Trane RTHD User Manual
Series R™ Helical Rotary
Liquid Chillers
Model RTHD
175-450 Tons (60 Hz)
125-450 Tons (50 Hz)
Built for Industrial and Commercial Applications
RLC-PRC020-ENApril 2003
Introduction
To meet a wide range of applications in
the medium-tonnage, water-cooled
market, Trane is proud to introduce the
model RTHD helical rotary liquid chiller.
The introduction of this next-generation
chiller an exciting step forward in
application versatility, ease of
installation, control precision, reliability,
energy-efficiency, and operational costeffectiveness. The new RTHD chiller is
designed to deliver proven Series R
performance, plus all the benefits of an
advanced heat transfer design and a
low-speed, direct-drive compressor.
Important Design Advances
and New Features
Major design advances include:
• Higher full-load energy efficiency
reduces both operating and life-cycle
costs.
• CH530 controls enable:
- scrolling access to inputs and
operating information via the LCD
touch-screen display;
- freedom from interoperability
concerns with LonMark
communications;
- job-specific communication options
that allow greater reporting flexibility.
• Improved startup temperature
capabilities and reduced sensitivity to
condenser water temperatures alleviate
the most common startup concerns.
• Removed Liquid Vapor Separator,
providing lighter unit weight and
simplified refrigerant piping, for less
expensive handling, separation, and
installation.
The industrial-grade design of the Series
R helical rotary chiller is ideal for both
industrial and commercial markets, in
applications such as office buildings,
hospitals, schools, retail buildings, and
industrial facilities. The linear unloading
compressor, wide operating temperature
range, advanced controls, electronic
expansion valve, short anti-recycle
timers, and industry-leading efficiencies
mean that this latest Trane Series R
chiller is the perfect choice for tight
temperature control in almost any
application temperatures, and under
widely varying loads.
RLC-PRC020-EN© 2003 American Standard Inc. All rights reserved.
Contents
Introduction
Features and Benefits
Options
Display
Application Considerations
Selection Procedure
Model Nomenclature
General Data
Electrical Data and Connections
Dimensions and Weights
Mechanical Specifications
2
4
6
8
9
11
13
15
17
20
27
RLC-PRC020-EN
3
Features and
Benefits
Application Versatility and High
Performance
• Screw compressor technology and the
electronic expansion valve provide
reliable performance in an expanded
range of operating temperatures.
• Tight water temperature control
extends to operation of multiple chillers
in parallel or series configurations,
offering further system design flexibility
for maximum efficiency.
• Advanced design enables chilled water
temperature control to +/- 0.5°F (.28°C)
for flow changes up to 10 percent per
minute, plus handling of flow changes
up to 30 percent per minute for comfort
cooling.
• Two-minute stop-to-start and fiveminute start-to-start anti-recycle timer
allows tight chilled water temperature
control in constant or transient lowload applications.
• LonMark communications capability
provides excellent, trouble-free
interoperability.
Applications in this catalog specifically
excluded from the ARI certification
program are:
• Low temperature applications,
including ice storage
• Glycol
• 50Hz units below 200 nominal tons
• Generic Building Automation System
points are available for easy access to
operational information.
• Extensive information on professional
design selection and layout is available
in a simple, highly readable electronic
format.
• Standard model RTHD configurations
are in stock and available for immediate
delivery, and Trane offers the fastest
ship cycles in the industry for built-toorder units.
• Industrial / Low Temperature Process
Cooling – Excellent operating
temperature range and precise control
capabilities enable tight control with
single chiller or series configuration.
• Ice/Thermal Storage – Specifiers and
operators benefit from dual setpoint
control and industry-leading
temperature, efficiency, and control
capabilities, plus outstanding support
through partnership with Calmac, a
strong Trane partner providing proven
installation examples, templates, and
references that minimize design time
and energy costs.
• Heat Recovery – Maximum condenser
temperature exceeds those of previous
technologies, providing hot water and
tight control that minimizes operating
costs for the chilled water plant and
boiler/hot water heater, and consistent
dehumidification.
Simple, Economical Installation
• Compact size makes the model RTHD
well suited for the retrofit and
replacement market.
• All units fit through standard doublewidth doors.
• Bolt-together construction makes for
fast, easy unit disassembly.
• Small RTHD footprint saves valuable
equipment room space and alleviates
access concerns for most retrofit jobs.
• Lightweight design simplifies rigging
requirements, further reducing
installation time requirements and
costs.
• Full factory refrigerant or nitrogen and
oil charges reduce required field labor,
materials, and installation cost.
• Only evaporator and condenser water
piping is required; no starter water
cooling (with its associated safety
concerns) or field piping is necessary.
• Oil cooler and purge system
connections have been eliminated.
• Simple power connection simplifies
overall installation.
• Standard unit-mounted starter for
Wye-Delta and Solid State eliminates
additional jobsite installation
considerations and labor requirements.
• Trane has conducted extensive factory
testing, and also offers options for inperson and/or documented system
performance verification.
• CH530 controls easily interface with
Tracer Summit™ building automation
systems through single twisted-pair
wire.
Pueblo
Business Unit
RLC-PRC020-EN4
Features and
Benefits
State-of-the-Art, Precision Control
• Microprocessor-based CH530 controls
monitor and maintain optimal
operation of the chiller and its
associated sensors, actuators, relays,
and switches, all of which are factoryassembled and extensively tested.
• Easy interface with computers hosting
Tracer Summit
energy management systems allows
the operator to efficiently optimize
comfort system performance and
minimize operating costs.
• PID (proportional integral derivative)
control strategy ensures stable, efficient
chilled water temperature control,
maintaining +/- 1°F (0.56°C) control by
proactively reacting to instantaneous
load changes of up to 50 percent.
• Adaptive Control
chiller operation under adverse
conditions, when many other chillers
might simply shut down.
• Easy-to-use operator interface displays
all operating and safety messages, with
complete diagnostics information, on a
highly readable panel with a scrolling
touch-screen display.
• The RTHD features a complete range of
chiller safety controls.
• Over 120 diagnostic and operating
points are available, with standard
displays including chiller current draw,
condenser pressure, and evaporator
pressure.
Reliability and Ease of Maintenance
• Direct drive, low-speed compressor – a
simple design with only three moving
parts – provides maximum efficiency,
high reliability, and low maintenance
requirements.
• Electronic expansion valve, with fewer
moving parts than alternative valve
designs, offers highly reliable
operation.
• Suction gas-cooled motor stays
uniformly cool at lower temperatures
for longer motor life.
™
building automation/
™
attempts to maintain
• The Trane helical rotary compressor is
a proven design resulting from years of
research and thousands of test hours,
including extensive testing under
extraordinarily severe operating
conditions.
• Trane is the world’s largest
manufacturer of large helical rotary
compressors, with tens of thousands of
commercial and industrial installations
worldwide demonstrating a reliability
rate of greater than 99 percent in the
first year of operation.
Operating and Life Cycle
Cost-Effectiveness
• Electronic expansion valve enables
exceptionally tight temperature control
and extremely low superheat, resulting
in more efficient full-load and part-load
operation than previously available.
• Precise compressor rotor tip clearance
ensures optimal efficiency.
• Condenser and evaporator tubes use
the latest heat transfer technology for
increased efficiency.
• The RTHD includes standard electrical
demand limiting.
• Chilled water reset based on return
water temperature is standard.
• High compressor lift capabilities and
tight chilled water temperature control
allow highly efficient system design
with minimal operational concerns.
Design capabilities include:
• variable primary flow;
• series chiller arrangements for
evaporator and/or condenser;
• low evaporator and condenser flow.
RLC-PRC020-EN
5
Options
Model RTHD Options
Insulation
All low-temperature surfaces are
covered with 3/4" (19.05 mm) Armaflex II
or equal (K = 0.28) insulation; this
includes the evaporator and water
boxes, suction line, motor housing, and
liquid/vapor separator.
Low-Temperature Evaporator
Addition of an oil cooler to the oil circuit
enables evaporator operation down to
minimum leaving water temperature of
10°F (-12.2°C).
High-Temperature Condenser
Addition of an oil cooler to the oil circuit
enables condenser operation up to
maximum leaving water temperature of
114°F (45.6°C).
Smooth-Bore Condenser Tubes
Smooth-bore copper or premium cupronickel condenser tubes, 3/4" (19.05 mm)
in diameter with .035" (0.889 mm) wall
thickness, are available for high fouling
water applications.
Refrigerant Isolation Valves
Factory-installed condenser inlet and
outlet refrigerant valves allow isolation
of the full refrigerant charge in the
condenser while servicing the chiller.
Marine Water Boxes
Addition of marine water boxes for the
condenser allows tube cleaning without
water pipe interference.
300 psig Evaporator and Condenser
Water Boxes
Water boxes are designed for 300 psig
maximum waterside working pressure,
and grooved pipe water connections are
provided for ease of installation.
Tracer Summit Communications
Link to factory-installed, tested
communication board, via single
twisted-pair wiring, adds Tracer Summit
communications to the system.
LonTalk LCI-C Interface
LonTalk (LCI-C) communications
capabilities are available, with
communication link via single twistedpair wiring to factory-installed, tested
communication board.
External Chilled Water Setpoint
External Chilled Water Setpoint is
communicated to a factory-installed,
tested communication board through a
2-10Vdc or 4-20mA signal.
External Current Limiting
External Current Limit Setpoint is
communicated to a factory-installed,
tested communication board through a
2-10Vdc or 4-20mA signal.
External Base Loading
External Base Loading is communicated
to a factory-installed and tested
communication board through a
2-10Vdc or 4-20mA signal.
Ice Making Control
Controls and safeties allow operation
with brine temperatures down to 20°F
(-6.7°C) , and dual setpoints enable both
ice making and daytime comfort cooling.
Programmable Relays
Default-set, factory-installed,
programmable relays allow the operator
to select four relay outputs from a list of
eight. Available relays are: AlarmLatching, Alarm-Auto Reset, General
Alarm, Warning, Chiller Limit Mode,
Compressor Running, Head Pressure
Relief Request, and Tracer Control.
Chilled Water Reset – Outdoor Air
Temperature
Controls, sensors, and safeties allow
reset of chilled water temperature, based
on temperature signal, during periods of
low outdoor air temperature. (Chilled
water reset based on return chilled water
temperature is standard.)
Condenser-Regulating Valve Control
Chiller applies a Proportional Integrative
Control (PID) algorithm to control water
regulating valve via 0-10Vdc signal.
Percent of Full Run Load Amps Output
Control system indicates the active
chiller percent of full run load amps,
based on a 0-10Vdc signal.
Condenser Pressure Output
Control system indicates chiller
differential pressure or condenser
pressure, based on a 0-10Vdc signal.
Refrigerant Monitor Input
Control system indicates refrigerant
monitor status of 0-100 or 0-1000 ppm
(user selectable), based on a 2-10Vdc /
4-20 mA signal.
Solid State Starter
Solid State Starter is unit-mounted with
a NEMA 1 gasketed enclosure. To extend
starter life, contactors bypass current
from the silicon control rectifiers (SCRs)
after startup.
Under/Over-Voltage Protection
Unit receives protection against
variations in voltage. (Current lag and
spike protection is standard.)
RLC-PRC020-EN6
Options
Main Power Disconnect
Options:
Non-fused Disconnect
A UL-approved non-fused molded case
disconnect switch, factory pre-wired with
terminal block power connections and
equipped with a lockable external
operator handle, is available to
disconnect the chiller from main power.
Standard Interrupting Capacity Circuit
Breaker
A UL-approved standard interrupting
molded case capacity circuit breaker,
factory pre-wired with terminal block
power connections and equipped with a
lockable external operator handle, is
available to disconnect the chiller from
main power.
High Interrupting Capacity Circuit
Breaker
A UL-approved high interrupting
molded case capacity circuit breaker,
factory pre-wired with terminal block
power connections and equipped with a
lockable external operator handle, is
available to disconnect the chiller from
main power.
Ground Fault Circuit Breaker
A UL-approved standard interrupting
molded case capacity circuit breaker
with ground fault interrupting capability,
factory pre-wired with terminal block
connections and equipped with a
lockable external operator handle, is
available to disconnect the chiller from
main power.
More Options:
2-Way Condenser Water Regulating Valve
For water regulation, a field-installed,
2-way butterfly-type (lug-style) valve,
with integral electrical operator and
factory-mounted valve actuator, is
available. The single-phase, reversible
motor can be factory-wired for 115 VAC,
60 Hz or 220 VAC, 50 Hz; the 2-way valve
is field-wired and controlled by the
chiller regulating valve control output;
valves are available in 6" and 8" (152.4
and 203.2 mm) sizes.
Nitrogen Charge
Unit is shipped with a nitrogen holding
charge in lieu of refrigerant.
Seal Kit for Reassembly
Ideal for situations when the bolttogether construction of the RTHD will
be separated for installation, this seal kit
provides replacement gaskets and rings
for reassembly.
Performance and Witness Tests
ARI-certified RTHD Performance and
Witness Tests are available, based on
requested operating points, to certify
chiller performance before delivery.
RLC-PRC020-EN
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Display
LCD Touch-Screen Display
with Multi-Language Support
The standard DynaView display
provided with the CH530 control panel
features an LCD touch-screen, allowing
access to all operational inputs and
outputs. This display supports eight
languages: English, Spanish, Traditional
Chinese, Simplified Chinese, Japanese,
Portuguese (for Brazil), Korean, and Thai.
Additional Display Features Include:
• LCD touch-screen with LED
backlighting, for scrolling access to
input and output operating information
• Weather-proof enclosure for reliable
operation in non-standard indoor
environments
• Spin value buttons to allow
continuously variable setpoints when
applicable
• Radio and action buttons for easy, onetime actions and settings
• Single-screen, folder/tab-style display
of all available information on
individual components (evaporator,
condenser, compressor, etc.)
• Automatic and immediate stop
capabilities for standard or immediate
manual shutdown
• Manual override indication
• Password entry/lockout system to
enable or disable display
• Fast, easy access to available chiller
data in tabbed format, including:
— Modes of operation, including
normal cooling and icemaking
— Water temperatures and setpoints
— Loading and limiting status and
setpoints
— Average line current
— Outdoor air temperature
— Start/stop differential timers
— Auto/Manual mode for EXV, slide
valve, and head pressure control
— Pump status and override
— Chilled water reset, start point, ratio,
and outdoor start point
— External setpoints, including:
- chilled water
- current limit
- ice building
- base loading
— Display specifics, including:
- date
- format
- time
- display lockout
- display units
- language setting
- Reports, listed on a single tabbed
screen for easy access, including:
• ASHRAE, containing all guideline
3 report information
• Evaporator
• Condenser
• Compressor
— Evaporator, condenser, and
compressor reports containing all
operational information on
individual components, including:
- Water and air temperatures
- Refrigerant levels, temperatures,
and approach
- Oil pressure
- Flow switch status
- EXV position
- Head pressure control command
- Compressor starts and run-time
- Line phase percent RLA, amps, and
volts
— Alarm and diagnostic information,
including:
- Flashing alarms with touch-screen
button for immediate address of
alarm condition
- Scrollable list of last ten active
diagnostics
- Specific information on applicable
diagnostic from list of over onehundred
- Automatic or manual resetting
diagnostic types
RLC-PRC020-EN8
Application
Considerations
Condenser Water Temperatures
Reduced sensitivity to condenser water
startup temperatures is one major
enhancement in the newest-generation
water-cooled Series R chiller. With the
model RTHD chiller, a condenser water
control method is necessary only if the
unit starts with entering water
temperatures below 55°F (12.8°C), or
between 45°F (7.2°C) and 55°F (12.8°C),
when a temperature increase of 1°F
(0.56°C) per minute to 55°F (12.8°) is not
possible.
When the application requires startup
temperatures below the prescribed
minimums, a variety of options are
available. To control a 2-way or 3-way
valve, Trane offers a Condenser
Regulating Valve Control option for the
CH530 controls. This option enables the
CH530 controls to send a signal for
opening and closing the valve as
necessary to maintain chiller differential
pressure. The 2-way valves are available
as a ship-with option. Tower bypass is
also a valid control method if the chiller
temperature requirements can be
maintained.
Trane Series R chillers start and operate
successfully and reliably over a range of
load conditions with controlled entering
condenser water temperature. Reducing
the condenser water temperature is an
effective method of lowering chiller
power input required, but the ideal
temperature for optimizing total system
power consumption will depend on the
overall system dynamics. From a system
perspective, some improvements in
chiller efficiency may be offset by the
increased tower fan and pumping costs
required to achieve the lower tower
temperatures.
Contact your local Trane
systems solution provider for more
information on optimizing system
performance.
The minimum acceptable refrigerant
pressure differential between condenser
and evaporator is 25 psid. The chiller
control system will attempt to obtain and
maintain this differential at startup, but
for continuous operation a design
should maintain a 25°F (13.9°C)
differential from evaporator leaving
water temperature to condenser leaving
water temperature.
Variable Evaporator Flow and Short
Evaporator Water Loops
Variable evaporator flow is an energysaving design strategy which has quickly
gained acceptance as advances in chiller
and controls technology have made it
possible. With its linear unloading
compressor design and advanced CH530
controls, the RTHD has excellent
capability to maintain leaving water
temperature control within +/-0.5°F
(0.28°C) , even for systems with variable
evaporator flow and small chilled water
volumes.
Some basic rules should be followed
whenever using these system design
and operational savings methods with
the RTHD. The proper location of the
chilled water temperature control sensor
is in the supply (outlet) water. This
location allows the building to act as a
buffer, and it assures a slowly changing
return water temperature. If there is
insufficient water volume in the system
to provide an adequate buffer,
temperature control can be lost,
resulting in erratic system operation and
excessive compressor cycling. To ensure
consistent operation and tight
temperature control, the chilled water
loop should be at least two minutes. If
this recommendation cannot be
followed, and tight leaving water
temperature control is necessary, a
storage tank or larger header pipe
should be installed to increase the
volume of water in the system.
For variable primary flow applications,
the rate of chilled water flow change
should not exceed 10 percent of design
per minute to maintain +/-0.5°F (0.28°C)
leaving evaporator temperature control.
For applications in which system energy
savings is most important and tight
temperature control is classified as
+/-2°F (1.1°C), up to 30 percent changes
in flow per minute are possible. Flow
rates should be maintained between the
minimum and maximum allowed for
any particular chiller configuration.
RLC-PRC020-EN
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