 25.0 24785 11.4 5.7 30.0 21236 12.6 6.3 35.0 18327 13.8 6.9 40.0 15900 15.1 7.6 45.0 13844 16.3 8.2 50.0 12080 17.5 8.8 55.0 10549 18.8 9.4 60.0

9050 20.0 10.0 65.0

Resulting Chilled

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2. Isolated 2-10 VDC Voltage Source Input

Set DIP Switch SW1-1 of Options Module 1U2 to “OFF”. Connect the voltage source to terminals TB1 -4 (+) and TB1 -5 (-) on Options Module 1U2. CWS is now based on the following equation:

CW Setpoint 0 F = (VDC x 8.125) -

16.25 Sample values for CWS vs. VDC

signals are shown in Table 13. Minimum setpoint

= 0 F (2.0 VDC input)

Maximum setpoint

= 65 F (9.4 VDC input)

Maximum continuous input voltage

= 15 VDC Input impedance = 40.1 Kohms SW1 -1 off)

3. Isolated 4-20 mA Current Source Input

Set DIP Switch SW1-1 of Options Module 1U2 to “ON”. Connect the current source to terminals TB1-4 (+)and TB1-5 (-). CWS is now based on the following equation:

Setpoint °F = (mA x 4.0625) - 16.25 Sample values for CWS vs. mA

signals are shown in Table 13. Minimum setpoint = 0 F (4.0 mA)

Maximum setpoint = 65 F (18.8 mA) Maximum continuous = 30 mA

input current Input impedance = 499 ohms SW1 -1 on)

Note: The negative terminal TB1 -5 is referenced to the UCM chassis ground. To assure correct operation, 2-10 VDC or 4-20 mA signals must be isolated or “floating” with respect to the UCM chassis ground. See Figures 34 thru 36.

External Current Limit Setpoint (CLS): Remote Resistor/ Potentiometer, Voltage Source 2-10 VDC or Current Source 4-20 mA

This option allows the external setting of the Current Limit Setpoint, independent of the Front Panel Current Limit Setpoint, by one of three means:

1. A remote resistor/potentiometer input (fixed or adjustable)

2. An isolated voltage input 2-10 VDC

3. An isolated current loop input 4-20 mA

Methods 2 and 3 are usually used in

To enable external Current Limit Setpoint operation, Item 31 of Menu 3, “External Current Limit Setpoint WE”, should be set to “E” using the Front Panel Operator Interface.

1. Remote Resistor/Potentiometer Input To cover the entire range of Current

Limit Setpoints; (40 to 120%), a field furnished 50 Kohm log taper potentiometer (±10%) and a fixed 820 ohm (±1 0%) 1/4 Waft resistor should be wired in series and connected to terminals TB1 -6 and TB1 -8, of options module 1U2, as shown in Figure 39.

interfacing with a Generic BAS.

Table 14 Input Values Vs. External Current Limit Setpoint

Inputs

Resistance (Ohms) Current (mA) Voltage (Vdc) Limit Setpoint (% RLA)

49000 4.0 2.0 40 29000 6.0 3.0 50 19000 8.0 4.0 60 13000 10.0 5.0 70

9000 12.0 6.0 80 6143 14.0 7.0 90 4010 16.0 8.0 100 2333 18.0 9.0 110 1000 20.0 10.0 120

Resulting Current

Figure 39 Resistor and Potentiometer Arrangement for External Current Limit Setpoint

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If the potentiometer is to be remotely mounted, it and the resistor must be connected to the UCM prior to mounting. Then, with the UCM display in Menu 0 and the display advanced to “Active Current Limit Setpoint”, the UCM can be used to calibrate the positions of the potentiometer to correspond with the desired settings for the current limits. External resistor input values for various current limit setpoints are shown in Table 14.

2. 2-10 VDC Voltage Source Input Set DIP Switch SW1-2 of Options

Module 1U2 to “OFF”. Connect the voltage source to terminals TB1 -7 (+) and TB1 -8 (-) of Options

Module 1U2. CLS is now based on the following equation:

CL Setpoint % = (VDC x 10) + 20 Sample values for CLS vs. VDC signals

are shown below: Minimum setpoint

= 40% (2.0 VDC input)

Maximum setpoint

= 120% (10.0 VDC input)

Maximum continuous input voltage

= 15 VDC Input impedance = 40.1 Kohms (SW1 -2 off)

3. 4-20 mA Current Source Input Set DIP Switch SW1-2 of Options

Module 1U2 to “ON”. Connect the current source to terminals TB1 -7 (+) and TB1 -8 (-) of Options Module 1U2. CLS is now based on the following equation:

CL Setpoint % = (mA x 5) + 20 Sample values for CLS vs. mA signals

are shown in Table 14. Minimum setpoint = 40% (4.0 mA)

Maximum setpoint = 120% (20.0 mA) Maximum continuous input current

= 30 mA Input impedance = 499 ohms (SW1 - 2 on)

Note: The negative terminal TB1 -8 is referenced to the UCM chassis ground. To assure correct operation, 2-10 VDC or 4-20 mA signals must be isolated or “floating” with respect to the UCM chassis ground. See Figures 31 thru 32.

Optional Bidirectional Communications Link (BCL)

This option allows the UCM in the control panel to exchange information (e.g. operating setpoints and Auto/ Standby commands) with a higher level control device, such as a Tracer, a multiple-machine controller or a remote display panel. A shielded, twisted-pair connection establishes the bidirectional communications link between the unit control panel and the Tracer, multiple-machine controller or remote display panel.

Note: The shielded, twisted-pair conductors must run in a separate conduit.

Caution: To prevent control malfunctions, do not run low voltage wiring (<30 V) in conduit with conductors carrying more than 30 volts.

General

Field wiring for the communication link must meet the following requirements:

1. All wiring must be in accordance with the NEC and local codes.

2. Communication link wiring must be 18 AWG shielded, twisted-pair wiring (Belden 8760, or equivalent).

3. The maximum total wire length for each communication link is 5,000 feet.

4. The communication link cannot pass between buildings.

5. All UCM’s on the communication link can be connected in a “daisy chain” configuration.

Communication Link Connection Procedure

1. Refer to the T racer installation literature to determine proper communication link termination connections at the Tracer unit.

2. Refer to RTAA-IOM-2 for installation/ operation of Remote Display Panel.

3. Connect the shield of the communication link wiring to the designated shield terminal at the Tracer unit.

4. Connect leads 561 and 562 from the proper terminals of 1U2,TB2 on the UCM to the T racer, as shown in Figures 31 thru 33. There is no polarity requirement for this connection.

5. At the UCM the shield should be cut and taped to prevent any contact between the shield and ground. See Figures 31 thru 33.

Note: On multiple-unit installations, splice the shielding of the two twisted-pairs that come into each UCM in the “daisy chain” system. Tape the spliced connections to prevent any contact between the shield and ground. At the last UCM in the chain, the shield should be cut and taped off.

6. For unit ICS address selection see menu item “4C”.

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Installation Check List

Complete this checklist as the unit is installed, to verify that all recommended procedures are accomplished before the unit is started.

This checklist does not replace the detailed Instructions given in the “Installation -Mechanical” and “Installation -Electrical” sections of this manual. Read both sections

completely, to become familiar with the installation procedures, prior to beginning the work.

Receiving

[ ] V erify that the unit nameplate data

corresponds to the ordering information.

[ ] Inspect the unit for shipping

damage and any shortages of materials. Report any damage or shortage to the carder .

Unit Location and Mounting

[ ] Inspect the location desired for

installation and verify adequate service access clearances.

[ ] Provide drainage for evaporator

water.

[ ] Remove and discard all shipping

materials (cartons, etc.)

[ ] Install optional spring isolators, if

required.

[ ] Level the unit and secure it to the

mounting surface.

Unit Piping

[ ] Flush all unit water piping before

making final connections to the unit.

Caution: If using an acidic commercial flushing solution, construct a temporary bypass around the unit to prevent damage to internal components of the evaporator .

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

[ ] Connect the chilled water piping to

the evaporator.

[ ] Install pressure gauges and shutoff

valves on the chilled water inlet and outlet to the evaporator.

[ ] Install a water strainer in the

entering chilled water line.

[ ] Install a balancing valve and flow

switch (discretionary) in the leaving chilled water line.

[ ] Install a drain with shutoff valve or a

drain plug on the evaporator.

[ ] Vent the chilled water system at

high points in the system piping.

[ ] Apply heat tape and insulation, as

necessary, to protect all exposed piping from freeze-up.

Electrical Wiring

WARNING: To prevent injury or death, disconnect electrical power source before completing wiring connections to the unit.

Caution: To avoid corrosion and overheating at terminal connections, use copper conductors only.

[ ] Connect the unit power supply

wiring with fused-disconnect to the terminal block (or unit-mounted disconnect) in the power section of the control panel.

[ ] Connect the control power supply

wiring with fused-disconnect to the terminal strip in the power section of the control panel.

[ ] Connect power supply wiring to the

evaporator heat tape. Connect leads 551 and 552 to terminals 11 and 12 of terminal strip 1TB3.

[ ] Connect power supply wiring to the

chilled water pump.

[ ] Connect power supply wiring to any

auxiliary heat tapes.

[ ] Connect the auxiliary contact of the

chilled water pump (5K1) in series with the optional flow switch, if installed, and then connect to the proper terminals.

[ ] For the External Start/Stop function,

install wiring from remote contacts (5K5, 5K21) to the proper terminals on terminal strip 1U1TB3.

Caution: Information in Interconnecting Wiring: Chilled Water Pump Interlock and External Auto/Stop must be adhered to or equipment damage may occur.

[ ] If the remote alarm/running/

maximum capacity contacts are used, install leads 525 thru 532 from the panel to the proper terminals on terminal strip 1U1TB4.

[ ] If the emergency stop function is

used, install low voltage leads 513 and 514 to terminals 3 and 4 of 1U1TB1.

[ ] If indoor zone temperature is to be

used, install leads 501 and 502 on 6RT4 to the proper terminals on 1U2TB1.

[ ] If the ice making-option is used,

install leads 501 and 502 on 5K20 to the proper terminals on 1U2TB1.

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Operating Principles – Mechanical

General

This section describes the mechanical operating principles of Series R aircooled chillers equipped with microcomputer-based control systems.

The 130 thru 400-ton Model RTAA units are dual-circuited, helical-rotary type air-cooled liquid chillers. The basic components of an RTAA unit are:

- Unit Control Module (UCM)

- Unit-mounted panel

- Helical-rotary compressor

- Direct Expansion evaporator

- Air-cooled condenser

- Oil supply system (hydraulic and lubrication)

- Interconnecting piping Components of a typical RTAA unit are

identified in Figures 1 thru 6.

Refrigeration (Cooling) Cycle

Cycle Description

Figures 40 and 41 represent the refrigeration system and control components. Vaporized refrigerant leaves the evaporator and is drawn into the compressor . Here it is compressed and leaves the compressor as a mixture of hot gas and oil (which was injected during the compression cycle).

The mixture enters the oil separator at the two in/out caps. The separated oil flows to the bottom of the separator , while the refrigerant gas flows out the top and passes on to the tubes in the condensing coils. Here circulating air removes heat from the refrigerant and condenses it.

The condensed refrigerant passes through the electronic expansion valve and into the tubes of the evaporator . As the refrigerant vaporizes, it cools the system water that surrounds the tubes in the evaporator.

Compressor Description

The compressors used by the Model RTAA Series “R” Air-cooled chiller consists of two distinct components: the motor and the rotors. Refer to Figure 42.

Compressor Motor

A two-pole, hermetic, squirrel-cage induction motor directly drives the compressor rotors. The motor is cooled by suction refrigerant gas from the evaporator, entering the end of the motor housing through the suction line, as shown in Figures 40 and 41.

Compressor Rotors

The compressor is a semi-hermetic, direct drive helical rotary type compressor. Each compressor has only three moving parts: T wo rotors “male” and ‘female” - provide compression, and a slide valve controls capacity. See Figure 42. The male rotor is attached to, and driven by, the motor, and the female rotor is, in turn, driven by the male rotor. Separately housed bearing sets are provided at each end

both rotors. The slide valve is located

of above, and moves along, the top of the rotors.

The helical rotary compressor is a positive displacement device. The refrigerant from the evaporator is drawn into the suction opening at the end of the motor barrel, through a suction strainer screen, across the motor, and into the intake of the compressor rotor section. The gas is then compressed and discharged directly into the discharge line.

There is no physical contact between the rotors and compressor housing. The rotors contact each other at the point where the driving action between the male and female rotors occurs. Oil is injected along the top of the compressor rotor section, coating both rotors and the compressor housing interior. Although this oil does provide rotor lubrication, its primary purpose is to seal the clearance spaces between the rotors and compressor housing.

A positive seal between these internal parts enhances compressor efficiency by limiting leakage between the high pressure and low pressure cavities.

Capacity control is accomplished by means of a slide valve assembly located in the rotor section of the compressor. Positioned along the top of the rotors, the slide valve is driven by a piston/cylinder along an axis that parallels those of the rotors.

Compressor load condition is dictated by the position of the slide valve over the rotors. When the slide valve is fully extended over the rotors and away from the discharge end, the compressor is fully loaded. Unloading occurs as the slide valve is drawn towards the discharge end. Slide valve unloading lowers refrigeration capacity by reducing the compression surface of the rotors.

Compressor Loading Sequence

When there is a call for chilled water , the UCM will start the compressor which has the least number of starts. If the first compressor cannot satisfy the demand, the UCM will start another compressor and then balance the load on all compressors by pulsing the load/ unload solenoids.

The load on the compressors will be kept in balance, as load fluctuates, until the demand for chilled water is reduced to a level that can be handled by one compressor . At this time, the UCM will drop off the compressor that has the greatest number of operating hours and will adjust the load on the other compressor, as required.

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Figure 40 Refrigeration System and Control Components Single Circuit

(Continued on Next Page)

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Figure 40 (Continued from Previous Page)

1 Schrader valve 2 Suction temperature sensor* 3 Manufacturing process tube 4 Suction service valve (optional) 5 Motor winding thermostat* 6 Discharge temperature sensor* 7 Pressure relief valve (450 psi) 8 High pressure cutout (405 psi)*

9 Discharge check valve 10 Evaporator waterside vent 11 Discharge line shutoff valve 12 Oil separator in/out cap 13 Saturated condensing temperature

sensor* 14 Condenser header 15 Subcooler header 16 Liquid line shutoff valve

17 25 micron filter/drier 18 Liquid line sight glass 19 Electronic expansion valve 20 Saturated evaporator temperature

sensor* 21 Evaporator waterside drain 22 Leaving water temperature sensor* 23 Leaving water connection 24 Entering water connection 25 Entering water temperature sensor* 26 Drain with Schrader valve 27 Oil line 28 Entering oil cooler header 29 Leaving oil cooler header 30 Schrader valve with stem depressor 31 Oil line shutoff valve 32 5 micron oil filter

33 Master solenoid valve* 34 Oil line to load/unload slide valve

solenoids 35 Injection oil check valve 36 Heater 37 Slide valve solenoids and orifices* 38 Oil flow differential pressure switch* 39 Compressor Drain Plug 40 Domestic water heater (option) 41 Oil line thermostat (option,

Domestic Water Heater) 42 Oil line bypass solenoid valve

(option, Domestic Water Heater) *UCM Input/Output Control

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Figure 41 Refrigeration System and Control Components Duplex Circuit

(Continued on Next Page)

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Figure 41 (Continued from Previous Page)

REFRIGERATION SYSTEM AND CONTROL COMPONENTS

1 Schrader valve 2 Suction temperature sensor* 3 Manufacturing process tube 4 Suction service valve (optional) 5 Motor winding thermostat* 6 Discharge temperature sensor 7 Pressure relief valve (450 psi) 8 High pressure cutout (405 psi)*

9 Discharge check valve 10 Evaporator waterside vent 11 Discharge line shutoff valve 12 Oil separator in/out cap 13 Saturated condensing temperature

sensor* 14 Condenser header 15 Subcooler header 16 Liquid line shutoff valve

Figure 42 Typical RTAA Compressor

17 25 micron filter/drier 18 Liquid line sight glass 19 Electronic expansion valve* 20 Saturated evaporator temperature

sensor* 21 Evaporator waterside drain 22 Leaving water temperature sensor* 23 Leaving water connection 24 Entering water connection 25 Entering water temperature sensor* 26 Drain with Schrader valve 27 Oil line 28 Entering oil, cooler header 29 Leaving oil cooler header 30 Schrader valve with stem depressor 31 Oil line shutoff valve 32 5 micron oil filter

33 Master solenoid valve* 34 Oil line to load/unload slide valve

Domestic Water Heater) 42 Oil line bypass solenoid valve

(option, Domestic Water Heater) *UCM Input/Output Control

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Oil System Operation

Overview

Oil that collects in the bottom of the oil separator is at condensing pressure during compressor operation; therefore, oil is constantly moving to lower pressure areas. Refer to Figure 43.

As the oil leaves the separator, it passes through the air-cooled oil cooler at the top of the condensing coils. It then goes through the service valve and filter . At this point, some of the oil is used to control the slide valve movement in the compressor , via the load/unload solenoids. The remaining oil passes through the oil master solenoid valve and performs the functions of compressor bearing lubrication and compressor oil injection. If the compressor stops for any reason, the master solenoid valve closes, isolating the oil charge in the separator and oil cooler during “off” periods.

To ensure proper lubrication and minimize refrigerant condensation in the compressor, a heater is mounted on the bottom of the compressor housing. A signal from the UCM energizes this heater during the compressor “Off” cycle to keep refrigerant from condensing in the compressor. The heater element is continuously energized.

Domestic Water Heater

The Domestic Water Heater option utilizes available waste heat from the compressor oil circuit, to heat domestic or process water. Normally, the excess heat is dissipated to the atmosphere by fans moving air over the oil cooler.

The high temperature oil that leaves the oil separator enters the domestic water heater. Heat is transferred from the oil to the cool water that enters the heater. The oil then passes either through the unit’s air-cooled oil cooler, where additional heat is removed, if required, or through the air-cooled oil cooler bypass solenoid, that is operated by a thermostat on the oil supply line.

Water that is heated in the domestic water heater exits the heater and flows to the system.

Figure 43 RTAA Compressor Oil System Schematic

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Oil Separator

The oil separator consists of a Ushaped tube, joined at the top by the refrigerant discharge line from the compressor. As shown in Figure 44, the discharge line is essentially tangential to the U-tubes. This causes the refrigerant to swirl in the tubes and throws the oil to the outside, where it collects on the walls and flows to the bottom. The compressed refrigerant vapor, stripped of oil droplets, exits out the top of the oil separator and is discharged into the condensing coils.

Compressor Bearing Oil Supply

Oil is injected into the bearing housings located at each end of both the male and female rotors. Each bearing housing is vented to compressor suction, so that oil leaving the bearings returns through the compressor rotors to the oil separator.

Figure 44 Oil Separator

Compressor Rotor Oil Supply

Oil flows through this circuit directly from the master solenoid valve through the oil filter to the top of the compressor rotor housing. There it is injected along the top of the rotors to seal clearance spaces between the rotors and the compressor housing and to lubricate the rotors.

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Slide Valve Movement

Movement of the slide valve piston determines slide valve position which, in turn, regulates compressor capacity. Oil flow into and out of the cylinder governs piston movement, and is controlled by the normally-closed, load and unload solenoid valves.

The solenoid valves receive momentary pulsating “load” and “Unload” voltage signals from the UCM based on system cooling requirements. the UCM opens the load solenoid valve while keeping the unload solenoid valve closed. The pressurized oil flow then enters the cylinder and forces the slide valve to move over the rotors.

The compressor is unloaded when the load solenoid valve is kept closed and the unload solenoid valve is opened. Oil “trapped” within the cylinder is drawn out into the lower-pressure suction area of the compressor. As the pressurized oil leaves the cylinder, the slide valve gradually moves away from the rotors.

both solenoid valves are closed,

When the present level of compressor loading is maintained.

Just prior to a normal compressor shutdown, the unload solenoid valve is energized and the slide valve moves to the fully-unloaded position, so the unit always starts fully unloaded.

To load the compressor,

Oil Filter

Each refrigerant circuit is equipped with replaceable-element oil filters. The filter(s) remove any impurities that could foul the solenoid valve orifices and compressor internal oil supply galleries. This also prevents excessive wear of compressor rotor and bearing surfaces. Refer to the maintenance portion of this manual for recommended filter element replacement intervals.

Condenser Fans

The RTAA Series offers either the 15 F or 0 F ambient fan configuration. On the 0 F ambient option, the lead fan(s) on each circuit is a half-airflow (halfpitch blade) fan(s). Half pitch fans have a blade pitch of 150 and full pitch fans have a blade pitch of 27°.

Figures 45 and 46 show the number of fans installed on each model, the designation of fan contactors and the staging of fans as the UCM calls for more condenser cooling. Fan staging is a function of the difference between the saturated condenser refrigerant temperature and the saturated evaporator refrigerant temperature, which in turn is a function of the load and ambient temperature. Any number of fans can be operating at a given time, depending on these variables.

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Figure 45 Fan Configurations – RTAA 130-200 Tons 15 F Minimum Ambient

All fans will be Full Airflow (Full Pitch Blade) Fans:

Circuit #1 is on the right side of the unit from the control panel. Circuit #2 is on the left side of the unit from the control panel.

# Of Fans # Of Fans UCM Outputs

Tons Circuit #1 Circuit #2 Per Circuit # Fan Steps/Circuit 130 5 5 4 5 & 5 respectively

140 5 5 4 5 & 5 respectively 155 6 5 4 6 & 5 respectively 170 7 5 4 7 & 5 respectively 185 7 6 4 7 & 6 respectively 200 7 7 4 7 & 7 respectively

For ST ANDARD air-cooled (RTAA) Chillers, the mapping of UCM outputs to fan staging shall be as follows: Fan Contactor 5 Fan Circuit 6 Fan Circuit 7 Fan Circuit

Circuit #1 K 9 K10 K11 K12 K9 K10 K11 K12 K9 K10 K11 K12 Circuit #2 K13 K14 K15 K16 K13 K14 K15 K16 K13 K14 K15 K16

Number of Fan(s)/ Contactor 1112 11 22 1123

Fan Steps 0 –––– –– –– –––– 1 x––– x– –– x––– 2 xx–– x x –– xx–– 3 xxx– x– x– x–x– 4 xx– x xx x– xx–x 5 xxx x x– xx x x– x 6 –––– xx xx x–xx 7 –––– –– –– xxxx

X = ON

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Figure 46 Fan Configurations - RTAA 130-400 Tons - 0 F Minimum Ambient

The 0 F AMBIENT OPTION will have Half Airflow (Half Pitch Blade) Fan.

Tons Circuit #1 Circuit #2 Per Circuit Fan Steps/Circuit 130 5* 6* 4 9 & 10 respectively

140 5* 6* 4 9 & 10 respectively 155 6* 6* 4 10 & 10 respectively 170 7* 6* 4 11 & 10 respectively 185 7* 7* 4 11 & 11 respectively 200 7* 7* 4 11 & 11 respectively 215 7* 7* 4 11 & 11 respectively 240 10** 7* 4 9 & 11 respectively 270 12** 7* 4 10 & 11 respectively 300 14** 7* 4 11 & 11 respectively 340 10** 14** 4 9 & 11 respectively 370 12** 14** 4 10 & 11 respectively 400 14** 14** 4 11 & 11 respectively

*The first fan on each single compressor circuit is a Half Airflow (Half Pitch Blade) Fan.

**The first two fans on each dual compressor circuit are Half Airflow (Half Pitch Blade) Fans.

For 0 F AMBIENT OPTION air-cooled (RTAA) Chillers, the mapping of UCM outputs to fan staging shall be as follows: Fan Contactor 5 & 10 Fan Circuit 6 & 12 Fan Circuit 7 & 14 Fan Circuit

Circuit #1 K9 K10 K11 K12 K9 K10 K11 K12 K9 K10 K11 K12 Circuit #2 K13 K14 K15 K16 K13 K14 K15 K16 K13 K14 K15 K16

Number of Fans/Contactor

Single Comp. Ckt. 1* 1 1 2 1* 1 2 2 1* 1 2 3 Dual Comp. Ckt. 2* 2 2 4 2* 2 4 4 2* 2* 2 4 6 * = Half AirFlow Fan

Single Dual Compr Compr Ckt Ckt

0.0 0.0 –––– –– –– ––––

0.5 1 x––– x– –– x––– 1 2 –x–– –x –– –x––

1.5 3 xx–– xx –– xx–– 2 4 –xx– –– x– ––x–

2.5 5 xx x– x– x– x–x– 3 6 –x–x –x x– –––x

3.5 7 x x – x x x x – x – – x 4 8 –xx x –– xx –x–x

4.5 9 xxxx x– xx xx–x

5.5 11 –––– xx xx x–xx

6.5 13 –––– –– –– xxxx X = ON

# Of Fans # Of Fans UCM Outputs

Fan Steps

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Operating Principles – Adaptive Control

™

Microprocessor Logic

General

The exclusive Trane Adaptive Control logic is comprised of a system of individual modules called the Unit Control Module (UCM), located in the Control Panel. The system consists of four types of microprocessor-based components and the operator interface, as shown in Figures 47 thru 51. The processors are:

Chiller Module (Base or Deluxe) - 1U1 Communication and Setpoint Reset

Option Module - 1U2 Expansion Valve Module - 1U3 Compressor Module (one per

compressor) - 1U4, 1U5, 1U6, 1U7 Slave Expansion Valve Module

(240 -400 ton units) - 1U8 The Adaptive Control Chiller Module is

available in two versions, a base model and a deluxe model. The deluxe model offers the additional features of:

1. Under/Over Voltage Protection

(Includes U/O voltage sense

transformer).

2. Display of Compressor Starts and

Hours

3. Display of % Line Volts

4. Alarm/Running/Max Capacity

Contacts Local operator interface with the

system is accomplished using the four display buttons on the LICK Data readouts are shown on the seven-digit, digital display. The three-position switch is used to set chiller operation.

Digital Display

The digital display shows:

both operating and diagnostic codes

•

compressor status indicators

•

settings of a local setpoints and

•

adjustments

actual controlling setpoints

•

specified temperatures

•

specified pressures

•

enable/disable status of features and

•

options

selection status of Sl units or English

•

units for display of temperatures and pressures

All display segments and any used decimal points will be briefly turned on to provide a visual test of their operation , following a Power-OnReset. The chiller operating codes (“A” prefix) will then be displayed. The data to be shown on the digital display is selected by using the Display Up and Display Down keys. Changing of the display and menus is discussed below.

The digital display will light an indicator at the bottom of the display, above the “A”, “B”, “C” or “D” and circuit 1 or circuit 2. In Menu 0, these indicators show which compressor/circuit is running. In Menu 2, these indicators show which compressor/circuit is related to the displayed parameter.

A “Circuit Lockout” indicator will be lit if either circuit is enabled (E) in Menu 1 A (Circuit Lockout) or either circuit is “OFF” on its external Circuit Lockout contacts and Menu 3B, (External Circuit Lockout) is enabled (E).

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Figure 47 RT AA Control Panel – 130 to 200 T ons

LEGEND:

Device Designation Description

1F1-6 Fan Fuses, Circuit 1 1F7-12 Fan Fuses, Circuit 2 1F15 Control Circuit Fuse 1F16, 1F17 Control Power

1K1, 1K5 Start Contactors 1K2, 1K6 Run Contactors 1K4, 1K8 Transition Contactors 1K3, 1K7 Shorting Contactors 1K9-12 Fan Contactors, Circuit 1 1K13-16 Fan Contactors, Circuit 2 1S1, 1S2 Non-fused Disconnect

1T1 Control Power 1T2 Under/Over Voltage 1T3-5 Compressor Current 1T6-8 Compressor Current 1TB1,1TB2 Line Voltage Terminal 1TB3 Terminal Strip, 115 V

1U1 Chiller Module 1U2 Options Module 1U3 Expansion Valve Module 1U4 Compressor Protection

1U5 Compressor Protection

Transformer Fuses

Switch Transformer Transformer Transformer, Circuit 1 Transformer, Circuit 2 Blocks

Module, Compressor A

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Figure 48 RTAA Control Panel – 240 to 300 T o ns

LEGEND:

Device Designation Description

1F1-6 Fan Fuses, Circuit 1 1F7-12 Fan Fuses, Circuit 2 1F15 Control Circuit Fuse 1F16, 1F17 Primary Transformer

1K1, 1K2 Start Contactors, Circuit 1 1K3, 1K4 Start Contactors, Circuit 2 1K9-12 Fan Contactors, Circuit 1 1K13-16 Fan Contactors, Circuit 2 1S1, 1S2 Non-fused Disconnect

1T1 Control Power 1T2 Under/Over Voltage 1T3-8 Compressor Current 1T9-14 Compressor Current 1TB1,1TB2 Line Voltage Terminal 1TB3,1TB4 Terminal Strip, 115 V

1U1 Chiller Module 1U2 Options Module 1U3 Expansion Valve Module 1U4 Compressor Protection

1U5 Compressor Protection 1U6 Compressor Protection 1U8 Slave Expansion Valve

Fuses

Switch Transformer Transformer Transformer, Circuit 1 Transformer, Circuit 2 Blocks

Module, Compressor A Module, Compressor B Module, Compressor C Module

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Figure 49 RT AA Control Panel – 340 to 400 T ons

LEGEND:

Device Designation Description

1F1-6 Fan Fuses, Circuit 1 1F7-12 Fan Fuses, Circuit 2 1F15 Control Circuit Fuse 1F16, 1F17 Primary Transformer

1K1, 1K2 Start Contactors, Circuit 1 1K3, 1K4 Start Contactors, Circuit 2 1K9-12 Fan Contactors, Circuit 1 1K13-16 Fan Contactors, Circuit 2 1S1, 1S2 Non-fused Disconnect

1T1 Control Power 1T2 Under/Over Voltage 1T3-8 Compressor Current 1T9-14 Compressor Current 1TB1,1TB2 Line Voltage Terminal 1TB3,1TB4 Terminal Strip, 115 V

1U1 Chiller Module 1U2 Options Module 1U3 Expansion Valve Module 1U4 Compressor Protection

1U5 Compressor Protection 1U6 Compressor Protection 1U7 Compressor Protection 1U8 Slave Expansion Valve

Fuses

Switch Transformer Transformer Transformer, Circuit 1 Transformer, Circuit 2 Blocks

Module, Compressor A Module, Compressor B Module, Compressor C Module, Compressor D Module

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Figure 50 RT AA Control Panel – 130 to 200 T o ns with Remote Evaporator Option

LEGEND:

Device Designation Description

1F1-6 Fan Fuses, Circuit 1 1F7-12 Fan Fuses, Circuit 2 1F15 Control Circuit Fuse 1F16, 1F17 Primary Transformer

1K1, 1K5 Start Contactors 1K2, 1K6 Run Contactors 1K4, 1K8 Transition Contactors 1K5, 1K7 Shorting Contactors 1K9-12 Fan Contactors, Circuit 1 1K13-16 Fan Contactors, Circuit 2 1S1, 1S2 Non-fused Disconnect

1T1 Control Power 1T2 Under/Over Voltage 1T3-5 Compressor Current 1T6-8 Compressor Current 1TB1, 1TB2 Line Voltage Terminal 1TB3 Terminal Strip, 115 V

1TB8, 1TB9 Terminal Strip, 24 V 1U1 Chiller Module 1U2 Options Module 1U3 Expansion Valve Module 1U4 Compressor Protection

1U5 Compressor Protection

Fuses

Switch Transformer Transformer Transformer, Circuit 1 Transformer, Circuit 2 Blocks

Module, Compressor A Module, Compressor B

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Figure 51 Operator Interface Controls

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Menus

There are six menus, four of which are shown on the operator interface panel and two factory displays, which are described later in this section. The menus are numbered as follows:

Operating Display - Menu 0 Service #1 Display - Menu 1 Service #2 Display - Menu 2 Auxiliary Options Display - Menu 3 Factory Display - Menu 4 Factory Display - Menu 5

Each menu can be considered to be a page of data, formatted as shown in Figure 52. The operator can view one line of the menu at a time (menu item) on the digital display and can scroll through the menu by using the Display Up and Display Down keys. For example, when the digital display shows “P 0”, the UCM is in the “Operating Display” menu. By depressing the Display Down key one time, the next line of the menu, “Operating Code”, will be shown as an “A”, along with the current unit operating status. All operating and diagnostic codes are described on the “Condition Codes” label, as shown in Figure 53.

There are a few exceptions to the scrolling function. When a menu selection represents multiple pieces of information:

“C” Menu Item - Other Diagnostic Codes”: When this menu item is selected, depressing the Display Down key will display diagnostic history in code number sequence. Use the Display Up key to return to the top of the list. While in the “C” menu item, flashing indicates that the information is currently “true”, whereas steady, or non-flashing indicates historic data only. The digital display will not advance to the next item (d) until all diagnostics have been displayed. If there are no diagnostics to display, the data field will be blank for one key stroke.

Compressor/Circuit Parameters: Because the unit has two, three or four compressors and two refrigerant circuits, items that refer to compressors or circuits will remain selected until information for all have been displayed. For example, assume a “29”, “Compressor Starts”, menu selection on a two compressor unit. The menu numbered “29” will be displayed and the indicator over the “A” compressor will be flashing. By depressing the Display Down key one time, the “29” will remain but the indicator light over the “B” compressor will be flashing. Another Display Down

key stroke will display menu “2A”, Compressor Hours, with compressor “A” indicator flashing. If either the Display Up or Display down keys are held down, the scrolling will continue until the key is released, or until reaching the top or bottom of the menu. In this case, the display will return to the “P” menu position and stop.

To change menus, scroll to the “P” menu position and use the Set Point Up or Set Point Down keys. For example, assume that the display shows “P 0” and it is desired to view the Auxiliary Options on Menu 3. Depress the Set Point Up key three times and the “P 3” menu will be displayed. To return to Menu 0, depress the Set Point Down key three times or Set Point Up key once (to wrap around) and “P 0” will be displayed. This procedure will work for menus 0 through 3.

A combination of key strokes is required to access menus 4 and 5. With the display in the “P” menu position (P), use the Set Point Up and Down keys to display “0, 1, 2, 1, 2, 3, 2, 3, 4”. Once in the “P 4” menu, use the Set Point Up key to access menu 5.

All menus are always accessible, whether the unit is in a “running” or ‘stopped” mode.

Figure 52 Menu Formats

OPERATING DISPLAY - MENU 0

Selected by setting the number 0 in the “P” menu item. Compressor/circuit indicators will be lit Continuously in this menu to indicate which compressors/ circuits are running. All items of Menu 0 are display only. Setpoint changes must be made in other menus.

Display Code and Description

P Menu Number A Operating Code b Last Diagnostic Code C Other Diagnostic Codes d Active Chilled Water Setpoint* E Evaporator Entering Water Temperature F Evaporator Leaving Water Temperature L Active Current Limit Setpoint

*Dashes are displayed for the setpoint when the chiller is either in the

“Ice Building” or “Ice Building Complete” mode.

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Figure 52 Menu Formats (Continued)

SERVICE #1 DISPLAY – MENU 1

Selected by setting the number 1 in the “P” menu item. The compressor circuit indicators will not be lit continuously in this menu to indicate which compressors are running. As the menu is advanced, the appropriate compressor/circuit indicator will flash.

Display Code and Description Defaults Range

P Menu Number 10 Front Panel Chilled Water Setpoint 44 F 0 to 65 F 11 Design Delta Temperature Setpoint 10 F 4 to 30 F 12 Differential to Start Setpoint 2 F 2 to 30 F 13 Front Panel Current Limit Setpoint 120% 40 to 120% 14 Outdoor Air Temperature (Optional) 15 Low Ambient Lockout - d/E (Optional) d 16 Low Ambient Lockout Setpoint - d/E (Optional)* 20 F -20 to 40 F 17 Cond. Entering Water Temperature (Optional) RTAA Non Applicable 18 Cond. Leaving Water Temperature (Optional) RTAA = Non Applicable 19 Service Pumpdown d/E (Stop/Reset only)** d 1A Circuit Lockout d/E** d 1b Circuit Diagnostics Reset** d

*Dashes are displayed for the setpoint when the Low Ambient Lockout (15) is disabled.

**Displayed by Compressor/Circuit

SERVICE #2 DISPLAY - MENU 2

Selected by setting the number 2 in the “P” menu item. Compressor/Circuit indicators shall not be lit continuously in this menu to indicate which compressors are running. As the menu is advanced, the appropriate compressor/circuit indicator will flash.

Display Code and Description Defaults Range

P Menu Number 20 Compressor Mode* 21 Compressor Suction Refrigerant Temp.* 22 Compressor Evap. Refrigerant Temp.* 23 Evaporator Refrigerant Pressure* 24 Saturated Condenser Refrigerant Temp.* 25 Condenser Refrigerant Pressure* 26 EXV Test - d/E (Only in STOP/RESET)* d 27 Compressor % RLA (Highest leg)* 28 % Line Volts (Optional) 29 Compressor Starts (Optional)* 2A Compressor Hours (Optional)* 2b Compressor Test d/E d

*Displayed by compressor/circuit Compressor Starts, Compressor Hours and % Line Volts will be displayed as dashes (e.g. “2A when this option is not installed. After the EXV test has been completed, the “E” will be automatically reset to “d”.

See “Electronic Expansion Valve (EXV) Test”. The Condenser Refrigerant Pressure and the Evaporator Refrigerant Pressure, displayed on the UCM, are the saturated

condenser and evaporator temperatures converted to R-22 pressure readings. The units are PSIG (Kilopascal gauge) and referenced to an elevation of sea level or 14.6960 psia (101.3289 KPa absolute).

UCM Based Setpoint

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Figure 52 Menu Formats (Continued)

AUXILIARY OPTIONS – MENU 3

Selected by setting the number 3 in the “P” menu number position. Compressor/circuit indicators will not be lit continuously in this menu to indicate which compressors/circuits are running.

UCM Based Setpoint

Display Code and Description Defaults Range

P Menu Number 30 External Chilled Water Setpoint - d/E d 31 External Current Limit Setpoint - d/E d 32 Ice Machine Control - d/E d 33 Active-Ice Termination Setpoint* 34 Front Panel Ice Termination Setpoint 27 F 20 to 31 F 35 Return Reset - d/E** d 36 Zone Reset - d/E** d 37 Outdoor Reset - d/E** d 38 Reset Ratio Setpoint***

39 Start Reset Setpoint***

3A Maximum Reset Setpoint***

3b External Circuit Lockout d/E d

***The UCM contains setpoints for each of the types of reset. The setpoint displayed will be for the type of reset enabled.

Return 50% 10 to 120% Zone 100% 50 to 300% Outdoor 10% -80 to 80%

Return 10 F 4 to 30 F Zone 78 F 55 to 85 F Outdoor 90 F 50 to 130 F

Return 5 F 0 to 20 F Zone 5 F 0 to 20 F Outdoor 5 F 0 to 20 F

*Dashes are displayed for the setpoint when the chiller is not in the “Ice Building” or “Ice Building Complete” mode.

**The UCM will permit only one type of reset (Return, Zone, or Outdoor) to be selected at one time. For example, if Return

Reset is enabled, an attempt to enable Zone Reset would disable RETURN RESET and enable Zone Reset automatically.

If no reset is enabled, dashes will be displayed.

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Figure 52 Menu Formats (Continued)

FACTORY DISPLAY #1 - MENU 4 Caution: Do not leave unit unattended while in Menu 4 or 5. Inadvertent unit safety setpoint changes could occur.

Selected by setting the number 4 in the “P” menu item. Unlike menus 0 through 3, the number 4 can only be set by entering a combination of numbers. This combination consists of a sequence of “P” menu numbers -0, 1, 2, 1, 2, 3, 2, 3. 4.

Compressor/circuit indicators will not be lit continuously in this menu to indicate which compressors are running. As the menu is advanced the appropriate compressor/circuit indicator will flash.

Display Code and Description Defaults Range

P Menu Number 40 Leaving water Temp. Cutout Setpoint 35 F -10 to 35 F 41 Low Refrigerant Temp. Cutout Setpoint 22 F -39 to 35 F 42 Condenser Limit Setpoint - % HPC 90% 80 to 120% 43 Lead/Lag - d/E E 44 SI Display Units - d/E d 45 Unit Line Voltage* 460 V 46 Under/Over Voltage Protection - d/E d 47 Phase Imbalance Protection d/E E 48 Phase Reversal Protection d/E E 49 Superheat Setpoint 8 F 4 to 20 F 4A EXV Control Response Setpoint** 20 2 to 200 4b LWT Control Response Setpoint 40 2 to 220 4C ICS Address (Optional) 4d Fan Control Deadband Bias** 0 -50 to +50 4E Programmable Relay Setup 1 1 to 12

(see Alarm/Running/Maximum Capacity Contact Outputs)

4F Restart Inhibit Timer 120 sec. 30 to 120 sec.

*Entry will be selected from 200, 220, 230, 346, 380, 415, 460, 500 or 575 volts. Dashes will be displayed if the Under/Over

Voltage Protection option is not installed.

**Displayed by circuit.

UCM Based Setpoint

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Figure 52 Menu Formats (Continued)

FACTORY DISPLAY #2 - MENU 5 Caution: Do not leave unit unattended while in Menu 4 or 5. Inadvertent unit safety setpoint changes could occur.

Selected by setting the number 5 in the “P” menu item. Unlike menus 0 through 3, the number 5 can only be set after menu 4 has been selected, as described on the previous page.

Compressor/circuit indicators menu is advanced the appropriate compressor/circuit indicator will flash.

Display Code and Description Defaults Range

P Menu Number 50 Number of Compressors 1 1, 2, 3, 4 51 Compressor Tons* 100 25, 30, 40,50, 60, 70, 85, 100 52 Low Water Temp EXV Gain Compensation d/e d 53 Fan Control - d/E E 54 Fans per Circuit** 7 4, 5. 6,7. 8, 10, 12, 14 55 Reduced Inrush Starting - d/E d 56 Compressor Current Overload Setting (to match DIP Switch)* 00 00 to 31 57 GP Compressor Unit d/E d 58 Low Ambient - Half Air Flow Fan d/E d 59 LATSM d/E d 5A NNS d/E d 5b Number of EXV Valves per Circuit** 1 1. 2 5c Future Option** d

*Displayed by compressor.

**Displayed by circuit

will not be lit continuously in this menu to indicate which compressors are running. As the

UCM Based Setpoint

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Figure 53 Condition/Diagnostic Codes

Condition Codes

UNIT OPERATING STATUS COMPRESSOR OPERATING STATUS

CODE DESCRIPTION CODE DESCRIPTION Blank UCM Power Off 00 Compressor Stop

888888.8 UCM Paw Up 16 Compressor Lockout 00 Unit Stop 17 Cprsr Service Pumpdown 01 Auto-Local 70 Cprsr Restart Inhibit 02 Auto-Remote 72 Cprsr Start 17 Service Pumpdown 74 Run Normal 70 Unit Restart Inhibit 75 Run: Current Limit 72 Unit Start 76 Run: Condenser Limit 74 Run:Normal 77 Run: Evaporator Limit 75 Run:Current Limit 7E Run:Unload 78 Run:Condenser Limit 77 Run:Evaporator Limit 7E Run:Unload 88 Reset 100 External Unit Stop 101 Ice Building Complete MMR Machine Shutdown-Manual Reset 118 EXV Test CMR Circuit Shutdown-Man Reset 174 Ice Building; Normal MAR Machine Shutdown-Auto Reset 175 Ice Building: Current Limit CAR Circuit Shutdown-Auto Reset 176 Ice Building: Condenser Limit IFW Informational-Warning 177 Ice Building: Evaporator Limit 200 Low Ambient Run Inhibit

FLASHING DISPLAY: MEANS: A xxx A A xxx ↔ C yyy Operating Code when MMR or MAR occurred. Diagnostic currently inhibiting operation. b yyy Manual reset required to restore full operation. This or other latching diagnostics exist. C yyy Condition creating MAR, CAR or IFW still exists. If MMR or CMR, manual reset required. 10 uu The chilled water setpoint is too close to a cutout setpoint.

DASHES: MEANS: d ---- The chiller is in either ice bldg or ice bldg compl; Ivg chld wtr stpt is not applicable. 33 ---- The chiller is in normal cooling; the active ice termination setpoint is not applicable. Other (e.g. 14----) Option either not installed or not enabled.

CODE DESCRIPTION TYPE CODE DESCRIPTION TYPE 87 Chock External Chilled Water Stpt IFW 19F Phase Loss - Cprsr D CMR 89 Check External Current Limit Stpt IFW 1AO Power Loss - Cprsr A CAR 8A Chilled Water Flow (Ent Wtr Temp) MMR 1A1 Power Loss - Cprsr 8 CAR 8E Evap Entering Water Temp Sensor MMR 1A2 Power Loss - Cprsr C CAR 8F Cond Rfgt Tamp Sensor - Ckt I CMR 1A3 Power Loss - Cprsr D CAR 90 Cond Rfgt Temp Sensor - Ckt 2 CMR 1A4 Remote communications Loss IFW 93 Evap Rfgt Temp Sensor - Ckt I CMR 1A5 Oil Flow Control - Cprsr A CMR 94 Evap Rfgt Tamp Sensor - Ckt 2 CMR 1A6 Oil Flow Control - Cprsr B CMR A0 Zone Temp Sensor IFW 1A7 Oil Flow Control - Cprsr C CMR A1 Outdoor Air Temp Sensor IFW 1A8 Oil Flow Control - Cprsr D CMR Ab Evap Leaving Wtr Temp Sensor MMR 1A9 EXV Elec Drive Ckt - Rfgt Ckt I CMR bA Overload Trip - Cprsr A CMR 1AA EXV Elec Drive Ckt - Rfgt Ckt 2 CMR bb Overload Trip - Cprsr 0 CMR 1Ad Memory Error T ype I (See Oper Manual) IFW bC Overload T rip - Cprsr C CMR 1AE Low Differential Press - Ckt I CMR bd Overload Trip - Cprsr D CMR 1AF Low Differential Press - Ckt 2 CMR bE High Pressure Cutout - Cprsr C CMR 1b2 Severe Phase Unbalance - Cprsr A CMR bF High Pressure Cutout - Cprsr D CMR 1b3 Severe Phase Unbalance - Cprsr B CMR C5 Low Chilled Water Temp (Unit off) IFW 1b4 Severe Phase Unbalance - Cprsr C CMR C6 Low Chilled Water Temp (Unit on) MAR 1b5 Severs Phase Unbalance - Cprsr 0 CMR CA Contactor - Cprsr A MMR 1b6 Compressor Overload Setting - Cprsr A IFW Cb Contactor - Cprsr B MMR 1b7 Compressor Over load Setting - Cprsr B IFW cc Contactor - Cprsr C MMR 1b8 Compressor Overload Setting - Cprsr C IFW Cd Contactor - Cprsr D MMR 1b9 Compressor Overload Setting - Cprsr D IFW d7 Over V oltage MAR 1bA Phase Unbalance - Cprsr A CMR d8 Under Voltage MAR 1bb Phase Unbalance - Cprsr 8 CMR Ed Chilled Water Flow Interlock MAR 1bC Phase Unbalance - Cprsr C CMR F5 High Pressure Cutout - Cprsr A CMR 1bd Phase Unbalance - Cprsr D CMR F6 High Pressure Cutout - Cprsr B CMR 1bE Winding Temp. - Cprsr A CMR Fd Emergency Stop Input MMR 1bF Winding Temp. - Cprsr B CMR 180 Starter Transition - Cprsr A CMR 1C0 Winding Temp. - Cprsr C CMR 181 Starter Transition - Cprsr B CMR 1C1 Winding Temp. - Cprsr D CMR 182 Starter Transition - Cprsr C CMR 1C2 Discharge Temp. - Cprsr A CMR 183 Starter Transition - Cprsr D CMR 1C3 Discharge Temp. - Cprsr 8 CMR 184 Phase Reversal - Cprsr A CMR 1C4 Discharge Temp. - Cprsr C CMR 185 Phase Reversal - Cprsr 8 CMR 1C5 Discharge Temp. - Cprsr D CMR 186 Phase Reversal - Cprsr C CMR 1C6 High Differential Pressure - Ckt I CMR 187 Phase Reversal - Cprsr D CMR 1C7 High Differential Pressure - Ckt 2 CMR 190 Low Superheat - Ckt I CMR 1d1 Memory Error Type 11 (See Oper Manual) IFW 191 Low Superheat - Ckt 2 CMR 1d2 Memory Error Type III (See Oper Manual) IFW 194 Low Evap Rfgt Tamp - Ckt I CMR 1d3 Cprsr Suction Temp. Sensor - Ckt 1 CMR 195 Low Evap Rfgt Temp - Ckt 2 CMR 1d4 Cprsr Suction Temp. Sensor - Ckt 2 CMR 198 Low Oil I Flow - Cprsr A CMR 1d7 Phase Reversal Prot. Lost - Cprsr A CMR 199 Low 01 1 Flow - Cprsr B CMR 1d8 Phase Reversal Prot. Lost - Cprsr B CMR 19A Low Oil Flow - Cprsr C CMR 1d9 Phase Reversal Prot. Lost - Cprsr C CMR 19b Low Oil Flow - Cprsr D CMR 1dA Phase Reversal Prot. Lost - Cprsr D CMR 19C Phase Loss - Cprsr A CMR 1db Slave-Exv Elec Drive Ckt - Rfgt Ckt 1 CMR 19d Phase Lose - Cprsr B CMR 1dc Slave-Exv Elec Drive Ckt - Rfgt Ckt 2 CMR 19E Phase Loss - Cprsr C CMR 4xy See Operator’s Manual – – –

New CMR, CAR. or IFW Diagnostic Exists.

UNIT DIAGNOSTICS CONDITION

X3956048201 Rev. B

DIAGNOSTIC TYPES

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Chiller Switch

The chiller switch has three positions:

Top Position AUTO REMOTE Middle Position AUTO LOCAL Bottom Position STOP/RESET

With the switch in the AUTO REMOTE position, the chiller will operate normally using remote setpoints. Read and write remote communications may be performed. Any call for cooling based on Leaving Water Temperature (LWT) and the remote (e.g. Tracer) setpoints, will start the unit. The active chilled water setpoint (CWS) can be the remote CWS, a reset remote setpoint based on return, zone, or outdoor temperature reset, or a 4-20 mA/0-10 VDC external CWS. The active Current Limit Setpoint (CLS) can be the Remote CLS or a 4-20 mA/0-10 VDC External CLS. If remote communication is lost, the UCM will revert to the Front Panel (or local) chiller settings.

When the chiller switch is in the AUTO LOCAL position, the chiller will operate normally using Front Panel (or local) setpoints. Read and write remote communications may be performed, but remote setpoints cannot be used for control. The unit will run when there is a call for cooling based on the LWT and the Front Panel or local setpoints. The active CWS can be the local setpoint, a reset setpoint based on return, zone, or outdoor temperature reset, or a 4-20 mA/0-10 VDC external CWS. The active Current Limit Setpoint can be the local setpoint or a 4-20 mA/ 0-10 VDC External CLS. Remote (e.g. Tracer) setpoints communicated over the serial communications link will be ignored, but remote devices can still read all unit control data.

In the STOP/RESET position, the UCM is powered but operation of the unit is prevented. All outputs are de-energized and the chiller is stopped. The alarm relay output may be energized if an alarm condition exists.

If any of the chillers are running when the chiller is put into the STOP/RESET position, the chiller will go into the Run: Unload mode for at least 20 seconds before shutting down the compressors.

Although not a “position” on the chiller switch, it can be used to perform the function of manually resetting all latching diagnostics and clearing all historic diagnostics. Latching diagnostics can be reset by manually toggling the chiller switch from the STOP/RESET position to either AUTO position.

Historic diagnostics (“C” menu item) can be cleared by depressing the “Display Down” key while manually toggling the chiller switch from the STOP/RESET position to either AUTO position (no compressor operating).

Moving the chiller switch from the STOP/RESET position to either AUTO position will reset the controls, with one exception. If the chiller operating status is Run:Unload, this sequence will go to completion before the reset is executed. During the completion of the Run:Unload, the reset is “queued up” and operated on only after completion of the Run:Unload. After reset is completed, the digital display will return to “A” Operating Code.

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Menu Function Descriptions and Selection

Selecting Variables and Options

All variables and options will be set by depressing the SET POINT UP and SET POINT DOWN keys. The setpoints will be increased or decreased by one least significant digit (1 F, 0. 1 C, or 1 integer value) with each key depression. If the key is held down, the setpoint will continue to be increased or decreased until the key is released. The minimum and maximum values of all setpoints are limited by system design and the setting operation will stop when either the minimum or maximum setpoint is displayed. See Figure 52 for setpoint ranges.

Options are also selected using the SET POINT UP and SET POINT DOWN keys. Use the SET POINT UP key to select the “Enable” option and the letter “E” will appear on the display. Use the SET POINT DOWN key to select the “Disable” option and the letter “d” will be displayed. Certain items in Menus 4 and 5 will be integers with various endpoints and units. See Figure 52.

Menu 0 – Operating Display

A - Operating Code: This is the current unit operating status, e.g. A 74, which, as shown in Figure 53, is Run:Normal.

b - Last Diagnostic Code: The last diagnostic detected by the UCM is stored and can be seen by displaying this I item.

C - Other Diagnostics: All diagnostics detected by the UCM will be stored in preprescribed code number sequence, as shown in Figure 53, rather than the order in which they occurred. All flashing codes found under this item are currently active or “Latched” diagnostics. For additional information, see “Menus”.

Diagnostics will be stored only once, even though the diagnostic may have occurred several times. There is no chronological sequence to the diagnostics that may be in the “C” menu item.

d - Active Chilled W ater Setpoint: The setpoint (display only) to which the chiller is controlling. This may be the same as the Front Panel Chilled water Setpoint (code 10 in Menu 1), but it may also be a setpoint that is being reset or loaded from a remote controller , such as a Tracer, multiplemachine controller, or a remote display panel.

E - Evap. Entering W ater Temp.: The temperature of the water as measured by the evaporator entering water temperature sensor . F - Evap. Leaving Water Temp.: The temperature of the water as measured by the evaporator leaving water temperature sensor.

L - Active Current Limit Setpoint: The current limit setpoint (display only) to which the chiller is controlled. This may be the same as the Front Panel Current Limit setpoint (code 13 in Menu 1), but it may also be a setpoint that was loaded from a remote controller, such as a Tracer, multiple-machine controller.

Menu 1 – Service #1 Display

10 - Front Panel Chilled Water Setpoint: The temperature selected at the UCM for the desired chilled water.

11 - Design Delta Temp. Setpoint: The difference between the entering and leaving chilled water temperatures at full load. This will be a function of GPM through the evaporator.

12 - Differential To Start Setpoint: This temperature, when added to the leaving chilled water setpoint, is the temperature at which the chiller will be started.

Note: 1.5 F below chill water setpoint, the UCM will initiate an integrator to shut off the l decrease in cooling load.

13 - Front Panel Current Limit Setpoint, The percent of current limit selected at the UCM for the system. See discussion in “Current Limit Setpoint”.

14 - Outdoor Air Temperature (Optional): The ambient temperature as measured by an outdoor temperature sensor.

ast compressor on a

15 - Low Ambient Lockout (Optional): If the unit is installed with optional Outdoor Air Temperature Sensor, the entry in this code will enable or disable the setpoint in code 16. See discussion in “Low Ambient Lockout”.

16 - Low Amb. Lockout Setpoint (Optional): The temperature of the outside air below which the unit will not be permitted to operate. See discussion in “Low Ambient Lockout”.

17 - Cond. Entering Wtr. Temp.: Not applicable, with this air-cooled condenser unit.

18 - Cond. Leaving Wtr. Temp.: Not applicable, with this air- cooled condenser unit.

19 - Service Pumpdown: Must be manually “Enabled” by service personnel from the UCM display. The unit must be in STOP/RESET and service pumpdown can be performed only once for every power-up of the UCM. Restart inhibit will be ignored, the EXV will be prepositioned (20 seconds) and the compressor selected will start and run for one minute. Manual closing of the liquid line angle valve will be required.

Caution: Do not pumpdown compressor more than once.

1A -Circuit Lockout: Allows service personnel to set a lockout, preventing a circuit from operating. With the display indicating the number of the circuit to be locked out, change the display to “E” for circuit lockout. Once circuit lockout is enabled, the circuit will remain locked out even through a reset or power down. Entering a “d” will return the circuit to operational status.

1b - Circuit Diagnostic Reset: Allows service personnel to reset a Circuit Manual Reset (CMR) diagnostic without having to terminate operation of the entire chiller via the STOP/RESET switch. With the display indicating the number of the circuit to be reset, change the display to “E” to reset. After reset, the display will automatically return to “d”.

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Trane RTAA-130, RTAA-340, RTAA-140, RTAA-185, RTAA-270 Installation, Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual