Trane RTHC, R Series Installation Operation & Maintenance

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Series R Helical Rotary Liquid Chillers

Installation RTHC-IOM-1C Operation Maintenance

Library Service Literature Product Section Refrigeration Product Rotary Liquid Chillers - W/C Model RTHC Literature Type Installation, Operation and Maintenance Sequence 1C Date August 1999 File No. RTHC-IOM-899

“E0” Design Sequence

Models RTHC 175-450 ton units (60 Hz) 125-450 ton units (50 Hz)

Part No. X39640508-03

Since the Trane Com pany has a pol icy of con tinuous pro duct imp rovem ent, it r eserves the ri ght to chang e specifications and designs without notice. The installation and servicing equipment referred to into this booklet should be done by qualified experienced technicians.

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IMPORTANT NOTICES

Effective July 1, 1992, all service operations must use recovery systems to minimize losses of refrigerant to the atmosphere when servicing units with Class I and Class II refrigerants.

Class I (CFC) and Class II (HCFC) refrigerants include CFC-12, HCFC-22, CFC-500, CFC-502, CFC-11, CFC113 and HCFC-123. Deliberate venting is prohibited by Section 608 of the Clean Air Act.

In the normal service of air conditioning systems, there are t hr ee ma jor ac tivi tie s ma nda ted b y th e EPA regulations: recovery, recycling and reclaiming.

1 Recovery - the act of removing refrigerant from

the air conditioning unit so that losses of refrigerant to the atmosphere are minimized.

Whenever a refrigeration circuit is opened, the recovery of the refrigerant is required. If there is no

reason to believe that the refrigerant is “bad”, such as during service of gaskets, expansion valves or solenoid valves, the refrigerant is often returned to the unit without treatment. (Note: Always follow the equipment manufacturers recommendations regarding replacement of unit filter driers during service.)

sold to a reclaimer rather than be serviced in the field.

3 Reclaiming - the act of purifying refrigerant and

testing it to ARI 700 “new” refrigerant standards. With reclamation, each batch of refrigerant undergoes extensive laboratory tests and the waste streams are disposed of according to environmental regulations.

Most reclamation will be done at centralized processing facilities because of the testing, waste handling and EPA certification requirements for reclamation. The Trane Company and others offer reclamation services for most refrigerants.

Reclamation is probably the most attractive alternative for users with salvaged and suspect refrigerant.

If there is reason to suspect that the refrigerant is bad, such as with a compressor failure, the refrigerant should either be replaced or recycled,

Recovery is also required when a piece of equipment is decommissioned. This prevents the loss of refrigerant upon disposal of the unit. The recovered refrigerant usually is sold to refrigerant reclaimers rather than reused in the customer's new equipment.

2 Recycling - the act of cleaning recovered

refrigerant for use in the customer’s equipment.

First, the refrigerant is boiled to separate the oil. Then it is run through a filter drier to separate moisture and acid.

Because of limited field testing capability, the quality and identity of any recycled refrigerant is suspect. For this reason, the EPA will most likely allow recycling of refrigerant only when it is returned to its original owner. Resale of the recycled refrigerant to third parties will not be allowed.

As a result, most servicers will only recycle refrigerant when the quantity of the refrigerant to be recycled and the expertise of the technician make it attractive to do so. Most suspect refrigerant will be

Installation, Operation and Maintenance i

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REFRIGERANT EMISSION CONTROL

Evidence from environmental scientists indicates that the ozone in our upper atmosphere is being reduced, due to the release of CFC fully halogenated compounds.

The Trane Company encourages every effort to eliminate, if possible, or vigorously reduce the emission of CFC, HCFC and HFC refrigerants into the atmosphere that result from installation, operation, routine maintenance, or major services on this equipment. Always act in a responsible manner to conserve refrigerants for continued use, even when acceptable alternatives are available. Conservation and emission reduction can be accomplished by following recommended Trane operation, maintenance and service procedures, with specific attention to the following:

1 Refrigerant used in any type of air conditioning or

refrigerating equipment should be recovered for reuse, recovered and/or recycled for reuse, reprocessed (reclaimed), or properly destroyed, whenever it is removed from equipment by an EPA certified Type 11 or Universal Technician. Never release refrigerant into the atmosphere.

7 Take extra care to properly maintain all service

equipment that directly supports refrigeration service work, such as gauges, hoses, vacuum pumps and recycling equipment.

8 Stay aware of unit enhancements, conversion

refrigerants, compatible parts and manufacturer’s recommendations which will reduce refrigerant emissions and increase equipment operating efficiencies. Follow manufacturer’s specific guidelines for conversion of existing systems.

9 In order to assist in reducing power generation

emissions, always attempt to improve equipment performance with improved maintenance and operations that will help conserve energy resources.

2 Always determine possible recycle or reclaim

requirements of the recovered refrigerant before beginning recovery by any method. Questions about recovered refrigerants and acceptable refrigerant quality standards are addressed in ARI Standard 700.

3 Use approved containment vessels and safety

standards. Comply with all applicable transportation standards when shipping refrigerant containers.

4 To minimize emissions while recovering

refrigerant, use recycling equipment. Always use methods which will pull the required vacuum while recovering and condensing refrigerant into containment.

5 When leak checking with a trace of refrigerant and

nitrogen, only use R-134a on R-134a units. Be aware of any new leak test methods which eliminate refrigerant as a trace gas, but consult Trane Pueblo technical service before adding any other substance besides R-134a to the system.

6 When cleaning system components or parts,

avoid using CFC-11 (R-11) or CFC-113 (R-113). Refrigeration system cleanup methods which use filters and dryers are preferred. Do not use solvents which have ozone depletion factors. Properly dispose of used materials.

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READ THESE IMPORTANT NOTICES

BEFORE SERVICING THE RTHC

Warnings and Cautions

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 pers onne l.

To prevent injury or death due to electrocution, use care when performing control setup, adjustments or any other service related operation when the electrical power is on. Position all electrical

disconnects in the “OPEN” position and lock them.

WARNING

Disconnect and Lockout or Tagout all electrical power, including remote disconnects, before servicing. Failure to do so can cause severe personal injury or death.

CAUTION

CAUTION: It is essential to confirm that proper phase rotation is established - Phase A to Ll, Phase B to L2, and Phase C to L3. Phase rotation must be checked with a phase sequence indicator before start-up, otherwise catastrophi c damage to the compressor may result.

CAUTION

CAUTION: Do not check the unit oil level with the unit operating. Severe oil loss will occur. Protective clothing must be worn when checking the oil level.

CAUTION

CAUTION: The compressor sump heater must be energized for a minimum of 24 hours prior to unit operation, to prevent compressor damage caused by liquid refrigerant in the compressor at start-up.

CAUTION

CAUTION: Do not use untreated or improperly treated water. To do so may result in equipment damage.

CAUTION

CAUTION: Proper water flow through the evaporator must be established prior to unit operation.

CAUTION

CAUTION: Do not charge the compressor with liquid refrigerant.

Installation, Operation and Maintenance iii

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CAUTION

CAUTION: When evacuating the refrigerant system

state starters

for units with solid

, first disconnect ALL electrical power, including remote disconnects. Power should not be applied to the chiller while the refrigerant system is in a vacuum. Failure to disconnect all electrical power prior to evacuating refrigerant, or applying power while the refrigerant system is in a vacuum, will damage the compressor motor.

iv RTHC-IOM-1C

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Contents

General Information........................................ 1 - 1

Literature Change History ............... ...... ....... .. 1 - 1

Unit Identification - Nameplates ..................... 1 - 1

Unit Inspection................................................ 1 - 1

Inspection Checklist ................. ....... ...... ....... .. 1 - 1

Loose Parts Inventory .................................... 1 - 2

Unit Description.............................................. 1 - 2

Model Number Coding System ...................... 1 - 2

Installation Overview ...................................... 1 - 9

Installation - Mechanical ............................... .. 2 - 1

Storage..... ....... ...... ...... ....... ...... ....... ...... ....... .. 2 - 1

Location Requirements .................................. 2 - 1

Access Restrictions ........................................ 2 - 2

Moving and Rigging........................................ 2 - 3

Lifting Procedure ............................................ 2 - 5

Isolation Pads................................................. 2 - 7

Unit Leveling................................................... 2 - 9

Water Piping................................................... 2 - 9

Water Pressure Drop Data ........................... 2 - 17

Condenser Water Regulating Valve............. 2 - 24

Condenser Water Regulating Valve Adjustment

Water Treatment .......................................... 2 - 24

Water Pressure Gauges and Thermometers 2 - 25

Water Pressure Relief Valves ...................... 2 - 25

Flow Sensing Devices .................................. 2 - 25

Refrigerant Pressure Relief Valve Venting... 2 - 26

Thermal Insulation........................................ 2 - 27

Installation - Electrical...................... ............... 3 - 1

2 - 24

Operator Interface - Controls.......................... 5 - 1

UCP2 Microprocessor Control System........... 5 - 1

Chiller Module - 1U1....................................... 5 - 2

Stepper Module - 1U3 .................................... 5 - 3

Starter Module - 1U2 ...................................... 5 - 3

Options Module - 1U5..................................... 5 - 3

COMM 3 or COMM 4 (Tracer Interface)- 1U6 5 - 3

Printer Interface Module - 1U7 ....................... 5 - 3

Clear Language Display (CLD) - 1U4............. 5 - 3

Key Functions................................................. 5 - 4

Communications and Settings Storage .......... 5 - 5

Custom Report Group - Programming

Instructions ..................................................... 5 - 6

Chiller Report.................................................. 5 - 6

Refrigerant Report........................................ 5 - 12

Compressor Report ...................................... 5 - 13

Operator Settings ......................................... 5 - 14

Service Settings (Non Password

Protected Service Settings Group).............. 5 - 17

Service Settings (Password Protected

Field Startup Group).................................... 5 - 20

Service Settings (Password Protected

Machine Configuration Group).................... 5 - 24

Service Settings (Password Protected

Refrigerant Monitor Settings Group).......... 5 - 30

Service Settings (Password Protected

Refrigerant Monitor Calibration Group)...... 5 - 30

Service Tests................................................ 5 - 30

Diagnostics................................................... 5 - 36

Unit Start-up..................................................... 6 - 1

General Recommendations............................ 3 - 1

Power Supply Wiring ...................................... 3 - 1

Other Supply Power Components.................. 3 - 3

Compressor Motor Phase Sequencing .......... 3 - 3

Correcting Improper Electrical Phase

Sequence ........ ...... ...... ....... ...... ...................... 3 - 3

Application Of Solid-state Starters ................. 3 - 4

Module Connections for

Interconnecting Wiring.................................... 3 - 9

Interconnecting Wiring

(Field Wiring Required) .................................. 3 - 9

Operating Principles - Mechanical................. 4 - 1

General..................................... ....... ...... ....... .. 4 - 1

Refrigeration (Cooling) Cycle ......................... 4 - 2

Compressor Description................................. 4 - 4

Oil Management System ................................ 4 - 5

Oil Filter.......................................................... 4 - 7

Oil Cooler ....................................................... 4 - 8

Series R Water-Cooled Chiller

Daily Unit Start-Up.......................................... 6 - 1

Seasonal Unit Start-Up Procedure ................. 6 - 3

Unit Shutdown.................................................. 7 - 1

Daily Unit Shutdown ....................................... 7 - 1

Seasonal Unit Shutdown ................................ 7 - 1

Periodic Maintenance...................................... 8 - 1

Overview......................................................... 8 - 1

Weekly Maintenance and Checks .................. 8 - 1

Monthly Maintenance and Checks ............... 8 - 1

Annual Maintenance....................................... 8 - 2

Scheduling Other Maintenance ...................... 8 - 2

Operating Log................................................. 8 - 2

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Maintenance Procedures ................................ 9 - 1

Cleaning the Condenser................................. 9 - 1

Cleaning the Evaporator................................. 9 - 1

Compressor Oil............................................... 9 - 1

Oil Sump Level Check .................................... 9 - 2

Removing Compressor Oil.............................. 9 - 2

Oil Charging Procedure .................................. 9 - 3

Replacing the Main Oil Filter (Hot Filter)......... 9 - 3

Replacing the Gas Pump Oil Filter ................. 9 - 4

Refrigerant Charging ...................................... 9 - 5

Diagnostics.... ....... ...... ...... ....... ...... ....... ...... .... 10 - 1

Wiring Schematics..... ...... ....... ...... ....... ...........11 - 1

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General Information

Literature Change History

RTHC-IOM-1 (August 1997) Describes installation, operation, and maintenance of

RTHC units. RTHC-IOM-1A (August 1998) revised to include C2/

C1 and D2/D1 chiller configurations, information on solid state starters.

RTHC-IOM-1B (March 1999) revised to include oil protection modifications.

RTHC-IOM-1C (August 1999) revised to include B1 and B2 chiller configurations.

Unit Identification - Nameplates

When the unit arrives, compare all nameplate data with ordering, submittal, and shipping information. A typical unit nameplate is shown in

Figure 1 Typical Unit Nameplate

Figure 1

q Unit device number. - Identifies unit electrical

requirements

- Lists correct operating charges of HFC-134a and

refrigerant oil

- Lists unit test pressures and maximum working

pressures.

The starter/control panel nameplate provides the following in formation:

q Panel model number q Rated load amps q Voltage q Electrical characteristics - starter type, wiring q Options included.

The compressor nameplate provides the following information:

q Compressor model descriptor q Compressor serial number q Compressor device number

Unit Nameplates

The RTHC “unit” nameplate ( location) is applied to the exterior surface of the starter/control panel. The “compressor” nameplate is applied to the compressor. The starter/control panel nameplate is located inside the panel.

The unit nameplate provides the following information:

q Unit model q Unit Serial Number

Figure 2

shows

q Motor serial number q Compressor electrical characteristics q Refrigerant.

Unit Inspection

When the unit is delivered, verify that it is the correct unit and that it is properly equipped.

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 office approval.

Inspection Checklist

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

Installation, Operation and Maintenance 1 - 1

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q Inspect the individual pieces of the shipment

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

q Inspect the unit for concealed damage as soon as

possible after delivery and before it is stored. Concealed damage must be reported within 10 days after receipt.

q If conceal ed 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.

q Notify the Trane sales representative and arrange

for repair. Do not repair the unit, however, until damage is inspected by the transportation representative.

Loose Parts Inventory

Check all items against the shipping list. Water vessel drain plugs, isolation pads, rigging and electrical diagrams, service literature and the starter/ control panel wire pullbox (required on some starters) are shipped unassembled in the starter control panel.

Unit Description

The RTHC units are single compressor, helical-rotary type, water-cooled liquid chillers designed for installation indoors. Each unit is a completely assembled, hermetic package that is factory-piped, wired, leak-tested, dehydrated, charged (optional), and tested for proper control operation before shipment.

Figure 2

and

Figure 3

show a typical RTHC unit and its components. Water inlet and outlet openings are covered before shipment. The oil tank is factory charged with the proper amount of refrigeration oil. The unit can be factory charged with refrigerant.

Model Number Coding System

The model numbers for the unit, the compressor, and the starter/control panel are composed of numbers and letters that represent features of the equipment. Shown in the three tables following are samples of typical unit, compressor, and panel model numbers, followed by the coding system for each.

Each position, or group of positions, in the model number is used to represent a feature. For example, in the first table, position 08 of the unit model

number, Unit Voltage, contains the letter “F”. An F in this position means that the unit voltage is 460/60/3.

Typical Service Model Number (located on unit nameplate ):

Number

Digit

RTHC

1,2,3,4

Table 1 Model Number for RTHC Chiller

1D2F0 A 0 G 3 L 4 G 3 L G 0 Q U C 0

5678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Selection Category

Chiller Series

Design

Control

Compressor

Frame

Compressor

Capacity

Description of Selection Model No. Digit

Series R Water-Cooled Chiller RTHC 1-4

WCBU (Pueblo, CO) 1 5

LCBU (Charmes, France) 2

B Frame B 6 C Frame C D Frame D E Frame E

Smaller capacity (minor) 1 7

Larger capacity (major) 2

Special 50 Hz capacity 3

1 - 2 RTHC-IOM-1C

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Table 1 Model Number for RTHC Chiller

Selection Category

Voltage

Specials

Specials not denoted elsewhere S

Design

Sequence

Evaporator

Frame

Evaporator

Capacity

Evaporator

Waterside

Pressure

Evaporator

Water Pass

Configuration

Condenser

Frame

Condenser

Capacity

Condenser

Waterside

Pressure

Condenser

Tubes

Description of Selection Model No. Digit

200/60/3 A 230/60/3 C 380/60/3 D 380/50/3 R 400/50/3 N 415/50/3 U 460/60/3 F 575/60/3 H

None O 9

Specials denoted elsewhere C

First Design (Factory Input) AO 10-11

B Frame B C Frame C D Frame D E Frame E F Frame F

G Frame G Tube count #1 1 13 Tube count #2 2 Tube count #3 3

150 psi L 14 300 psi H

2 pass 2 15 3 pass 3

4 pass 4 B Frame B C Frame C D Frame D E Frame E F Frame F G Frame G

Tube count #1 1 17 Tube count #2 2 Tube count #3 3

150 psi L 18 300 psi H

Enhanced Fin Copper F 19

Smooth Bore Copper G

Smooth Bore 90/10 Cu/Ni H

Installation, Operation and Maintenance 1 - 3

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Table 1 Model Number for RTHC Chiller

Selection Category

Isolation

Valves

Thermal

Insulation

C/UL Listing

Oil Cooler

Differential

Pressure

Description of Selection Model No. Digit

Without 0 20

With V

Without 0 21

With Q

Without 0 22

With U

Without 0 23

With C

Without 0 24

With D

Transducer

RTHC Compressor Model Number (located on compressor nameplate):

Number

Table 2 Compressor Model Number for RTHC

Selection Category

Compressor

Digit

CHHC 1 B 1 C - AO

1,2,3,456 78910, 11

Description of Selection Model No. Digit

Semi-Hermetic Heli-Rotor Compressor CHHC 1-4

Series

Design

Control

Compressor

Frame

Compressor

Capacity

Motor

Specials

Uncategorized Special not denoted elsewhere S

Smaller capacity (minor) 1 7

Larger capacity (major) 2

Special 50 Hz capacity 3

460V/60Hz/3 or 400V/50Hz/3 F

Specials Denoted Elsewhere C

Pueblo 1 5

B Frame B 6 C Frame C D Frame D E Frame E

200V/60Hz/3 A 230V/60Hz/3 C 380V/60Hz/3 D

575V/60Hz/3 H

No Specials O 9

1 - 4 RTHC-IOM-1C

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Table 2 Compressor Model Number for RTHC

Selection Category

Design

Description of Selection Model No. Digit

1st Design (Factory Input) AO 10-11

Sequence

RTHC Starter/Control Panel Model Number:

Number

Digit

RTSC #### C A0 A B 0 P 0 0 M E C

1,2,3,4 5, 6, 7, 8 9 10, 1 1 12 13 14 15 16 17 18 19 20

Table 3 Starter/Control Pane l Model Number for RTHC

Selection Category

Description of Selection Model No. Digit

Panel Series

Rated Load

Amps

Voltage

Design

1st Design (Factory Input) A0 10-11

Sequence

Starter Type

Panel

Connection

Non-Fused Disconnect D

Hi Int Circuit Breaker H

Potential

Transformers

C/UL Listing

Options

Module

Printer

Interface

Module

RTSC 1-4

per sales order #### 5-8

200V/60Hz/3 A

230V/60/3 C 380V/60/3 D 380V/50/3 R 400V/50/3 N 415V/50/3 U 460V/60/3 F 575V/60/3 H

Wye-Delta A 12

Solid State B

Terminal Block B 13

Circuit Breaker C

Without 0 14

With P

Without 0 15

With U

Without 0 16

With P

Without 0 17

With P

Installation, Operation and Maintenance 1 - 5

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Table 3 Starter/Control Pane l Model Number for RTHC

Selection Category

ICS Interface

Module

Operator Interface

Description of Selection Model No. Digit

Without 0 18

Summit Communications M

Tracer Communications T

Std Clear Language Display E 19

Complex Character CLD C

Module

No Specials 0 20

Specials

Uncategorized special not denoted elsewhere S

Specials denoted elsewhere C

1 - 6 RTHC-IOM-1C

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Figure 2 Component Location for Typical RTHC Unit

Starter/Control Panel

Clear Language Display (CLD)

Disconnect Switch

Liquid/Vapor Separator

EXV

Condenser Water Outlet

Evaporator

Gas Pump

Nameplate

Relief

Liquid Level Sensor

Valve

Evaporator

Condenser Water Inlet

Evaporator Water Inlet

NOTE: The evaporator inlets and outlets are located opposite from those on the RTHA and RTHB units. The water inlet must be at the bottom of the shell for proper operation.

Installation, Operation and Maintenance 1 - 7

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Figure 3 Component Location for Typical RTHC Unit (Back View)

Relief Valves

Oil Separator

Oil Distribution System

Compressor

Discharge Lines

Oil Separator

Unit Nameplate (on side of starter/control panel)

Lifting Holes

NOTE: The evaporator inlets and outlets are located opposite from those on the RTHA and RTHB units. The water inlet must be at the bottom of the shell for proper operation.

1 - 8 RTHC-IOM-1C

Condenser

Evaporator Water Outlet

Oil Sump

(located between condenser and evaporator)

8” vessels have ASME nameplate

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Installation Overview

For convenience,

Tab le 4

summarizes responsibilities that are typically associated with the RTHC chiller installation process.

Tab le 4 Installation Responsibility Chart for RTHC Units

Requirement Trane-supplied, Trane-installed Trane-supplied, Field-installed Field-supplied , Fie ld-installed

Rigging

Isolation Electrical

Water piping

Pressure Relief Insulation

Isolation pads Isolation pads

Circuit breakers or non-fused

disconnects (optional)

Unit-mounted starter Temperature sensor (optional

outdoor air)

Flow switches (may be field-

supplied)

Condenser water regulating valve

controller (optional: may be field-

supplied)

High condenser pressure interlock

Chilled water pump contactor and

Condenser water pump contactor

Flow switches (may be field-

supplied)

Condenser water regulating valve

controller (optional: may be field-

supplied)

Pressure relief valves (for water

Relief valves Vent line and flexible connector

Insulation (optional) Insulation

Safety chains

Clevis connectors

Lifting beam

Circuit breakers or fusible

disconnects (optional)

Terminal lugs

Ground connection(s)

Jumper bars

BAS wiring (optional)

IPC wiring

Control voltage wiring

wiring

and wiring

Optional relays and wiring

Thermometers

Water flow pressure gauges

Isolation and balancing valves

water piping

Vents and drain valves

boxes as required)

Refer to the Installation Mechanical and Installation Electrical sections of this manual for detailed installation instructions.

q Locate and maintain the loose parts, e.g.

isolators, temperature sensors, flow sensor s or other factory-ordered, field-installed options, for installation, as required. Loose parts are located in the starter/control panel.

Installation, Operation and Maintenance 1 - 9

q Install the unit on a foundation with flat support

surfaces, level within 1/4” (6.35 mm) and of sufficient strength to support concentrated loading. Place the manufacturer-supplied isolation pad assemblies under the unit.

q Install the unit per the instructions outlined in the

Mechanical Installation section.

q Complete all water piping and electrical

connections.

Page 18

NOTE: Field piping must be arranged and supported to avoid stress on the equipment. It is strongly recommended that the piping contractor provide at least 3 feet (914 mm) of clearance between the preinstallation piping and the planned location of the unit. This will allow for proper fit-up upon arrival of the unit at the installation site. All necessary piping adjustments can be made at that time. Refer to the current engineering bulletin for further details on installation.

q Where specified, supply and install valves in the

water piping upstream and downstream of the evaporator and condenser water boxes, to isolate the shells for maintenance and to balance/trim the system.

q Supply and install condense r water con t rol

valve(s) per

Trane RLC-EB-4.

q Supply and install flow switches or equiv ale nt

devices in both the chilled water and condenser water piping. Interlock each switch with the proper pump starter and UCP2, to ensure that the unit can only operate when water flow is established (ref. Section 3).

q Supply and install taps for thermometers and

pressure gauges in the water piping, adjacent to the inlet and outlet connections of both the evaporator and the condenser.

q Supply and install drain valves on each water box. q Supply and install vent cocks on each water box.

q Where specified, supply and install strainers

ahead of all pumps and automatic modulating valves.

q Supply and install refrigerant pressure relief

piping from the pressure relief to the atmosphere.

q If necessary, supply enough HCFC-134

refrigerant and dry nitrogen (75 psig) for pressure testing.

q Start the unit under supervision of a qualified

service technician.

q Where specified, supply and insulate the

evaporator and any other portion of the unit, as required, to prevent sweating under normal operating conditions .

q For unit-mounted starters, cutouts are provided at

the top of the panel for line-side wiring.

q Supply and install the wire terminal lugs to the

starter.

q Supply and install field wiring to the line-side lugs

of the starter.

Tab le 5 General Data

General

Refrigerant Type Refrigerant Charge (lb (kg)) Oil Charge (gal (l)) Operating Weight (lb (kg )) Shipping Weight (lb (kg))

Overall Dimensions

Length (in (mm))* Width (in (mm))* Height (in (mm))*

Evaporator

Water Storage (gal (l)) Minimum Flow (gpm (l/s))

Unit Designator

D1D1E1 D1F1F2 D1G2G2 D2D2E2 D2F2F3 D2G3G3

HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a

575 (261) 740 (336) 850 (385) 575 (261) 740 (336) 850 (385)

6 (23) 10 (35) 11 (39) 6 (23) 10 (35) 11 (39) 15,850 (7189) 17,900 (8119) 21,400 (9707) 15,900 (7212) 18,700 (8482) 22,100 (10,024) 15,000 (6804) 16,700 (7575) 19,600 (8890) 15,000 (6804) 17,400 (7892) 20,100 (9117)

134 (3404) 149 (3785) 153 (3886) 134 (3404) 149 (3785) 153 (3886)

68 (1727) 69 (1753) 70 (1778) 68 (1727) 69 (1753) 70 (1778) 76 (1930) 76 (1930) 80 (2032) 76 (1930) 76 (1930) 80 (2032)

69 (261) 102 (386) 144 (545) 74 (280) 107 (405) 159 (602)

454 (29) for

2-pass

303 (19) for

3-pass

(corresponds to digits 6, 7, 12, 13, 16, 17 of unit model number)

626 (39) for

2-pass

417 (26) for

3-pass

606 (38) for

3-pass

454 (29) for

4-pass

498 (31) for

2-pass

332 (21) for

3-pass

669 (42) for

2-pass

446 (28) for

3-pass

690 (43) for

3-pass

518 (33) for

4-pass

1 - 10 RTHC-IOM-1C

Page 19

Tab le 5 General Data

Unit Designator

D1D1E1 D1F1F2 D1G2G2 D2D2E2 D2F2F3 D2G3G3

Maximum Flow (gpm (l/s))

Condenser (all are 2-pass)

Water Storage (gal (l)) Minimum Flow (gpm (l/s)) Maximum Flow (gpm (l/s))

Notes: All weights Operating weights include refrigerant, oil, and water charges.

If oil cooler is installed, add 1.0 gal (4 liters) to the oil charge value given

* Overall dimensions are based on 3-pass evap/2 pass cond and LH/RH water connections. Refer to submittals for exact job configurations

Tab le 6 General Data

3%, include standard 150 psig water boxes.

1666 (105)

for 2-pass

1111 (70)

for 3-pass

44 (166) 57 (216) 91 (344) 47 (178) 61 (231) 97 (367) 348 (22) 425 (27) 644 (40) 380 (24) 463 (29) 708 (45)

1276 (80) 1558 (98) 2360 (148) 1392 (88) 1699 (107) 2597 (164)

Unit Designator

D3D2E2 D3F2F3 D3G3G3 E3D2E2 E3F2F3 E3G3G3

General

Refrigerant Type Refrigerant Charge (lb (kg)) Oil Charge (gal (l)) Operating Weight (lb (kg )) Shipping Weight (lb (kg))

Overall Dimensions

Length (in (mm)) Width (in (mm)) Height (in (mm))

Evaporator

Water Storage (gal (l)) Minimum Flow (gpm (l/s))

Maximum Flow (gpm (l/s))

Condenser (all are 2-pass)

Water Storage (gal (l)) Minimum Flow (gpm (l/s)) Maximum Flow (gpm (l/s))

HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a

575 (261) 740 (336) 850 (385) 575 (261) 740 (336) 850 (385)

6 (23) 10 (35) 11 (39) 6 (23) 10 (35) 11 (39) 15,900 (7189) 18,700 (8482) 22,100(10,024) 16,150 (7326) 18,950 (8596) 22,350 (10,138) 15,000 (6804) 17,400 (7892) 20,100 (9117) 15,250 (6917) 17,650 (8006) 20,350 (9231)

134 (3404) 149 (3785) 153 (3886) 137 (3480) 149 (3785) 153 (3886)

69 (1753) 69 (1753) 70 (1778) 69 (1753) 69 (1752) 70 (1778) 76 (1930) 76 (1930) 80 (2032) 76 (1930) 76 (1930) 80 (2032)

74 (280) 107 (405) 159 (602) 74 (280) 107 (405) 159 (602)

498 (31) for

2-pass

332 (21) for

3-pass

1827 (115)

for 2-pass 1218 (72)

for 3-pass

47 (178) 61 (231) 97 (367) 47 (178) 61 (231) 97 (367) 380 (24) 463 (29) 708 (45) 380 (24) 463 (29) 708 (45)

1392 (88) 699 (107) 597 (164) 1392 (88) 699 (107) 597 (164)

(corresponds to digits 6 , 7 , 1 2 , 13, 16, 17 of unit model number)

2292 (144)

for 2-pass

1528 (96)

for 3-pass

(corresponds to digits 6 , 7 , 1 2 , 13, 16, 17 of unit model number)

669 (42) for

2-pass

446 (28) for

3-pass

2453 (154)

for 2-pass

1636 (103)

for 3-pass

2221 (140)

for 3-pass

1666 (72)

for 4-pass

690 (43) for

3-pass

518 (33) for

4-pass

2531 (154)

for 3-pass

1898 (119)

for 4-pass

1827 (115)

for 2-pass 1218 (72)

for 3-pass

498 (31) for

2-pass

332 (21) for

3-pass

1827 (115)

for 2-pass 1218 (72)

for 3-pass

2453 (154)

for 2-pass

1636 (103)

for 3-pass

669 (42) for

2-pass

446 (28) for

3-pass

2453 (154)

for 2-pass

1636 (103)

for 3-pass

2531 (154)

for 3-pass

1898 (119)

for 4-pass

690 (43) for

3-pass

518 (33) for

4-pass

2531 (154)

for 3-pass

1898 (119)

for 4-pass

Installation, Operation and Maintenance 1 - 11

Page 20

Unit Designator

C1B2C1 C1B3C2 C1E1F1 C2B3C2 C2D3E3

General

Refrigerant Type Refrigerant Charge (lb (kg)) Oil Charge (gal (l)) Operating Weight (lb (kg )) Shipping Weight (lb (kg))

Overall Dimensions

Length (in (mm))* Width (in (mm))* Height (in (mm))*

Evaporator

Water Storage (gal (l)) Minimum Flow (gpm (l/s))

Maximum Flow (gpm (l/s))

Condenser (all are 2-pass)

Water Storage (gal (l)) Minimum Flow (gpm (l/s)) Maximum Flow (gpm (l/s))

Notes: All weights Operating weights include refrigerant, oil, and water charges. If oil cooler is installed, add 1.0 gal (4 liters) to the oil charge value given * Overall dimensions are based on 3-pass evap/2 pass cond and LH/RH water connections. Refer to submittals for exact job configurations

Tab le 7 General Data

3%, include standard 150 psig water boxes.

HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a

420 (191) 420 (191) 600 (272) 420 (191) 575 (261)

6 (23) 6 (23) 10 (35) 6 (23) 6 (23) 13,900 (6307) 14,250 (6466) 16,700 (7574) 14,175 (6430) 1 5,550 (7055) 13,300 (6034) 13,600 (6171) 15,600 (7076) 13,500 (6124) 1 4,600 (6624)

129 (3277) 129 (3277) 145 (3683) 129 (3277) 129 (3277)

68 (1727) 68 (1727) 68 (1727) 68 (1727) 68 (1727) 72 (1829) 72 (1829) 76 (1930) 72 (1829) 76 (1930)

45 (170) 52 (197) 82 (311) 52 (197) 78 (295)

319 (20) for

2-pass

213 (13) for

3-pass

1171 (74) for

2-pass

781 (49) for

3-pass

29 (110) 32 (121) 50 (189) 32 (121) 47 (178) 248 (16) 293 (18) 450 (28) 293 (18) 387 (24) 908 (57) 1074 (68) 1640 (103) 1074 (68) 1421 (90)

Unit Designator

(corresponds to digits 6 , 7 , 1 2 , 13, 16, 17 of unit model number)

386 (24) for

2-pass

257 (16) for

3-pass

1413 (89) for

2-pass

942 (59) for

3-pass

(corresponds to digits 6 , 7 , 1 2 , 13, 16, 17 of unit model number)

499 (31) for

2-pass

332 (21) for

3-pass

1827 (115) for

2-pass

1218 (77) for

3-pass

386 (24) for

2-pass

257 (16) for

3-pass

1413 (89) for

2-pass

942 (59) for

3-pass

542 (34) for

2-pass

362 (23) for

3-pass

1989 (125) for

2-pass

1326 (84) for

3-pass

C2G1G1 B1B1B1 B1C1D1 B2B2B2 B2C2D2

General

Refrigerant Type Refrigerant Charge (lb (kg)) Oil Charge (gal (l)) Operating Weight (lb (kg )) Shipping Weight (lb (kg))

Overall Dimensions

Length (in (mm))* Width (in (mm))* Height (in (mm))*

Evaporator

1 - 12 RTHC-IOM-1C

HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a

850 (386) 410 (186) 450 (204) 410 (186) 450 (204)

11 (39) 4.5 (17.0) 4.5 (17.0) 4.5 (17.0) 4.5 (17.0) 20,150 (9142) 10,250 (4649) 11,000 (4990) 10,400 (4717) 11,200 (5080) 18,500 (8394) 9700 (4400) 10,300 (4672) 9800 (4445) 10,450 (4740)

149 (3785) 125 (3175) 143 (3632) 125 (3175) 143 (3632)

70 (1778) 65 (1651) 65 (1651) 65 (1651) 65 (1651) 80 (2032) 71 (1803) 71 (1803) 71 (1803) 71 (1803)

Page 21

Unit Designator

C2G1G1 B1B1B1 B1C1D1 B2B2B2 B2C2D2

Water Storage (gal (l)) Minimum Flow (gpm (l/s))

Maximum Flow (gpm (l/s))

Condenser (all are 2-pass)

Water Storage (gal (l)) Minimum Flow (gpm (l/s)) Maximum Flow (gpm (l/s))

Notes: All weights Operating weights include refrigerant, oil, and water charges. If oil cooler is installed, add 1/4 gal (1 liter) to the oil charge value given for B family units; add 1.0 gal (4 liters) for all other units. * Overall dimensions are based on 3-pass evap/2 pass cond and LH/RH water connections. Refer to submittals for exact job configurations

3%, include standard 150 psig water boxes.

136 (515) 41 (155) 55 (208) 45 (170) 58 (220)

558 (35) for

3-pass

419 (26) for

4-pass

2046 (129) for

3-pass

1535 (96) for

4-pass

79 (299) 28 (114) 31 (117) 29 (110) 34 (129) 553 (34) 232 (15) 232 (15) 254 (16) 254 (16)

1956 (123) 852 (54) 852 (54) 933 (59) 933 (59)

(corresponds to digits 6 , 7 , 1 2 , 13, 16, 17 of unit model number)

275 (17) for

2-pass

184 (12) for

3-pass

1010 (64) for

2-pass

673 (42) for

3-pass

352 (22) for

2-pass

234 (15) for

3-pass

1292 (82) for

2-pass

862 (54) for

3-pass

319 (20) for

2-pass

213 (13) for

3-pass

1171 (74) for

2-pass

781 (49) for

3-pass

385 (24) for

2-pass

257 (16) for

3-pass

1414 (89) for

2-pass

942 (59) for

3-pass

Installation, Operation and Maintenance 1 - 13

Page 22

1 - 14 RTHC-IOM-1C

Page 23

Installation - Mechanical

Storage

If the chiller is to be stored at least one month prior to installation, observe the following precautions:

q Do not remove the protective coverings from the

electrical panel.

q Store the chiller in a dry, vibration-free, secure

area.

q At least every three months, attach a gauge and

manually check the pressure in the refrigerant circuit. If the refrigerant pressure is below 71 psig at 70°F (or 46 psig at 50°F), call a qualified service organization and the appro pr iat e Trane sales office.

NOTE: Pressure will be approximately 20 psig if shipped with the optional nitrogen charge.

Location Requirements

Noise Considerations

Refer to Trane Engineering Bulletin RLC-EB-3 for sound consideration applications.

q Locate the unit away from sound-sensitive areas. q Install the isolation pads under the unit. Refer to

“Unit Isolation.”

q Install rubber vibration isolators in all water piping. q Use flexible electrical conduit for final connection

to the UCP2.

NOTE: Consult an acoustical engineer for critical applications.

Foundation

Provide rigid, non-warping mounting pads or a concrete foundation of sufficient strength and mass to support the chiller operating weight (including completed piping and full operating ch ar ges of refrigerant, oil and water). Refer to

for unit operating weights.

Table 8

and

Table

The Trane Company is not responsible for equipment problems resulting from an improperly designed or constructed foundation.

Vibration Eliminators

q Provide rubber boot type isolators for all water

piping at the unit.

q Provide flexible conduit for electrical connections

to the unit.

q Isolate all pipe hangers and be sure they are not

supported by main structure beams that could introduce vibration into occ upied spaces .

q Make sure that the piping does not put additional

stress on the unit.

NOTE: Do not use metal braided type eliminators on the water piping. Metal braided eliminators are not effective at the frequencies at which the unit will operate.

Clearances

Provide enough space around the unit to allow the installation and maintenance personnel unrestricted access to all service points. Refer to submittal drawings for the unit dimensions.

Allow adequate clearance for condenser and compressor servicing. A minimum of three feet is recommended for compressor service and to provide sufficient clearance for the opening of control panel doors. Refer to required for condenser tube service. In all cases, local codes will take precedence over these recommendations.

Figure 4

for minimum clearances

NOTES: Required vertical clearance above the unit

is 36” (914.4 mm). There should be no piping or conduit located over the compressor motor.

If the room configuration requires a variance to the clearance dimensions, contact your Trane sales office representative.

Once in place, level the chiller within 1/4” (6.35 mm) over its length and width.

Installation, Operation and Maintenance 2 - 1

Page 24

Figure 4 Recommended Operating and Service Clearances

3’- 0” (914 mm) Service Clearance

3’- 0” (914 mm)

Service Clearance

(Opp. Tube Rem oval)

35.6” radius

swing

105

Tube Removal Clearance (Either End)

DDE, CEF, CBC, BBB: 108” (2743 mm) DFF, CDE, BCD: 126” (3200 mm) DGG, CGG: 130” (3302 mm)

26.4” (671 mm) radius

3’- 0” (914 mm) Service Clearance

NOTE: Maximum clearances are given. Depending on the unit configuration, some units may require less clearance than others in the same category.

Ventilation

The unit produces heat even though the compressor is cooled by the refrigerant. Make provisions to remove heat generated by unit operation from the equipment room. Ventilation must be adequate to maintain an ambient temperature lower than 122°F (50°C).

Vent the evaporator, condenser and compressor pressure relief valves in accordance with all local and

national codes. Refer to “Pressure Relief Valves.” Make provisions in the equipment ro om to keep the

chiller from being exposed to freezing temperatures (32°F/0°C).

2 - 2 RTHC-IOM-1C

Water Drainage

Locate the unit near a large capacity drain for water vessel drain-down during shutdown or repair. Condensers and evaporators are provided with drain connections. Refer to “Water Piping.” All local and national codes apply.

Access Restrictions

Door clearances for the RTHC units are given in

Figure 4

unit” dimensional information.

. Refer to the unit submittals for specific “per

Page 25

Moving and Rigging

The Model RTHC chiller should be moved by lifting at designated lift points only. Refer to

Tab le 8

and

Table 7

for typical unit lifting and

operating weights. Refer to the rigging diagram that

ships with each unit for specific “per unit” weight data.

Figure 5 Unit Weights and Dimensions for Rigging

Figure 5

and

WARNING

Always use lifting equipment with a capacity exceeding unit lifting weight by an adequate safety factor. (+10%). Follow the procedures and diagrams in this manual and in the submittal. Failure to do so can result in personal injury or death.

Dimensions are the same for D1 and D2 units

= C.G. (see Table 9)

BBB, BCD: 71” (1803 mm) CBC: 72” (1829 mm)

CDE, DDE, CEF,

DFF: 76”

(1930 mm)

CGG, DGG: 80” (2032 mm)

BBB: 125” (3175 mm) CBC, CDE: 129” (3400 mm) DDE: 134” (3404 mm) BCD: 143” (3632 mm) CEF: 145” (3683 mm) DFF, CGG: 149” (3785 mm)

Installation, Operation and Maintenance 2 - 3

CBC: 68” (1727 mm)

CDE, DDE, CEF: 68” (1727 mm) DFF: 69” (1753 mm) CGG, DGG: 70” (1778 mm) BBB, BCD: 65” (1651 mm)

Page 26

Tab le 6 Unit Weights (lb(kg)) (see Figure 5 )

Location (Point)

A 2599

B 2051

C 1979

D 3049

Unit Wt (without water)

Est. Water Wt Total Installed Wt

Tab le 7 Unit Weights (lb(kg)) (see Figure 5 )

B1B1B1 B1C1D1 B2B2B2 B2C2D2 C1B2C1 C1B3C2 C1E1F1 C2B3C2

(1179)

(930)

(898)

(1383)

9678

(4390)

572 (259) 716 (325) 622 (282) 765 (347) 617 (280) 700 (318) 1101 (499) 700 (318)

10250 (4649)

Unit Designator

3274

(1485)

2369

(1075)

1823

(827)

2818

(1278) 10284

(4665)

11000

(4990)

Unit Designator

(corresponds to digits 6, 7, 12, 13, 16, 17 of unit model number)

2624

(1190)

2076 (942)

2002 (908)

3076

(1395)

9778

(4435)

10400 (4717)

(corresponds to digits 6, 7, 12, 13, 16, 17 of unit model number)

3309

(1501)

2411

(1094)

1860 (844)

2855

(1295) 10435

(4733)

11200

(5080)

3460

(1569)

2533

(1149)

2940

(1334)

4350

(1973) 13283

(6025)

13900 (6307)

3523

(1598)

2602

(1180)

3009

(1365)

4416

(2003)

13550

(6146)

14250

(6466)

4438

(2013)

3250

(1474)

3404

(1544)

4507

(2044) 15599

(7076)

16700 (7574)

3504

(1589)

2583

(1172)

2991

(1357)

4397

(1994) 13475

(6112)

14175 (6431)

Location (Point)

A 3742

B 2844

C 3263

D 4656

Unit Wt (without water)

Est. Water Wt Total Installed Wt

C2D3E3 C2G1G1 D1D1E1 D1F1F2 D1G2G2 D2D2E2 D2F2F3 D2G3G3

(1697)

(1290)

(1480)

(2112) 14505

(6579)

1045 (474) 1791 (812) 948 (430) 1324 (601) 1954 (886) 1004 (455) 1396 (633) 2130 (966)

15550 (7055)

5043

(2288)

4155

(1885)

4038

(1832)

5123

(2324) 18359

(8328)

20150 (9142)

3846

(1745)

2879

(1306)

3340

(1515)

4837

(2194) 14902

(6760)

15850 (7189)

4634

(2102)

3535

(1603)

3702

(1679)

4705

(2134) 16576

(7519)

17900 (8119)

5310

(2409)

4420

(2005)

4305

(1953)

5411

(2454) 19446

(8821)

21400 (9707)

3841

(1742)

2880

(1306)

3343

(1516)

4832

(2192) 14896

(6757)

15900 (7189)

4870

(2209)

3670

(1665)

3833

(1739)

4931

(2237)

17304

(7849)

18700

(8482)

5445

(2470)

4559

(2068)

4431

(2010)

5535

(2511) 19970

(9058)

22100

(10024)

2 - 4 RTHC-IOM-1C

Page 27

Tab le 8 Unit Weights (lb (kg)) (see Figure 5 )

Unit Designator

Location (Point)

A 3841 (1742) 4870 (2209) 5445 (2470) 3906 (1772) 4940 (2241) 5489 (2490)

B 2880 (1306) 3670 (1665) 4559 (2068) 2919 (1324) 3715 (1685) 4588 (2081) C 3343 (1516) 3833 (1739) 4431 (2010) 3397 (1541) 3886 (1763) 4505 (2043) D 4832 (2192) 4931 (2237) 5535 (2511) 4924 (2234) 5013 (2274) 5638 (2557)

Unit Wt (without water)

Est. Water Wt Total Installed Wt

Tab le 9 Center of Gravity (in) (see Figure 5 )

*Unit Configuration X Y Z

E3G3G3 30.80 63.81 37.62

E3F2F3 27.64 63.46 38.33 E3D2E2 25.90 60.05 40.50

D2G3G3 30.85 63.48 37.44

D2F2F3 27.70 63.40 38.14 D2D2E2 25.97 59.95 40.31 D1G2G2 30.77 63.55 37.72

D1F1F2 27.92 63.47 38.70 D1D1E1 25.91 60.00 40.47 C2G1G1 30.58 63.46 38.15 C2D3E3 26.13 59.74 40.08 C2B3C2 24.81 59.96 40.52

C1E1F1 26.36 63.49 40.95 C1B3C2 24.81 59.96 40.52 C1B2C1 24.71 60.01 40.78 B2C2D2 22.40 58,29 33.51

B2B2B2 22.88 58.11 35.43 B1C1D1 22.32 58,23 33.65

B1B1B1 22.84 58.13 35.59

*Designator corresponds to digits 6, 7, 12, 13, 16, 17 of model

number

D3D2E2 D3F2F3 D3G3G3 E3D2E2 E3F2F3 E3G3G3

14896 (6757)

1004 (455) 1396 (633) 2130 (966) 1004 (455) 1396 (633) 2130 (966)

15900 (7189)

(corresponds to digits 6, 7, 12, 13, 16, 17 of unit model number)

17304

(7849)

18700

(8482)

19970

(9058)

22100

(10024)

15146 (6870)

16150 (7325)

17554 (7962)

18950 (8596)

20220

(9172)

22350

(10138)

Lifting Procedure

CAUTION

CAUTION: Unit Moving! Never use a forklift to move the unit. The skid is not designed to support the unit at any one point and using a forklift to move the equipment may cause unit damage.

NOTE: If absolutely necessary, the chiller can be pushed or pulled across a smooth surface if it is bolted to wood shipping mounts.

WARNING

Do not remove the wood mounts until the unit is in its final location. Removal of wood shipping mounts prior to unit final locating could result in injury or death and equipment damage.

1 When the unit is at its final location, remove the

shipping bolts that secure the unit to the wood base mounts.

2 Rig the unit properly and lift from above or jack

the unit (alternate moving method). Use the points shown on the rigging diagram that ships with the unit as shown in mounts.

Figure 6

. Remove the base

Installation, Operation and Maintenance 2 - 5

Page 28

W ARNING

Do not use the threaded holes in

CAUTION

the compressor to lift or assist in lifting the unit. They are not intended for that purpose and could create a dangerous situation.

3 Install clevis connectors in lifting holes provided

on the unit. Attach lifting chains or cables to clevis connectors as shown in alone must be strong enough to lift the chiller.

CAUTION: Lifting Beam Location! Always position the lifting beam so that cables do not contact the unit. Failure to do so may result in unit damage.

Table 10 Weights and Rigging (Use with Figure 6 )

Unit Model

Number

E3G3G3 E3F2F3 E3D2E2

Lifting

Weight (lb)

20400 12 11 17700 12 11 15300 10 9

Figure 6

. Each cable

Dimension (ft) (Fig. 6)

A B

Unit Model

Number

D3G3G3 D3F2F3 D3D2E2 D2G3G3 D2F2F3 D2D2E2 D1G2G2 D1F1F2 D1D1E1 C2G1G1 C2D3E3 C2B3C2 C1E1F1 C1B3C2 C1B2C1 B2C2D2 B2B2B2 B1C1D1 B1B1B1

Designator corresponds to digits 6, 7, 12, 13, 16, 17 of model

number

Lifting

Weight (lb)

20100 12 11 17400 12 11 15000 10 9 20100 12 11 17400 12 11 15000 10 9 19600 12 11 16700 12 11 15000 10 9 18500 12 11 14600 10 9 13500 10 9 15600 12 11 13600 10 9 13300 10 9 10500 12 11

9800 10 9

10300 12 11

9700 10 9

Dimension (ft) (Fig. 6)

A B

Figure 6 Lifting the Unit

Attach of three compressor housing mounting holes

Anti-rolling

Cable

Eyebolt

to one

Lifting Cable

inside

discharge pipe -

No Contact

A Beam

Anti-rolling

Cable

24”

Eyelet

Starter

Anti-rolling

Cable

Controls

Lifting holes

Evap

Cond

Unit Model Number

location

Note: Refer to specific unit submittal s or Fi gure 5 for weight distribution

WARNING

To prevent personal injury or equipment damage, refer to Trane RTHC-SB-2 for units that must be disassembled due to limited access.

positioned

2 - 6 RTHC-IOM-1C

Page 29

4 Attach cables to lifting beam. Total lifting weight,

lifting weight distribution and required lifting beam dimensions are shown in the rigging diagram shipped with each unit and in beam crossbar must be positioned so the lifting cables do not contact unit piping or electrical panel enclosure.

Figure 6

. The lifting

Alternate Moving Method

6 If it is not possible to rig from above as shown in

the figures, the unit may also be moved by jacking each end high enough to move an equipment dolly under each tube sheet support. Once securely mounted on the dollies, the unit may be rolled into position.

W ARNING

Connect an anti-rotation strap between the lifting beam and compressor before lifting unit. Failure to do so may result in personal injury or death should a lifting cable fail.

5 Connect an anti-rotation strap or cable loosely

between the lifting beam and the threaded coupling or eyelet provided at the top of the compressor. Use an eyebolt or clevis to secure the strap at the coupling or eyelet.

NOTE: The anti-rotation strap is not a lifting chain, but a safety device to ensure that the unit cannot tilt during lifting.

Proper jacking locations are shown in and by the rigging diagram that ships with the unit.

Figure 6

Isolation Pads

NOTE: The elastomeric pads shipped (as standard) are adequate for most installations. For additional details on isolation practices, refer to Trane Engineering Bulletin RLC-EB-3, or consult an acoustical engineer for sound-sensitive installations.

7 During final positioning of the unit, place the

isolation pads under the evaporator and condenser tube sheet supports as shown in

Figure 7

main paragraph.

NOTE: Durometer values for isolator pads are a measure of resilience. See Figure 7 .

. Level the unit as described in the next

Installation, Operation and Maintenance 2 - 7

Page 30

Figure 7 Isolator Pad Placement

(hidden leg)

Durometer: 50 +/-5

Note: Level unit to 1/4” (6.35 mm) across width and length

Typical Elastomeric Isolation Pad

Durometer: 40 +/-5 Durometer: 55 +/-10

Pads extend the full width of legs

0.31

Acceptable Pad Configurations

8 The unit is shipped with four spacers (only three

on B family) on the compressor mount that protect the isolation pads during shipping and in handling. Remove these spacers

(Figure 9)

before the unit

is operated.

9 Remove the shipping brackets from the bottom

sides of the oil separator(s) (see

Figure 8

NOTE: Once shipping bracket(s) is removed, the oil separator is only supported by the discharge line.

0.31

Figure 8 Oil Separator with Shipping Bracket Installed

Oil Separator

0.31

Shipping Bracket

2 - 8 RTHC-IOM-1C

Page 31

Figure 9 Shipping Spacer Removal

Compressor Housing

M20 bolt

Remove

Spacers (only 3 on B family)

4 Shipping

Unit Leveling

NOTE: The electrical panel side of the unit is

designated as the “front” of the unit.

1 Check unit level end-to-end by placing a level on

the top surface of the evaporator shell.

2 If there is insufficient surface available on the top

of the evaporator shell, attach a magnetic level to the bottom of the shell to level the unit. The unit

should be level to within 1/4” (6.35 mm) over its length.

Make water piping connections to the evaporator and condenser. Isolate and support piping to prevent stress on the unit. Construct piping according to local and national codes. Insulate and flush piping before connecting to unit.

Use grooved pipe connectors for all water piping connections. Evaporator and condenser water inlet and outlet sizes and locations are shown by the unit submittals and in

Figure 10

through

Figure 12

. The designation in the tables corresponds to the compressor frame code followed by the evaporator shell code followed by the condenser shell code as given in the unit model number, digits 6, 7, 12, 13, 16, and 17.

Table 11

gives additional water

connection information.

Reversing Water Boxes

All water boxes may be reversed end-for-end. Do not rotate water boxes. Remove the sensors from the wells before removing the water box. Complete the water box switch procedure and replace the sensors. See

Figure 10

through

Figure 12

for correct

orientation of the water inlet and outlet. If the water boxes are reversed, be sure to properly

rewire the water temperature sensors in the control panel.

NOTE: Be certain to replace water boxes right-sideup to maintain proper baffle orientation. Use new orings.

3 Place the level on the evaporator shell tube sheet

support to check side-to-side (front-to-back) level. Adjust to within 1/4” (6.35 mm) of level front-toback.

NOTE: The evaporator MUST be level for optimum heat transfer and unit performance.

4 Use full-length shims to level the unit.

Water Piping

Piping Connections

CAUTION

CAUTION: To prevent equipment damage, bypass the unit if using an acidic flushing agent.

Installation, Operation and Maintenance 2 - 9

Page 32

Figure 10 Condenser and Evaporator Water Connections -

D1F1F2, D2F2F3, D3F2F3, C1E1F1, and E3F2F3

25-7/8”

(657mm)

14-1/8” (359mm)

10-3/4” (273mm) for 150 & 300 psi

OUT

Cond

12-1/2” (317mm)

69” (1752mm) 67-3/4” (1721mm) [CEF]

Evap

76” (‘930mm)

3-3/4” (96mm)

16-1/4” (412mm)

Evaporator

118” (2997mm)

3-1/8” (79mm)

8” (203mm) for 150 psi 8-1/2” (216mm) for 300 psi

Compressor

9-1/4” (235mm)

6” (152mm) for 150 psi 6-1/2” (165mm) for 300 psi

OUT

27-3/4” (705m) for 150 & 300 psi

9-1/2” (241mm) for 150 psi 10-3/4” (273mm) for 300 psi

2 Pass 2 Pass

Connection Configuration (Left or Right Hand)

126” (3200mm)

Std. 3 Pass

8-3/4” (222mm) for 2 Pass

Depends on Water Inlet

OUT

11” (279mm)

9-1/2” (241mm)for 150 psi 10-3/4” (273mm) for 300 psi

26-5/8” (703mm)

11-7/8” (302mm)

2 - 10 RTHC-IOM-1C

Page 33

Figure 11 Condenser and Evaporator Water Connections -

C2G1G1, D2G3G3, D1G2G2, D3G3G3, and E3G3G3

7-1/4” (184mm) for 150 psi 7-5/8” (194mm) for 300 psi

129-3/4” (3296mm)

9-1/4” (235mm) for 150 psi 10” (254mm) for 300 psi

28-3/8” (721mm)

14-3/8” (365mm)

14-5/8” (371mm)

9-1/2” (241mm) for150 psi 9-3/8” (238mm) for 300 psi

OUT

Cond

70” (1778mm) 68-5/8” (1743mm) [CGG]

32” (813mm) for 150 psi 32-1/8” (816mm) for 300 psi

OUT

Evap

OUT

11” (279mm) for 150psi 12” (305mm) for 300 psi

80” (2032mm)

1-1/4” (32mm)

18-5/8” (473mm)

Evaporator

126” (3200mm)

Std. 4 Pass

Compressor

13-1/4” (337mm) 9-1/4” (235mm) [CGG]

9-3/8” (238mm) for 150 psi, 4 Pass 10-5/8” (271mm) for 300 psi, 4 Pass or 6 Pass

10-3/4” (273mm)

12-1/2” (318mm)

Connection Configuration (Left or Right Hand)

Installation, Operation and Maintenance 2 - 11

3 Pass

Depends on Water Inlet

OUT

30-3/4” (781mm)

12-1/2” (318mm)

3 Pass

Page 34

Figure 12 Condenser and Evaporator Water Connections -

D1D1E1, D2D2E2, D3D2E2, C2D3E3, and E3D2E2

7-3/4” (197mm)

97-1/2” (2476mm)

8” (203mm) for 150 psi 8-1/2” (216mm) for 300 psi

76” (1930mm)

OUT

25-7/8” (657mm)

14-1/8” (359mm)

9-1/8” (232mm) for 150 psi

9-1/2” (241mm) for 300 psi

Cond

13-1/8” (333mm)

for 150 psi

13-3/8” (340mm)

for 300 psi

Evap

12-1/2” (317mm)

69” (1752mm)

5-5/8” (142mm)

14-3/8” (365mm)

Evaporator

107-5/8” (2734mm)

Std. 3 Pass

Compressor

6” (152mm) for 150 psi 6-1/2” (165mm) for 300 psi

OUT

28-1/2” (724m) for 150 psi

28-3/8” (721mm) for 300 psi

9-1/8” (232mm) for 150 psi 9-1/2” (241mm) for 300 psi

2 Pass

Connection Configuration (Left or Right Hand)

2 - 12 RTHC-IOM-1C

7-5/8” (194mm)

Depends on Water Inlet

OUT

9-5/8” (245mm)

2 Pass

13-5/8” (346mm)

28” (711mm)

Page 35

Figure 13

Condenser and Evaporator Water Connections -

71-3/4 (1822mm)

C1B2C1, C1B3C2, and C2B3C2

7-3/4” (197mm)

97-1/2” (2476mm)

8” (203mm) for 150 psi 8-1/2” (216mm) for 300 psi

OUT

23-1/2” (597mm)

13-1/2” (343mm)

11-1/2” (292mm) for 150 psi 11-5/8” (295mm) for 300 psi

Cond

9-1/2” (241mm)

65-3/4” (1710 mm)

8-3/8” (213mm) for 150 psi

8-1/2” (216mm) for 300 psi

Evap

6-5/8 (168mm)

13-3/8 (340mm)

Evaporator

107-5/8” (2734mm)

Std. 3 Pass

Compressor

9-1/4” (235mm)

4-3/4” (121mm) for 150 psi 5-1/4” (133mm) for 300 psi

OUT

26-3/8” (292mm) for 150 psi

26-1/8” (295mm) for 300 ps

8-3/8 (213mm) for 150 psi

8-1/2” (216mm) for 300 psi

2 Pass

Connection Configuration (Left or Right Hand)

Installation, Operation and Maintenance 2 - 13

6-7/8” (175mm)

Depends on Water Inlet

OUT

2 Pass

12-7/8” (327mm)

25” (635mm)

9” (229mm)

Page 36

Figure 14Condenser and Evaporator Water Connections -

70-3/4 (1797mm)

23-1/2” (597mm)

OUT

Cond

Evap

B1B1B1/B2B2B2

10-1/4 (260mm)

97-1/2” (2476mm) 8” (203mm) for 150 psi 8-1/4” (210mm) for 300 psi

Compressor

13-1/2” (343mm)

11-5/8” (295mm) for 150 psi 11-3/4” (298mm) for 300 psi

8-3/8” (213mm) for 150 psi 8-1/2” (216mm) for 300 psi

11-1/2” (292mm)

64-1/2” (1638 mm)

9-5/8 (245mm) 13-3/8 (340mm)

Evaporator

107-5/8” (2734mm)

Std. 3 Pass

4-3/4” (121mm) for 150 psi 5-1/4” (133mm) for 300 psi

OUT

26-3/8” (670mm) for 150 psi 26-1/4” (667mm) for 300 psi

8-3/8 (213mm) for 150 psi

8-1/2” (216mm) for 300 psi

6-7/8” (175mm)

2 Pass

2 - 14 RTHC-IOM-1C

OUT

8-7/8” (225mm)

2 Pass

12-7/8” (327mm)

25-1/8” (638mm)

Page 37

Figure 15Condenser and Evaporator Water Connections -

B1C1D1/B2C2D2

OUT

23-1/2” (597mm)

13-1/2” (343mm)

11-5/8” (295mm) for 150 psi 11-3/4” (298mm) for 300 psi

Cond

11-1/2” (292mm)

64-1/2” (1638 mm)

Evap

70-3/4 (1797mm)

9-5/8 (245mm) 13-3/8 (340mm)

8” (203mm) for 150 psi 8-1/4” (210mm) for 300 psi

Evaporator

118” (2997mm)

Compressor

4-3/4” (121mm) for 150 psi 5-1/4” (133mm) for 300 psi

OUT

26-3/8” (670mm) for 150 psi

26-1/4” (667mm) for 300 psi

8-3/8” (213mm) for 150 psi 8-1/2” (216mm) for 300 psi

6-7/8” (175mm)

2 Pass

126” (3200mm)

Std. 3 Pass

OUT

2 Pass

8-3/8 (213mm) for 150 psi

8-1/2” (216mm) for 300 psi

12-7/8” (327mm)

25-1/8” (638mm)

8-7/8” (225mm)

Installation, Operation and Maintenance 2 - 15

Page 38

Table 11 Evaporator and Condenser Data

Compressor Frame Code

(Digit 6,7 of

Model No.)

Evap Shell Code

(Digits 12, 13 of

Model No.)

Evap. Shell

Diameter (in)

Nominal Connector size

(NPS)*

Cond Shell Code

(Digits 16,17 of

Model No.)

Cond. Shell

Diameter (in)

2-Pass 3-Pass 4-Pass 2-Pass

D2 26.5 8 8 - E2 22.0 8 F2 29.0 8 8 - E2 22.0 8 G3 33.5 - 10 8 G3 25.75 8 D2 26.5 8 8 - E2 22.0 8 F2 29.0 10 8 - F3 22.0 8 G3 33.5 - 10 8 G3 25.75 8 D2 26.5 8 8 - E2 22.0 8 F2 29.0 10 8 - F3 22.0 8 G3 33.5 - 10 8 G3 25.75 8 D1 26.5 8 8 - E1 22.0 8 F1 29.0 10 8 - F2 22.0 8 G2 33.5 - 10 8 G2 25.75 8 B3 23.0 8 6 - C2 18.75 6 D3 26.5 8 8 - E3 22.0 8 G1 33.5 - 10 8 G1 25.75 8 B2 23.0 8 6 - C1 18.75 6 B3 23.0 8 6 - C3 18.75 6 E1 33.5 8 8 - F1 22.0 8 C2 23.0 - 6 - D2 18.75 6 B2 23.0 - 6 - B2 18.75 6 C1 23.0 - 6 - D1 18.75 6 B1 23.0 - 6 - B1 18.75 6

Nom.

Conn.

Size

(NPS)*

*Note: Metric Conversion is 6 NPS = 150 mm nominal 8 NPS = 200 mm nominal 10 NPS = 250 mm nominal

2 - 16 RTHC-IOM-1C

Page 39

Water Pressure Drop Data

Condenser Pressure Drop

100

2-Pass, E1

delta-P, Ft H2O

100 1000 10000

GPM

Condenser Pressure Drop

100

2-Pass, F2

Condenser Pressure Drop

100

delta-P, Ft H2O

100 1000 10000

2-Pass, E2

GPM

Condenser Pressure Drop

100

2-Pass, F3

delta-P, Ft H2O

100 1000 10000

GPM

Condenser Pressure Drop

100

2-Pass, G2

delta-P, Ft H2O

100 1000 10000

GPM

delta-P, Ft H2O

100 1000 10000

GPM

Condenser Pressure Drop

100

delta-P, Ft H2O

100 1000 10000

2-Pass, G3

GPM

Installation, Operation and Maintenance 2 - 17

Page 40

Water Pressure Drop Data (continued)

Condenser Pressure Drop

100

2-Pass, C1

delta-P, Ft H2O

100 1000

GPM

Condenser Pressure Drop

100

2-Pass , E3

delta-P, Ft H2O

Condenser Pressure Drop

100

2-Pass, C2

delta-P, Ft H2O

100 1000 10000

GPM

Condenser Pressure Drop

100

2-Pass, F1

delta-P, Ft H2O

100 1000 10000

GPM

Condenser Pressure Drop

100

2-Pass, G1

delta-P, Ft H2O

100 1000 10000

GPM

100 1000 10000

GPM

2 - 18 RTHC-IOM-1C

Page 41

Water Pressure Drop Data (continued)

Condenser Pressure Drop

100

2-Pass , B1

delta-P, Ft H2O

100 1000

GPM

Condenser Pressure Drop

100

2-Pass, D1

Condenser Pressure Drop

100

2-Pass , B2

delta-P, Ft H2O

100 1000

GPM

Condenser Pressure Drop

100

2-Pass, D2

delta-P, Ft H2O

100 1000

GPM

delta-P, Ft H2O

100 1000

GPM

Installation, Operation and Maintenance 2 - 19

Page 42

Water Pressure Drop Data (continued)

Evaporator Pressure Drop

100

delta-P, Ft H2O

100 1000 10000

GPM

3-Pass, D1 2-Pass, D1

Evaporator Pressure Drop

100

delta-P, Ft H2O

3-Pass, F1 2-Pass, F1

Evaporator Pressure Drop

100

delta-P, Ft H2O

100 1000 10000

GPM

3-Pass, D2 2-Pass, D2

Evaporator Pressure Drop

100

delta-P, Ft H2O

3-Pass, F2 2-Pass, F2

100 1000 10000

GPM

Evaporator Pressure Drop

100

delta-P, Ft H2O

100 1000 10000

GPM

4-Pass, G2 3-Pass, G2

100 1000 10000

GPM

Evaporator Pressure Drop

100

delta-P, Ft H2O

100 1000 10000

GPM

4-Pass, G3 3-Pass, G3

2 - 20 RTHC-IOM-1C

Page 43

Water Pressure Drop Data (continued)

Evaporator Pressure Drop

100

delta-P, Ft H2O

100 1000 10000

GPM

3-Pass, B3 2-Pass, B3

Evaporator Pressure Drop

100

delta-P, Ft H2O

3-Pass, E1 2-Pass, E1

Evaporator Pressure Drop

100

3-Pass, D3

delta-P, Ft H2O

100 1000 10000

GPM

2-Pass, D3

Evaporator Pressure Drop

100

delta-P, Ft H2O

4-Pass, G1 3-Pass, G1

100 1000 10000

GPM

Evaporator Pressure Drop

100

delta-P, Ft H2O

100 1000 10000

GPM

3-Pass, B1

100 1000 10000

GPM

Evaporator Pressure Drop

100

delta-P, Ft H2O

100 1000 10000

GPM

3-Pass, B2

2-Pass, B2

Installation, Operation and Maintenance 2 - 21

Page 44

Water Pressure Drop Data (continued)

Evaporator Pressure Drop

100

3-Pass, C1

delta-P, Ft H2O

100 1000 10000

GPM

Evaporator Pressure Drop

100

3-Pass, C2

delta-P, Ft H2O

100 1000 10000

GPM

2 - 22 RTHC-IOM-1C

Page 45

Making Grooved Pipe Connections

Leaving Chilled Water Piping

CAUTION

CAUTION: To prevent damage to water piping, do not overtighten connections.

NOTE: Make sure that all piping is flushed and cleaned prior to starting the unit.

CAUTION

CAUTION: To prevent equipment damage, bypass the unit if using an acidic flushing agent.

Vents and Drains

Install pipe plugs in evaporator and condenser water box drain and vent connections before filling the water systems.

To drain water, remove vent and drain plugs, install a NPT connector in the drain connection and connect a hose to it.

Evaporator Piping Components

NOTE: Make sure all piping components are between the shutoff valves, so that isolation can be accomplished on both the condenser and the evaporator.

“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

q Air vents (to bleed air from system)

q Air vents (to bleed air from system) q Water pressure gauges with shutoff valves q Pipe unions q Vibration eliminators (rubber boots) q Shutoff (isolation) valves q Thermometers q Cleanout tees q Balancing valve q Pressure relief valve

CAUTION

CAUTION: To prevent evaporator damage, do not exceed 150 psig (10. 3 bar) evaporator water pressure for standard water boxes. Maximum pressure for high pressure water boxes is 300 psig (20.7 bar). Ref e r to digit 14 of the Model No.

To prevent tube damage, install a strainer in the evaporator water inlet piping.

To prevent tube corrosion, ensure that the initial water fill has a balanced pH.

Condenser 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.

q Water pressure gauges with shutoff valves q Pipe unions q Vibration eliminators (rubber boots) q Shutoff (isolation) valves q Thermometers q Cleanout tees q Pipe strainer q Flow switch

Installation, Operation and Maintenance 2 - 23

Entering condenser water piping.

q Air vents (to bleed air from system) q Water pressure gauges with shutoff valves q Pipe unions q Vibration eliminators (rubber boots) q Shutoff (isolation) valves. One per each pass q Thermometers

Page 46

q Cleanout tees

CAUTION

q Pipe strainer

Condenser Water Regulating Valve Adjustment

q Flow switch

Leaving condenser wate r piping .

q Air vents (to bleed air from system) q Water pressure gauges with shutoff valves q Pipe unions q Vibration eliminators (rubber boots) q Shutoff (isolation) valve - one per each pass q Thermometers q Cleanout tees q Balancing valve q Pressure relief valve.

CAUTION: To prevent condenser damage, do not exceed 150 psig (10. 3 bar) water pressure for standard water boxes. Maximum pressure for high pressure water boxes is 300 p si g (20.7 bar). Refer to digit 18 of the Model No.

To prevent tube damage, install a strainer in condenser water inlet piping.

Refer to adjustment of the optional condenser water regulating valve.

Trane RTHC-SB-7

for installation and

Water Treatment

CAUTION

CAUTION: Water Treatment! Do not use untreated or improperly treated water. Use of untreated or improperly treated water may result i n equipment damage.

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 RTHC unit:

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.

To prevent tube corrosion, ensure that the initial water fill has a balanced pH.

Condenser Water Regulating Valve

The water regulating valve is used when the condenser water temperature is expected to fall below 60°F. It maintains condensing pressure and temperature by throttling water flow leaving the condenser in response to condenser pressure or differential system pressu re s.

Adjust the valve for proper operation during unit startup.

2 - 24 RTHC-IOM-1C

Page 47

Water Pressure Gauges and Thermometers

Install field-supplied thermometers and pressure gauges (with manifolds, whenever practical) as shown in in a straight run of pipe; avoid placement near elbows, etc. Be sure to install the gauges at the same

Figure 16 Typical Thermometer, V al ving, and Manifold Pressure Gauge Set-up

Figure 16

. Locate pressure gauges or taps

elevation on each shell if the shells have oppositeend water connections.

To read manifolded water 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.

Flow Switch

Manifold

Thermometers

Relief Valve

Evap Water Flow

Shutoff

Valves Isolation Valves

Pressure Differential Gauge

NOTE: Refer to Trane Engineering Bulletin RLC-EB-3 for sound-sensitive applications.

Water Pressure Relief Valves

CAUTION

CAUTION: Install a pressure relief valve in both evaporator and condenser water systems. Failure to do so could result in shell damage.

Install a water pressure relief valve in one of the condenser and one of the evaporator water box drain connections or on the shell side of any shutoff valve. 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.

Manifold

Cond Water Reg. Valve (Opt.)

Isolation Valves

Cond

Water

Flow

Relief Valve

Flow Switch

Shutoff Valves

Thermometers

Pressure Differential Gauge

To provide chiller protection, install and wire flow switches in series with the water pump interlocks, for both chilled water and condenser water circuits (refer to the Installation Electrical section). Specific connections and schematic wiring diagrams are shipped with the unit.

Flow switches must stop or prevent compressor operation if either system water flow drops off below the required minimum shown on the pressure drop

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

q Mount the switch upright, with a minimum of 5

pipe diameters straight, horizontal run on each side.

Flow Sensing Devices

Use field-provided flow switches or differential pressure switches with pump interlocks to sense system water flow. Flow switch locations are schematically sh own in

Installation, Operation and Maintenance 2 - 25

Figure 16

q Do not install close to elbows, orifices or valves.

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

q To prevent switch fluttering, remove all air from

the water system

Page 48

NOTE: The UCP2 provides a 6-second time delay on

W ARNING

CAUTION

the flow switch input before shutting down the unit on a loss-of-flow diagnostic. Contact a qualifi ed se rvic e organization if nuisance machine shutdowns persist.

q Adjust the switch to open when water flow falls

below nominal. Refer to the General Data table in Section 1 for minimum flow recommendations for specific water pass arrangements. Flow switch contacts are closed on proof of water flow.

Figure 17 Relief Valve Locations

Refrigerant Pressure Relief Valve Venting

To prevent injury due to inhalation of HFC-134 gas, do not discharge refrigerant anywhere. If multiple chillers are installed, each unit must have separate venting for its relief valves. Consult local regulations for any special relief line requirements.

NOTE: Vent pipe size must conform to the ANSI/ ASHRAE Standard 15 for vent pipe sizing. All federal, state, and local codes take precedence over any suggestions stated in this manual.

All relief valve venting is the responsibility of the installing contractor.

All RTHC units use evaporator, compressor, and condenser pressure relief valves ( must be vented to the outside of the building.

Figure 17

) that

Evaporator Shell

Discharge Pipes

Condenser Shell

* Valve is hidden by pipe

NOTE: Once opened, relief valves tend to leak and must be replaced.

Relief valve connection sizes and locations are shown in the unit submittals. Refer to local codes for relief valve vent line sizing information.

CAUTION: Do not exceed vent piping code specifications. Failure to heed specifications could result in cap acity reduction, unit damage and/or relief valve damage.

Relief valve discharge setpoints and relief rates are given in it will reclose when pressure is reduced to a safe level.

2 - 26 RTHC-IOM-1C

Table 12

. Once the relief valve has opened,

Pressure relief valve discharge setpoints and relief rates will vary with shell diameter and length and also compressor displacement. Relief rates should be calculated as required by ASHRAE Standard 15-94

Page 49

Thermal Insulation

Table 12 Pressure Relief Valve Data

Number of

Valve Locat ion

Evap - B1 Evap - B2 Evap -B3 Evap -C1 Evap - C2 Evap - D1 Evap - D2 Evap - D3 Evap - F1 Evap - F2 Evap - E1 Evap - G1 Evap - G2 Evap - G3 Cond - B1 Cond - B2 Evap - C1 Evap - C2 Cond - D1 Cond - D2 Cond - E1 Cond - E2 Cond - E3 Cond - F1 Cond - F2 Cond - F3 Cond - G1 Cond - G2 Cond - G3 Comp - B1/B2* Comp - C1/C2* Comp - D1/D2/D3* Comp -E3

Rated

Capacity

per Relief

Valves

1 43.5 1 1 43.5 1 1 43.5 1 1 43.5 1 1 43.5 1 1 43.5 1 1 43.5 1 1 43.5 1 1 43.5 1 1 43.5 1 1 43.5 1 1 76.2 1-1/4 1 76.2 1-1/4 1 76.2 1-1/4 1 43.5 1 1 43.5 1 1 43.5 1 1 43.5 1 1 43.5 1 1 43.5 1 2 43.5 1 2 43.5 1 1 43.5 1 1 43.5 1 2 43.5 1 2 43.5 1 1 43.5 1 2 43.5 1 2 43.5 1 2 76.2 1-1/4 3 76.2 1-1/4 3 76.2 1-1/4 3 76.2 1-1/4

Valve

(lba/min)

Pipe Size

(in NPT)

All RTHC units are available with optional factory installed thermal insulation. If the unit is not factory insulated, install insulation over the areas shaded in

Figure 18

. Refer to

Table 13

for types and quantities

of insulation required.

NOTES: Liquid line filter, refrigerant charging valves, water temperature sensors, drain and vent connections when insulated must remain accessible for service.

Use only water-base latex paint on factory-applied insulation. Failure to do so may result in insulation shrinkage.

More (thicker insulation may be required in areas with high humidity.

* Only used with isolation valve option

Installation, Operation and Maintenance 2 - 27

Page 50

Figure 18 Typical R THC Insulation Requirements

Front View Rear View

Table 13 Recommended Insulation Types

Location Type Sq. Feet

1 2 3

3/4” wall 90 3/4” wall 25 3/4” wall 160

1 = evaporator and liquid vapor separator 2 = compressor 3 = all components and piping on low side of system (gas pump,

return oil line, filter from pump)

NOTE: Units in environments with higher humidity may require thicker insulation.

2 - 28 RTHC-IOM-1C

Page 51

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General Recommendations

For proper electrical component operation, do not locate the unit in areas exposed to dust, dirt, corrosive fumes, or excessive humidity. If any of these conditions exist, corrective action must be taken.

WARNING

Hazardous Voltage! Disconnect all electrical power, including remote disconnects before servicing. Failure to disconnect power before servicing can cause severe personal injury or death.

All wiring must comply with local and National Electric Codes. Minimum circuit ampacities and other unit electrical data is on the unit nameplate. See the unit order specifications for actual electrical data. Specific electrical schematics and connection diagrams are shipped with the unit.

NOTE: typical wiring diagrams are in the back of this manual.

Do not allow conduit to interfere with other components, structural members or equipment. All conduit must be long enough to allow compressor and starter removal.

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

Power Supply Wiring

Model RTHC chillers are designed according to NEC Article 310-15; therefore, all power supply wiring must be sized and selected accordingly by the project engineer.

For a complete discussion on the use of conductors, see Trane Engineering Bulletin EB-MSCR-40.

Refer to Trane Engineering Bulletin CTV-EB-93 for power wire sizing.

Water Pump Power Supply

Provide power supply wiring with fused disconnect for both the chilled water and condenser water pumps.

CAUTION

CAUTION: It is strongly recommended that only copper conductors be used! Unit terminals are not designed to accept other types of conductors. Failure to do so may cause damage to the equipment.

Table 12 Wire Selection Chart for Starter Panels

Min. Wire

Size

Copper 75

840 652 468 360

1 Conduit

3 Wire

1 Conduit

6 Wire

****** ****** ****** ******

Electrical Panel Power Supply

Power supply wiring instructions for the starter/ control panel are:

1 Run line voltage wiring in conduit to access

opening(s) on starter/control panel or pull-box. See CTV-EB-93 for wire sizing and selection information and refer to that show typical electrical connection sizes and locations. Always refer to submittal information for your actual unit specifications.

Supply Leads for All Starters (0 - 2000 Volts)

1 Conduit

9 Wire

2 Conduits

6 Wire

2 Conduits

12 Wire

Table 12

3 Conduits

9 Wire

and

Figure 22

4 Conduits

12 Wire

Installation, Operation and Maintenance 3 - 1

Page 52

Table 12 Wire Selection Chart for Starter Panels

Min. Wire

Size

Copper 75

292 1104 0120 00 140 000 160 0000 184 250 204 300 228 350 248 400 268 500 304

* Conductors to the starter and motor connected in parallel (electrically joined at both ends to form a single conductor) must be sized 0 (1/0)

or larger per NEC 310-4. Each phase must be equally represented in each conduit.

Figure 17 Electrical Installation

1 Conduit

3 Wire

1 Conduit

6 Wire

******

****** 192 252 360 384 360 480 224 294 420 448 420 560 256 336 480 512 480 640 294 386 552 589 552 736 326 428 612 653 612 816 356 479 684 730 684 912 397 521 744 794 744 992 429 563 804 858 804 1072 486 638 912 973 912 1216

7” x 10” (178 x 254 mm) opening for incoming line power

Supply Leads for All Starters (0 - 2000 Volts)

1 Conduit

9 Wire

2 Conduits

6 Wire

2 Conduits

12 Wire

3 Conduits

9 Wire

4 Conduits

12 Wire

(5) 7/8” (22 mm) dia knockout for low voltage (max 30V) UCP2 connections

Field installe d terminal bo x (for units with circuit breaker or a mechanical disconnect and RLA >

445

11.75” (298 mm)

Starter/Control Panel

Evaporator

14.12” (359 mm)

(1) 1’-1/4” (32 mm) dia knockout for printer cable

(10) 7/8” (22 mm) dia knockout for 120 VAC control voltage UCP2 connections

3 - 2 RTHC-IOM-1C

Page 53

Other Supply Power Components

disconnect) as follows:

Fused Disconnect Switches

Size fused disconnects in accordance with NEC Article 440-22(a).

Compressor Motor Phase Sequencing

Always verify that proper rotation of the Series R compressor is established before the machine is started. Proper motor rotation requires confirmation of the electrical phase sequence of the power supply. The motor is internally connected for clockwise rotation with incoming power supply phased A, B, C.

To confirm the correct phase sequence (ABC), use a Model 45 Associated Research Phase indicator or equivalent.

Basically, voltages generated in each phase of a polyphase alternator or circuit are called phase voltages. In a three-phase circuit, three sine wave voltages are generated, differing in phase by 120 electrical degrees. The order in which the three voltages of a three-phase system succeed one another is called phase sequence or phase rotation. This is determined by the direction of rotation of the alternator. When rotation is clockwise, phase

sequence is usually called “ABC,” when counterclockwise, “CBA.”

Phase Seq. Lead 1TB1 Terminal

Black (Phase A) L1

Red (Phase B) L2

Yellow (Phase C) L3

4 Turn power on by closing the unit supply power

disconnect switch.

5 Read the phase sequence on the indicator. The

“ABC” indicator on the face of the phase indicator will glow if phase is “ABC”.

WARNING

Hazardous Voltage! Disconnect all electrical power, including remote disconnects before servicing. Failure to disconnect power before servicing can cause severe personal injury or death.

6 If the “CBA” indicator glows instead, open the unit

main power disconnect and switch two line leads on the line power terminal block (or the unit mounted disconnect). Reclose the main power disconnect and recheck phasing.

This direction may be reversed outside the alternator by interchanging any two of the line wires. It is this possible interchange of wiring that makes a phase sequence indicator necessary if the operator is to quickly determine the phase rotation of the motor.

Correcting Improper Electrical Phase Sequence

Proper compressor motor electrical phasing can be quickly determined and corrected before starting the unit. If using an Associated Research Model 45 Phase Sequence Indicator, follow this procedure:

1 Press the STOP button to insure the unit will not

attempt to start the compressor.

2 Open the electrical disconnect or circuit protection

switch that provides line power to the line power terminal block in the control panel (or to the unitmounted disconnect).

3 Connect the phase sequence indicator leads to

the line power terminal block (or the unit mounted

7 Reopen the unit disconnect and disconnect the

phase indicator.

Compressor Motor Power Wiring

Provide line voltage wiring from the starter/control panel to the proper terminals in the compressor motor junction box. See motor wire sizing information.

Terminal Lugs.

Proper starter/control panel line-side lug sizes are specified on the starter submittals. These lug sizes must be compatible with conductor sizes specified by the electrical engineer or contractor. Appropriate lug sizes are provided.

Rated Load Ampacity (RLA)

The compressor motor RLA for a particular chiller is determined by the field selection program and indicated on the compressor nameplate.

Figure 22

and

Table 12

for

Installation, Operation and Maintenance 3 - 3

Page 54

Minimum Circuit Ampacity (MCA)

The MCA is equal to 1.25 x the compressor RLA (on nameplate).

Maximum Fuse/Circuit Breaker Size

The maximum fuse/circuit breaker size is equal to

2.25 x the compressor RLA in accordance with UL 1995, para. 36.15.

The recommended dual element (RDE) fuse size is equal to 1.75 x RLA in accordance with NEC Table 430-152.

For recommended field connection lug sizes (RTHC starters) see

Table 13 Recommended Field Connection Starter Lug Sizes

Starter/Control

Panel

Connection

Terminals only

Main Circuit Breaker or Nonfused Disconnect Switch

Table 13

RLA Range

000-760 (2) #4-500 MCM 761-935 (4) #4/0-500 MCM 000-185 (1) #4-350 MCM 186-296 (2) 2/0-250 MCM 297-444 (2) 3/0-350 MCM 445-592 (2) #1-500 MCM 593-888 (4) 4/0-500 MCM

Lug Size L1 - L3

(each phase)

closes, which bypasses the SCRs. The bypassing of the SCRs eliminates the inefficiencies and heating that would result if they carried current continuously. The contactor, however, will experience greatly reduced contact wear and increased life, since it only has to carry running currents and neither has to make or break the inductive motor load.

In the unlikely event that the motor does not come up to speed within the factory Maximum Acceleration time, the contactor will be pulled in by the UCP2 starter module and the motor will be put directly across the line for full starting torque availability. However, if the associated transient to the power system is unacceptable, UCP2 can be programmed to instead abort the start upon failure to accelerate. Refer to Section 4 for UCP2 settings and descriptions.

On RTHC chillers, solid-state starters are connected “inside the delta” of the motor connection. This means that, whereas most solid-state starters may be applied “in the line connection”, on the RTHC chiller each SCR pair is connected in series with a motor winding coil. When applied in this fashion the solid-state starter provides reduced inrush starting with smaller, more economical controls, which will see about 57% of the line current. The connections between the line, the main circuit breaker, the solidstate starter, and the compressor motor terminals is illustrated in

Figure 18

Note: Lug sizes are dependent on starter type

Application Of Solid-state Starters

The starter is a pre-wired platform consisting of a 3pole bypass contactor mounted in parallel with three triacs (each composed of a pair of back to back Silicon Controlled Rectifiers (SCRs)), and two gating/ logic/controller PC boards. The SCRs control the inrush currents to the motor until it is up to speed,

through cycle by cycle “switching” of the voltage applied to the motor winding. Such a reduced voltage starting method reduces, significantly, the high inrush currents normally associated with an across the line starting method. This in turn reduces the voltage dips that would otherwise be experienced by the power system during startup, as well as limiting starting torque and motor stator heat up rates and their accompanying motor stresses.

The current is controlled according to a factory preset ramp time and current limit settings on the starter. Once the motor is fully up to speed, the contactor

Starters are selected and control settings are made for a given compressor motor maximum amp rating, voltage and frequency. Selected starters are from the Eaton Eazy-Start EA product family. In general the nominal ratings were reduced about 10% to allow operation in ambients up to 122°F. These control settings should not be reduced for the same model chiller, which happens to have a lower nameplate marking because of different application conditions.

All chillers must be capable of starting under the worst-case starting conditions (typically 90° F entering the chiller). Under these conditions the starter must provide the necessary torque to start the motor. For a given motor design, regardless of the chiller’s nameplate marking, the required starting current is a prescribed value. The solid-state starter selected for each chiller has taken this into account, and control settings have been prescribed so the chiller starts reliably.

If the starter control settings are lowered, chances are that the motor may not come up to full speed in the available time, and the motor will then momentarily draw full locked rotor current when the

3 - 4 RTHC-IOM-1C

Page 55

bypass contactor closes. This would result in line voltage dips and dimming of lights whenever the chiller starts, and should be avoided. Following the prescribed selections and control settings will result in reliable chiller starting, while maximizing motor and contactor life.

Selections in the following table are based on the following startup ramp. The initial current is limited to 200% of the max compressor rated load amps. Over a period of 5 seconds the inrush is allowed to increase to a value approximately equal to 300% of the max load amps. These settings produce reliable

starting over the chiller’s operating range. For the controller settings prescribed, the compressor motor comes up to full speed consistently within the Maximum Accelera tion T im e as facto ry set on U CP2. See Section 5 for factory settings of the Maximum Acceleration Timer.

Solid-state Starter Controller Settings

Installation, Operation and Maintenance 3 - 5

Page 56

Table 14

WARNING

Solid State Starter Selections

Precautions When Using Solid-State Starters

When using solid-state starters, there are two precautions servicing personnel need to be aware of.

STARTER AND MOTOR TERMI-

NALS REMAIN “HOT” AT HIGH VOLTAGE EVEN WHEN MOTOR AND STARTER ARE “OFF.” Be Certain To Disconnect All Power To The Unit Before Performing Any Work In The Starter Panel.

3 - 6 RTHC-IOM-1C

The “In the Phase” starter does not remove voltage from any of the six motor leads when it is off. Three of the six motor leads remain directly connected to line voltage with respect to ground. The remaining three terminals are pulled up to the line voltage through the motor impedance of each phase. See

Figure 18

Page 57

Figure 18 Solid State Starter Connections

Shunt Trip Circuit

Breaker\Disconnect

Line

Phase

Triac "In

the Phase"

Contactor

Bypass

Note that even a Solid State Starter with its triacs “in the line” represent a similar hazard. Should a person contact any of the motor terminals, even with the motor off, the triac “off-state” leakage and finite snubber impedance would be enough to cause a severe, even fatal, electrical shock. In the case of the “in the phase” starter, the currents available could be quite high, as little or no impedence would be in series with the voltage source.

Figure 19 Caution label on starters panels equipped with solid-state starters

T4T2T5

BREAKER OPENED. EVEN WHEN THE COMPRESSOR IS NOT RUNNING, VOLTAGE IS PRESENT AT THE COMPRESSOR MOTOR TERMINALS, PROVIDING THE POTENTIAL FOR CURRENT TO FLOW THROUGH A LOW IMPEDANCE PATH.

As the chiller is evacuated below atmospheric pressure, the dielectric strength (resistance to arcing) of the gaseous atmosphere is significantly reduced.

Because the SCRs are connected “inside the delta,” three of the motor terminals are connected directly to the line voltage. An “arc over” can occur between motor terminals under conditions seen in the evacuation process. If this occurs the circuit breaker (or other external protective devices) will trip in response to high fault currents, and motor damage may also occur. This can be avoided through being certain that the chil ler is

fully disconnected from all power sources before beginning pumpdown or evacuation procedures

, as well as guaranteeing that the disconnect cannot be accidentally closed while the chiller is in a vacuum.

WARNING

Contacting any of the motor terminals, even with the motor off can cause a severe, potentially fatal, shock.

IMPORTANT! WHEN EVACUATING THE

CHILLER’S REFRIGERANT SYSTEM, ALWAYS HAVE THE MAIN POWER DISCONNECT/CIRCUIT

Installation, Operation and Maintenance 3 - 7

Page 58

Figure 20 Y- D St arter Panel showing cables to compressor motor terminals

Figure 21 Solid State Starter Panel showing cables to compressor motor terminals

3 - 8 RTHC-IOM-1C

Page 59

Figure 22 Motor Termi na l J unc t ion Box Wiring (Wye Delt a Starter)

Ground Lugs

L1 L2 L3

1K1

1K2

1K3

1 2

1K4

T6 T4

1T1

1T2

1T3

Current Transformers

Module Connections for Interconnecting Wiring

All connectors can be unplugged or the wires can be removed from the screw assembly. If an entire plug is removed, make sure the plug and the associated jack are marked for proper locat ion identi fication during reinstallation.

CAUTION

CAUTION: Plugs and jacks must be clearly marked before disconnecting, because specific plugs will fit into other jacks. Possible damage to equipment may occur if the plugs are reversed with the jacks.

Interconnecting Wiring (Field Wiring Required)

Important

chilled water pump interlocks.

When making field connections, refer to the appropriate field layout, wiring, schematics and controls diagrams that ship with the unit. The

: Do not turn chiller on or off using the

diagrams in this manual are typical only and may not match the unit.

Whenever a contact closure (binary output) is referenced, the electrical rating is:

7.2 amp resistive

At 120 VAC

At 240 VAC

2.88 amp pilot duty

1/3 hp, 7.2 FLA, 43.2 LRA

5.0 amp resistive

2.0 amp pilot duty

1/3 hp, 3.6 FLA, 21.6 LRA

Whenever a dry contact input (binary input) is referenced, the electrical rating is 24VDC, 12 mA.

Whenever a control voltage contact input (binary input) is referenced, the electrical rating is 120 VAC, 5mA.

NOTE: Asterisked connections require the user to provide an external source of power. The 115V control power transformer is not sized for additional load.

Chilled Water Pump Control*

The chiller module (1U1) provides a contact closure output (J12-1, J12-2) to control the chilled water pump starter. This contact closure pulls in when the

Installation, Operation and Maintenance 3 - 9

Page 60

external auto stop input is closed and opens when the timeout period, specified in the Service Settings group, expires after the external auto stop input opens.

Chilled Water Flow Interlock

The chiller module (1U1) requires a control voltage contact input (1TB3-14, J26-1) through a flow proving switch (5S1) and an auxiliary contact (5K1 AUX) from the chilled water pump starter that provides proof of flow.

Relay 3 - Programmable*

The chiller module (1U1) provides a normally open (J20-2, J20-1) contact closure output that may be used to remotely indicate a load limit condition (condenser, evaporator or current) existed for more than 20 minutes.

Figure 23 RTHC Electrical Installation Programmable Relays

1U1

IMPORTANT! DO NOT cycle the chiller through starting and stopping the chilled water pump. This will cause the compressor to shut down full y loaded. Use the externalstop/start input to cycle the chiller.

Condenser Water Pump Control*

The chiller module (1U1) provides a contact closure output (J14-1, J14-2) to control the condenser water pump starter. This contact closure pulls in anytime the UCP2 generates a need for cooling based on the leaving chilled water temperature versus setpoint and opens when the compressor is stopped.

Condenser Water Flow Interlock

The chiller module (1U2) requires a control voltage contact input (1TB3-15, J28-2) through a flow proving switch (5S2) and an auxiliary contact (5K2 AUX) from the condenser water pump starter that provides proof of flow.

NOTE: The following three connections have programmable functions. Each relay can be configured individually as an alarm contact, compressor contact, or a limit warning contact. Their default functions are described as follows.

See Section 5, Service Settings for details on other functions that can be assigned to these contacts.

Relay 1 - Programmable*

The chiller module (1U1) provides a normally open (J16-3, J16-1) and a normally closed (J16-3, J16-2) contact closure output that may be used to remotely indicate the compressor is running in any mode except Run Unload.

Relay 2 - Programmable*

The chiller module (1U1) provides a normally open (J18-3, J18-1) and a normally closed (J18-3, J18-2) contact closure output that may be used to remotely indicate a latching diagnostic exists.

J16-3

Relay 1

Relay 2

Relay 3

J16-2 J16-1

J18-3 J18-2

J18-1

J20-2

J20-1

Customer-provided 115VAC Power; Max fuse Size: 15 amp

Outdoor Air Temperature Sensor

The chiller module (1U1) provides for connection (J55, J5-6) of an outdoor air temperature sensor (5RT1) that may be used for outdoor air chilled water reset. The UCP2 contains the logic required, based on menu items selected, to perform these functions.

External Auto Stop

The chiller module (1U1) provides a dry contact input (J5-1, J5-2) that must be used to enable or disable the chiller from a remote location, unless a Tracer is performing this function. If this feature is not used, a jumper must be placed across this input. If the chilled water pump is controlled by the UCP2 (chiller module J12-2, J12-1), the external auto stop will start and stop the pump as described above.

Emergency Stop

The chiller module (1U1) provides a dry contact input (J5-3, J5-4) that may be used to immediately shut the chiller down. If this feature is not used, a jumper must be placed across this input.

This method of stopping the chiller should only be used for emergency shutdowns

, because the slide valve will

3 - 10 RTHC-IOM-1C

Page 61

not have a chance to return to the unloaded position for the next startup.

NOTE: A “panic” stop (similar to “emergency” stop) can be manually commanded using the Clear Language Display. By pressing the STOP button twice in a row, the chiller will immediately shut down, but without creating a latching diagnostic.

Tracer Controlled Contact

The options module (1U5) provides a Tracercontrolled relay normally open contact closure output (J18-1, J18-3) and normally closed contact output (J18-2, J18-3). This feature can be used for any customer-specified requirement, via programming Tracer to energize this relay.

The CLD Stop, Tr acer, commanded stop, or External Auto Stop are acceptable routine stops. In these cases, a pre-stop run-unload period is allowed for the compressor to fully unload prior to shutdown.

Operation and diagnostics are discussed in detail in sections 5 and 10.

External Base Loading

The chiller module (1U1) provides for external hard-

wired control of the chiller in a mode known as “base loading.”

Primarily for process control requirements, base loading provides for immediate start and loading of a chiller up to an externally or remotely adjustable current limit setpoint without regard to differential to start or stop, or to leaving water temperature control. This allows the flexibility to prestart or preload a chiller in anticipation of a large load application. It also allows you to keep a chiller on line between processes when leaving water temperature control would normally cycle the unit.

This feature is controllable either through a Tracer communication interface or a 4-20mA or 2-10VDC hard-wired analog input (J7-11, J7-12) with a binary input (J7-1, J7-2) for enable/disable. When the binary input is closed, the base load function will be enabled and the chiller will attempt to start (subject to all normal safeties and interlocks. The chiller will then load up to a current limit defined by the analog input. a 2VDC or 4 mA input corresponds to a base load of 40% RLA and a 10 VDC or 20 mA input corresponds to 100% RLA. Dip switch SW2-1 must be set ON for 4-20 mA operation.

Head Relief Request Contact

The options module (1U5) provides a contact closure output (J12-1, J12-2) that may be used to control indicating and/or auxiliary equipment in emergency situations, to provide additional heat rejection requirements. Note that this contact closes at an extreme head condition and should not be used for normal cycling of heat rejection equipment.

Ice Making Contact

The options module (1U5) provides a relay contact closure output (J8-1, J8-2) that is energized any time the UCP2 is in the ice making mode. This contact can be used for any customer-specified logic such as controlling valves and pumps and transition to normal cooling after ice-making is complete.

Ice Machine Control

The options module (1U5) uses a dry contact input (J3-7, J3-8) to enable the chiller in ice-making mode. When this contact input is closed, the chiller will use the evaporator return water temperature sensor input and the active ice termination setpoint to determine if ice making is required. Ice machine control must be enabled in the UCP2 machine configuration group to perform this function.

External Chilled Water Setpoint

The options module (1U5) will accept either a 2-10 VDC or a 4-20 mA input (J9-4, J9-5) signal, to adjust the chilled water setpoint from a remote location. DIP switch SW3-1 must be set to ON fo r 4-20 mA or OFF for 2-10 VDC. The 2-10VDC or 4-20 mA input corresponds to a 0-65 F chilled water setpoint range, i.e. 2VDC or 4mA corresponds to 0 F and 10VDC or 20mA corresponds to 65°F.

Both external chilled water setpoint and current limit setpoint must use the same input type. External chilled water setpoint input must be installed and the type selected in the UCP2 machine configuration group.

External Current Limit Setpoint

The options module (1U5) will accept either a 210VDC or a 4-20mA input (J7-11, J7-12) signal to adjust the current limit setpoint from a remote location. DIP switch SW2-1 must be set to ON for 420mA or OFF for 2-10VDC. The 2-10VDC or 4-20mA input corresponds to a 40-120 percent current limit setpoint range i.e. 2VDC or 4 mA corresponds to 40 percent and 10VDC or 20mA corresponds to 120 percent.

Installation, Operation and Maintenance 3 - 11

Page 62

Both external chilled water setpoint and current limit setpoint must use the same input type. External current limit setpoint input must be installed and the type selected in the UCP2 machine configuration group.

Tracer Temperature Sensor Option

The options module (1U5) accepts input (J7-7, J7-8) from a temperature sensor (5RT2) that may be used by Tracer for chilled water reset, ambient lockout, or other user-specified functions performed by the Tracer logic.

Percent Condenser Pr ess ure Ou tp ut

The options module (1U5) provides a 2-10 VDC output (J7-1, J7-2) signal that is proportional to the percent condenser pressure. At 2 VDC output, the condenser pressure is 0 psia and at 10 VDC output, the condenser pressure is equal to the high pressure cutout (psia) specified in the UCP2 machine configuration group. This output may be used for any user-specified function such as cooling tower water temperature control or input to a generic building automation system. Note that in many applications such as to w er c on t ro l, ev en t s must take p l ac e be f o re reaching either end of the scale, and an appropriate band must be selected for proper, steady control. Refer to the instructions supplied with the controlled device for setup.

Compressor Percent RLA Output

The options module (1U5) provides a 2-10 VDC output (J7-3, J7-4) signal that is proportional to the percent compressor RLA.

3 - 12 RTHC-IOM-1C

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2SHUDWLQJ3ULQFLSOHV0HFKDQLFDO

This section contains an overview of the operation and maintenance of Series R chillers equipped with microcomputer-based control systems. It describes the overall operating principles of the Series R design.

Following the section is information regarding specific operating instructions, detailed descriptions of the unit controls and options (section 5), and maintenance procedures that must be performed regularly to keep the unit in top condition (sections 8,

9). Diagnostic information (section 10) is provided to allow the operator to identify system malfunctions.

NOTE: To ensure proper diagnosis and repair, contact a qualified service organization if a problem should occur.

General

The Model RTHC units are single-compressor, helical-rotary type water-cooled liquid chillers. These

Figure 24 RTHC - Basic Unit Components

units are equipped with unit-mounted starter/control panels.

The basic components of an RTHC unit are: q Unit-mounted panel containing starter and UCP2

microprocessor

q helical-rotary compr ess or q evaporator q electronic expansion valve and liquid-vapor

separator

q water-cooled condenser with integral subcooler q oil supply system q oil cooler (application dependent) q related interconnecti ng pip in g.

Components of a typical RTHC unit are identified in

Figure 24

Starter/Control

Panel

Liquid Vapor Separator

Compressor

Oil Supply System

Evaporator

Condenser

Installation, Operation and Maintenance 4 - 1

Page 64

Refrigeration (Cooling) Cycle

The refrigeration cycle of the Series R chiller is conceptually similar to that of other Trane chiller products. It makes use of a shell-and-tube evaporator design with refrigerant evaporating on the shell side and water flowing inside tubes having enhanced surfaces.

The compressor is a twin-rotor helical rotary type. It uses a suction gas-cooled motor that operates at lower motor temperatures under continuous full and part load operating conditions. An oil management system provides oil-free refrigerant to the shells to maximize heat transfer performance, while providing lubrication and rotor sealing to the compressor. The lubrication system ensures long compressor life and contributes to quiet operation.

Condensing is accomplished in a shell-and-tube heat exchanger where refrigerant is condensed on the shell side and water flows internally in the tubes.

Refrigerant is metered through the flow system using an electronic expansion valve, that maximizes chiller efficiency at part load.

A unit-mounted starter and control panel is provided on every chiller. Microprocessor-b ased unit control modules (UCP2) provide for accurate chilled water control as well as monitoring, protection and adaptive

limit functions. The “adaptive” nature of the controls intelligently prevents the chiller from operating outside o f its limi ts, or compensates for unusual operating conditions, while keeping the chiller running rather than simply tripping due to a safety concern. When problems do occur, diagnostic messages assist the operator in troubleshooting.

Cycle Description

The refrigeration cycle for the RTHC chiller can be described using the pressure-enthalpy diagram shown in on the figure and are referenced in the discussion following. A schematic of the system showing the refrigerant flow loop as well as the lubricant flow loop is shown in

Evaporation of refrigerant occurs in the evaporator that maximizes the heat transfer performance of the heat exchanger while minimizing the amount of refrigerant charge required. A metered amount of refrigerant liquid enters a distribution system in the evaporator shell and is then distributed to the tubes in the evaporator tube bundle. The refrigerant vaporizes as it cools the water flowing through the

Figure 25

Figure 26

. Key State Points are indicated

evaporator tubes. Refrigerant vapor leaves the evaporator as saturated vapor (State Pt. 1).

The refrigerant vapor generated in the evaporator flows to the suction end of the compressor where it enters the motor compartment of the suction-gascooled motor. The refrigerant flows across the motor, providing the necessary cooling, then enters the compression chamber. Refrigerant is compressed in the compressor to discharge pressure conditio ns. Simultaneously, lubricant is injected into the compressor for two purposes: (1) to lubricate the rolling element bearings, and (2) to seal the very small clearances betw een the compressor’s twin rotors. Immediately following the compression process the lubricant and refrigerant are effectively divided using an oil separator. The oil-free refrigerant vapor enters the condenser at State Pt. 2. The lubrication and oil management issues are discussed in more detail in the compressor description and oil management sections that follow.

Baffles within the condense r sh ell dist ribut e th e compressed refrigerant vapor evenly across the condenser tube bundle. Cooling tower water, circulating through the condenser tubes, absorbs heat from this refrigerant and condenses it.

As the refrigerant leaves the bottom of the condenser (State Pt. 3), it enters an integral subcooler where it is subcooled before traveling to the electronic expansion valve (State Pt. 4). The pressure drop created by the expansion process vaporizes a portion of the liquid refrigerant. The resulting mixture of liquid and gaseous refrigerant then enters the liquid-vapor separator chamber (State Pt. 5). At this point the av a il a bl e r ef ri g er an t va po r i s r o ute d di r e ctly to the compressor suction (State Pt. 1). All remaining liquid refrigerant enters the evaporator (State Pt. 6).

The RTHC chiller maximizes the evaporator heat transfer performance while minimizing refrigerant charge requirements. This is accomplished by metering the liquid refrigerant flow to the evaporator’s distribution system using the electronic expansion valve. A relatively low liquid level is maintained in the evaporator shell, which contains a bit of surplus refriger ant liquid and accumulated lubricant. A liquid level measurement device monitors this level and provides feedback information to the UCP2 unit controller, which commands the electronic expansion valve to reposition when necessary. If the level rises, the expansion valve is closed slightly, and if the level is dropping, the valve is opened slightly such that a steady level is maintained.

4 - 2 RTHC-IOM-1C

Page 65

Figure 25 Pressure /Enthalpy Curve

Pressure

Figure 26 Refrigerant Flow Diagram

Liquid

Gas

Enthalpy

Liquid/Vapor

Separator

EXV

Compressor

Evaporator

Oil Separators

Condenser

Installation, Operation and Maintenance 4 - 3

Page 66

Compressor Description

Figure 27 RTHC Compressor

Female Rotor

Male Rotor

Unload Solenoid

Load

Solenoid

Bearings

Piston Housing

Bearing Housing

Suction

Motor Housing

Rotor Housing

Discharge Check Valve

Oil Reclaim Port

4 - 4 RTHC-IOM-1C

Unloader Piston

Bearing Lubricant Port

Rotor Injection Port

Discharge Plenum

Primary Mounting Holes

Motor Stator

Slide Valve

Discharge Check Valve

Page 67

The compressor used by the Series R chiller consists of three distinct sections: the motor, the rotors and the bearing housing. Refer to

Figure 27

Compressor Motor

A two-pole, hermetic, squirrel-cage induction motor directly drives the compressor rotors. The motor is cooled by suction vapor drawn from the evaporator and entering the end of the motor housing

27)

(Figure

valve unloading lowers refrigeration capacity by reducing the compression surface of the rotors.

Slide Valve Movement

Movement of the slide valve piston (

Figure 27

) determines slide valve position which, in turn, regulates compressor capacity. Compressed vapor flowing into and out of the cylinder governs piston movement, and is controlled by the load and unload solenoid valves, 4L2 and 4L3.

Compressor Rotors

Each Series R chiller uses a semi-hermetic, directdrive helical rotary type compressor. Excluding the bearings, each compressor has only 3 moving parts:

2 rotors - “male” and “female” - provide compression, and a slide valve that controls capacity. See

. The male rotor is attached to, and driven by, the

Figure

motor, and the female rotor is, in turn, driven by the male rotor. Separately housed bearing sets are provided at each end of both rotors on the RTHC units. The slide valve is located below (and moves along) the rotors.

The helical rotary compressor is a positive displacement device. As shown in

Figure 27

, refrigerant from the evaporator is drawn into the suction opening at the end of the motor section. The gas is drawn across the motor, cooling it, and then into the rotor section. It is then compressed and released directly into the discharge plenum.

There is no physical contact between the rotors and compressor housing. Oil is injected into the bottom 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/bearing housing sections of the compressor. Positioned along the bottom of the rotors, the slide valve is driven by a piston/cylinder along an axis that parallels those of the rotors (

Figure 27

Compressor load condition is dictated by the coverage of the rotors by the slide valve. When the slide valve fully covers the rotors, the compressor is fully loaded. Unloading occurs as the slide valve moves away from the suction end of the rotors. Slide

The solenoid valves (both normally closed) receive “load” and “unload” signals from the UCP2, based on system cooling requirements. To load the compressor, the UCP2 opens the load solenoid valve (4L2). The pressurized vapor flow then enters the cylinder and, with the help of the lower suction pressure acting on the face of the unloader valve, moves the piston over the rotors toward the suction end of the compressor.

The compressor is unloaded when the unload solenoid valve (4L3) is open. Vapor “trapped” within the cylinder is drawn out into the lower-pressure suction area of the compressor. As the pressurized vapor leaves the cylinder, the slide valve slowly moves away from the rotors toward the discharge end of the rotors.

When both solenoid valves are closed, the present level of compressor loading is maintained.

On compressor shutdown, the unload solenoid valve is energized. Springs assist in moving the slide valve to the fully-unloaded position, so the unit always starts fully unloaded.

Oil Management System

Oil Separator

The oil separator consists of a vertic al cy li nd er surrounding an exit passageway. Once oil is injected into the compressor rotors, it mixes with compressed refrigerant vapor and is discharged directly into the oil separator. As the refrigerant-and-oil mixture is discharged into the oil separator, the oil is forced outward by centrifugal force, collects on the walls of the cylinder and drains to the bottom of the oil separator cylinder. The accumulated oil then drains out of the cylinder and collects in the oil sump located near the bottom of the chiller.

Installation, Operation and Maintenance 4 - 5

Page 68

Figure 28

Oil Flow Diagram

Trap

Oil/Refrigerant Mixture

Oil Recovery

Check Valve

Optional Oil Cooler

Oil Filter

Manual

Service

Valve

capacity

vertical line

Large

Optical Oil

Detector

Oil Return Gas Pump

Vent

Oil Flow

Loss DP

Switch

Master Oil Line Solenoid

Evaporator

Oil Sump

Oil Heater

Restrictor Orifice

Drain Solenoid

Check Valve

Oil Charging Service Port

Valve

To Bearings

Injection to

Rotors

Oil Separators

Oil/Refrigerant

Mixture

Vent Line

Fill Solenoid

Valve

To Condenser

Pressure

Compressor

LVS

Primary Oil System Refrigerant & Oil Mixture-

Oil Recovery System

Condenser

EXV

Low Diff

Rfgt Pres

Switch

Oil that collects in the oil tank sump is at condensing pressure during compressor operation; therefore, oil is constantly moving to lower pressure areas.

Oil Flow Protection

Oil flowing through the lubrication circuit flows from the oil sump to the compressor (see

Figure 28

). As the oil leaves the oil sump, it passes through two service valves, an oil cooler (if used), oil filter, and master solenoid valve. Oil flow then splits into two distinct paths, each performing a separate function: (1) bearing lubrication and cooling, and (2) compressor oil injection.

Oil flow and quality is proven through a combination of a number of sensors, most notably two differential pressure switches and the optical oil level sensor.

If for any reason oil flow is obstructed because of a plugged oil filter, closed service valve, faulty master solenoid, or other source, a differential pressure (DP)

switch will give a “high” reading (as factorycalibrated) and shut down the chiller. The differential pressure switch is factory set to open and trip on a pressure rise above 20 psid for systems without an oil cooler and 35 psid for systems with an oil cooler.

Likewise, the optical oil level sensor can detect the lack of oil in the primary oil system (which could result from improper oil charging after servicing, or oil logging in other parts of the system). The sensor can prevent the compressor from starting or running unless an adequate volume of oil is present. The combination of these two devices, as well as diagnostics associated with extended low system differential pressure and low superheat conditions, can protect the compressor from damage due to severe conditions, component failures, or improper operation.

If the compressor stops for any reason, the master solenoid valve closes; this isolates the oil charge in the sump during “off” periods. The check valves in the primary oil system prevent reverse flow that the solenoid valve may be unable to contain or “injectorto-bearing” oil flow immediately following compressor shutdown. Such flows would otherwise clear out oil from the lines and the oil sump, which is an undesirable effect.

T o ensure the required system differential pressure is adequate to move oil to the compressor, the UCP2 monitors both the 7.7 psid differential switch mounted between the evaporator and the condenser and the temperature sensors mounted in both the evaporator

4 - 6 RTHC-IOM-1C

Page 69

and condenser. If the differential is lower than

required, the unit will latch out and may start a “low system differential restart inhibit timer,” if necessary, to cool the rotors.

To ensure proper lubrication and minimize refrigerant condensation in the oil sump, a heater is mounted on the side of the oil sump. A signal from the UCP2 energizes this heater during the compressor off cycle to maintain proper oil temperature. The heater element is continuously energized while the compressor is of f an d does no t cycl e on te mpe rat ure.

Oil Filter

All Series R chillers are equipped with replaceableelement oil filters. Each removes any impurities that could foul the compressor internal oil supply galleries. This also prevents excessive wear of compressor rotor and bearing surfaces and promotes long bearing life. Refer to the Section 9 for recommended filter element replacement intervals.

Compressor Bearing Oil Supply

Oil is injected into the rotor housing where it is routed to the bearing groups located in the motor and bearing housing sections. Each bearing housing is vented to compressor suction so oil leaving the bearings returns through the compressor rotors to the oil separator.

Lubricant Recovery

Gas Pump

Despite the high efficiency of the oil separators, a small percentage of oil will get past them, move through the condenser, and eventually end up in the evaporator. This oil must be recovered and returned to the oil sump. The function of active oil return is accomplished by a pressure-actuated pump referred to as the “gas pump.”

Compressor Rotor Oil Supply

Oil flowing through this circuit enters the bottom of the compressor rotor housing. From there it is injected along the rotors to seal clearance spaces around the rotors and lubricate the contact line between the male and female rotors.

Installation, Operation and Maintenance 4 - 7

Page 70

The gas pump, mounted just beneath the evaporator, is a cylinder with four ports controlled by two solenoids. The pump serves to return accumulating oil in the evaporator to the compressor at regular time intervals. As the refrigerant-oil mixture enters the gas pump from the bottom of the evaporator, a fill solenoid opens to allow refrigerant vapor to be vented into the top of the evaporator, and is then closed. A second solenoid then opens to allow refrigerant at condenser pressure to enter the gas pump. Simultaneously, a check valve prevents reverse flow back into the evaporator. A liquid refrigerant and oil mixture is displaced from the gas pump cylinder and is directed through a filter to the compressor. The oil then combines with oil injected into the compressor and returns to the oil sump via the oil separators.

Oil Cooler

The oil cooler is a brazed plate heat exchanger located near the oil filter. It is designed to transfer approximately one ton of heat from the oil to the suction side of the system. Subcooled liquid is the cooling source.

The oil cooler is required on units running at high condensing or low suction temperatures. The high discharge temperatures in these applications increase oil temperatures above the recommended limits for adequate lubrication and reduce the viscosity of the oil.

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Page 71

2SHUDWRU,QWHUIDFH&RQWUROV

This section contains an overview of the operator interface with the Series R chillers equipped with microcomputer-based control systems. It presents the array of options available using the Clear Language Display and the associated keypad.

The section is organized first as a discussion of the control system and the individual modules, showing their relationship and functions.

The remainder of the section presents information on accessing available chiller information using the screens to either monitor or change settings and setpoints. This part of the section covers information available to you by pressing each report key followed by the settings, tests, and diagnostics keys.

The display information is for reference only and not in the form of sequential operating or controls instructions, although certain specific instructions as to programming and changing settings is given. In many cases, background information on specific key or controls functions is provided.

In all cases, other than report data displays, caution should be observed before changing any parameters until the impact of the change on chiller performance is understood.

Following this section, sections 6 and 7 cover the actual startup and shutdown sequences. Maintenance schedules and procedures that must be performed to keep the unit in top condition are in sections 8 and 9. Diagnostic information (section 10) is provided to allow you to identify system malfunctions.

UCP2 Microprocessor Control System

The Unit Control Panel version 2 (UCP2) microprocessor control system is a collection of modules and software that perform system control, protection, and optimization functions for the RTHC chiller. All module control elements reside in the

control panel usually “stacked” on top of one another and mounted on the panel’s backplane. Additionally, the Clear Language Display operator interface is mounted on the panel door.

The “Control System Block Diagram.” on page 2 accompanies the discussion in the following paragraphs that describe the modules and the specific chiller operating characteristics that are displayed and reported.

Installation, Operation and Maintenance 5 - 1

Page 72

Figure 29 Control System Block Diagram.

Line Power

Circuit Breaker/ Disconnect/ Fuse / Terminal Block Options

Y-D or Solid State Starter

Starter Section

Starter/Control Panel

Hard Wired Customer Interfaces

Starter Mod.

Industry Std Interface

To Other Tracer

or Other BAS

Tracer(Comm 3)

or Summit (Comm 4)

(Optional)

To Other UCMs

ICS Proprietory

Printer

RS232

1U8 Buffer

1U6

TCI IV

Comm 3 or Comm 4

(Opt.)

IPC

1U2 1U1 1U3 1U5

1U4

Clear

Language

Display

Chiller Mod

Unit Proprietary

Stepper Mod. EXV

Printer Interface Mod. (Opt.)

Options Mod. (Opt.)

Control Section

1U7

Chiller Module - 1U1

The chiller module is the central processing unit of the chiller communicating commands to other modules and collecting data/status/diagnostic information from other modules over the IPC (inter processor communications) link. The chiller module performs the leaving chilled water temperature and

Hard Wired Factory Connections

KEY

Factory Wired Serial Comm Factory Hard Wired

Customer Wired Serial Comm

Customer Hard Wired

limit control algorithms, setting capacity against any operating limit constraining the chiller.

The chiller module contains non-volati le mem or y, checking for valid set points and retaining them on any power loss.

Inputs and outputs include chilled water system level input/output (I/O) such as evaporator and condenser

5 - 2 RTHC-IOM-1C

Page 73

water temperatures, evaporator and condens er water pump control, and general status and alarm relays. Other machine inputs and outputs include compressor load and unload pulse outputs, oil return pump control and oil lubrication system control and flow protection.

Stepper Module - 1U3

The stepper module is designed to drive the stepper motor electronic expansion valve. The stepper module uses liquid level inputs and stepper motor outputs to run the algorithm to control liquid level in the evaporator. The output of the control algorithm drives the electronic expansion valve. Other module I/O capabilities support general machine protection and control, including evaporator and condenser refrigerant temperatures.

Printer Interface Module - 1U7

The printer interface module provides a preformatted chiller log to the printer. The printer interface can be programed, via the Clear Language Display, to print a chiller log on command at the time of a diagnostic or on a periodic basis.

Clear Language Display (CLD) - 1U4

The local Clear Language Display is mounted on the control panel door and displays chiller data and gives access to operation/service controls, set points and chiller setup information or configuration. All setpoints and other settings are stored in non-volatile memory in the chiller module. The interface is programmed with a variety of languages.The display on the Clear Language Display is a two-line, 40 character liquid crystal. The display has a backlight so that it can be read in low light conditions.

Starter Module - 1U2

The starter module provides control of the starter when starting, running and stopping the motor. The starter module provides interface to, and control of, Y-Delta and solid state starters. The starter module also provides protection to both the motor and the compressor such as running overload, phase reversal, phase loss, phase unbalance and momentary power loss.

Options Module - 1U5

The options module satisfies control or interface requirements for a number of options. Some of these options are standalone such as generic BAS interface. Other options support either addition s or modifications to the chiller itself. Some features supported by the options module are ice making, external chilled water setpoint and external current limit setpoint.

In addition to the alpha-numeric liquid crystal display,

a red “alarm” LED is installed that flashes ON-OFF whenever a latching diagnostic (requiring manual reset) is present. The red LED is also used to indicate that a function or control has been set to manual from within the service test menu for a maintenance task such as oil line charging. If a control has been set to manual, the LED is ON continuously. If a diagnostic is active while some function is in a manual mode, the LED will flash ONOFF. Diagnostic displays and resetting procedures are discussed in Section 10.

A membrane keypad is used on the unit-mounted operator interface. The keypad is sealed, making it weather-proof and dirt-proof. The keypad has 16 keys arranged in a 4-by-4 matrix as shown in

Figure 30

COMM 3 or COMM 4 (Tracer Interface)1U6

Two communication modules are available for various communication functions. One available option provides a 9600 baud non-isolated link to Tracer Summit (Comm 4) and another can provide a similar, but isolated, communications link to existing Tracer 100 systems (Comm 3).

Installation, Operation and Maintenance 5 - 3

Page 74

Figure 30

CHILLER

REFRIGERANT

COMPRESSOR

CUSTOM

OPERATOR SETTINGS

SERVICE SETTINGS

SERVICE TESTS

DIAGNOSTICS

Previous + Enter Auto

Cancel Stop

REPORT

REPORT REPORT

See pages 12 - 13

See pages 30 - 33

See pages 17 - 30

See pages 14 - 17

See pages 36 - 38

See pages 6 - 11

See page 6

See page 13

Clear Language Display Key Assignments

Complex Character Clear Language Display (CCCLD)

The CCCLD is available as an option. This display functions identically to the CLD, but has a higher resolution that can support complex character sets such as those peculiar to Chinese, Korean, and Kanji.

Keypad functions are identical but the keys are “soft labeled” with the text describing them incorporated into the display in the appropriate language.

Key Functions

Report Groups

The top row of keys on the CLD provides for “view only” access to all the available chiller information in the form of three major Report Groups and one userdefined Custom Report.

The Chiller, Refrigerant, and Compressor Reports each contain a number of related items (temperatures, pressures, currents, etc.) arranged in a pre-determined order. (Values displayed are updated approximately every 2 seconds.) These items can be accessed by selecting and pressing the desired Report key that brings up the group’s “header” screen describing the type of information available in that group.

may be bypassed by disabling the “Menu Headings” feature under the Service Settings Group, in which case the first data item in the group will be shown.)

The <Next> and <Previous> keys can then be used to scroll from one report item to the next. As the last item is reached, continued scrolling will cause the

(NOTE: The header screen

display to wrap around to the beginning of the report group.

More information about what items are included in each of the reports is provided later in this section.

The Custom Report allows you to select items from any of the other thre e Report Groups, in any order, so that frequently read information can be more quickly accessed. Refer to the paragraph on Custom Report Group Programming for information on how to set up the Custom Report.

Settings Groups

The second row of keys provide access to all adjustable setpoints, settings, and commands as divided into four major Settings Groups. Items in the Operator Settings, Service Settings, Service Tests, and Diagnostics Group can be accessed by selecting and pressing the desired Settings Group Key that will bring up the Header screen describing the type of settings available in that menu.

The <Next> and <Previous> keys allow you to move

through the menu’s items not just to view the settings but to change them. Some items are passwordprotected; others or all, however, can be locked out within any of these settings groups without requiring the password. Items included in each of the Settings Groups, as wel l as pa ssw or d pro tec ti on f eat ure s, ar e discussed later in this section.

Changing Settings or Setpoint s

Once the particular setting is displayed on the screen, pressing the <+> or <-> key will cause the setting that is displayed to increment or decrement (increase or decrease), respectively. If the <+> or <-> key is held down for more than 1/2 second, it will increase or decrease the setting continuously, at approximately 10 counts per second, until the key is released. If the key is held down for 10 seconds, the setting will change at ten times its normal incremental value.

T o prevent inadvertent changes, a changed setting is not stored until the <Enter> key is pressed. The <Cancel> key may be pressed if a changed setting should not be saved. Once the <+> or <-> key has been pressed to change a particular setting, the display will show that setting but not store or save it

until the <Enter> or <Cancel> key is pressed

. The display will blank out for a moment after the <Enter> key is pressed, to indicate to the user that the key stroke has been recognized.

5 - 4 RTHC-IOM-1C

Page 75

Note that the <Stop> and <Auto> keys act immediately and do not require the use of the <Enter> key.

STOP, AUTO

The chiller will stop when the <Stop> key is pressed, entering the run unload mode. The <Stop> key has a red background. If <Stop> is pressed a second time

within five seconds, an immediate “panic stop” will be executed, bypassing the normal compressor unload period. During the five second period, a message is displayed indicating the optional command.

If the <Stop> key is pressed again during this fivesecond period, a message will be displayed for two seconds indicating that the panic stop is being executed.

To execute a panic stop, first press the <Stop> key. The message displayed during the five seconds after

the <Stop> key is pressed is:

Communications and Settings Storage

The individual modules identified earlier in this section communicate via the InterProcessor Communication (IPC) link. The IPC allows the modules to work together to direct overall chiller operation, each module handling specific functions.

In the IPC communication protocol, the 1U1 is the initiator and arbitrator of all module communication. The 1U1 requests “packets” of information from each module in a preset sequence. The other modules respond only and cannot initiate communication. Specific IPC diagnostic techniques are discussed in section 10.

The settings used by the unit are stored in the chiller module, not in the Clear Language Display. The chiller module is also responsible for verifying that the settings memory is not corrupted. It substitutes safe default settings if the stored settings become corrupted and generates appropriate warnings or diagnostics.

IF (STOP) IS PRESSED DURING THIS DISPLAY

*** A PANIC ST OP WILL BE EXECUTED ***

If the <Stop> key is pressed

again

during this five second period, the following message will be displayed for two seconds before reverting to the first screen of the chiller report where the current unit operating mode message is given. (These messages are discussed in the chiller report section.)

*** EXECUTING PANIC STOP ***

If the <Stop> key is not pressed during this five second period, the chiller will enter the Run Unload mode and the display will go to the first display of the chiller report.

If the chiller is in the Stop mode, pressing the <Auto> key causes the chiller to go into the auto/local or Auto/Remote mode. The <Auto> key is recognized by its green background color.

When the <Auto> or <Stop> keys are pressed, the display will go to the first display of the chiller report.

If there is no IPC communication between the chiller module and the Clear Language Display at power up, the following is displayed:

No Communications - Data Not Valid

Once IPC communications have been established, the “Data Not Valid” display is used if all chiller module communications are lost for more than 5 seconds.

The Clear Language Display automatically displays the chiller operating mode (the first screen in the chiller report) after a normal power-up or after communications is re-established.

Internal communications with the Clear Language Display is not necessary for the chiller to run. However, the chiller will require Clear Language Display communications to occur at least once in 15 seconds or an informational diagnostic screen will result.

If the operator changes a setting that is communicated to the chiller module but not accepted (after 30 seconds of no key activity), the following message is displayed at the end of the chiller report:

Installation, Operation and Maintenance 5 - 5

Setting Was Not Acknowledged By Chiller

Press (Next) (Prev) To Continue

Page 76

If many settings are changed in a short time or if setting changes are communicated to the chiller module but not acknowledged, the transmit buffer may become full and not able to accept additional changes. If that happens the following message is displayed for 2 seconds:

Press (Next) (Previous) to Continue

If items are selected for the custom report, the report heading and the selected items are displayed sequentially as <Next> or <Previous> is pressed.

HI Xmit Buffer is Full

The Clear Language Display will generally clear its transmit buffer without the message indicating the cause of the communications problem. Persistent problems should be referred to Trane Service.

Custom Report Group - Programming Instructions

Reports are added to the custom report group by pressing the <+> key when the desired report is being displayed from its normal report location.

Reports are removed from the custom re port group by pressing the <-> key when the desired custom report is being displayed.

The custom report group can contain a maximum of 20 displays. If you attempt to add more than 20 displays, the following message:

Should no entries be selected for the custom report, however, the second entry is:

No Items Are Selected For Custom Report

See Operator’s Manual To Select Entries

The report then wraps around to the report heading when <Next> is pressed.

Chiller Report

The Chiller Report displays chiller status, water temperatures settings, and setpoints. The sequence of displays is as follows:

Chiller Status, Water Temps & Setpts

“Press (Next) (Previous) to Continue*

Continuing, the following report option is given:

Custom Report Is Full, Report Not Added

is displayed for two seconds, indicating that the custom report is full.

If you attempt to add a report to custom report when it is already stored in custom report, the message:

Report Already In Custom Menu

will be displa yed for two seconds.

NOTE: Only displays from the chiller refrigerant or compressor reports can be added to the custom report.

The custom report sequence is as follows:

User Defined Custom Report

Press (Enter) for ASHRAE Guideline 3 Rpt

Press (Next) (Previous) To Continue

If <Enter> is pressed, the ASHRAE Guideline 3 Report menu comes up. Pressing <Next> brings up the standard report as described in the following paragraphs beginning with the chiller operating mode. The report selection is a matter of preference, although slightly different parameters are displayed as shown in the comparison

Table 15

following, the

numbers corresponding to the order displayed:

Table 15

Sequence

Parameter Displayed

Operating Mode 1 2 Chilled Water Setpoint/Source Evap Leaving Water Temp

Standard Report

ASHRAE Report

5 - 6 RTHC-IOM-1C

Page 77

Table 15

Sequence

Parameter Displayed

Ice Termination Setpoint/Source 3 4 Reset Chilled Water Setpoint/

Source Evap Entering Water Temp 5 4 Condenser Entering Water Temp. Condenser Leaving Water Temp Current Limit Setpoint/Source 7 5 Active Current Limit Setpt/Setting

Source Outdoor Air Temp 9 Time/Refrigerant Type 1 Refrigerant Monitor (option only) 6 Saturated Evap Refgt Temp Compressor Discharge Temp Compressor Starts/Running Time 8 Evap Refgt Pressure 9 Evap Approach Temp 10 Chilled Water Flow Switch Status 11 Saturated Cond Temp Condenser Refrigerant Pressure Condenser Approach Temp 14 Cond Water Flow Switch Status 15

Standard Report

612

ASHRAE Report

The chiller operating modes display comes up first in the standard report:

[Operating mode line 1] [Operating mode line 2]

Line 1 (and 2 if needed) indicates a current condition of the unit as shown in the following table

(Table 16)

In some cases, an associated timer or system parameter will be displayed that assures the transition to an expected mode is in progress, particularly during the unit start-up sequence.

Installation, Operation and Maintenance 5 - 7

Page 78

Table 16 Operating Modes

Operating Mode Display*

Unit Operation

Stop

Auto

Initialize

Start Starting Compressor Unit Is Building Ice

Run

* Displays are not in any sequence. Some displays will never appear, depending on options and situation

(First Line/Second Line)

Resetting

Local Stop: Cannot Be Overridden By

Any External Or Remote Device

Remote Display Stop: Chiller May Be

Set To Auto By Any Ext Or Rmt Device

Remote Run Inhibit

From External Source

Remote Run Inhibit

From Tracer

Diagnostic Shutdown Stop Unit is Running; Base Loaded

Diagnostic Shutdown Auto Unit Is Running; Base Loaded

Auto

Waiting For Evaporator Water Flow

Auto

Waiting For A Need To Cool

Waiting For Tr acer Comm unicat ions

T o Est ablish Operating Status

Starting Is Inhibited By Staggered Start

Time Remaining: MIN:SEC

Starting Is Inhibited By Restart

Inhibit Timer: Time Remaining MIN:SEC

Low Diff Rfgt Pres- Overheated Cprsr

cool-down Time Remaining: [min:sec]

Establishing Cond Water Flow

Positioning Electronic Expansion Valve

Establishing Cond Water Flow

Time Remaining: MIN:SEC

Cond Water Is Flowing

Positioning Electronic Exp Valve

Cond Water Is Flowing

PreS tart Unload Time Remaining:

MIN:SEC

Unit Is Running Ice Building Is Complete Unit Is Running

Capacity Limited By High Current

Unit Is Running

Capacity Limited By Phase Unbalance

Unit Is Running

Capacity Limited By High Cond Press

Unit Is Running

Capacity Limited By Low Evap Temp

Unit is Running

Establishing Minimum Capacity Limit

Unit Operation

Run

Auto Auto

Run

Run-Unload Unit Is Preparing To Shutdown

Run-Ice Build

Stop

Operating Mode Display*

(First Line/Second Line)

Unit Is Running; Capacity Limited By

Pulldown Rate Based Soft Loading

Unit Is Running; Capacity Limited By

Current Based Soft Loading

Waiting For Condenser Water Flow

Unit is Running; Base Loaded

Capacity Limited By High Current

Capacity Limited By Phase Unbalance

Capacity Limited By High Cond Press

Unit Is Running; Base Loaded

Capacity Limited By Low Evap Temp

Unit is Running; Base Loaded

Establishing Minimum Capacity Limit

Unit Is Running; Base Loaded

Pulldown Rate Based Soft Loading

Unit Is Running; Base Loaded

Current Based Soft Loading

Unit Is Building Ice

Capacity Limited By High Current

Unit Is Building Ice

Capacity Limited By Phase Unbalance

Unit Is Building Ice

Capacity Limited By High Cond Press

Capacity Limited By Low Evap Temp

Unit Is Running; Transitioning Ice Building

To Normal MIN:SEC

Immediate Shutdown

Panic Stop

Starter Dry Run

5 - 8 RTHC-IOM-1C

Page 79

Chilled Water Setpoint and Source/Evap Leaving Water Temp (Standard Report)

Chilled Water Setpoint [source]: xxx.x F Evap Leaving Water Temp: xxx.x F

This is the actual setpoint currently in use by the

chiller. The “source,” fro m w h er e it is de ri ve d, ca n b e either External, Tracer or Reset (meaning reset is enabled); otherwise the source is not displayed and Front Panel setoint source is implied.

The second line displays the fundamental temperature (and its source) upon which the reset is based. This represents the lowest setpoint possible when no reset is applied.

Ice Termination Setpoint/Ice Termination Setpoint Source

(Standard Report)

If the ice building option is installed and the chiller is not in the ice making or ice making completion mode, the following is displayed:

Ice Termination Setpt [source]: xxx.x F

Press (Next) (Previous) To Continue

If the chiller is in the ice making or ice making complete state, the following display is substituted for the above display:

Ice Termination Setpt [source]: xxx.x F Evap Entering Water Temp: xxx.x F

where source, if displayed is Tracer; otherwise it’s the Front Panel.

NOTE: The setpoint source may change

automatically from the implied “Front Panel “(no source displayed) to “Tracer” if Tracer is communicating a chilled water setpoint to the chiller. The only way to override Tracer-communicated setpoints is through the operator setting menu (global setpoint override).

Reset Chilled Water Setpoint and Type/Starting Chilled Water Setpoint and Source

(Standard

Report)

The following will only be displayed if chilled water reset is enabled:

where the “source” is Tracer or the Front Panel (no source field display).

Evaporator Entering and Leaving Water T emperatures

Evap Entering Water Temp: xxx.x F Evap Leaving Water Temp: xxx.x F

(Standard Report)

Condenser Entering and Leaving Water T emperatures

(Standard Report)

Dashes “-------” will be di splayed for the condenser entering or leaving water temperature if the corresponding input is open or shorted

Cond Entering Water Temp: xxx.x F Cond Leaving Water Te mp: xxx.x F

Current Limit Setpoint and Source

(Standard

Report)

[reset type] CWS: xxx.x f/c [source] CWS: xxx.x f/c

with [reset type] being outdoor air reset, return reset, or constant return reset and [source] being Front Panel, External, or Tracer.

The first line displays the actual setpoint to which the chiller is controlling, as reset upward depending on the reset type, reset ratio, and maximum reset parameters set elsewhere on the operator settings menu.

Installation, Operation and Maintenance 5 - 9

Current Limit Setpoint [source]: xxx%

Press (Next) (Previous) To Continue

If the source is displayed, it is Tracer, External, or ice building.

Outdoor Temperature

(Standard Report)

If the outdoor air temperature input is open or shorted, and neither outdoor air reset nor low ambient lockout is enabled, “-------” (dashes) is

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displayed. Otherwise the temperature received from the chiller module is displayed.

Chilled Water Setpoint and Source/Evap Leaving Water Temperature (ASHRAE Report)

Outdoor Air Temperature: xxx.x F

Press (Next) (Previous) To Continue

If Tracer is installed, the Tracer outdoor air temperature is displayed. If no Tracer is installed, the chiller module outdoor air temperature sensor is used.

* * * End of Standard Report * * *

ASHRAE Guideline 3 Report Menu

If the ASHRAE Guideline 3 Report Entry option was selected with the chiller report heading, the following header is displayed and a new sequence is established as indicated in .

ASHRAE Guideline 3 Report

Press (Next) (Previous) To Continue

Time of Day/Refrigerant Type (ASHRAE Report)

Chilled Wtr Setpt [source]: xxx.x F Evap Leaving Water Temp: xxx.x F

This is the actual setpoint currently in use by the chiller where the [source], from where it is derived. If no source is displayed, Front Panel setpoint source is implied.

If the chiller is in the ice making or ice making complete state, the following will appear instead of the above display:

Ice termination Setpt [source]: xxx.x F Evap Entering Water Temp: xxx.x F

where the [source] is External or Tracer.

Current Limit Setpoint and Source (ASHRAE Report)

Current Time/Date HH:MM xm Mon, XX XXXX Refrigerant Type: R134a

Chiller Operating Mode (ASHRAE Report

[Operating mode line 1] [Operating mode line 2]

Operating mode line 1 (and line 2 if needed) is a

continuous message and display the chiller’s current state or activity. It may also show an associated timer or system parameter, in some cases. The message is one from Table 16, “Operating Modes,” on page 8 and identical to the operating mode given in the standard report.

Current Limit Setpt [source] xxx%

Press (Next) (Previous) To Continue

Setting source will be Front Panel (field not displayed), Tracer, External, or ice building.

Refrigerant Monitor (ASHRAE Report)

If the analog refrigerant monitor is installed with or without the scanner option, the following item will be displayed:

Refrigerant Monitor xxx.x PPM

Press (Next) (Previous) to Continue

If the IPC MSA refrigerant monitor allows you to scan various channels, the following item will be displayed:

5 - 10 RTHC-IOM-1C

Refrigerant Monitor: Scanner Channel Y: XXXX PPM [Rfgt Type]

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where Y is the channel currently being scanned and XXXX is the refrigerant concentration of that channel.

Saturated Evap Temperature/Compressor Discharge Temperature (ASHRAE Report)

Chilled Water Flow Switch Status (ASHRAE Report)

The screen displays the status of the chilled water flow switch at the input to the UCM.

Saturated Evap Rfgt Temp: xxx.x F Compressor Discharge Temp: xxx.x F

Compressor Starts and Running Time (ASHRAE Report)

The starts and hours counters are displayed:

Compressor Starts: xxxxx Compressor Running Time: HRS:MIN:SEC

The compressor starts counter is increased with each start or attempted start of the compressor.

Evaporator Entering and Leaving Water Temperatures (ASHRAE Report)

Evap Entering Water Temp: xxx.x F Evap Leaving Water Temp: xxx.x F

Chilled Water Flow Switch Status:

Flow Switch is [y]

where [Y] is “Open/No Flow” or “Closed/Flow”

Condenser Entering and Leaving Water Temperatures (ASHRAE Report)

Cond Entering Water Temp: xxx. x F Cond Leaving Water Te mp: xxx.x F

Dashes will be displa yed f or eit her t emp erat ure if the input is open or shorted.

Saturated Condenser Temperature/Condenser Refrigerant Pressure (ASHRAE Report)

Saturated Cond Temp: xxx.x F Cond Rfgt Pressure: xxx.x psig

Saturated Evap Temperature/Evaporator Refrigerant Pressure (ASHRAE Report)

Saturated Evap Rfgt Temp: xxx.x F Evap Rfgt Pressure: xxx.x psig

Evaporator Approach Temperature (ASHRAE Report)

Evaporator Approach Temp: xxx.x F

Press (Next) (Previous) to Continue

Note: If a negative approach temperature is displayed, check the senso rs fo r prope r operat ion .

Condenser Approach Temperatures (ASHRAE Report)

Condenser Approach Temp: xxx.x F

Press (Next) (Previous) to Continue

Condenser Water Flow Switch Status (ASHRAE Report)

The screen displays the status of the conden ser water flow switch at the input to the UCM if and only if the differential water pressure sensor option is not installed.

Condenser Water Flow Switch Status:

Flow Switch is [y]

where [Y] is “Open/No Flow” or “Closed/Flow”

* * * End of ASHRAE Report * * *

Installation, Operation and Maintenance 5 - 11

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Refrigerant Report

Electronic Expansion Valve Position

Report Heading

Refrigerant Temp & Pressure Report

Press (Next) (Previous) to Continue

Evaporator and Condenser Refrigerant Pressure

Evap Rfgt Pressure: xxx.x psig Cond Rfgt Pressure: xxx.x psig

NOTE: The evaporator and condenser pressures are not measured directly but derived from associated temperatures assuming saturated conditions for R134a refrigerant.

Evaporator Refrigerant Liquid Level

Evap Liquid Level: sx.x inches [modifier]

Press (Next) (Previous) To Continue

Expansion Valve Position: xxx.x% Open Expansion Valve Position: xxxx Steps Open

This displ ay shows the po sition of th e EXV op en, fi rst as a percentage of valve stroke and also in steps (02040 for smaller EXV (200 T), 0-2760 for the two larger EXVs (300 and 400 T)). If pre-position of the valve is required (to allow delta P to be generated) for startup, 571 steps (28%) or 773 steps (28%), respectively, would be displayed at that time.

Just prior to compressor start, the EXV will go into a normal liquid level control, gradually opening, then closing, as determined by the liqu id level sensor .

Just prior to normal compressor shutdown, at the start of the run unload mode, the EXV opens at its maximum rate to its wide open position. This helps equalize the differential pressure in the system and reduces compressor action at shutdown. Upon shutdown, the EXV is automatically recalibrated.

Saturated Evap Temperature/Evap Refrigerant Pressure

The display will show the refrigerant liquid level in inches relative to the center of the range of the liquid level sensor as installed on the evaporator shell.

The sign “s,” either + and - or - and the modifiers “or more” used with + measurements and “or less” used with - measurements indicate the limited range of the sensor. When the sensor reads +1.0 or -1.0, the display will read +1.0 inches or more” or “-1.0 inches or less,” indicating the sensor is at the extremes of its range.

Normal operation should produce an evaporator liquid level of “0” inches meaning no deviation from the design level in the evaporator.

During normal operation and within 20 minutes of startup, the liquid level should be well within the sensor’s range of ±1 inch. Small variations in liquid level of ±.3 to .5 inch during steady state or with small load disturbances are normal.

If the liquid level remains at the extremes of its range for a long time, this indicates problems that could damage the compressor or severely reduce performance.

Sat Evap Rfgt Temp: xxx.x F Evap Rfgt Pressure: xxx.x psig

Saturated Cond Temperature/Cond Refrigerant Pressure

Sat Cond Temp: xxx.x F Cond Rfgt Pressure: xxx.x psig

Saturated Evap Temperature and Discharge Temp

Saturated Evap Rfgt Temp: xxx.x F Compressor Discharge Temp: xxx.x F

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Compressor Discharge Temperature/Discharge Superheat

Compressor Discharge Temp: xxx.x F Discharge Superheat: xxx.x F

Evaporator and Condenser Approach Temperatures

Compressor Report

Report Heading

Compressor Hours, Starts & Amps

Press (Next) (Previous) to Continue

Compressor Line Currents% RLA

Evaporator Approach Temp.: xxx.x F Condenser Approach Temp.: xxx.x F

Note: Malfunctioning or miswired sensors should be suspected if negative approach temperatures are encountered.

Compressor Line Currents -% RLA

A xxxx.x% B xxxx.x% C xxxx.x%

Compressor Line Currents Amps

Compressor Line Currents - Amps

A xxxx amps B xxxx amps C xxxx amps

Compressor Line Voltages

AB xxxx v BC xxxx v CA xxxx v

This data is displayed only if the line voltage sensing option is installed. if not installed, no screen is displayed.

Compressor Starts and Running Time

The starts and hours counters are displayed as follows:

Installation, Operation and Maintenance 5 - 13

Compressor Starts: xxxxx Compressor Running Time: HRS:MIN:SEC

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Operator Settings

Time Of Day Setting

Operator Settings Group Heading

Chilled Water & Current Limit Setpts Press (Next) (Previous) to Continue

Menu Settings Password

If the menu settings password is enabled in the service setup group, the following will be displayed after each setting group heading

Settings In This Menu Are [Status]

[password message]

Likewise, if the menu settings password is disabled in the service setup group, the above screen will not appear.

The possible values for status are “Locked” or “Unlocked.” If the password status is locked, the password message will be “Enter Password to Unlock”. Press <-> <+> <-> <+><-><+> followed by the <Enter> key to unlock.

NOTE: The last six keystrokes represent the current password and up to 20 keystrokes can be entered.

Current Time/Date HH:MM xm Mon, XX, XXXX

(Enter) to Change: (Next) to Continue

The top level “Current Time/Date” is displayed when this screen is first selected. Pressing the <Next> or <Prev> key will go to the next or previous screen.

If the <Enter> key is selected, five separate screens can be displayed to make changes to the time and date. The “Current Time/Date” will be displayed on line one of each screen. Each screen will allow the changing of one element in the time/date at a time. The second line of each screen indicates the element that can be changed and its current value.

If the first time element changing screen (hours) is displayed and the <Prev> key is pressed, the top level “Current Time/Date” screen will be displayed and the <Enter> key

must

be pressed to re-enter the

time changing screens. If the last (fifth) time/date changing screen is

displayed and the <Next> key is pressed, the next screen will be displayed. If the <Prev> key is pressed at this point, the top level “Current Time/ Date” screen will be displayed and the <Enter> key will have to be pressed to re-enter the time/date changing screens.

If the password status is unlocked, the password message will be “Press (Enter) to Lock.” Pressing <Enter> locks the settings in all the menus. If the password is entered to unlock the settings, this unlocks the settings in ALL menus.

Whenever a password is in use, the “Press (+) (-) to change setting” message will be suppressed on setpoint screens. Any attempt to change the setting will result in the message “Setting is Locked”. The password once entered will remain valid until canceled.

Set Contrast - (CCCLD Display Only)

The following screen is used with the complex character Clear Language Display only.

Set Contrast: Press (X) to Save Press (+) (-) To Change Setting

To change an element of the current time or date, press <Enter> from the top level “Current Time/Date” screen. Press <Next> or <Prev> to get to the desired screen. Then press the <+> or <-> keys to change the element to its proper value and then press the <Enter> key to store the new time/date. The message “Updating Chiller Clock, Please Wait” is displayed for two seconds after the key is pressed.

The five time/date changing screens under the top level (“current time/date”) are as follows:

Current Time/Date HH:MM xm Mon, XX, XXXX

To Change Hour, Press (+) (-) & (Enter)

Current Time/Date HH:MM xm Mon, XX, XXXX

T o Change Minute, Press (+) (-) & (Enter)

Current Time/Date HH:MM xm Mon, XX, XXXX

To Change Month, Press (+) (-) & (Enter)

5 - 14 RTHC-IOM-1C

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Current Time/Date HH:MM xm Mon, XX, XXXX

To Change Day, Press (+) (-) & (Enter) XX

Current Time/Date HH:MM xm Mon, XX, XXXX

T o Change Year, Press (+) (-) & (Enter) XXXX

Front Panel Chilled Water Setpoint

Front Panel Current Limit Setpoint

Front Panel Current Limit Stpt: xxx%

Press (+) (-) to Change Setting

The range of values is 40 to 100% in increments of 1%. The ROM default is 100%.

Print Report

Front Panel Chilled Wtr Setpt: xxx.x F

Press (+) (-) to Change Setting

The range of values is 0 to 65°F (-17 to 18.3°C), in increments of 1 or 0.1°F or C depending on the service setup screen. The ROM default is 44.0°F (6.7°C).

The second line of the setting display shown above will change if an attempt is made to increase or decrease the setpoint out of the setpoint range. The second line would then become:

Top of Range, Press (-) to Change

or, if low,

Bottom of Range, Press (+) to Change

Also, if a wrong key is pressed, the display will prompt:

This screen is shown only when the print option is installed.

Press (Enter) to Print Report

Press (Next) (Previous) To Continue

After <Enter> is pressed, a two-second message appears briefly indicating that the print command has been sent to the printer.

Chilled Water Reset Type

Chilled Wtr Reset Type: [type]

Press (+) (-) to Change Setting

The possible values for [type] are: disable (ROM default), return, constant return, and outdoor air.

If either disable or constant return is selected, the remaining chilled water reset displays are skipped. If either return or outdoor air are selected, the first word of the remaining chilled water reset displays will be the type of reset.

Press (+) (-) (Enter) (Cancel) to Continue

The exception is pressing the <Stop> key, which is always active. Other messages may display in special cases with explanations.

When the front panel chilled water setpoint is within

1.7°F of the leaving water temperature cutout setpoint or within 6°F of the low refrigerant temperature cutout setpoint, the second line of this display will read:

Limited by Cutout Setpt, (+) to Change

Installation, Operation and Maintenance 5 - 15

Reset Ratio

[type] Reset Ratio: xxx%

Press (+) (-) to Change Setting

The ratio range is 10 to 120% for return reset with a ROM default of 50% and 80 to -80% for outdoor reset with the ROM default of 10%.

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Start Reset Setpoint

[type] Start Reset: xxx.x F

Press (+) (-) to Change Setting

The start reset range is 4 to 30°F (2.2 to 16.7°C) for return reset with the ROM default of 10°F (5.6°C). For outdoor reset, the range is 50 to 130°F (10 to

54.4°C) for with the ROM default of 90°F (32.2°C).

Ice Making To Normal Cooling Transition Timer

This data will be displayed only if the ice making option is installed.

Ice-To-Normal Cooling Timer: xx min

Press (+) (-) to Change Setting

The range of values is 0 to 10 minutes. The ROM default is 5 minutes.

Max Reset Setpoint

[type] Max Reset Setpoint: xxx.x F

Press (+) (-) to Change Setting

The maximum reset range is 0 to 20°F (0.0 to

11.1°C) for return reset with the ROM default of 5°F (2.8°C). For outdoor reset, the range is 0 to 20°F (0.0 to 11.1°C) for with the ROM default of 5°F (2.8°C).

Ice Building Enable

This data will be displayed only if the ice making option is installed.

Ice Building [d/e]

Press (+) (-) to Change Setting

where disable is the ROM default.

Front Panel Ice Termination Setpoint

Chilled Water Setpoint Source

This screen will only be displayed if the external chilled water setpoint is installed at the machine configuration menu. If the Tracer option is installed,

the word “Default” will appear in front of the setpoint source.

[Default] Chilled Water Setpoint Source:

[source]

Possible values of [source] are Front Panel (ROM default) and External source.

Current Limit Setpoint Source

This screen will only be displayed if the external chilled water setpoint is installed in the machine configuration menu. If the Tracer option is installed, the word “Default” will appear in front of the setpoint source.

[Default] Current Limit Setpoint Source:

[source]

Panel Ice Termination Setpoint: xxx.x F

Press (+) (-) to Change Setting

This data will be displayed only if the ice-making option is installed.

NOTE: When the chiller is in the “ice building” mode, it will run at full load to make ice until the return water (glycol) drops below the above setpoint.

The range of values is 20.0 to 32.0°F (-6.7 to 0.0°C) in increments of 1 or 0.1°F or C, depending on the service setup screen. The ROM default is 27.0°F (-2.8°C).

5 - 16 RTHC-IOM-1C

where [source] is Front Panel (ROM default) or External.

Setpoint Source Override

[source]

Possible values of [source] are none (ROM default), “Use Front Panel setpoints,” and “Override Tracer. Use default setpoints” for which the Tracer option must be installed. this is a global override that will

Page 87

prevent Tracer, External, or Chilled Water Reset from asserting control on the chilled water setpoint.

Service Settings (Non Password Protected Service Settings Group)

heading display appears

Service Settings: Basic Setups

Press (Next) (Previous) to Continue

All service settings are accessed by pressing the <Service Settings> key on the CLD.

The service settings menu has three distinct grouping of items as shown in

Figure 31

. The first group is the non-password protected group that consists of all of the settings, feature enables, setpoints, etc., that are unlikely to be changed often by a user or operator, changes in them do not seriously affect the standard protection or reliability of the chiller.

Figure 31 Service Settings Key Menu Structure

Service Settings Key

Service Settings Group

(+)(+)(-)(-)(+)(+)

(+)(-)(+)(-)(+)(-)

Field Startup Gr oup

Machine Configuration

Group

Password Screen Password Screen

The other two groupings are protected, each with a separate password. These two groups are for changing parameters and settings for field commissioning and fundamental protection and control of the chiller subsystems (Service Set-up) or for programming of the UCM (machine configuration) if, for example, a UCM must be replaced.

Once properly set, the items in these protected menus should NEVER be changed again without specific knowledge of the effects of the changes. These are accessible only for field commissioning and to allow for field programming of service replacement UCMs.

Menu Settings Password

Only if the menu settings password is enabled in the service setup group, will the following be displayed after each setting group heading:

Settings In This Menu Are (status)

Enter Password to Unlock

Likewise, if the menu settings password is disabled in the service setup group (See page X), the above screen not appear.

Status can be “locked” or “unlocked.” If the password status is locked, the password message will be “Enter Password to Unlock.” Press <-> <+> <-> <+> <-> <+> followed by the <Enter> key to do so. An incorrect password will result in the message “Incorrect Password” message to be displayed for 1 second.

Once the password status is unlocked, the password message will be “Press Enter to Lock.” Pressing <Enter> will lock all of the setpoint menus. Likewise, if the password status is locked and the correct password is en ter ed, a ll of th e set poi nt me nus will be unlocked.

Whenever a password is in use the “Press (+) (-) to change setting” message will not appear on setpoint screens. Any attempt to change a setpoint will result in the message “Setting is Locked” being displayed for 1 second. The password, once entered, will remain valid until canceled.

Keypad/Display Lockout

This feature allows you to lock the keypad and display. After access to the service settings is given, the following display appears

Press (Enter) to Lock Display & Keypad

Password will be required to Unlock

Once the Service Settings key is pressed, the group

Installation, Operation and Maintenance 5 - 17

If the <Enter> key is pressed to lock the keypad, the following message is displayed, and all further input

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from the keypad is ignored, including the <Stop> key, until the password is entered.

Display Menu Headings

The password consists of pressing the <Previous> and <Enter> keys at the same time.

*****DISPLAY AND KEYPAD ARE LOCKED*****

*****ENTER PASSWORD TO UNLOCK*****

If the keypad is locked and the password is entered, the display will go to the Chiller Operating Mode display of the Chiller Report.

Language Setting

Language: xxxxxxx

Press (+) (-) to Change Setting

Possible Language Selections are: English (factory default), Francais, Deutsch, Espanol, Nippon (also know as Katakana, Use Japanese Characters), Italiano, Nederlands, CODED, and Portugues.

Display Menu Headings: (d/e)

Press (+) (-) to Change Setting

The factory default value is enabled. If disabled the menu headings in each menu or group will not appear.

Clear Custom Menu

Press (Enter) To

Clear the Custom Menu

Pressing <Enter> will cause a brief message to appear indicating that the menu has been cleared.

Differential to Start

Differential to start is the number of degrees above setpoint that the return water temperature must drift before the chiller will start.

Possible language selections for the CCCLD are English (ROM default), Traditional Chinese, and Simplified Chinese.

Display Units

Display Units: (type)

Press (+) (-) to Change Setting

where (type) is English (factory default) or SI.

Decimal Places Displayed

Decimal Places Displayed: (status)

Press (+) (-) to Change Setting

The choices for [status] are XXX.X (factory default) and XXX.

Differential to Start Chiller: xxx.x F

Press (+) (-) to Change Setting

The range of values is 1 to 10°F (0.5 to 5.5°C) in increments of 1 or 0.1°F or C depending on the service setup screen xxx or x xx.x. The factory defaul t is 5°F (2.8°C).

Differential to Stop

Differential to stop is the number of degrees below setpoint that the supply water temperature must drift before the chiller will shut down. This is used to prevent nuisance shutdowns on momentary drops in temperature.

Differential to Stop Chiller: xxx.x F

Press (+) (-) to Change Setting

The range of values is 1 to 10°F (0.5 to 5.5°C) in increments of 1 or 0.1°F or C depending on the service setup screen. The factory default is 5°F (2.8°C).

5 - 18 RTHC-IOM-1C

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Evap/Cond Pump Off Delay Time

This time delay is used to keep the chilled water pump on during the run-unload cycle, after the UCP2 has been given the command to stop. This stop command could come from the Clear Language Display, Tracer, or External Auto/Stop.

increments. The ROM default is 8 hours.

Print on Diagnostic [d/e]

Press (+) (-) to Change Setting

Evap Pump Off Delay: xx min

Press (+) (-) to Change Setting

The range of values is 0 to 30 minutes in increments of 1 minute. Factory default is 1 minute.

Printer Setups

NOTE: This series of screens is shown only when the printer option is installed. An RS-232 commuication-type serial printer as well as the printer interface are required for this option. Refer to the electrical drawings for details

Printer Setups

(Enter) to Change (Next) to Continue

If <Next> is pressed, the following setup screens are skipped. If <Enter> is pressed, the following screens are displayed for modifying the printer setups.

Refer to printer hardware documentation for settings and specifications when installing the printer.

where enabled is the ROM default.

Number of Pre-Diag Reports: xx

Press (+) (-) to Change Setting

The range of values is 1 to 5 in increments of 1. The ROM default is 5.

Diagnostic Report Interval: xxx sec

Press (+) (-) to Change Setting

The range of values is 2 to 120 seconds in increments of 1 second. The ROM default is 5 seconds.

Printer Baud Rate: [Status]

Press (+) (-) to Change Setting

with the choices for status: 300, 1200, 2400, 4800, 9600 (ROM default), or 19200.

Print on Tim e In terval [d/e]

Press (+) (-) to Change Setting

where enabled is the ROM default.

Print on Time Interval xxx Hours

Press (+) (-) to Change Setting

The range of values is 1 to 24 hours in one hour

Installation, Operation and Maintenance 5 - 19

Printer, Parity: [Status]

Press (+) (-) to Change Setting

The choices for [status] are none (ROM default), odd,

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or even.

Field Startup Group Password Request

Printer, Data Bits: [Status]

Press (+) (-) to Change Setting

The choices for status are 8 (ROM default) or 7.

Printer, Stop Bits: [Status]

Press (+) (-) to Change Setting

The choices for [status] are 1 (ROM default) or 2.

Printer Handshaking: [Status}

Press (+) (-) to Change Setting

The choices for status are XON/XOFF (ROM default), DTR, RTS, or none.

Clear Restart Inhibit Timer

The restart inhibit timer function is used to protect the compressor motor from heat caused by repeated starts within a short time. It allows for motor heating and cool down. This override should only be used with caution. Should the motor overheat because of too many successive starts, motor damage could result.

Pswd Reqd to Access Field Startup Group

Please Enter Password

The service setup password is <+> <+> <-> <-> <+> <+> <Enter>. Successf ull y ente ring the password sends you to the service setup group heading screen below.

Press (Enter) To

Access Field Startup Group

Machine Configuration Group Password Request

Password Reqd to Access Machine Config Group

Please Enter Password

The service setup password is <+> <-> <+> <-> <+> <-> <Enter>. Successfully entering the password sends you to the machine configuration group heading screen below.

Press (Enter) To

Access Machine Configuration Group

Press (Enter) to

Clear the Restart Inhibit Timer

Service Settings (Password Protected Field Startup Group)

The field startup group password is <+> <-> <-> <+>

When <Enter> is pressed, the timer is cleared and the compressor start sequence is allowed to begin immediately. A 2-second message appears as follows and then returns to the above screen.

<+> <Enter>. The field startup group contains items that are primarily associated with field commissioning of the chiller as well as the fundamental control and protection of the chiller subsystems.

If the field startup password is entered, the display

Restart Inhibit Timer Has Been Cleared

goes to the menu defined below. If a key is not pressed within 10 minutes in this password-protected menu, the display returns to the chiller operating mode display of the chiller report, and the password must be entered again to return to this menu.

5 - 20 RTHC-IOM-1C

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Field Startup Group Heading

Field Start-up Group Settings

“Press (Next) (Previous) to Continue”

This header is displayed when the headers are not displayed in the service settings menu.

Keypad/Display Lock Feature Enable

This feature permits the entire keypad and display to be locked out. A message appears on the screen to describe this condition. No access is permitted to either the report screens or the setting screens when this feature is both enabled here and locked at the service settings menu.

NOTE: In this locked condition both the <Stop> and <Auto> keys do not function.

As with other keypad lock features, <Previous> and <Enter> must be pushed together to unlock.

Keypad/Display Lock Feature: [d/e]

Press (+)(-) to Change Setting

Where disabled is the ROM default. When the keypad lock feature is disabled, the

keypad lock display does not appear in the nonpassword protected area of the Service settings menu and the Keypad/Display cannot be locked. When the keypad/display lock feature is enabled, the keypad lock display will appear in the service settings menu so the keypad can be locked.

When the feature is disabled, the menu setting password display does not appear at the top of each of the settings menus and the menu settings cannot be password protected. When the menu setting password feature is enabled, the menu settings password display appears just below each of the settings menu headers so the settings can be changed if the proper password is entered.

Password Duration Time

Password Duration Time xxx min

Press (+) (-) to Change Setting

where the range of values is 1 to 60 minutes in increments of one minute. The ROM default is 10 minutes.

Once a password has been successfully entered, the password entry screen for

only that

password-

protected menu is replaced by a “Press (Enter) To Access” screen, the only entry into that menu for the duration of the timer. The timer is set to the value of the password duration setpoint every time a button is pressed on the CLD. If there is no key activity and the timer expires, the password protection is reenabled on all three menus. If that happens, the password must be re-entered on each menu for access.

ICS Address

ICS Address: xx

Press (+)(-) to Change Setting

Menu Settings Password Enable

The menu settings password permits the settings in each of the menus to be password protected. All report menus and setting menus can still be viewed at any time if this feature is either enabled or disabled; the <Stop> and <Auto> keys also remain active. If this feature is enabled, then all menu settings are password protected.

Menu Settings Password Feature: [d/e]

Press (+)(-) to Change Setting

where disabled is the ROM Default.

Installation, Operation and Maintenance 5 - 21

The range of values is 1 to 127 in increments of 1. The ROM default is 65

Power Up Start Delay Time

For system installations, this delay time is used to prevent multiple chillers from cycling on at the same time after power is supplied or restored to the UCP2. A programmed delay can stagger the start sequence minimizing the amount of inrush current required.

Power Up Start Delay Time: xxx sec

Press (+)(-) to Change Setting

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The range of values is 0 to 600 seconds in increments of 1. The ROM default is 0 sec.

Design Delta Temperature

This value should be set at the delta temperature specified for the chiller during the initial selection, based on all operating conditions expected. If operating conditions change significantly, check with Trane technical service to see if modifications may be required.

Design Delta Temperature: xxx.x F

Press (+)(-) to Change Setting

The range of values is 4 to 30°F (2.2 to 16.7°C) in increments of 1 or 0.1°F or C depending on the service setup screen. The ROM default is 10°F (5.5°C).

Leaving Water Temperature Cutout Setpoint

Lvg Wtr Temp Cutout Setpoint: xxx.x F

Press (+)(-) to Change Setting

When this setpoint is within 6°F of the front panel chilled water setpoint, the front panel chilled water setpoint is increased along with this setpoint to maintain the differential. A message will be displayed for 2 seconds to indicate that the FPCW setpoint has been increased.

When this setpoint is adjusted below 28.5°F the following is displayed on the second line: “Warning: Adequate Antifreeze Required.”

Condenser Limit Setpoint

Condenser Limit Setpoint: xx% HPC

Press (+)(-) to Change Setting

The range of values is 80 to 120% in increments of 1%. The ROM default is 93%.

NOTE: This setting in relative to the high pressure cutout switch setting as defined in the machine configuration menu, and defines where the condenser limit control will take effect to avoid a high pressure cutout.

Maximum Restart Inhibit Timer Setting

The range of values is -10 to 36°F (-23.3 to 2.2°C) in increments of 1 or 0.1°F or C depending on the service setup screen. The ROM default is 36.0°F (2.2°C).

When this setpoint is within 1.7°F of the front panel chilled water setpoint, the front panel chilled water setpoint is increased along with this setpoint to maintain the differential. A message will be displayed for 2 seconds to indicate that the FPCW setpoint has been increased.

When this setpoint is adjusted below 35.3°F the

following is displayed on the second line: “Warning: Adequate Antifreeze Requir ed ”.

Low Refrigerant Temperature Cutout Setpoint

Low Rfgt Temp Cutout Setpt: xxx.x F

Press (+)(-) to Change Setting

The range of values is -5 to 36°F (-37.2 to 2.2°C) in increments of 1 or 0.1°F or C depending on the service setup screen. The ROM default is 32.0°F (0.0°C.

Maximum RI Timer: xxx minutes

Press (+)(-) to Change Setting

The range of values is 5 to 20 minutes in increments of 1 minute. The ROM default is 5 Minutes.

Under/Over Voltage Protection Enable

This feature is disabled if the line voltage sensing option is not installed.

Under/Over Voltage Protection: [d/e]

Press (+)(-) to Change Setting

where disabled is the ROM default.

Phase Reversal Protection Enable

Phase Reversal Protection: [d/e]

Disabling could result in Cprsr Damage

where enabled is the ROM default.

5 - 22 RTHC-IOM-1C

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Phase Unbalance Limit Enable

The UCM provides non-defeatable phase unbalance protection that stops compressor operation with more than 30% phase unbalance. If this unbalance limit is

enabled, the motor will be “limited” from running at full load as a function of % unbalance. This feature prevents excessive overheating that otherwise would result. If the limit is disabled, then no current limit is imposed due to phase unbalance.

Soft Load Current Limit Rate Of Change

Soft Load Current Limit Rate: x.x%/min

Press (+)(-) to Change Setting

The range of values is 0.5 to 5%/Min in increments of 1 or 0.1%/Min depending on the service setup screen. The ROM default is 5%/Min.

Phase Unbalance Limit: [d/e]

Press (+)(-) to Change Setting

where enabled is the ROM default.

Momentary Power Loss Protection Enable

Momentary Power Loss Protection: [d/e]

Press (+)(-) to Change Setting

where enabled is the ROM default.

Soft Load Control Enable

Soft Load Control: [d/e]

Press (+)(-) to Change Setting

where disabled is the ROM default

Soft Load Starting Current Limit

Soft Load Lvng Wtr Temp Rate of Change

Soft Load Lvg Water Rate: x.x F/min

Press (+)(-) to Change Setting

The range of values is 0.5 to 5°F/Min (0.3 to 2.8°C/ Min) in increments of 1 or 0.1°F/Min depending on the service setup screen. The ROM default is 5°F/ Min (2.8°C/MIn).

LWT Control Proportional Gain

LWT Control Proportional Gain: xxx.x%/F

Factory Default is 6.0%/F & 10.8%/C

The range of values is 0 to 100%/F (0 to 180%/C) in increments of 0.1. The ROM default is 6.0%/F (10.8%/C).

LWT Control Integral Reset Time

Soft Load Starting Current Limit: xxx%

Press (+)(-) to Change Setting

The range of values is 40 to 100% in increments of 1%. The ROM default is 100%.

Installation, Operation and Maintenance 5 - 23

LWT Control Integral Reset Time: xx sec

Press (+)(-) to Change Setting

The range of values is 5 to 500 Seconds in increments of 1. The ROM default is 60 sec.

LWT Control Rate T ime

LWT Control Rate Time: xx sec

Press (+)(-) to Change Setting

The range of values is 0 to 25 in increments of 0.1. The ROM Default is 0 sec.

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Higher numbers would improve the response of the control to transient loads, but also tend to cause control instability . Use caution and small incremental changes when making adjustments.

Liquid Level Control Proportional Gain

Liq Lvl Cntrl Proportion Gain: xx.x%/in

Press (+)(-) to Change Setting

Service Settings (Password Protected Machine Configuration Group)

The machine configuration password is <+> <-> <+> <-> <+> <-> <Enter>. If the machine configur ation password is entered, the display goes to the menu series following. If a key is not pressed within the time set on the Password Duration Screen, the display returns to the chiller operating mode display of the chiller report, and the password must be entered again to return to this menu.

The range of values is 0.2 to 30 in increments of 0.1. The ROM default is 10. Refer to the General Factory Settings Table.

Liquid Level Control Integral Reset Time

Liq Lvl Cntrl Integral Rset Time: xxx sec

Press (+)(-) to Change Setting

The range of values is 5 to 500 in increments of 1. The ROM default is 50. Refer to the General Factory Settings Table.

Liquid Level Control Rate Time

Liq Lvl Control Rate Time: xx.x sec

Press (+)(-) to Change Setting

The range of values is 0 to 25.5 in increments of 0.1. The ROM default is 0. Refer to the General Factory Settings Table.

Local Atmospheric Pressure

Machine Configuration Group Heading

Machine Configuration Group Settings

Press (Next)(Previous) To Continue

This header appears when the headers do not appear in the service settings menu.

Compressor Model Number Frame Size and Capacity.

Compressor Frame Size & Capacity: [YY]

Press (+)(-) to Change Setting

Values for [YY] are taken from the 6th and 7th digits of the compressor model number on the compressor

nameplate. The ROM default is “C2”.

Refrigerant Monitor Type

Refrigerant Monitor Type: [type]

Press (+)(-) to Change Setting

Local Atmospheric Pressure: xx.x psia

Press (+)(-) to Change Setting

The range of settings is 10 to 16 psia in increments of 1 or 0.1 psia or kPa depending on the service setup screen. The ROM default is 14.7 psia.

5 - 24 RTHC-IOM-1C

Possible values for type are none; (ROM default), analog interface, and IPC interface.

Starter Type

Starter Type: [type]

Press (+)(-) to Change Setting

Possible values for type are Y Delta (ROM default); X line; solid state, C515 series; solid state, EA series; auto transformer; and primary reactor. For the RTHC

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chiller with a solid state starter option, only the EA series type starter applies. See section 3 for an overview of the solid state starter and its settings.

Startup Contactor Test - Y-D Starters Only

This screen shall be displayed only when the starter type is Y-Delta, otherwise this screen is skipped.

Level 2 Contactor Integrity Test: [d/e]

Press (+)(-) to Change Setting

where disabled is the ROM default.

Rated Load Amps

This value should be set at the design rated load amps as determined during the initial selection process. If conditions change, contact Trane Technical Support for new settings based on the new operating conditions.

Rated Load Amps: xxxx Amps

Press (+)(-) to Change Setting

Current Overload Setting #1

Current Overload Setting #1: xxx

Press (+)(-) to Change Setting

The range of values is decimal 00 through 31. The ROM default is 00. Both the maximum acceleration timers and the overload settings are not adjustable from either the remote CLD or Tracer or any other remote/external devic e.

The UCP2 will continuously monitor compressor current to provide running overcurrent and locked rotor protection. Overcurrent protection is based on the phase with the highest current. It will trigger a manually resettable diagnostic, shutting the unit down, when the current exceeds a specified time-trip curve.

The compressor overload is based on the unit RLA. RLA is set in the UCP2 menu items along with the current overload settings specific to a certain current transformer (CT) and machine nameplate RLA. Use the following procedure to set the current overload #1 and #2.

The range of values is 0-2500 in 1 amp increments. The ROM default is 300 amps.

Motor Heating Constant

Motor Heating Constant: xxx min

Press (+)(-) to Change Setting

The range of values XXX is 0 to 100 minutes in 1 minute increments. The ROM default is 5 minutes. This value is used in the calculation of the restart inhibit timer. Refer to the following table for proper settings based on compressor size.

Table 17 Recommended Motor Heating Constant Settings

Motor Heating Constant

Compressor

B1 3 B2 3 C1 4 C2 4 D1 5 D2 5 D3 5 E3 5

(minutes)

First determine the CT Factor where

CT Factor = Unit Nameplate RLA/ CT Rating x 100%

Look up the CT rating from the table below. The CT Factor must be 66% or greater, but no more that 100% of the Nameplate RLA. Where more than one selection is possible, use the CT rating that will give the lowest CT Factor.

Unit Nameplate

RLA

33-50 -09 50 50-75 -10 75

67-100 -01 100 100-150 -02 150 134-200 -03 200 184-275 -04 275 267-400 -05 400 334-500 -06 500 467-700 -07 700

667-1000 -08 1000

Extension

(X13580269-)

CT Rating Amp

From the calculated CT Factor, the Motor Current Overload Settings # 1 and #2 can be found in

following. Note that when one setting is changed,

Table

Installation, Operation and Maintenance 5 - 25

Page 96

the other must be changed also and the sum of the two must always be 255.

Current Overload Setting #2

Table 18 Current Overload Settings #1 and #2 as a Function of CT Factor

Factor

Setting #1Setting #2CT

Factor

66 00 255 84 19 236 67 01 254 85 20 235 68 02 253 86 21 234 69 03 252 87 22 233 70 04 251 88 22 233 71 06 249 89 23 232 72 07 248 90 24 231 73 08 247 91 25 230 74 09 246 92 25 230 75 10 245 93 26 229 76 11 244 94 27 228 77 12 243 95 28 227 78 13 242 96 28 227 79 15 240 97 29 226 80 15 240 98 30 225 81 16 239 99 30 225 82 17 238 100 31 224 83 18 237

Setting #1Setting

The range of values is 2 to 64 Sec. The ROM default is 6 seconds. Refer to the table following for proper settings based on compressor size. Both the maximum acceleration timers and the overload settings are not adjustable from either the remote CLD or Tracer or any other remote/external device. Adjusting this value to a longer time than suggested for a particular compressor, is not recommended as it can compromise the motor protection. Failure of the motor to fully accelerate within this time will cause either an aborted start, or an immediate starter transition or bypass depending on the setting of the Acceleration Time Out Action (entry below). In either case, an appropriate diagnostic is generated.

Table 19 Recommended Max. Acceleration Timer Settings

Max Accel Timer #1Max Accel Timer

Compressor

B1 3 252 B2 3 252 C1 5 250 C2 5 250 D1 6 249 D2 6 249 D3 6 249 E3 6 249

ALL Sizes with

Solid State Starter

6 249

Current Overload Setting #2: xx

Press (+)(-) to Change Setting

The range of values is decimal 224 through 255. The ROM default is 255. For security purposes the

second setting is the 8-bit one’s complement of the first setting above. Both the maximum acceleration timers and the overload settings are not adjustable from either the remote CLD or Tracer or any other remote/external devic e.

Maximum Acceleration Timer #1

This value indicates the time at which the UCP2 expects full acceleration of the motor to occur either under part-winding phase of the Y-Delta start sequence or under current limit control of the solid state starter.

Maximum Acceleration Timer #1: xx sec

Press (+)(-) to Change Setting

Maximum Acceleration Timer #2

Maximum Acceleratio n Timer #2: xxx sec

Press (+)(-) to Change Setting

The range of values is 191 to 253 sec. The ROM default is 249. Timer #1 and Timer #2 settings must equal 255. Both the maximum acceleration timers and the overload settings are not adjustable from either the remote CLD or Tracer or any other remote/ external device.

5 - 26 RTHC-IOM-1C

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Acceleration Time Out Action

External Current Limit Setpoint Option

Acceleration Time Out Action: [action]

Press (+)(-) to Change Setting

This setting defines the action that th starter will take if the motor is not accelerated within the maximum acceleration timer #1 above.

Possible values for action include shutdown; transition [non-solid state starter types only] (ROM default); and bypass; [solid state starter types only] (ROM default). If shutdown is selected, the start will

be aborted upon failure to accelerate. “Bypass” or “Transition” is the recommended setting, as it will allow the chiller to start safely in the rare event it cannot accelerate with the reduced inrush starting method, however, inrush currents similar to an “across the line” starting would occur.

EXV Size

EXV Size (TPN) Ext.): [size(-xx)]

Press (+)(-) to Change Setting

External Current Limit Setpt: [Status]

Press (+)(-) to Change Setting

Possible values for status are installed or not installed (ROM default ).

High Pressure Cutout Setting

High Pressure Cutout Setting: xxxx Psig

Press (+)(-) to Change Setting

The range of values is 5-500 psig (35-3447 kPa) in increments of 5 psig/kPa. The ROM default is 180 psig (1241 kPa).

NOTE: 6.8948 kPa = 1 psi.

Line Voltage Sensing Option

Line Voltage Sensing Option: [status]

Press (+)(-) to Change Setting

Possible values for status are installed or not installed (ROM default ).

Where size(-xx) is the EXV size rating and Trane part number extension in parentheses as follows:

Table 20 EXV Size

Unit EXV Size (-xx)

200 -01 400C -03 300C -04

To confirm proper EXV setting, the EXV valve terminal housing has the valve size stamped on it.

NOTE: if stamped “300,” use setting 300C (-04)

External Chilled Water Setpoint Option

External Chilled Wtr Stpt: [Status]

Press (+)(-) to Change Setting

Possible values for status are installed or not installed (ROM default).

Unit Line Voltage

This screen only appears if the line voltage sensing option is installed.

Unit Line Voltage: [volt] V

Press (+)(-) to Change Setting

Possible values of [volt] are 180 through 6600 in 5 volt increments. The ROM default is 460 volts. See the follow ing tables.

Table 21 Voltage Utilization Range, 60Hz

Unit

Nameplate

200/208 208 220 180

220/230/240 240 253 207

380 380 418 342

440/460/480 480 508 416

575/600 600 635 520

UCP2 Selected

Volts

Max.

Voltage

Min.

Voltage

Installation, Operation and Maintenance 5 - 27

Page 98

Table 22 Voltage Utilization Range, 50Hz

Tracer Communication Interface Module Option

Unit

Nameplate

220 220 N/A N/A 380 380 418 342

400/415 415 457 373

UCP2 Selected

Volts

Max.

Voltage

Min.

Voltage

Ice Building Option

Ice Building Option: [status]

Press (+)(-) to Change Setting

Possible values for status are installed or not installed (ROM default).

External Setpoint Analog Input Type Selection, 420 ma/2-10 vdc

External Setpoint Inputs: [type]

Press (+)(-) to Change Setting

TCI Module Option: [status]

Press (+)(-) to Change Setting

Possible values for status are installed or not installed (ROM default ).

Notes: the Tracer communication interface module option will automatically be installed if communication with a TCI module occurs. This screen is only necessary to de-install the TCI module in the event of inadvertent installation (should a chiller module, for example, be swapped in the field).

It also can be used in factory test procedures.

Printer Option

Printer Op ti o n : [status]

Press (+)(-) to Change Setting

Possible values for status are installed or not installed (ROM default ).

Possible values for type are: 4-20ma (ROM default) and 2-10vdc.

Tracer Option

Tracer Option: [status]

Press (+)(-) to Change Setting

Possible values for status are installed or not installed (ROM Default).

NOTE: the Tracer option will automatically be installed if communication with a Tracer occurs. This screen is only necessary to de-install Tracer communication in the event of an inadvertent automatic installation (such as might occur if a chiller module is swapped in the field).

NOTE: the printer option will NOT automatically be installed if communication with a printer module occurs.

Programmable Relay Assignments

The UCP2 allows you to program specific use of three relays on the chiller module. These relays are available for use as signaling various outputs. Use the following screens to assign specific types of events to energize particular relays.

Once assignments are determined, begin the programming function with:

Press Enter To Access

Programmable Relays

If <Next> or <Previous> is pressed, skip to the next heading item in the menu. If <Enter> is pressed, the following screens are displayed in order:

5 - 28 RTHC-IOM-1C

Relay #1: [event]

Press (+)(-) to Change Setting

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Relay #2: [event]

Press (+)(-) to Change Setting

Relay #3: [event]

Press (+)(-) to Change Setting

If “delta” is selected, the output voltage will be linear with the endpoints defined by th following two menu items:

NOTE: this function does not use actual measured pressures, but rather temperature sensor readings and assumes sturated conditions for R134a refrigerant.

Where [event] is one of the following:

Not Used Compressor Running (ROM Default for Programmable Relay

#1) MMR Diagnostics MAR Diagnostics MMR & MAR Diagnostics (ROM Default for Programmable

Relay #2) Chiller Limit Modes (ROM Default for Programmable Relay #3)

(20-minute filter applied).

Any assignment change must be confirmed by pressing <Enter>.

NOTE: the particular annunciator relay on the chiller module will ene rgi ze w hen the assi gne d ev ent is t rue i.e. when that mode is present for 20 minutes or more

or diagnostic type is active. The category “none” is provided to allow a relay to be turned off or defeated, as well as to document to Tracer that a given relay is not being used. However, the defaults are set to assign each of the relays according to the most common usage. For chiller Limit Mode assignment only , the following limits will apply: Current, Soft Load Current, and Phase Unbalance Limits. NOTE on Relay Ratings: Contact loads shall not exceed 120 VAC/240 VA. Minimum premissable load is 100 mA, 5 VDC. See Interconnecting Wiring (Field Wiring Required) in Section 3.

Figure 32 Condenser Pressure Analog Output

9 8 7 6

VDC

5 4 3 2 1 0

0 psia

0100

0 percent

Condenser Pressure analog Output with “%HPC” selected

9 8 7 6 5

VDC

4 3 2 1 0

0100

Min. Delta P Setting Max. Delta P Setting

Condenser Pressure analog Output with “Delta” selected

HPC in psia 100 percent

Refrigerant Pressure Analog Output Option

Rfgt Pressure Output Option: [status]

Press (+)(-) to Change Setting

Possible values for status are % HPC [ROM default], or delta. If %HPC is set, the optional analog pressure output (see electrical drawings for Options Module connections) will present a voltage in proportion to the condenser pressure as a percent of the High Pressure Cutout setting in absolute pressure.

Installation, Operation and Maintenance 5 - 29

Min Delta Pressure Calibration

The following will be displayed only if the “refrigerant pressure analog output option” is set to “delta.”

Min Delta Press Calib (2 VDC) XXXX PSID

Press (+)(-) to Change Setting

The range of values shall be 0-400 Psid (0-2758 kPa) in increm ents of 1 Psid/kP a. The ROM default is 0 Psid (0 kPa). 6.8948 kPa = 1 Psi.

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Max Delta Pressure Calibration

The following will be displayed only if the “refrigerant pressure analog output option” is set to “delta.”

Max Delta Press Calib (10 VDC) XXXX PSID

Press (+)(-) to Change Setting

The range of values shall be 1-400 Psid (7-2758 kPa) in increments of 1 Psid/kPa. The ROM default is 160 Psid (1103 kPa). 6.8948 kPa = 1 Psi.

Service Settings (Password Protected Refrigerant Monitor Settings Group)

This group is only used if the refrigerant monitor is installed. For further information on the monitor, see the refrigerant monitor service literature.

If the refrigerant monitor settings password is entered, the display would go to a prescribed menu covering alarms and scanners.

Service Settings (Password Protected Refrigerant Monitor Calibration Group)

This group is only used if the refrigerant monitor is installed. For further information on the monitor, see the refrigerant monitor service literature.

If the refrigerant monitor settings password is entered, the display would go to a prescribed menu covering calibration.

Service Tests

The service tools group contains items that are primarily associated with either test or manual override of the chiller or chiller subsystems. If the service tools password is entered, the display goes to the menu below.

If a key is not pressed for the duration of the password timer, the display returns to the chiller operating mode display of the chiller report, and the password must be entered again to return to this menu.

If any item in the service tools group is in manual override, the red alarm LED will be on (non-flashing). The following table contains the service tools setpoints that affect the alarm light.

To turn the alarm light off (from an on and nonflashing state), all the conditions must be satisfied.

Function/Setpoint: Condition to Turn Alarm Off:

“Chilled Water Pump” Auto “Condenser Water Pump” Auto “EXV Control” Auto “Slide Valve Control” Auto “Master Oil Line Solenoid

Valve” “Oil Return Fill Solenoid

Valve” “Oil Return Drain Solenoid

Valve”

Auto

5 - 30 RTHC-IOM-1C

Trane RTHC, R Series Installation Operation & Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual