Trane RTWB Helical-Rotary Installation Operation & Maintenance

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RTWB Helical-Rotary Chillers

200 to 700 kW Sizes 207-224

RTWB-SVN01B-E4

Installation Operation Maintenance

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Personal protection

Safety glasses with side shields before entering construction sites or manufacturing areas.

Goggles and gloves when handling chemicals; when welding, cutting, brazing or grinding.

Hard hat wherever there is potential danger from falling or flying objects.

Gloves before touching any part of the machine that is operating or one that has recently been shutdown. Assume that metal is hot.

Hearing protection.

Safety shoes.

CCAAUUTTIIOONN

Risk of damage to equipment.

WWAARRNNIINNGG

Risk for safety or health.

Pressure vessel

Do not attempt to remove fittings and covers or break

lines while the machine is under pressure or while it is running.

Do not weld or flamecut any vessel or line until all refrigerant has been removed.

Do not use oxygen to purge lines, leak test, or pressurize a machine.

Do not pressure test any vessel at its design pressure (found on the equipment nameplate). Testing at the pressures must be done in a special enclosure or be using hydraulic, refer to national regulation.

RTWB-SVN01B-E4

Important Notice

©American Standard Inc. 2001

Refrigerant emission control

In respect of the environment all service operation must use recovery systems to minimize losses of refrigerant to the atmosphere when servicing units with HFC refrigerants.

Leak check and inspect all relief devices in accordance with national regulation.

Handling refrigerant

Heavy concentration of refrigerant within a confined area can displace enough oxygen to cause suffocation.

Do not weld or flamecut in an atmosphere containing refrigerant vapor until the area has been well ventilated.

Avoid breathing refrigerant fumes.

Hazardous voltage

Disconnect and lockout or tagout all

electrical power, including remote disconnects before servicing.

Trane assume no liability for installation or service procedures performed by unqualified personnel.

Regulations on safety, construction, and environment vary from one country to another. Make sure that the equipment complies with local regulations.

In addition to this publication, read carefully Société Trane’s and/or the Seller’s General Terms and Conditions of Sale and any specific instruction which you may have received.

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RTWB-SVN01B-E4

Contents

General Information

Literature change history Unit inspection Inspection checklist Loose parts inventory Unit description Installation overview

Installation – Mechanical

Storage Location requirements Access restrictions Moving and rigging Lifting procedure Isolation pads Shipping items Unit leveling Water piping Water pressure-drop data Water treatment Water pressure gauges and thermometers Water pressure-relief valves Flow sensing devices Refrigerant pressure-relief valve venting Thermal insulation

Installation – Electrical

General recommendations Power supply wiring Compressor-motor phase sequencing Module and control panel connectors Interconnecting wiring (field wiring required)

Operating Principles – Mechanical

General

Unit Start-Up Procedure

Daily unit start-up procedure Seasonal unit start-up procedure

Unit Shutdown Procedure

Daily unit shutdown procedure Seasonal unit shutdown procedure

Periodic Maintenance

Overview Weekly maintenance and checks Maintenance Contract and Training

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RTWB-SVN01B-E4

General Information

Literature change history

This manual describes the installation, operation, and maintenance of RTWB units.

When the unit arrives, compare all nameplate data with ordering, submittal, and shipping information. A typical nameplate is shown in Figure 1.

Figure 1 – Typical unit name plate

An Owner Guide on the operation of the UCM-CLD chiller controls is available as a separate document.

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RTWB-SVN01B-E4

General Information

Unit inspection

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

Inspect all interior 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 the installation of a damaged unit without sales office approval.

Inspection checklist

To protect against loss due to damage incurred in transit, complete the 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 72 hours after receipt and confirmed by registered delivery to the carrier and the Trane sales office.

•

If concealed damage is discovered,

stop unpacking the shipment. Do not remove the 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 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 flow switch (option), water-vessel drain plugs, isolation pads, rigging and electrical diagrams, and service literature are shipped in the starter panel.

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RTWB-SVN01B-E4

Unit description

The RTWB units are helical-rotary type, water-cooled, liquid chillers designed for indoor installation . The units have two independent refrigerant circuits, with one compressor per circuit.

Each RTWB unit is completely assembled, wired, leak-tested, dehydrated, charged, and tested for proper control operation prior to shipment. The chilled-water inlet and outlet openings are covered for shipment.

The RTWB series features Trane's exclusive Adaptive Control

™

logic with Clear Language Display. It monitors the control variables that govern the operation of the unit. Adaptive Control logic can correct these variables, when necessary, to optimize operational efficiencies, avoid chiller shutdown, and keep producing chilled water.

Compressor unloaders are oil pressure operated. Each refrigerant circuit is provided with filter, electronic expansion valve, and charging valves.

Figure 2 -– Component location for typical RTWB unit

Figure 3 – Component location for typical RTWB unit (back view)

1 Starter panel 2 Control panel 3 Evaporator 4 Oil separator 5 Helical-Rotary Compressor 7 Condenser-water outlet 8 Condenser-water inlet

3 Evaporator 5 Helical-Rotary Compressor 6 Condenser

9 Evaporator-water outlet 10 Evaporator-water inlet 11 Electronic expansion valve 12 Filter dryer

General Information

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RTWB-SVN01B-E4

General Information

Installation overview

For convenience, Table 1 summarizes responsibilities that are typically associated with the RTWB chiller installation process.

•

Locate and maintain the loose

parts, for example, isolators, bulb wells, temperature sensors, flow sensors, or other factory-ordered, field-installed options, for installation, as required.

•

Install the unit on a foundation

with flat support surfaces, level within 6 mm and of sufficient strength to support concentrated weight. Place the manufacturersupplied isolation pad assemblies under the unit.

•

Install the unit per the instructions

outlined in the mechanical installation section. Complete all water piping and electrical connections.

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 1 m 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.

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 and trim the system.

•

Supply and install flow switches or equivalent 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.

•

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.

•

Supply and install drain valves on each water box.

•

Supply and install vents cocks on each water box.

•

Where specified, supply and install strainers ahead of all pumps and automatic modulating valves.

•

Supply and install refrigerant pressure-relief piping from the pressure relief to the atmosphere.

•

Start the unit under supervision of a qualified service technician.

•

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

•

For unit-mounted starters, cutouts are provided at the top of the panel for line-side wiring.

•

Supply and install the wire terminal lugs to the starter.

•

Supply and install field wiring to the line-side lugs of the starter.

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RTWB-SVN01B-E4

Table 1 – Installation overview

Refer to the installation mechanical and electrical sections of this manual for detailed installation instructions.

Requirement Trane supplied Trane supplied Field supplied

Trane installed Field installed Field installed

Rigging Safety chains

Clevis connectors

Lifting beam Isolation Isolation pads Isolation pads Electrical Disconnect switch (optional) Disconnect switch

Flow switches (may be field supplied) BAS wiring (optional)

Water pump contactor Water piping Flow switches (may be field supplied) Thermometers

Water flow pressure gauges

Isolation and balancing valves water piping

Vents and drain valves

Pressure relief valves Pressure relief Relief valves Vent line Insulation Insulation (optional) Insulation

Table 2 - General data

207 208 210 211 212 214 216 217 218 220 222 224 Evaporator type EG 120 EG 120 EG 140 EG 170 EG 170 EG 200 EG 200 EG 200 EG 250 EG 250 EG 340 EG 340 Condenser type CG 120 CG 120 CG140 CG 170 CG 170 CG 200 CG 200 CG 200 CG 230 CG 230 CG 230 CG 230 Compressor type K1/K1 K2/K2 L1/L1 L2/L1 L2/L2 M1/M1 M2/M1 M2/M2 N1/M2 N1/N1 N2/N1 N2/N2 Oil charge (l) 6/6 6/6 7/7 7/7 7/7 8/8 8/8 8/8 8/8 8/8 11/8 11/11 Oil type OIL 023 E or OIL 048 E Refrigerant charge

(kg) 39/39 39/39 60/60 60/60 60/60 60/60 60/60 60/60 69/69 69/69 74/74 74/74

Operating weight

(kg) 2620 2620 3370 3450 3450 3725 3725 3725 4325 4500 4925 5000 Shipping weight (kg) 2450 2450 3050 3150 3150 3500 3500 3500 3900 4050 4250 440 0 Length (mm) 2880 2880 4150 4150 4150 4150 4150 4150 4150 4150 4150 4150 Width (mm) (1) 890 890 890 890 890 890 890 890 890 890 890 890 Height (mm) (1) 1789 1789 1832 1832 1832 1832 1832 1832 1932 1932 2041 2041 (1) With compressor sound enclosure and disconnect switch handle not mounted.

General Information

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RTWB-SVN01B-E4

Installation Mechanical

Figure 4: Minimum service clearance

1 Minimum clearance for maintenance. 2 Minimum clearance for tube removal of the evaporator or condenser (at

either end of the unit).

Dimensions in mm

Storage

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

– Do not remove the protective

coverings from the unit.

– Store the chiller in a dry, vibration-

free secure area.

– At least every three months, check

the pressure in the refrigerant circuit. If the condensing pressure is below 4 bar at 20°C, call a qualified service organization and the appropriate Trane sales office.

Location requirements

Noise considerations

– Refer to the engineering bulletin

for noise-consideration applications.

– Locate the unit away from sound-

sensitive areas.

– Install the isolation pads under the

unit.

– Install the rubber vibration

isolators in all water piping.

– Use flexible electrical conduit.

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 charges of refrigerant, oil, and water). Refer to Table 2 for unit operating weights.

When in place, level the chiller within 6 mm over its length and width. The Trane Company is not responsible for equipment problems resulting from an improperlydesigned or -constructed foundation.

Vibration eliminators

– Provide rubber boot-type isolators

for all water piping at the unit.

– Provide flexible conduit for

electrical connections to the unit.

– Isolate all pipe hangers and be

sure they are not supported by main structure beams that could introduce vibration into occupied spaces

– Make sure that the piping does

not put additional stress on the unit.

Note: Do not use metal-braidedtype 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 1 meter is recommended for compressor service and to provide sufficient clearance for the opening of the control panel doors. Refer to Figure 4 for minimum clearances required for condenser-tube service. In all cases, local codes will take precedence over these recommendations.

Note: Required vertical clearance above the unit is 1 meter. 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.

Note: Maximum clearances are given depending on the unit configuration; some units may require less clearance than others in the same category.

Local regulations may provide for specific requirements.

Size “A”

207 and 208 1615

210 to 224 2250

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RTWB-SVN01B-E4

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 40°C.

Vent the evaporator, condenser, and compressor pressure-relief valves venting.

Make provisions in the equipment room to keep the chiller from being exposed to freezing temperatures (0°C).

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“.

CCAAUUTTIIOONN

To prevent unit damage, position the lifting beam so that cables do not come in contact with the unit.

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

Do not remove the wood shipping 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.

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

Installation Mechanical

Figure 5 – Lifting and rigging

Table 3 – Shipping weights and sling lengths for lifting

1 2 3 4 5 6 Shipping Weight

Unit Size (mm) (mm) (mm) (mm) (mm) (mm) (kg)

207 - - 250 0 3000 2650 2200 260 0 208 - - 250 0 3000 2650 2200 260 0 210 2500 3030 2400 3000 3650 3050

211 2500 3030 240 0 30 00 3650 3150 212 2500 3030 2400 30 00 3650 3150 214 2500 3030 2400 3000 3650 3500 216 2500 3030 2400 30 00 3650 3500 217 2500 3030 2400 30 00 3650 3500 218 2470 3060 2450 30 00 3650 3900 220 2470 3060 2450 30 00 3650 4050 222 2450 3100 2500 30 00 3650 4250 224 2450 3100 2500 30 00 3650 4400

Access restrictions

Door clearances for the RTWB units are given in Figure 8. Refer to the unit submittals for specific “per unit“ dimensional information.

Lifting procedure

The unit can be moved by using a fork lift or chains, cables, and a lifting beam. The total lifting weight and required lifting-beam dimensions are shown in Figure 5 and on the lifting diagram shipped with each unit. Lifting-beam crossbars must be positioned so that lifting cables do not come in contact with the sides of the unit.

Dimension of the holes for the forklift

Sizes 207 and 208

Sizes 210-224

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RTWB-SVN01B-E4

Installation Mechanical

Isolation pads

The elastomeric pads shipped are adequate for most installations. For additional details on isolation practices, consult an acoustical engineer for sensitive installations.

Water piping

Piping connections

CCAAUUTTIIOONN

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

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. Isolate and flush piping before connecting it to the unit.

Figure 6 – Isolator pad location

Evaporator water piping

Figure 7 illustrates typical

evaporator piping components.

Components and layout will vary

slightly, depending on the location

of connections and the water

source.

The chilled-water connections are

on the back of the unit, when facing

the control panel.

A vent is provided on the top of the

evaporator at the return end. Be

sure to provide additional vents at

high points in the piping to bleed air

from the chilled-water system.

Install necessary pressure gauges to

monitor the entering and leaving

chilled-water pressures.

To prevent damage to chilled-water

components, do not allow

evaporator pressure (maximum

working pressure) to exceed 10 bar.

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

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

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

Dimensions in mm

Size “A”

207 and 208 2880

210 to 224 4150

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RTWB-SVN01B-E4

Installation Mechanical

Flow switch

Balance valve

Air vent

Stop valves

Thermometers

Expansion joints

Stop valves

Evaporator

Filter

Drainage

Manometer

Figure 7 – Suggested piping for typical RTWB evaporator

Evaporator piping components

“Piping components“ include all devices and controls used to provide proper water-system operation and unit operating safety.

These components and their general location are given above:

Entering chilled-water piping

•

Air vents (to bleed air from system)

•

Water pressure gauges with shutoff

valves

•

Vibration eliminators

•

Shutoff (isolation) valves

•

Thermometers (if desired)

•

Cleanout tees

•

Pipe strainer

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

Leaving chilled-water piping

•

Air vents ( to bleed air from

system).

•

Water pressure gauges with shutoff

valves.

•

Vibration eliminators.

•

Shutoff (isolation) valves.

•

Thermometers.

•

Cleanout tees.

•

Balancing valve.

•

Flow switch

•

Pressure-relief valve.

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RTWB-SVN01B-E4

Installation Mechanical

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.

Entering condenser-water piping.

•

Air vents (to bleed air from system)

•

Water pressure gauges with shutoff valves

•

Vibration eliminators

•

Shutoff (isolation) valves.

•

Thermometers

•

Cleanout tees

•

Pipe strainer

Leaving condenser-water piping

•

Air vents (to bleed air from system)

•

Water pressure gauges with shutoff valves

•

Pipe unions

•

Vibration eliminators

•

Shutoff (isolation) valve

•

Thermometers

•

Cleanout tees

•

Balancing valve

•

Pressure relief valve

To prevent condenser damage do not exceed 10 bar water pressure.

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

Condenser Water Limitation (RTWB only)

The RTWB starts and operate satisfactorily over a wide range of load conditions with controlled entering condenser water temperature. Reducing the condenser water temperature is an effective method of lowering the power input to the compressors. The optimum condenser water temperature is related to the leaving chilled water temperature and the percentage of load on the chiller. Nevertheless it is required to maintain a minimum temperature differential of 18°C between the leaving chilled water temperature and the leaving condenser temperature. This minimum temperature differential must be reached within 2 minutes from startup and maintained thereafter.

Furthermore, the entering condenser water temperature should never drop below 20°C, whatever the other operating conditions of the chiller.

When one of these 2 parameters is expected to drop below the limit stated here above, even at start up, it is required that some form of condenser water temperature control be implemented to satisfy compressor safety and to ensure optimum chiller performance.

There are numerous methods to control condenser water temperature. Methods other than those shown can be employed to achieve the same results. Contact your local Trane office for details.

Throttling valve

This method maintains condensing pressure and temperature by throttling water flow leaving the condenser in response to condenser pressure or system differential pressures.

Figure 8

1 = 2-way valve 2 = Customer controller 3 = Condenser water pump 4 = To/from cooling device 5 = Temperature sensor

Advantages:

• Good control with proper valve sizing at relatively low cost.

• Pumping cost can be reduced.

Disadvantages:

• Increased rate of fouling due to lower condenser water velocity.

• Requires pumps that can accommodate variable flow.

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Installation Mechanical

RTWB-SVN01B-E4

Water treatment

Do not use untreated or improperly treated water. Use of untreated or improperly treated water may result in equipment damage.

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 watertreatment 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 responsibility for the results of the use of untreated or improperly treated water, or saline or brackish water.

Figure 9

Cooling device bypass

Cooling device bypass is also a valid control method if the chiller temperature requirements can be maintained.

1 = 3-way valve or 2 2-way valves 2 = Customer controller 3 = Condenser water pump 4 = To/from cooling device 5 = Temperature sensor

Advantage:

• Excellent control by maintaining constant water flow through the condenser.

Disadvantage:

• Higher cost because of the dedicated pump required for each chiller if condenser pressure is the control signal.

Figure 10

Condenser water pump with variable frequency drive

1 = Customer controller 2 = Condenser water pump with VFD 3 = To/from cooling device 4 = Temperature sensor

Advantages:

• Pumping cost can be reduced. Good cooling device temperature control.

• Relatively low first cost.

Disadvantages:

• Increased rate of fouling due to lower water velocity in the condenser.

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RTWB-SVN01B-E4

Installation Mechanical

Water pressure gauges and thermometers

Install field-supplied thermometers and pressure gauges (with manifolds, whenever practical) as shown in Figure 7. Locate pressure gauges or taps in a straight run of pipes -avoid placement near elbows. Be sure to install the gauges at the same elevation on each shell if the shell has opposite-end 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.

Water-pressure-relief valves

Install pressure-relief valves in both evaporator and condenser systems. Failure to do so could result in shell damage.

Install water-pressure-relief valves 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 with a water temperature increase. Refer to the applicable regulation for relief-valve installation guidelines.

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 shown in Figure 7.

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

•

Mount the flow switch upright,

with a minimum of 5 pipe diameters of straight, horizontal run on each side.

•

Do not install close to elbows,

orifices, or valves.

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

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

Note:The Unit Control Module provides a 6-second time delay on the flow-switch input before shutting down the unit on a loss-of-flow diagnostic. Contact a qualified service organization if machine shutdowns persist.

Adjust the switch to open when water flow falls below nominal. Refer to the evaporator and condenser data table for minimum flow recommendations. Flow-switch contacts are closed on proof of water flow.

WWAARRNNIINNGG

Refrigerant pressure reliefvalve venting

To prevent injury due to inhalation of R134a 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.

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

All RTWB units use evaporator, compressor, and condenser pressure-relief-valves that must be vented to the outside of the building. Relief-valve connection sizes and location are shown in the unit submittals. Refer to national regulation for relief valve vent line sizing information.

To prevent capacity reduction and relief-valve damage, do not exceed vent piping code specifications.

Note: After being opened once, relief

valves tend to leak.

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RTWB-SVN01B-E4

Figure 11 – Dimensions for RTWB units

Unit size 1 (mm) 2 (mm) 3 (mm) 4 (mm) 5 (mm) 6 (mm) 7 (mm) 8 (mm) 9 (mm) 10 (mm)

207 1800 1789 1792 544 384 911 318 215 806 1016 208 1800 1789 1792 544 384 911 318 215 806 1016 210 1898 1832 2844 653 408 959 258 279 854 1064 211 1898 1832 2844 653 408 959 258 279 854 1064 212 1898 1832 2844 653 408 959 258 279 854 1064 214 1898 1832 2844 653 408 959 258 279 854 1064 216 1898 1832 2844 653 408 959 258 279 854 1064 217 1898 1832 2844 653 408 959 258 279 854 1064 218 20 08 1932 2952 599 498 1063 181 215 958 1168 220 2008 1932 2952 599 498 1063 181 215 958 1168 222 2097 2041 2952 599 522 1150 95 215 1045 1255 224 2097 2041 2952 599 522 1150 95 215 1045 1255

1: Evaporator drain 21: 1 pass condenser 22: condenser 2 passes right 23: condenser 2 passes left

Installation Mechanical

Sizes 210-224

Sizes 207-208

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RTWB-SVN01B-E4

Installation Mechanical

Table 4 –Evaporator and condenser data

Evaporator water content Condenser water content

Model RTWB Evaporator code Condenser code Liter Liter

207 EG 120 CG 120 105 60 208 EG 120 CG 120 105 60 210 EG 140 CG 140 265 55 211 EG 170 CG 170 220 66 212 EG 170 CG 170 220 66 212 EG 170 CG 170 220 66 214 EG 200 CG 200 200 75 216 EG 200 CG 200 200 75 217 EG 200 CG 200 200 75 218 EG 250 CG 230 415 78 220 EG 250 CG 230 415 78 222 EG 340 CG 230 560 78 224 EG 340 CG 230 560 78

Minimum and maximum evaporator water flow (L/s)

Evaporator Code Pass Number Minimum Water Flow Maximum Water Flow Connection Diameter (in.)

EG 120 1 4.5 13.4 5 EG 140 1 6.0 18.0 6 EG 170 1 7.0 21.0 6 EG 200 1 9.0 25.0 6 EG 250 1 11.0 33.0 6 EG 340 1 14.0 43.0 6

Minimum and maximum condenser water flow (L/s)

Condenser Code Pass Number Minimum Water Flow Maximum Water Flow Connection Diameter (in.)

CG 120 1 8.4 31.0 5

CG 140 1 9.5 34.9 5 CG 170 1 11.9 43.7 5 CG 200 1 17.0 61.0 5 CG 230 1 17.0 61.0 5

Table 5 – RTWB Evaporator water pressure drop (kPa)

Water flow (L/s)

Model RTWB 5 10 15 20 25 30 35 40 45

207 1 6 24 - 208 1 6 24 - 210 1 - 57 122 211 1 - 29 61 104 212 1 - 29 61 104 214 1 11 24 41 62 216 1 11 24 41 62 217 1 11 24 41 62 218 1 17 29 45 64 220 1 17 29 45 64 222 1 23 35 49 66 85 106 224 1 23 35 49 66 85 106

Table 6 – RTWB Condenser water pressure drop (kPa)

Water flow (L/s)

Model RTWB 10 15 20 25 30 35 40 45 50 55 50

207 1 1020345171 - 208 1 1020345171 - 210 1 6 12 20 30 42 211 1 - 8 14 21 29 38 48 212 1 - 8 14 21 29 38 48 214 1 12 18 24 32 40 48 58 68 79 216 1 12 18 24 32 40 48 58 68 79 217 1 12 18 24 32 40 48 58 68 79 218 1 12 18 24 32 40 48 58 68 79 220 1 12 18 24 32 40 48 58 68 79 222 1 12 18 24 32 40 48 58 68 79 224 1 12 18 24 32 40 48 58 68 79

Pass

Number

Pass

Number

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RTWB-SVN01B-E4

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.

WWAARRNNIINNGG

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

Table 7 – Electrical data

RTWB 207 208 210 211 212 214 216 217 218 220 222 224 Nominal voltage (V) 400 400 400 400 400 400 400 400 400 400 400 400 Frequency (Hz) 50 50 50 50 50 50 50 50 50 50 50 50

(V) Mini 360 360 360 360 360 360 360 360 360 360 360 360

Maxi 440 440 440 440 440 440 440 440 440 440 440 440

Max. unit kW (kW) 90 106 132 142 152 182 202 222 243 264 292 320

(A) 147 170 215 235 255 297 329 360 396 432 477 521

Starting Amps (1) (A) 170 196 228 264 279 332 374 398 430 457 520 554 Power factor 0.91 0.92 0.90 0.89 0.88 0.89 0.90 0.90 0.89 0.89 0.89 0.89 Fuse size (2) 80A 100A 125A 60/125 160A 2*160 160+200 2*200 250+200 2*250 2*315 2*315

(A) 315 315 315 400 400 400 630 630 630 630 800 800

mm² 240 240 240 240 240 240 2*300 2*300 2*30 0 2*300 2*300 2*300

(1) Star delta start. Maximum starting Amps: one compressor at full load, the other one starting. (2) With disconnect switch option (3) mm²/phase

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

All wiring must comply with national electrical regulations. Electrical characteristics and other unit electrical data are on the unit nameplate. Specific electrical schematics and connection diagrams are shipped with the unit.

Use copper conductors only. Unit terminals are not designed to accept other types of conductors. Failure to do so may cause damage to the equipment.

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

Installation Electrical

Maximum connecting wire (2)(3)

Maximum Rated Load Amps

Voltage utilization range

Disconnect switch size

Page 19

RTWB-SVN01B-E4

Installation Electrical

Power supply wiring

Model RTWB chillers are designed according to European standard EN60204. All power-supply wiring must be sized and selected accordingly by the project engineer.

Water pump power supply

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

Electrical panel power supply

Power supply wiring instructions for the starter/control panel are: run line voltage wiring in conduit to access opening(s) on the starter/control panel.

Compressor-motor phase sequencing

Always verify that proper rotation of the RTWB compressors 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 the incoming power supply phased A,B,C (L1,L2,L3).

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.

Page 20

RTWB-SVN01B-E4

Installation Electrical

Control power transformer

The RTWB units are equipped with a control power transformer as standard. It is not necessary to provide control power voltage to these units.

Figure 12 - Electrical panel layout

1 Line voltage entrance 2 Power section 3 Control section 4 Free space for customer pump control 5 Wye-delta, closed-transition starter circuit A 6 Wye-delta, closed-transition starter circuit B 7 Unit disconnect, non-fused 8 CKT # 1 Lockout (module A20-1 6X7-8)

9 CKT # 2 Lockout (module A20-2 6X9-10) 10 Emergency stop (Normal/Stop contact - module A1 TB1 3-4) 11 Zone temperature sensor (6R3) or ice-machine control (6S55) option (6R3 and 6S55 cannot be used together) (module A9 TB1 1-2) 12 External chilled-water setpoint 4-20 mA or 2-10 V (dc)with communication interface option (module A9 TB1 4-5 7-8) 13 Communication serial link (A9 TB2 1…4) 14 Leaving condenser-water temperature sensor (5R53-2) option (with option PCM A70) 15 Chilled-water flow switch (6S56 - MODULE A1 TB3-4) 16 External Auto/Stop (6S1 - module A1 TB3 3-4) 17 Customer output:

Remote alarm indicator (from normally-closed signal) Maximum capacity indicator Compressor running indicator

Remote alarm indicator (from normally-open signal) 18 Chilled-water pump starter (TRANE UCM pump control - module A1 TB4 8-9) 19 Chilled-water pump starter (Auxiliary Interlock - MODULE A1 TB3 1-2 20 Tracer (Option - module A9 TB2 1…4)

Page 21

RTWB-SVN01B-E4

Installation Electrical

Interconnecting wiring

IIMMPPOORRTTAANNTT

Do not turn the chiller on or off using the chilled-water interlocks.

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

Chilled-water pump control

CCAAUUTTIIOONN

The chilled-water pump must operate for a minimum of one minute after the UCM receives a command, through the external Auto/Stop input, to shut down the chilled-water system.

On the RTWB units, the controller will initiate the “Run:Unload“ mode to terminate a cycle from any of the following:

- Stop key pressed

- Loss of load

- External Auto/Stop input opened

The “Run:Unload“ operating mode commands the compressor to completely unload, which takes about ½ minute. This will allow the compressors to be totally unloaded for the next start-up. If only the proof-of-chilled-water-flow interlock is used, the chiller will shut down with an immediate (non-friendly) shutdown and initiate an automatic reset diagnostic.

1. External Auto/Stop (terminals A1 TB3-3 and -4) This input is supplied by the field. A contact closure will start the chiller water pump and chiller, via the UCM pump control contacts. Opening the contact will put the operating compressors into “Run:Unload“ mode and initiate a timing period (1 to 30 minutes, adjustable through the Clear Language Display). This will delay termination of the chilled-water pump operation via the UCM pump control contacts. Examples of the input terminals 1UTB3-3 and -4 would be a time clock, ambient thermostat, building automation system.

2. UCM Pump Control Contacts (Terminals A1 TB4-8 and -9) This output is a set of contacts that will close, starting the chilledwater pump when the external Auto/Stop contacts are closed. When the contacts are opened, 1 to 30 minutes later (adjustable through the Clear Language Display), the UCM pump control contacts open.

3. Proof-of-Chilled-Water-Flow Interlock (Terminals A1 TB3-1 and

-2) This terminal must be fieldinstalled. Contact closure between the terminals indicates proof of chilled-water flow. Examples of this are a pump starter auxiliary contact, flow switch, differential pressure switch, or a contact from a building automation system. Opening of this contact will immediately shut down the chiller and initiate an automatic reset diagnostic, indicating loss of chilled-water flow

4. Condenser-Water Pump For the condenser-water pump interlock on the RTWB units, connect leads from terminals 6X3 to 6X6 and the water pump control. The circuit is 110 V (ac)and the load is not to exceed 1150 VA inrush, 115 VA sealed. This will interlock the condenserwater pump operation with the unit operation. This insures that the condenser-water pump is operating before the compressor(s) is started.

5. Alarm/Running/Maximum Capacity Outputs Terminals 1 to 7 on terminal strip TB4 of the A1 board provide a variety of contact outputs on the RTWB. These are dependent on the setting of Programmable Relay Setup (Service Setting Menu) and its relationship to diagnostics, compressors operating, and the system operating at full capacity.

As shown in Figure 13, there are three relays.

Figure 13 – Alarm / Running / Maximum capacity relay output for the RTWB unit.

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RTWB-SVN01B-E4

Installation Electrical

Table 9 – Alarm / Running / Maximum capacity menu setting

Programmable Relay Setup Setting Relay Output Configuration Diagnostic that the Alarm relay(s) is active

(service setting menu) (Table 6) MMR / CMR diag. MAR / CAR diag. IFW diag.

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

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

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

Table 8 – Alarm / Running / Maximum capacity relay output configuration

Relay output configuration

1 Relay 1 Alarm

Relay 2 Compressor running Relay 3 Maximum capacity

2 Relay 1 Circuit 1 alarm

Relay 2 Circuit 2 alarm Relay 3 Maximum capacity

3 Relay 1 Alarm

Relay 2 Circuit 1 running Relay 3 Circuit 2 running

Page 23

RTWB-SVN01B-E4

Low-voltage wiring

The remote devices described below require low-voltage wiring. All wiring to and from these remote input devices to the UCM, as described in the hereafter paragraph, must be made with shielded, twisted-pair conductors. Be sure to ground the shielding only at the Clear Language Display.

CCAAUUTTIIOONN

To prevent control malfunction, do not run low-voltage wiring (<30V) in conduits with conductors carrying more than 30 V.

Emergency stop (normal trip)

The Clear Language Display provides auxiliary control for a customer-specified or -installed latching tripout. When this remote contact 6S2 (furnished by the customer) is provided, the chiller will run normally when the contact is closed. When the contact opens, the unit will trip off on a manuallyresettable diagnostic. This condition requires manual reset at the chiller switch on the front of the Clear Language Display.

Installation Electrical

To connect, first remove the jumper located between terminal 3 and 4 of A1 TB1. Refer to the field diagrams that are shipped with the unit.

External circuit lockout - Circuit number 1

The UCM provides auxiliary control of a customer-specified or -installed contact closure, for individual operation of circuit number 1. If the contact is closed, the refrigerant circuit will not operate. The refrigerant circuit will run normally when the contact is opened.

External circuit lockout will only function if External Circuit Lockout (service setting Menu) is enabled.

Connections are shown in the field diagrams that are shipped with the unit.

Page 24

RTWB-SVN01B-E4

External circuit lockout - Circuit number 2

The UCM provides auxiliary control of a customer-specified or -installed contact closure, for individual operation of circuit number 2. If the contact is closed, the refrigerant circuit will not operate. The refrigerant circuit will run normally when the contact is opened.

External circuit lockout will only function if External Circuit Lockout (service setting Menu) is enabled.

Connections are shown in the field diagrams that are shipped with the unit.

Ice-making option

Ice-machine control (Operator Setting Menu) must be enabled. The UCM provides auxiliary control for a customer-specified or -installed contact closure for ice making. When contact 6S55, module A9, terminals TB1 1 and 2, is provided, the chiller will run normally when the contact is open. Upon contact closure, the UCM will initiate an icebuilding mode, in which the unit runs fully loaded at all times. Icebuilding shall be determined either by opening the contact or based on the entering evaporator-water temperature setting under Active Ice Termination Setting (Chiller Report Menu). The UCM will not permit icebuilding mode to be reentered until the unit has been switched out of ice-building mode (open 6S55 contacts) and then switched back into ice-building mode.

In ice-building, the current setpoint will be set at 120%. For example, if the front panel or external current limit setpoint is set to 80%, in icebuilding the active current limit is 120%.

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

External chilled-water setpoint: voltage source 2-10 V (dc), or Current source 4-20 mA

This option allows the external setting of the chilled-water setpoint, independent of the front panel chilled-water setpoint, by one of the two means:

1 - An isolated voltage input 2-10 V

(dc)

2 - An isolated current loop input 4-

20 mA

Isolated 2-10 V (dc)voltage source input

Set dip switch SW1-1 of the option module A9 to “OFF.“ Connect the voltage source to terminals 4 (+) and 5 (-) on option module A9 TB1. CWS is now based on the following equation:

CW Setpoint °C = (V (dc) * 4.88) -

27.56

Sample values for CWS vs. V (dc) signals are shown in Table 10.

Table 10: Input values vs. External chilled-water setpoint

Voltage (V (dc)) Current (mA) Resulting chilled-water setpoint (°C)

3.6 7.2 -10

4.6 9.2 -5

5.6 11.3 0

6.7 13.3 5

7.7 15.4 10

Installation Electrical

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RTWB-SVN01B-E4

Installation Electrical

Isolated 4-20 mA current source input

Set dip switch SW1-1 of the option module A9 to “ON.“ Connect the current source terminals 4 (+) and 5 (-). CWS is now based on the following equation:

Setpoint (°C) = (mA * 2.44) - 27.56

External current limit setpoint: voltage source 2-10 V (dc)or current source 4-20 mA.

This option allows the external setting of the current limit setpoint, independent of the front panel current-limit setpoint, by one of the two means:

1 - an isolated voltage input 2-10 V

(dc)

2 - an isolated voltage input 4-20 mA

To enable external current-limit setpoint operation, external currentlimit setpoint (operator setting menu) should be set to “E“ using the clear language display.

1- 2-10 V (dc) voltage source input Set dip switch SW1-2 of the option module A9 to “OFF.“ Connect the voltage source to terminals 7 (+) and 8 (-) of the option module A9. CLS is now based on the following equation:

CL Setpoint % = (V (dc)*10) + 20

Sample values for CLS vs. V (dc)signals are shown in Table 9.

Minimum setpoint : 40% (2.0 V (dc)input)

Maximum setpoint : 120% (10.0 V (dc)input)

4-20 mA Current source input Set dip switch SW1-2 of the option module A9 to “ON.“ Connect the current source to terminal 7 (+) and 8 (-) of option module A9. CLS is now based on the following equation:

CL Setpoint % = (mA * 5) + 20

Sample values for CLS vs mA signals are shown in Table 9.

Minimum setpoint = 40% (4.0 mA)

Maximum setpoint = 120% (20.0 mA)

Table 11: Input values vs. external current-limit setpoint

Voltage (V (dc)) Current (mA) Resulting current-limit setpoint (% RLA)

2.0 4.0 40

3.0 6.0 50

4.0 8.0 60

5.0 10.0 70

6.0 12.0 80

7.0 14.0 90

8.0 16.0 100

9.0 18.0 110

10.0 20.0 120

Outdoor air-temperature sensor

This sensor is used for low ambient lockout and chilled-water reset by outdoor air temperature. This sensor is optional on the RTWB units.

Remove the sensor from its shipping location in the control panel and install it in the fresh-air intake on the north wall of the building. Protect the sensor from direct sunlight and shelter it from the elements.

Connect leads to terminals 1 and 2 from module A9 TB1. All wiring to and from the remote sensor must be made with shielded, twisted-pair conductors. Be sure to ground the shielding only at the UCM. Apply tape to the sensor end of the shielding to prevent it from contacting the surface.

WWAARRNNIINNGG

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

CCAAUUTTIIOONN

To prevent overheating at the terminal connections, use copper conductors only.

Communication card

This option allows the Clear Language Display in the control panel on RTWB units to exchange information (operating setpoints and Auto/Standby commands) with a higher-level control device, such as Tracer. A shielded, twisted-pair connection establishes the bidirectional communications link between the unit control panel and the Tracer.

CCAAUUTTIIOONN

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

CCAAUUTTIIOONN

To prevent control malfunction, do not run low-voltage wiring (<30V) in conduits with conductors carrying more than 30 volts.

Page 26

RTWB-SVN01B-E4

General

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

1. All wiring must be in accordance with local codes.

2. Communication link wiring must be shielded, twisted-pair wiring.

3. The maximum total length for each communication link is 1,500 meters.

4. The communication link cannot pass between buildings.

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

Installation Electrical

Communication-link connection procedure

1. Refer to the Tracer installation literature to determine proper communication-link termination connections at the Tracer module.

2. Connect the shield of the communication-link wiring to the designated shield terminal at the Tracer module.

3. Connect leads to terminals 1 and 2 of TB2 of the module A9 of the UCM to the Tracer. There is no polarity requirement for the connection.

4. At the UCM, the shield should be cut and taped to prevent any contact between the shield and ground.

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

5. To get the chiller to communicate with a Tracer on a multiple-unit controller, the ICS address under the “service settings“ menu must be set and the optional A9 module must be installed. The Tracer will look for chiller addresses 55,56,57,58,59, or 60. Each chiller must have a unique address.

Page 27

RTWB-SVN01B-E4

Installation Electrical

Installation check list

Complete this checklist as the unit is installed, to verify that all recommended procedures are accomplished before the unit is started. This checklist does not replace the detailed instructions given in sections 2 and 3 of this manual. Read both sections completely, to become familiar with the installation procedures, prior to beginning the work.

Receiving

[ ] Verify that the unit nameplate data corresponds to the ordering

information.

[ ] Inspect the unit for shipping damage and any material shortage. Report

any damage or material shortage to the carrier.

Unit location and mounting

[ ] Inspect the location desired for installation and verify adequate service-

access clearances.

[ ] Provide drainage for evaporator and condenser water, if applicable.

[ ] Remove and discard all shipping materials.

[ ] Install optional neoprene if required.

[ ] Level the unit and secure it to the mounting surface.

Unit water piping

[ ] Flush all unit water piping before making final connections to the unit.

CCAAUUTTIIOONN

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

CCAAUUTTIIOONN

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

[ ] Connect the water piping to the evaporator and condenser.

[ ] Install pressure gauges and shutoff valves on the water inlet and outlet, if

applicable.

[ ] Install a water strainer in the entering chilled-water line, if applicable.

[ ] Install a balancing valve and flow switch in the leaving chilled-water line,

if applicable.

[ ] Install a drain with shutoff valve or a drain plug on the evaporator, if

applicable.

[ ] Vent the chilled-water and condenser-water systems at high points in the

system piping, if applicable.

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RTWB-SVN01B-E4

Operating Principles – Mechanical

General

This section describes the mechanical operating principles of the RTWB chillers equipped with microprocessor-based control systems.

The model RTWB chillers are dualcompressor, helical-rotary-type, water-cooled liquid chillers. The basic components of a RTWB unit are:

- Clear Language Display and control modules

- Helical-rotary compressor

- Direct-expansion evaporator

- Water-cooled condenser

- Oil supply system

- Interconnecting piping

Components of a typical RTWB unit are identified in Figure 2 and 3.

Figure 14 – RTWB refrigeration system and control components

1 Compressor 2 Condenser 3 Evaporator 4 Oil separator 5 Electronic expansion valve 6 Oil cooler (option) 7 Low-pressure switch 8 High-pressure switch

9 Solenoid valve 10 Refrigerant charging valve 11 Oil-separator draining valve 12 Oil-cooler expansion valve 13 Compressor discharge valve (option) 14 Liquid-line service valve 15 Oil-circuit service and charging valve 16 Filter 17 Chilled-water outlet connection 18 Chilled-water inlet connection 19 High-pressure safety valve (supply if required by code vessel approval) 20 Low-pressure safety valve 21 Low-pressure gauges (option) 22 High-pressure gauges (option) 23 Saturated refrigerant temperature sensor (condenser) 24 Saturated Refrigerant temperature sensor (evaporator) 25 Refrigerant temperature sensor (suction) 26 Oil temperature sensor 27 Leaving chilled-water temperature sensor 28 Entering chilled-water temperature sensor (option)

Page 29

RTWB-SVN01B-E4

Pre-start checkout

General

When installation is complete, but prior to putting the unit into service, the following pre-start procedures must be reviewed and verified:

[ ] Inspect all wiring connections to

be sure they are clean and tight.

WWAARRNNIINNGG

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

CCAAUUTTIIOONN

Check the tightness of all connections in the compressor power circuit (disconnects, terminal block, contactors, compressor junction box terminals, …). Loose connections can cause overheating at the connections and undervoltage conditions at the compressor motor.

[ ] Verify that all refrigerant valves

are open.

CCAAUUTTIIOONN

Do not operate the unit with the compressor, oil discharge, or liquid line valves closed. Failure to have these open may cause serious compressor damage.

[ ] Check the power supply voltage

to the unit at the main-power, fused disconnect switch. Voltage must be within the voltage utilization range, given in Table 7 and also stamped on the unit nameplate. Voltage imbalance must not exceed 2%

WWAARRNNIINNGG

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

[ ] Check the unit power phasing to

be sure that it has been installed in an “ABC“ sequence.

WWAARRNNIINNGG

It is imperative that l1-l2-l3 in the starter be connected in the A-B-C phase sequence to prevent equipment damage due to reverse rotation.

[ ] Fill the evaporator and condenser

chilled-water circuits. Refer to Table 2 for liquid capacities. Vent the system while it is being filled. Open the vents on the top of the evaporator and condenser during filling, and close them when filling is completed

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 of 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.

CCAAUUTTIIOONN

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

[ ] Close the fused disconnect

switch that supplies power to the chilled-water pump starter and the condenser pump starter.

[ ] Start the chilled-water pump and

condenser-water pump to begin circulation of the water. Inspect all piping for leakage and make any necessary repairs.

[ ] With water circulating through

the system, adjust the water flow and check the water-pressure drop through the evaporator and condenser. Refer to Tables 5 and

[ ] Adjust the chilled-water flow

switch and the condenser-water flow switch (if installed) for proper operation.

[ ] Prove all interlock and

interconnecting wiring interlock as described in section 3.

[ ] Check and set, as required, all

Clear Language Display menu items.

[ ] Stop the chilled-water pump and

the condenser-water pump.

Unit Start-Up Procedures

Page 30

RTWB-SVN01B-E4

Unit voltage power supply

Voltage to the unit must meet the criteria given in Table 7. Measure each phase of the supply voltage at the unit main-power, fused disconnect. If the measured voltage on any phase is not within the specified range, notify the supplier of the power and correct the situation before operating the unit.

CCAAUUTTIIOONN

Inadequate voltage to the unit can cause control components to malfunction and shorten the life of relay contacts, compressor motors, and contactors.

Unit voltage imbalance

Excessive voltage imbalance between the phases of a three-phase system can cause motors to overheat and eventually fail. The maximum allowable imbalance is 2%. Voltage imbalance is determined using the following calculations:

% imbalance =(Ux - U average)

U average

U average = (U1 + U2 + U3) / 3

Ux = phase with greatest difference

from U average (without regard to sign).

For example, if the three measured voltages are 401, 410, and 407 volts, the average would be:

401 + 412 + 417 = 410

The percentage of imbalance is then:

100 * ( 410 - 401) = 2.2%

410

This exceeds the maximum allowable (2%) by 0.2%.

Unit voltage phasing

WWAARRNNIINNGG

It is imperative that L1-L2-L3 in the starter be connected in the A-B-C phase sequence, to prevent equipment damage due to reverse rotation.

It is important that proper rotation of the compressors be established before the unit 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 the incoming power supply phased A,B,C.

When rotation is clockwise, phase sequence is usually called “ABC;“ when counterclockwise, “CBA.“

Water system flow rates

Establish a balanced chilled-water flow through the evaporator. The flow rates should be between the minimum and maximum values given in Table 4.

The flow rates through the condenser must also be balanced according to the flow rates table (Table 4).

Water system pressure drop

Measure the water pressure drop through the evaporator and condenser at the field-installed pressure taps, on the system water piping. Use the same gauge for each measurement. Do not include valves, strainers, or fittings in the pressure drop reading.

Unit Start-Up Procedures

Page 31

RTWB-SVN01B-E4

Start up procedure

General

If the pre-start checkout, as discussed above, has been completed, the unit is ready to start. The Clear Language Display is shown in Figure 12. Complete each step in sequence, as follows:

[ ] Press the Stop key on the Clear

Language Display.

[ ] As necessary, adjust the setpoint

values in the Clear Language Display menus.

[ ] Close the fused disconnect

switch for the chilled-water pump and the condenser-water pump. Energize the pumps to start the water circulation.

[ ] Check the service valves on the

discharge line, suction line, oil line, and liquid line for each circuit. These valves must be open before starting the compressors.

CCAAUUTTIIOONN

To prevent compressor damage, do not operate the unit until all refrigerant and oil-line service valves are opened.

[ ] Verify that the chilled-water pump

runs for one minute after the chiller is commanded to stop (for normal chilled-water systems).

[ ] Press the Auto key. If the chiller

control calls for cooling and all safety interlocks are closed, the unit will start. The compressor(s) will load and unload in response to the temperature of the leaving chilled-water temperature.

After the system has been operating for approximately 30 minutes and has become stabilized, complete the start-up procedures as follows.

[ ] Check the evaporator refrigerant

pressure and the condenser refrigerant pressure under the Refrigerant Report on the Clear Language display.

[ ] Measure the system superheat.

[ ] Measure the system subcooling.

[ ] A shortage of refrigerant is

indicated if the operating pressures are low and the subcooling is also low. If the operating pressures, superheat, and subcooling readings indicate a refrigerant shortage, gas-charge refrigerant into each circuit as required. With the unit running, add refrigerant vapor by connecting the charging line to the suction service valve and charging through the backseat port until operating conditions become normal.

CCAAUUTTIIOONN

If both suction and discharge pressures are low and subcooling is normal, a problem other than refrigerant shortage exists. Do not add refrigerant, as this may result in overcharging the circuit.

Use only the refrigerant specified on the unit nameplate, to prevent compressor damage and insure full system capacity.

[ ] If operating conditions indicate a

refrigerant overcharge, remove refrigerant at the liquid line service valve. Allow refrigerant to escape slowly to minimize oil loss. Do not discharge refrigerant into the atmosphere.

WWAARRNNIINNGG

Do not allow refrigerant to directly contact skin, or injury from frostbite may result.

System superheat

Normal suction superheat for each circuit is approximately 3°C at full operating load. Superheat temperature can be expected to be moving around a 3°C setpoint when the chiller is pulling down or when the compressor slide valve is being modulated.

System subcooling

Normal subcooling for each circuit ranges from 5.5°C to 11°C, depending on the unit. If subcooling for either circuit does not approximate these figures, check the superheat for the circuit and adjust it, if required. If superheat is normal but subcooling is not, contact a qualified service technician.

Unit Start-Up Procedures

Page 32

RTWB-SVN01B-E4

Unit shutdown procedures

Temporary shutdown and restart

To shut the unit down for a short time, use the following procedure:

• Press the Stop key on the Clear Language Display. The compressors will continue to operate and, after unloading for 20 seconds, will stop when the compressor contactor deenergizes.

• Stop the water circulation by turning off both the chilled-water pump and the condenser-water pump.

To restart the unit after a temporary shutdown, restart the chilled-water pump and the condenser-water pump, and press the Auto key. The unit will start normally if the following conditions exist:

• The UCM must receive a call for cooling and the differential-to-start must be above the setpoint.

• All system operating interlocks and safety circuits must be satisfied.

Extended shutdown procedure

The following procedure is to be followed if the system is to be taken out of service for an extended period of time as a seasonal shutdown:

Test the unit for refrigerant leakage and repair as necessary.

Open the electrical disconnect switches for the chilled-water pump and the condenser-water pump. Lock the switches in the “open“ position.

CCAAUUTTIIOONN

Lock the chilled-water and condenser-water pump disconnects open, to prevent pump damage.

• Close all chilled-water supply valves and the condenser-water supply valves. Drain the water from the evaporator and the condenser.

• Open the unit main electrical disconnect and the unit-mounted disconnect (if installed), and lock in the “Open“ position.

CCAAUUTTIIOONN

Lock the disconnects on the “Open“ position to prevent accidental startup and damage to the system when it has been set up for extended shutdown.

At least every three months, check the pressure in the unit to verify that the refrigerant charge is intact.

System restart after extended shutdown

• Follow the procedures below to restart the unit after an extended shutdown:

• Verify that the liquid-line service valves, oil line, and compressor discharge service valves are open.

CCAAUUTTIIOONN

To prevent damage to the compressor, be sure that all refrigerant valves are open before starting the unit.

• Check the oil-separator oil level. See the Maintenance paragraph.

• Fill the evaporator- and condenserwater circuits. Refer to Table 4 for evaporator- and condenser-water content. Vent the system while it is being filled. Open the vents on the tops of the evaporator and condenser during filling and close them when filling is completed.

CCAAUUTTIIOONN

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

• Close the fused disconnect switches that provide power to the chilled-water pump and the condenser-water pump.

• Start both the evaporator- and condenser-water pumps and, while water is circulating, inspect all piping for leakage. Make any necessary repairs before starting the unit.

• While the water is circulating, adjust the water flows and check the water pressure drops through the evaporator and the condenser. Refer to “Water System Flow Rates“ and “Water System Pressure Drop.“

• Adjust the flow switch (s) on the evaporator piping and the condenser piping (if installed) for proper operation.

• Stop both water pumps. The unit is now ready for the start-up procedure.

Unit Shutdown Procedures

Page 33

RTWB-SVN01B-E4

Periodic Maintenance

Periodic maintenance

General

Perform all maintenance procedures and inspections at the recommended intervals. This will prolong the life of the equipment and minimize the possibility of costly failures.

Weekly maintenance

After the unit has been operating for approximately 30 minutes and the system has stabilized, check the operating conditions and complete the procedures below:

[ ] Check the evaporator refrigerant

pressure and the condenser refrigerant pressure in the Refrigerant Report Menu on the Clear Language Display.

[ ] If operating pressure conditions

seem to indicate a refrigerant shortage, measure the system superheat and system subcooling. Refer to the Start-up procedure paragraph.

[ ] If operating conditions indicate a

refrigerant overcharge, remove refrigerant at the liquid-line service valve. Allow refrigerant to escape slowly to minimize oil loss. Do not discharge refrigerant into the atmosphere.

WWAARRNNIINNGG

Do not allow refrigerant to directly contact skin, or injury from frostbite may result.

[ ] Inspect the entire system for

unusual conditions.

Monthly maintenance

[ ] Perform all weekly maintenance

procedures

[ ] Measure and record the system

superheat. Refer to the Start-up procedure paragraph.

[ ] Measure and record the system

subcooling. Refer to the Start-up procedure paragraph.

WWAARRNNIINNGG

Position all electrical disconnects in the “Open“ position and lock them, to prevent injury or death due to electrical shock.

Annual maintenance

[ ] Perform all weekly and monthly

maintenance procedures.

[ ] Check the refrigerant charge and

oil level. Refer to the Refrigerant charging paragraph. Routine changing of oil is not required.

[ ] Have a qualified laboratory

perform a compressor-oil analysis to determine the system moisture content and acid level. This analysis is a valuable diagnostic tool.

[ ] Check the pressure drop across

the oil filter. See the Maintenance paragraph.

[ ] Contact a qualified service

organization to leak-test the chiller, to check operating and safety controls, and to inspect electrical components for deficiencies.

[ ] Inspect all piping components for

leakage and damage. Clean out any inline strainers.

[ ] Clean and repaint any areas that

show signs of corrosion.

WWAARRNNIINNGG

Position all electrical disconnects in the “Open“ position and lock them, to prevent injury or death due to electrical shock.

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RTWB-SVN01B-E4

Maintenance

General

This section describes specific maintenance procedures that must be performed as a part of the normal maintenance program for this unit. Be certain that electrical power to the unit is disconnected before performing these procedures.

WWAARRNNIINNGG

Position all electrical disconnects in the “Open“ position and lock them, to prevent injury or death due to electrical shock.

Cleaning the evaporator

The evaporator water system is a part of a closed loop and should not accumulate an appreciable amount of scale or sludge. If it is determined that the chiller is fouled, attempt to dislodge any foreign material by backflushing the system several times. If this does not work satisfactorily, chemically clean the chiller using the procedures outlined in the following section.

Cleaning the condenser

General

Water that is available for condensing frequently contains minerals or other contaminants that collect on the inside of the condenser tubes. Scale accumulation will accelerate with high condensing temperatures and the use of water with high mineral content. Cooling devices collect dust and foreign material that are also deposited on the condenser tubes, forming sludge.

To maintain maximum efficiency, the condenser must remain as free of these deposits as possible. Even a very thin layer on the inside tube surfaces reduces the heat-transfer ability of the condenser. Indications of scale deposits are: decreased water flow through the condenser, reduced temperature differential between the entering and leaving condenser-water, and abnormally high condensing temperatures.

There are two accepted methods of cleaning the condenser tubes, as discussed in the following paragraphs.

Mechanical cleaning

The mechanical cleaning method is used primarily to remove sludge and other loose material from the condenser tubes.

Follow the steps below:

Turn off the chiller and condenser water supplies.

Break piping connections and the unions.

Remove the condenser heads.

Run a round nylon brush from the end through the tubes, to loosen deposits.

Flush the tubes with water. Then inspect the tubes for scale accumulation. If there is no scale in the tubes, reassemble the condenser and piping.

If there is scale in the tubes, follow the procedures in the following paragraph.

Chemical cleaning

Chemical cleaning is the most satisfactory method of cleaning scale from the condenser. With this treatment, scale is dissolved and flushed away by circulating a chemical solution through the tubes and headers.

Internal condenser components are composed of copper, steel, and cast iron. With this information, water treatment firms will be able to recommend a suitable chemical for this purpose. If water treatment is not available, consult a chemical supply house.

Water treatment

The use of untreated or improperly treated water in the unit may result in the formation of scale, algae, or slime. It may also cause erosion or corrosion. It is recommended that a qualified water treatment specialist provide recommendations for proper water treatment. The Trane Company assumes no responsibility for equipment failure caused by the use of untreated or improperly treated water.

Periodic Maintenance

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RTWB-SVN01B-E4

Oil separator check level

Follow the steps listed below and refer to the notes listed in Figure 12.

1. Turn off the unit.

2. Attach the hoses and sight glass to the oil-separator Schrader valves, as shown in Figure 12. Remove non-condensibles.

3. After the unit has been off for 10 minutes, move the sight glass up and down until the level can be seen.

4. After the level has been determined, remove the sight glass and hoses.

Figure 15 – System Oil Specifications

1: Oil separator 2: Valve 3: ¼" refrigeration hose 4: Sight glass 5: Minimum oil level 6: Maximum oil level

Table 12 – Oil level limit

Oil separator diameter

152 mm 203 mm 254 mm Minimum oil level (mm) 90 120 145 Maximum oil level (mm) 155 205 235

Periodic Maintenance

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RTWB-SVN01B-E4

Oil filter change

Note: Routine changing of the oil or the oil filter is not recommended. The oil filter is oversized for this application.

The oil and filter should be replaced only if analysis reveals that the oil is contaminated. Oil type and system capacities are shown in Table 2.

Pressure drop across the oil filter is shown in Figure 13. Oil filter pressure drop is the difference between the two pressure-control ports.

Refrigerant filter change

If the temperature drop through the filter is higher than 4K, the filter should be changed.

Figure 16 – Oil filter pressure drop

Periodic Maintenance

Oil Filter Pressure Drop

Normal Pressure Drop

Maximum Pressure Drop

Oil Filter Pressure Drop (Bar)

Condensing Pressure – Suction Pressure (Bar)

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RTWB-SVN01B-E4

To change the oil filter in the unit, refer to Figure 14 and follow the steps listed below.

For units without the discharge valve option:

1. Shut off the compressor and disconnect all electrical service to the compressor.

2. Vacuum the refrigerant out of the circuit.

3. Remove the seven bolts on the oil filter cover. A pan may be necessary to catch any oil that is released after the cover is loosened.

4. Remove the cover and the oil filter element.

5. Install the new filter element.

6. Coat the new cover gasket with refrigerant oil.

7. Install the cover plate and cover plate gasket.

Periodic Maintenance

8. Install a new copper gasket under the bolt head that had one at time of removal. Replace all other bolts and tighten to 89.5 Nm.

9. Vacuum the refrigerant circuit at 500 micron and isolate the vacuum pump.

10. Confirm that no moisture or leaks are present by letting the vacuum stand for 2 hours. The pressure should not raise more than 250 microns.

11. Charge the unit with oil, in a quantity equal to what has been removed, by using the charging valve placed on the oil filter.

Note: the oil is very sensitive to moisture. Use the oil immediately after the oil can has been opened.

12. Charge the unit with refrigerant R134a (refer to the charging procedure)

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RTWB-SVN01B-E4

Figure 17 – Oil filter change

1: Oil charging valve 2: Oil pressure control port 3: Oil pressure control port

Periodic Maintenance

For units with the discharge valve option:

1. Closed the angle valve placed on the refrigerant liquid line to store the refrigerant in the condenser.

2. After the compressor stops, closed the compressor discharge valve and disconnect the unit.

Note: Do not make successive vacuums by using the compressor. Irreversible compressor damage could occur.

3. Vacuum the refrigerant remaining in the evaporator.

4. Remove the seven bolts on the oil filter cover. A pan may be necessary to catch any oil that is released after the cover is loosened.

5. Remove the cover and the oil filter element.

6. Install the new filter element.

7. Coat the new cover gasket with refrigerant oil.

8. Install the cover plate and cover plate gasket.

9. Install a new copper gasket under the bolt head that had one at time of removal. Replace all other bolts and tighten to 89.5 Nm.

10. Vacuum the refrigerant circuit at 500 micron and isolate the vacuum pump.

11. Confirm that no moisture or leaks are present by letting the vacuum stand for 2 hours. The pressure should not raise more than 250 microns.

12. Charge the unit with oil, in a quantity equal to what has been removed, by using the charging valve placed on the oil filter.

Note: the oil is very sensitive to moisture. Use the oil immediately after the oil can has been opened.

13. Charge the unit with refrigerant R134a (refer to the refrigerant charging paragraph).

14. Open all the valves before restarting the chiller.

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RTWB-SVN01B-E4

Refrigerant charging

If the refrigerant needs to be adjusted, be certain to monitor the subcooling and superheat measurements. The subcooling needs to be between 6 and 12°C when the unit is running fully loaded. The superheat needs to be close to, or at, the superheat setpoint entered in the UCM.

CCAAUUTTIIOONN

The evaporator water flow must be established and maintained while adjusting the charge. Refrigerant pressures below 2,3 bar gauge can cause freezing and rupturing of the evaporator tubes.

Adding refrigerant

The RTWB units are shipped with an entire charge of refrigerant and oil. If the unit has no pressure, the system must be leak tested prior to adding refrigerant. Evacuate the system down to at least 500 microns prior to adding the refrigerant.

CCAAUUTTIIOONN

Water must be flowing through the tube bundles during this entire process. Refrigerant pressures below 2,3 bar gauge can cause freezing and rupturing of the heat exchangers.

1. Connect 110 V power to the female stepload solenoid and the male load/unload solenoids. This must be done to evacuate all of the cavities in the compressor.

2. Open all service valves.

3. Connect hoses from the vacuum pump to the LP and HP ports on the unit.

4. Evacuate the system to 500 microns and isolate the vacuum pump.

Periodic Maintenance

5. Confirm that no moisture or leaks are present by letting the vacuum stand for 2 hours. The pressure should not raise more than 250 microns.

6. Close the liquid line valve placed at the outlet of the condenser.

7. Open the EXV and add refrigerant by using the charging valve placed on the liquid line.

8. After the pressure between the refrigerant bottle and the refrigerant circuit is balanced, make a vacuum by using the compressor in order to store the refrigerant in the condenser.

9. Continue to charge the machine by using the refrigerant charging valve placed on the liquid line.

10. After the pressure is balanced between the bottle and the machine, open the liquid line valve and start the compressor.

11. Complete the charge by using the charging valve placed on the suction line. For the correct refrigerant charge refer to the Table 2.

Page 40

Trane A business of American Standard Companies www.trane.com

For more information contact your local district office or e-mail us at comfort@trane.com

Literature Order Number

Date

Supersedes

Stocking Location

Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. Only qualified technicians should perform the installation and servicing of equipment referred to in this publication.

RTWB-SVN01B-E4

100 3

RTWB-SVN01A-E4_0801

Europe

Société Trane – Société Anonyme au capital de 61 005 0 00 Euros – Siège Social: 1 rue des Amériques – 88190

Golbey – France – Siret 306 050 188-00011 – RSC Epinal B 306 050 188

Numéro d’identification taxe intracommunautaire: FR 83 3060501888

Maintenance Contract

It is strongly recommended that you sign a maintenance contract with your local Service Agency. This contract provides regular maintenance of your installation by a specialist in our equipment. Regular maintenance ensures that any malfunction is detected and corrected in good time and minimizes the possibility that serious damage will occur. Finally, regular maintenance ensures the maximum operating life of your equipment. We would remind you that failure to respect these installation and maintenance instructions may result in immediate cancellation of the warranty.

Training

The equipment described in this manual is the result of many years of research and continuous development. To assist you in obtaining the best use of it, and maintaining it in perfect operating condition over a long period of time, the constructor have at your disposal a refrigeration and air conditioning service school. The principal aim of this is to give operators and maintenance technicians a better knowledge of the equipement they are using, or that is under their charge. Emphasis is particularly given to the importance of periodic checks on the unit operating parameters as well as on preventive maintenance, which reduces the cost of owning the unit by avoiding serious and costly breakdowns.