Trane RTUB 207-224, RTCA 108-216 User Manual

Installation
Operation
Maintenance

RTUB 207-224 - Liquid chillers with
helical rotary compressors

RTCA 108-216 - Remote air-cooled
condenser

RLC-SVX03A-E4

RLC-SVX03A-E4

Foreword

These installation, operation and
maintenance instructions are given
as a guide to good practice in the
installation, putting into service,
operation, and maintenance by the
user of Trane RTUB and RTCA units.
They do not contain full service
procedures necessary for the
continued successful operation of
this equipment; The services of a
qualified technician should be
employed through the medium of a
maintenance contract with a
reputable service company.

Warranty

Warranty is based on the general
terms and conditions of Société
Trane or Trane UK Ltd. The warranty
is void if the equipment is repaired
or modified without the written
approval of Trane, if the operating
limits are exceeded or if the control
system or the electrical wiring is
modified.

Damage due to misuse, lack of
maintenance or failure to comply
with the manufacturer's instructions
or recommendations is not covered
by the warranty obligation.

If the user does not conform to the
rules of chapter "Maintenance", it
may entail cancellation of warranty
and liabilities by Trane.

Reception of the
unit

On arrival, inspect the unit before
signing the delivery note. Specify
any damage on the delivery note,
and send a registered letter of
protest to the last carrier of the
goods within 72 hours of delivery.
Notify the local Trane Sales Office at
the same time. The unit should be
totally inspected within 7 days of
delivery. If any concealed damage is
discover, send a registered letter of
protest to the carrier within 7 days of
delivery and notify the local Trane
Office.

Units are shipped with the
refrigerant operating or holding
charge and should be examined with
an electronic leak detector to
determine the hermetic integrity of
the unit. The refrigerant charge is not
included in the standard Trane
Warranty Cover.

Cautions and
warnings

Cautions and warnings appear at
appropriate places in this instruction
manual. Your personal safety and the
proper operation of this machine
require that you follow them
carefully. The constructor assumes
no liability for installations or
servicing performed by unqualified
personnel.

Refrigerant

The refrigerant provided by Société
Trane or Trane UK Ltd meets all the
requirements of our units. When
using recycled or reprocessed
refrigerant, it is advisable to ensure
its quality is equivalent to that of a
new refrigerant. For this, it is
necessary to have a precise analysis
made by a specialized laboratory. If
this condition is not respected, the
Société Trane UK Ltd warranty could
be cancelled.

©American Standard Inc. 2002

RLC-SVX03A-E4 3

Contents

Foreword 2

Warranty 2

Reception of unit 2

Cautions and warnings 2

Refrigerant 2

General information

Unit Inspection 5

Inspection Checklist 5

Loose Parts Inventory 6

Description of the Unit 6

General Data RTUB 7

General Data RTCA 8

Installation

Installation Responsibilities 9

Storage 9

Special Lifting and Moving Instructions 10

Isolation 10

Foundation 10

Clearances 11

Drainage 12

Releasing the Nitrogen Holding Charge 12

Water Connections (RTUB) 12

Flow Switch Installation 13

Water Pressure Gauges 13

Refrigeration Safety Valves 14

Water Pressure Relief Valves 14

Installing and Connecting Temperature Sensors 14

Connecting RTUB with the Remote Air-cooled Condenser 15

4

Operation

Pre-start Checkout 21

Unit Voltage Power Supply 21

Unit Voltage Imbalance 21

Unit Voltage Phasing 21

Water System Flow Rates 22

Water System Pressure Drop 22

Daily Unit Start-up Procedure 22

Seasonal Unit Start-up Procedure 23

Temporary Shutdown and Restart 23

Extended Shutdown Procedure 23

System Restart after Extended Shutdown 23

Maintenance

Periodic Maintenance 25

Refrigerant and Oil Charge Management 27

R134a Field-charging Procedure 28

Charge Isolation on the High or Low Side of the System 28

Filter Replacement Procedure 29

Lubrication System 29

Oil Charging Procedure 29

Safety Recommendations 32

Maintenance Contract 32

Training 32

CG-PRC010-E4

Contents

RLC-SVX03A-E4

5

General information

This manual describes installation,
operation, and maintenance of RTUB
and RTCA units.
A separate manual is available for
the use and maintenance of the
RTUB controls (UCM-CLD).

Unit Inspection

When the unit is delivered, verify
that it is the correct unit and that it is
property equipped. Compare the
information that appears on the unit
nameplate with the ordering and
submittal information. A typical unit
nameplate is shown in Figure 1.
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.

• Inspect the individual pieces of the
shipment before accepting the unit.
Check for obvious damage to the
unit or packing material.

• Inspect the unit for concealed
damage as soon as possible after
delivery and before it is stored.
Concealed damage must be
reported within 15 days.

If concealed damage is discovered,
stop unpacking the shipment. Do not
remove damaged material from the
receiving location. Take photos of the
damage, if possible. The owner must
provide reasonable evidence that the
damage did not occur after delivery.

• Notify the carrier's terminal of the
damage immediately, by phone and
by mail. Request an immediate,
joint inspection of the damage with
the carrier and the consignee.

6

• Notify the Trane sales
representative and arrange for
repair. Do not repair the unit,
however, until damage is inspected
by the carrier's representative.

Loose Parts Inventory

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

Description of the Unit

The RTUB units are liquid chillers
equipped with two helical rotary
compressors and an evaporator
designed to operate with remote
RTCA air-cooled condensers or other
manufacturers' remote condensers.
The RTUB is shipped once it has

been assembled and wired in the
factory. The discharge piping is
blocked at the oil separator outlet.
Water connections - chilled water
inlet and outlet - are blocked for
transportation. Both RTUB and RTCA
units are dried and vacuum-pumped
in the factory, and contain a nitrogen
holding charge when shipped.

General information

RLC-SVX03A-E4

RTCA

RTUB

Figure 1 - Typical Unit Nameplates

é

7

Table 1 - General data - RTUB

Unit size 207 208 210 211 212 214
Compressor

Type/quantity Helical rotary/2
Nominal size (tons) 35/35 40/40 50/50 60/50 60/60 70/70

Evaporator

Evaporator Model EG 120 EG 120 EG 140 EG 170 EG 170 EG 200
Water Storage (l) 105 105 365 220 220 200
Minimum Flow (l/s) 4.5 4.5 6.0 7.0 7.0 9.0
Maximum Flow (l/s) 13.4 13.4 18.0 21.0 21.0 25.0
Evaporator inlet diameter (inches) 556666
Evaporator outlet diameter (inches) 556666

Minimum Starting/
Operating Ambient (°C) 5

Refrigerant R134a
Number of Independent
Refrigerant Circuits 2
Percent Minimum Load (%) 17
Refrigerant Charge (kg) 26 26 40 40 40 40
Oil Charge (l) 12 12 14 14 14 16
Operating Weight (kg) 2130 2130 2845 2845 2845 3250
Shipping Weight (kg) 1860 1860 2570 2570 2570 2975

Unit size 216 217 218 220 222 224
Compressor

Type/Quantity Helical rotary/2
Nominal size (tons) 70/85 85/85 100/85 100/100 120/100 120/120

Evaporator

Evaporator Model EG 200 EG 200 EG 250 EG 250 EG 340 EG 340
Water Storage (l) 200 200 415 415 560 560
Minimum Flow (l/s) 9.0 9.0 11.0 11.0 14.0 14.0
Maximum Flow (l/s) 25.0 25.0 33.0 33.0 43.0 43.0
Evaporator inlet diameter (inches) 666666
Evaporator outlet diameter (inches) 666666

Minimum Starting/
Operating Ambient (°C) 5

Refrigerant R134a
Number of Independent
Refrigerant Circuits 2
Percent Minimum Load (%) 17
Refrigerant Charge (kg) 40 40 46 46 50 50
Oil Charge (l) 16 16 16 16 19 22
Operating Weight (kg) 3250 3250 3880 4050 4480 4550
Shipping Weight (kg) 2975 2975 3405 3575 3855 3925

General information

RLC-SVX03A-E4

RLC-SVX03A-E4

8

General information

Table 2 - General data - RTCA

Unit size 108 109 111 113 115 116
Condenser

Condenser type Aluminium fins/copper tubes
Fin spacing (fins/ft) 168 168 144 168 168 144
Frontal surface area (m²) 5.7 6.9 6.9 11.3 11.7 13.7

Airflow

Standard unit (m3/h) 42500 50400 69300 77200 84700 98500
Low noise unit (m3/h) 34500 40900 56300 62700 68800 80000

Condenser fans

Number of fans 4468812

Fan speed

Standard unit (rpm) 690
Low noise unit (rpm) 560

Nominal fan power

Standard unit (kW) 0.85
Low noise unit (kW) 0.54

Current fan amps

Standard unit (A) 2.4
Low noise unit (A) 1.2

Minimum Starting/
Operating Ambient (1) (°C) 7 Standard units/-18 Low ambient units

Refrigerant R134a
Number of Independent
Refrigerant Circuits 111111
Refrigerant Charge (kg) 22 26 36 44 52 72
Operating Weight (2) (kg) 810 890 1090 1535 1770 2050
Shipping Weight (2) (kg) 1020 110 0 1300 1870 2170 2450
Hot gas connection (inches) 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8
Liquid connection (inches) 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8

Unit size 208 209 211 213 215 216
Condenser

Condenser type Aluminium fins/copper tubes
Fin spacing (fins/ft) 168 168 144 168 168 144
Frontal surface area (m²) 5.7 6.9 6.9 11.3 11.7 13.7

Airflow

Standard unit (m3/h) 42500 50400 69300 77200 84700 98500
Low noise unit (m3/h) 34500 40900 56300 62700 68800 80000

Condenser fans

Number of fans 2 x 2 2 x 2 2 x 3 2 x 4 2 x 4 2 x 6

Fan speed

Standard unit (rpm) 690
Low noise unit (rpm) 560

Nominal fan power

Standard unit (kW) 0.85
Low noise unit (kW) 0.54

Current fan amps

Standard unit 2.4
Low noise unit 1. 2

Minimum Starting/
Operating Ambient (1) (°C) 7 Standard units/-18 Low ambient units

Refrigerant R134a
Number of Independent
Refrigerant Circuits 222222
Refrigerant Charge (kg) 2 x 11 2 x 13 2 x 18 2 x 22 2 x 26 2 x 36
Operating Weight (2) (kg) 810 890 1090 1535 1770 2050
Shipping Weight (2) (kg) 1020 110 0 1300 1870 2170 2450
Hot gas connection (inches) 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8
Liquid connection (inches) 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8
(1) Based on a 2.2 m/s wind across the condenser
(2) With aluminium fins

RLC-SVX03A-E4

9

Installation responsibilities

Generally, the contractor must do the
following when installing an
RTUB/RTCA unit.

• Install the units on a flat
foundation, level (within 1/4"
[6 mm] across the length of the
unit), and strong enough to support
unit loading.

• Install the units per the instructions
contained in the Installation section
of this manual.

• Install any optional sensors and
make electrical connections at the
UCM-CLD.

• Where specified for the RTUB,
provide and install valves in the
water piping upstream and
downstream of the evaporator
water connections, to isolate the
evaporator for maintenance and to
balance and trim the system.

• Furnish and install a flow switch
and/or auxiliary contacts to prove
chilled-water flow.

• Furnish and install pressure gauges
in the inlet and outlet piping of the
evaporator (for RTUB).

• Furnish and install a drain valve to
the bottom of the evaporator water
box (for RTUB).

• Supply and install a vent cock to the
top of the evaporator water box (for
RTUB).

• Furnish and install strainers ahead
of all pumps and automatic
modulating valves.

• Furnish and install check valves on
the discharge lines (between oil
separators and condenser) in order
to avoid any refrigerant migration
leading to catastrophic damages to
evaporator and/or compressor (due
to freeze-up or liquid slugging).

• Interconnect the RTUB and the
remote condenser.

• Provide and install field wiring.

• Install heat tape and insulate the
chilled-water lines and any other
portions of the system, as required,
to prevent sweating under normal
operating conditions or freezing
during low-ambient temperature
conditions.

• Start the unit under the supervision
of a qualified service technician.

Storage

If the chiller is stored for a long period
of time prior to installation, the
following precautionary measures must
be taken:

• Store the unit in a safe place
sheltered from bad weather

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

• Close the discharge and liquid-line
isolation valves.

Installation

10

Special Lifting and Moving
Instructions

A specific lifting method is
recommended as follows:

1. Four lifting points are built into the
unit.

2. Slings and spreader bar to be

provided by rigger and attached to
the four lifting points.

3. Minimum rated lifting capacity

(vertical) of each sling and
spreader bar shall be no less than
the tabulated unit shipping weight.

 CCAAUUTTIIOONN

This unit must be lifted with the
utmost care. Avoid shock load by
lifting slowly and evenly.

 WWAARRNNIINNGG

To prevent any damage, position the
lifting bar so that the slings do not
touch the unit.

Isolation

The most effective form of isolation
is to locate the unit away from any
sound-sensitive area. Structurally
transmitted sound can be reduced by
elastomeric vibration eliminators.
Spring isolators are not
recommended for units equipped
with helical rotary compressors.
Consult an acoustical engineer in
critical sound applications. For
maximum isolation effect, isolate
water lines and electrical conduit.
Wall sleeves and rubber- isolated
piping hangers can be used to
reduce the sound transmitted
through water piping. To reduce the
sound transmitted through electrical

conduit, use flexible electrical
conduit. State and local codes on
sound emissions should always be
considered.

Foundation

Provide rigid, non-warping mounting
pads or a concrete foundation of
sufficient strength and mass to
support the unit's operating weight
(that is, including completed piping,
and full operating charges of
refrigerant, oil, and water). After it is
in place, the unit must be level
within 1/4" [6 mm] over its length
and width. Use shims if necessary.
The manufacturer is not responsible
for equipment problems resulting
from an improperly designed or
constructed foundation.
Note for RTCA: The unit must be
positioned so that the airflow
through the condensation coils is not
hindered by any obstacle. The

Installation

Figure 2- Rigging the unit - RTUB 207-208 Figure 3- Rigging the unit - RTUB 210-224 Figure 4- Rigging the unit - RTCA 108-216

Table 3 - Sling Lengths (mm) for lifting

ABCDE

RTUB unit size

207-208 2200 3000 2600 2100 ­210-211-212 2400 3000 2550 3150 3650
214-216-217 2500 3000 2550 3150 3650
218-220 2450 3050 2600 3150 3650
222-224 2450 3100 2650 3150 3650

RTCA unit size

108/109/111/208/209/211 2240 1700 1700 - ­113/115/115/213/215/216 2240 2800 2800 - -

RLC-SVX03A-E4