Trane Sintesis RTAF Installation, Operation And Maintenance Manual

Page 1

Installation, Operation, and Maintenance

Sintesis™ Air-Cooled Chillers Model RTAF

Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury.When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment.

June 2015

SAFETY WARNING

RTAF-SVX001A-EN

Page 2

Introduction

Read thismanual thoroughly before operating orservicing this unit.

Warnings, Cautions, and Notices

Safety advisories appear throughout this manual as required.Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

The three types of advisories are defined as follows:

WARNING

Proper Field Wiring and Grounding Required!

Failure to follow code could result in death or serious injury. All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state electrical codes.

WARNING

CAUTIONs

NOTICE

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It could also be used to alert against unsafe practices.

Indicates a situationthat could result in equipment or property-damage only accidents.

Important Environmental Concerns

Scientific research has shown that certain man-made chemicals can affect the earth’s naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment.Trane advocates the responsible handling of all refrigerants-including industry replacements for CFCs such as HCFCs and HFCs.

Important Responsible Refrigerant Practices

Trane believes that responsible refrigerant practices are

important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified.The Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.

WARNING

Personal Protective Equipment (PPE) Required!

Installing/servicing this unit could result in exposure to electrical, mechanical and chemical hazards.

• Before installing/servicing this unit, technicians MUST put on all PPE required for the work being undertaken (Examples; cut resistant gloves/sleeves, butyl gloves, safety glasses, hard hat/bump cap, fall protection, electrical PPE and arc flash clothing).

ALWAYS refer to appropriate Material Safety Data

Sheets (MSDS)/Safety Data Sheets (SDS) and OSHA guidelines for proper PPE.

• When working with or around hazardous chemicals,

ALWAYS refer to the appropriate MSDS/SDS and

OSHA/GHS (Global Harmonized System of Classification and Labelling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection and handling instructions.

• If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other country-specific requirements for arc flash protection, PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE

TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASH CLOTHING. ENSURE ELECTRICAL

METERS AND EQUIPMENT ARE PROPERLY RATED FOR INTENDED VOLTAGE.

Failure to follow instructions could result in death or serious injury.

Page 3

WARNING

Refrigerant under High Pressure!

Failure to follow instructions below could result in an explosion which could result in death or serious injury or equipment damage. System contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use nonapproved refrigerants, refrigerant substitutes, or refrigerant additives.

Factory Warranty Information

Compliance with the following is required to preserve the factory warranty:

All Unit Installations

Startup MUST be performed byTrane, or an authorized agent ofTrane, to VALIDATE this WARRANTY. Contractor must provide a two-week startup notification toTrane (or an agent ofTrane specifically authorized to perform startup).

Introduction

This document and theinformation in it are the propertyof Trane, and may not be used or reproduced in whole or in

part without written permission.Trane reserves the right to revise this publication at any time, and to make changes to its content without obligation to notify any person of such revision or change.

Trademarks

All trademarks referenced in this document are the

trademarks of their respective owners.

RTAF-SVX001A-EN 3

Page 4

Table of Contents

Introduction ............................. 2

Warnings, Cautions, and Notices ........ 2

Important Environmental Concerns ..... 2

Important Responsible Refrigerant

Practices ........................... 2

Table of Contents ........................ 4

Model Number Description ............... 6

Nameplates ........................... 6

Outdoor Unit Nameplate .............. 6

Compressor Nameplate ............... 6

Model Number Descriptions .............. 7

Unit Model Number .................... 7

Compressor Model Number ............ 8

Compressor Serial Number ............. 8

General Information ..................... 9

Accessories and Loose Parts ............ 9

General Data ......................... 10

Pre-Installation ......................... 11

Inspection ........................... 11

Inspection Checklist ................. 11

Storage ............................. 11

Installation Requirements .............. 12

Dimensions and Weights ................ 13

Service Clearance .................... 13

Unit Dimensions ...................... 13

Weights ............................. 13

Installation Mechanical .................. 14

Location Requirements ................ 14

Sound Considerations ............... 14

Foundation ........................ 14

Clearances ......................... 14

Lifting and Moving Instructions ........ 14

Center of Gravity ..................... 15

Isolation and Sound Emission .......... 16

Unit Isolation and Leveling ........... 16

Chilled Water Piping Recommendations .18

Drainage .......................... 18

Water Treatment ....................18

Evaporator Piping .....................18

Evaporator Piping Components ........18

Entering Chilled Water Piping ..........19

Leaving Chilled Water Piping ..........19

Waterbox Drains and Vents ...........19

Pressure Gauges ....................19

Pressure Relief Valves ................19

Evaporator Flow Switch ..............20

Evaporator Waterside ..................21

Pressure Drop Curves ................21

Freeze Avoidance ......................23

Low Evaporator Refrigerant Cutout and

Glycol Requirements .................24

Installation Electrical .....................25

General Recommendations .............25

Installer-Supplied Components ..........25

Power Supply Wiring .................25

Control Power Supply ................25

Programmable Relays ..................27

Relay Assignments Using Tracer TU

.............................27

Low Voltage Wiring ....................28

Emergency Stop .....................28

External Auto/Stop ...................28

Ice Building Option ..................28

External Chilled Water Setpoint (ECWS)

Option .............................28

External Demand Limit Setpoint (EDLS)

Option .............................29

Chilled Water Reset (CWR) ............29

AFD Drive ............................30

AFD Drive Installation ................31

Communication Interfaces ..............32

LonTalk Interface (LCI-C) ..............32

BACnet Interface (BCI-C) ..............32

Modbus Remote Terminal Unit Interface .32

Operating Principles .....................33

Refrigerant Circuit .....................33

4 RTAF-SVX001A-EN

Page 5

Table of Contents

Refrigerant Cycle ..................... 33

Refrigerant and Oil .................... 33

Compressor and Lube Oil System ...... 33

Condenser and Fans .................. 33

Evaporator ........................... 34

Controls ............................... 35

Overview ............................ 35

UC800 Specifications .................. 35

Wiring and Port Descriptions ......... 35

Communication Interfaces ............ 36

Rotary Switches .................... 36

LED Description and Operation ........ 36

Tracer AdaptiView TD7 Display ......... 36

Operator Interface .................. 36

Main Display Area/Home Screen ...... 36

Viewing Chiller Operating Modes ..... 37

Alarms ........................... 39

Reports ........................... 39

Equipment Settings ................. 42

Display Settings .................... 44

Viewing the Settings Screen ......... 44

Cleaning the Display ................ 45

Security Settings ................... 45

Disabling/Enabling Security .......... 45

Tracer TU ............................ 47

Pre-Start ............................... 48

Start-Up and Shutdown ................. 49

Unit Start-Up ......................... 49

Temporary Shutdown And Restart ...... 49

Extended Shutdown Procedure ......... 49

Seasonal Unit Start-Up Procedure ...... 50

System Restart After Extended Shutdown 50

Sequence of Operation ................ 51

Software Operation Overview ......... 51

Timelines .......................... 51

Power Up Diagram .................. 52

Power Up to Starting ................ 53

Stopped to Starting ................. 54

Running (Lead Compressor/Circuit Start

and Run) .......................... 55

Running (Lag Compressor/Circuit Start

and Run) ...........................56

Satisfied Setpoint ....................57

Normal Shutdown to Stopped

or Run Inhibit .......................58

Immediate Shutdown to Stopped

or Run Inhibit .......................59

Ice Making (Running to Ice Making

to Running) .........................60

Ice Making (Auto to Ice Making to

Ice Making Complete) ................61

Maintenance ............................62

Recommended Maintenance ............62

Weekly ...............................62

Monthly ..............................62

Annual ...............................62

Refrigerant and Oil Charge Management

...................63

Lubrication System ....................63

Oil Sump Level Check ................63

Microchannel Condenser Coils ..........65

Coil Cleaning .......................65

Diagnostics .............................66

AFD Diagnostics .......................67

Starter Diagnostics ....................67

Main Processor Diagnostics .............69

Communication Diagnostics ............79

Wiring ..................................85

Log and Check Sheets ...................86

RTAF-SVX001A-EN 5

Page 6

Model Number Description

Nameplates

The Sintesis outdoor unit nameplates are applied to the

exterior of the Control Panel. A compressor nameplate is located on each compressor. When the unit arrives, compare all nameplate data with ordering, submittal, and shipping information.

Outdoor Unit Nameplate

See Figure 1 for a typical unit nameplate.The outdoor unit nameplate provides the following information:

• Unit model and size description.

• Unit serial number.

• Identifies unit electrical requirements.

• Lists correct operating charges of R-134a and refrigerant oil (Trane OIL00311).

• Lists unit test pressures.

• Identifies installation, operation and maintenance and service data literature.

• Lists drawing numbers for unit wiring diagrams.

Model Number Coding System

Model numbers are composed of numbers andletters that represent features of the equipment. Shown below is a sample of typical unit model number.

An example of a typical unit model number (M/N) is:

RTAF 130E UA0V XUA2 N21X 1NXN CVSC AXXX XPAX 1XXX X

Each position, or group of positions, in the model number is used to represent a feature. Unit model number digits are selected and assigned in accordance with the definitions as listed in “Unit Model Number,” p. 7.For example, position 08 of the unit model number above contains the letter “E”. An “E” in this position means that the unit voltage is 460/60/3.

Compressor Nameplate

The compressor nameplate provides the following

information:

• Compressor model number. See “Compressor Model

Number,” p. 8.

• Compressor serial number. See “Compressor Serial

Number,” p. 8.

• Compressor electrical characteristics.

• Utilization range.

• Recommended refrigerant.

Figure 1. Typical unit nameplate

6 RTAF-SVX001A-EN

Page 7

Model Number Descriptions

Unit Model Number

Digits 1, 2 — Unit Model

RT = Rotary Chiller

Digit 3 — Unit Type

A = Air-cooled

Digit 4 — Development

Sequence

F = Development Sequence

Digits 5-7 — Nominal Capacity

115 = 115 NominalTons 130 = 130 NominalTons 150 = 150 NominalTons 170 = 170 NominalTons 180 = 180 NominalTons 200 = 200 Nominal Tons 215 = 215 NominalTons

Digit 8— Unit Voltage

C = 380/60/3 D = 400/50/3 E = 460/60/3

Digit 9 — Manufacturing

Location

U = Trane Commercial Systems,

Pueblo, CO USA

Digits 10, 11— Design Sequence

XX = Factory assigned

Digit 12 — Unit Efficiency

H = High Efficiency

Digit 13— Unit Sound Package

X = Standard Noise

Digit 14 — Agency Listing

U = UL/CUL Listing

Digit 15 — Pressure Vessel Code

A = ASME PressureVessel Code C = CRN or Canadian Equivalent

Pressure Vessel Code

D = Australia PressureVessel Code

Digit 16 — Factory Charge

1 = Refrigerant Charge R-513A 2 = Refrigerant Charge R-134a 3 = Nitrogen Charge

(R-513A Field Supplied)

4 = Nitrogen Charge

(R-134a Field Supplied)

Digit 17 — Evaporator

Application

N = Standard Cooling

(above 40°F/5.5°C)

P = LowTemp Process Cooling

(below 40°F/5.5°C)

C = Ice Making

Digit 18 — Evaporator

Configuration

2 = 2-pass Evaporator

T = 2-pass Evaporator

withTurbulators

Digit 19 — Evaporator Fluid

Type

1 = Water 2 = Calcium Chloride 3 = Ethylene Glycol 4 = Propylene Glycol 5 = Methanol

Digit 20 — Water Connection

X = Grooved Pipe Connection

W = Grooved Pipe + Flange

Digit 21 — Flow Switch

1 = Factory Installed - Other Fluid

15 cm/s

2 = Factory Installed - Water

35 cm/s

3 = Factory Installed - Water

45 cm/s

Digit 22 — Insulation

N = Factory Insulation

All Cold Parts 0.75”

Digit 23 — Unit Application

X = Standard Ambient

(14 to 115°F/-10 to 46°C)

L = Low Ambient

(-4 to 115°F/-20 to 46°C

H = High Ambient

(14 to 130°F/-10 to 54.4°C)

W = Wide Ambient

(-4 to 130°F/-20 to 54.4°C)

Digit 24 — Condenser Fin

Options

N = Aluminum Microchannel

Digit 25 — Fan Type

C = Variable Speed Fans

Digit 26 — Oil Cooler

C = Oil Cooler

Digit 27 — Compressor Starter

V = Variable Speed Compressors

Digit 28 — Incoming Power Line

Connection

1 = Single Point Power Connection

Digit 29 — Power Line

Connection Type

X = Terminal Block C = Circuit Breaker H = Circuit Breaker with High Fault

Rated Control Panel

Digit 30— Short Circuit Current

Rating

A = Default Amp Short Circuit Rating B = High Amp Short Circuit Rating

Digit 31 — Electrical

Accessories

X = No Convenience Outlet P = 15A 115V Convenience Outlet

Digit 32 — Remote

Communication Options

X = None B = BACnet®Interface M = Modbus™ Interface L = LonTalk®Interface

Digit 33 — Hard Wire

Communication

X = None

A = Hard Wired Bundle - All

B = Remote LeavingWaterTemp

Setpoint

C = Remote LeavingTemp and

Demand Limit Setpoints D = Programmable Relay E = Programmable Relay and

Leaving Water and Demand

Limit Setpoint F = Percent Capacity G = Percent Capacity and Leaving

Water and Demand Limit

Setpoint H = Percent Capacity and

Programmable Relay

Digit 34 — Energy Meter

X = N-one

Digit 35 — Smart Flow Control

X = None

Digit 36 — Structural Options

A = Standard Unit Structure

Digit 37 — Appearance Options

X = No Appearance Options

Digit 38 — Unit Isolation

X = None 1 = Elastomeric Isolators

Digit 39 — Shipping Package

X = No Shipping Package

A = Containerization Package

T = Shipped with Tarp Covering

Full Unit

Digits 40-42

XXX= Reserved for future use

Digit 43 — Special Requirement

0 = None S = Special Requirement

RTAF-SVX001A-EN 7

Page 8

Model Number Descriptions

Compressor Model Number

Digits 1-3 — Compressor Family

CHH= Positive displacement,

refrigerant, helical rotary, hermetic compressor

Digit 4— Compressor Type

T = GP2+

Digit 5

0 = All compressors

Digit 6 — Frame Size

K = K Frame L = L Frame M = M Frame N = N Frame

Digit 7 — Compressor Capacity

3 = GP2+ Smaller capacity (minor) 4 = GP2+ Larger capacity (major)

Compressor Serial Number

Digits 1-2 — Year

YY = Last two digits of year of

manufacture

Digits 3-4 — Week

WW= Week of build, from 00 to 52

Digit 5 — Day

1 = Monday 2 = Tuesday 3 = Wednesday 4 = Thursday 5 = Friday 6 = Saturday 7 = sunday

Digits 6-8 — Coded Time Stamp

TTT = Used to ensure uniqueness of

Digit 9 — Assembly Line

L = Varies with facility

Digit 10— Build Location

A = Monterrey

serial number

8 RTAF-SVX001A-EN

Page 9

General Information

The Sintesis RTAF units are helical-rotary type, air-cooled

chillers designed for outdoor installation.The refrigerant circuits are factory-piped, leak tested and dehydrated. Every unit is electrically tested for proper control operation before shipment.

Chilled water inlet and outlet openings are covered for shipment.The Sintesis RTAF featuresTrane’s exclusive

Adaptive Control™ logic, which monitors the control

variables that govern the operation of the chiller unit.

Adaptive control logic can adjust capacity variables to

avoid chiller shutdown when necessary, and keep producing chilled water.The units feature two independent refrigerant circuits. Each compressor is controlled by a dedicated variable speed Adaptive Frequency Drive. Each refrigerant circuit is provided with filter,sight glass, electronic expansionvalve, and charging valves.The shell-and-tube CHIL™ (Compact-High performance-Integrated design-Low charge)evaporator is manufactured in accordance with the ASME standards or other international codes. Each evaporator is fully insulated and equipped with water drain and vent connection.

Units are shipped with full oil charge and can be ordered with either a factory refrigerant charge or optional nitrogen charge.

Accessories and Loose Parts

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

If optional elastomeric isolators are ordered with the unit (model number digit 37=1) they are shipped mounted on the horizontal support frame of the chiller.

RTAF-SVX001A-EN 9

Page 10

General Information

General Data

Table 1. General data table

Unit Size (tons) 115 130 150 170 180 200 215

Compressor Model (ckt1/ckt 2)

Quantity # 2222222

Evaporator

Water Connection Size in 4455566

Water Storage gal 14.0 15.8 19.3 20.6 21.6 21.9 23.9

Minimum Flow gpm 128 150 171 187 199 202 228

Maximum Flow gpm 470 551 626 684 731 742 835

Condenser

Qty of Coils (ckt 1/ckt 2) 5/5 5/5 6/6 6/6 6/6 7/7 7/7

Coil Length in 77.4 77.4 77.4 77.4 77.4 77.4 77.4

Coil Height in 47.8 47.8 47.8 47.8 47.8 47.8 47.8

Condenser Fans

Quantity (ckt 1/ckt 2) # 5/5 5/5 6/6 6/6 6/6 7/7 7/7

Diameter in 31.5 31.5 31.5 31.5 31.5 31.5 31.5

Nominal speed rpm 810 810 810 810 810 909 909

Tip Speed ft/min 6673 6673 6673 6673 6673 7500 7500

Ambient Temperature Range

Standard Ambient °F (°C) 14 to 115 (-10 to 46)

Low Ambient °F (°C) -4 to 115 (-20 to 46)

High Ambient °F (°C) 14 to 130 (-10 to 54.4)

Wide Ambient °F (°C) -4 to 130 (-20 to 54.4)

General Unit

Refrigerant R-134a or R-513A

Refrigerant Ckts # 2222222

Minimum Load % 15 15 15 15 15 15 15

Refrigerant Charge (ckt 1/ckt 2) lb

Oil Charge/ckt gal 1.53 1.56 1.56 1.56 1.64 1.96 2.01

(a) Nominal tonnage at 60 Hz.

(a)

L 53.1 59.9 73.2 78.0 81.9 82.8 90.5

l/s 8.1 9.5 10.8 11.8 12.6 12.8 14.4

l/s 29.7 34.8 39.5 43.2 46.1 46.8 52.7

mm 1967 1967 1967 1967 1967 1967 1967

mm 1214 1214 1214 1214 1214 1214 1214

mm 800 800 800 800 800 800 800

Airflow cfm 9959 9959 9959 9959 9959 11230 11230

m3/s 4.7 4.7 4.7 4.7 4.7 5.3 5.3

m/s 33.9 33.9 33.9 33.9 33.9 38.1 38.1

kg 39.2/38.5 39.3/38.5 46.0/44.9 50.4/44.9 49.5/43.7 60.9/58.7 61.1/59.0

Oil Trane Oil 00311 (bulk)/OIL00315 (1 gal)/OIL00317 (5 gal)

L 5.8 5.9 5.9 5.9 6.2 7.4 7.6

55/55 65/65 70/70 85/70 85/85 100/85 100/100

2-Pass

86.4/

84.9

86.6/

84.9

101.4/

99.0

111.1/

99.0

109.0/

96.3

134.3/129.4 134.7/129.8

10 RTAF-SVX001A-EN

Page 11

Pre-Installation

Inspection

When the unit is delivered, verify that it is the correct unit

and that it is properly equipped.

Inspect all exteriorcomponents for visibledamage. 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 appropriateTrane Sales Office.

Do not proceedwith installation ofa damaged unitwithout 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 10 days after receipt.

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

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

• Notify theTrane sales representative and arrange for repair. Do not repair the unit, however, until damage is inspected by the transportation representative.

Storage

Extended storage of the unit prior to the installation requires the following precautions:

Store the unit in a secured area, to avoid intentional damages.

Close the suction, discharge and liquid-line isolation valves.

At least every three months, connect a gauge and

manually check the pressure in the refrigerant circuit. If the refrigerant pressure is below 13 Bar at 20°C (or 10 Bar at 10°C), call a qualified service organization and the appropriateTrane sales office.

Note: If the unit is stored before servicing near a

construction site it is highly recommended to protect micro-channel coils from any concrete dust. Failure to do so may considerably reduce reliability of the unit.

RTAF-SVX001A-EN 11

Page 12

Pre-Installation

Installation Requirements

A list of the contractor responsibilities typically associated

with the unit installation process is provided in Table 2.

Table 2. Installation requirements

Type

Foundation • Meet foundation requirements

Rigging

Isolation

Electrical

Water piping • Flow switch

Insulation • Insulation • Insulation

Water Piping Connection Components • Grooved pipe

Other Materials

“Sintesis Model RTAF Installation Completion Check Sheet and Request for Trane Service” (RTAF-ADF001*-EN, see “Log and Check Sheets,” p. 86)

Chiller Start-up Commissioning

(a) Start-up must be performed by Trane or an agent of Trane specifically authorized to perform start-up and warranty of Trane® products. Contractor shall

provide Trane (or an agent of Trane specifically authorized to perform start-up) with notice of the scheduled start-up at least two weeks prior to the scheduled start-up.

(a)

Trane Installed

• Circuit breakers (optional)

• Unit mounted starter

• R-134a or R-513A refrigerant

• Dry nitrogen (optional)

• Trane, or an agent of Trane specifically authorized to perform start-up of Trane products

Trane Supplied

Trane Supplied Field Installed

• Elastomeric isolators (optional)

• Flange kit (optional)

Field Supplied Field Installed

• Safety chains

• Clevis connectors

• Lifting beam

• Spreader bar

• Elastomeric isolators (optional)

• Circuit breakers (optional)

• Electrical connections to unit mounted starter

• Wiring sizes per submittal and NEC

• Terminal lugs

• Ground connection(s)

• BAS wiring (optional)

• Control voltage wiring

• Chilled water pump contactor and wiring

• Option relays and wiring

• Taps for thermometers and gauges

• Thermometers

• Water flow pressure gauges

• Isolation and balancing valves in water piping

• Vents and drain

• Waterside pressure relief valves

• Water strainer

12 RTAF-SVX001A-EN

Page 13

Dimensions and Weights

Service Clearance

Figure 2. RTAF service clearances

Notes:

• Area above unit required for operation, maintenance,

panel access and airflow. NO OBSTRUCTIONS ABOVE UNIT

• For installations with obstructions or multiple units, see Close Spacing and Restricted Airflow Bulletin RLCPRB037*-EN.

• Clearance of 78” (1981 mm) on the side of the unit is required for coil replacement. Preferred side for coil

replacement is shown (right side of unit, as facing control panel). However, either side is acceptable.

• A full 36” (914 mm) clearance is required in front of the control panel. Must be measured from front of panel, not end of unit base.

• Clearances shown are sufficient for tube pull.

Unit Dimensions

See unit submittals for specific unit dimensions and water connection locations.

Weights

Table 3. Sintesis unit weights

Shipping Weight Operating Weight

Unit Size (tons)

115 7974 3617 8091 3670

130 8071 3661 8203 3721

150 9467 4294 9628 4367

170 9497 4308 9669 4386

180 9821 4455 10002 4537

200 10829 4912 11012 4995

215 11155 5060 11355 5151

lb kg lb kg

RTAF-SVX001A-EN 13

Page 14

Installation Mechanical

Location Requirements

Sound Considerations

• Locate the unit away from sound-sensitive areas.

• Install the optional elastomeric isolators under the unit. See

• Chilled water piping should not besupported by chiller frame.

• Install rubber vibration isolators in all water piping.

• Use flexible electrical conduit.

• Seal all wall penetrations.

Note: Consult an acoustical engineer for critical

Foundation

Provide rigid, non-warping mounting pads or a concrete foundation of sufficient strength and mass to support the applicable operating weight (i.e., including completed piping, and full operating charges of refrigerant, oil and water). See Table 3, p. 13 for unit operating weights. Once in place, the unitmust be level within 1/4” (6.4 mm) across the length and width of the unit.TheTrane Company is not responsible for equipment problems resulting from an improperly designed or constructed foundation.

Clearances

Provide enough space around the unit to allow the installation and maintenance personnel unrestricted access to all service points. See submittal drawings for the unit dimensions, to provide sufficient clearance for the opening of control panel doors and unit service. See

Figure 2, p. 13 for minimum clearances. In all cases, local

codes which require additional clearances will take precedence over these recommendations.

For close spacing information, see RLC-PRB037*-EN.

“Isolation and Sound Emission,” p. 16.

applications

Lifting and Moving Instructions

WARNING

Heavy Objects!

Failure to follow instructions below or properly lift unit could result in unit dropping and possibly crushing operator/technician which could result in death or serious injury, and equipment or property-only damage. Ensure that all the lifting equipment used is properly rated for the weight of the unit being lifted. Each of the cables (chains or slings), hooks, and shackles used to lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or slings) may not be of the same length. Adjust as necessary for even unit lift.

WARNING

Improper Unit Lift!

Failure to properly lift unit could result in unit dropping and possibly crushing operator/technician which could result in death or serious injury, and equipment or property-only damage. Test lift unit approximately 24 inches to verify proper center of gravity lift point. To avoid dropping of unit, reposition lifting point if unit is not level.

WARNING

Proper Lifting Configuration Required!

Use only lift locations designated with label shown in

Figure 3. Do NOT use locations marked with label

shown in Figure 4. Use unit lifting configuration as shown in Figure 5, p. 15. Other lifting arrangements could result in death, serious injury or equipment damage.

Figure 3. Label - lift location

14 RTAF-SVX001A-EN

X39003897001A

Figure 4. Label - do not lift

X39003894001A

Page 15

Figure 5. Lifting configuration — 4 point

Installation Mechanical

Center of Gravity

Figure 6. Center of gravity

96” (2438mm) Spreader Bar

Lifting Location 2 (Lifting location 3 located on other side of unit)

Control Panel

Lifting Location 1 (Lifting location 4 located on other side of unit)

Table 4. Lift weights by location

Location

1234

Tons lb kg lb kg lb kg lb kg

115 2322 1053 2125 964 1662 747 1998 906

130 2215 1005 2292 1040 1808 820 1887 856

150 2575 1168 2655 1204 2159 979 2239 1016

170 2582 1171 2674 1213 2172 985 2241 1016

180 2600 1179 2802 1271 2224 1009 2376 1078

200 3071 1393 3059 1387 2447 1110 2435 1104

215 3113 1412 3195 1449 2482 1126 2565 1163

Table 5. Centers of gravity

CGx CGy CGz

Tons

115 93.0 2363 43.8 1112 36.7 932

130 93.1 2364 43.8 1112 36.4 926

150 103.9 2638 43.7 1109 36.6 928

170 103.8 2636 43.7 1109 36.5 927

180 104.4 2651 44.4 1128 35.9 912

200 112.7 2862 42.9 1090 36.7 932

215 112.9 2867 43.6 1107 36.2 918

in mm in mm in mm

RTAF-SVX001A-EN 15

Page 16

Installation Mechanical

Isolation and Sound Emission

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. 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. Since the environment in which a sound source is located affects sound pressure, unit placement must be carefully evaluated. Sound power levels for Sintesis™ chillers are available on request.

Unit Isolation and Leveling

For additional reduction of sound and vibration, install the optional elastomeric isolators.

Construct an isolated concrete pad for the unit or provide concrete footings at the unit mounting points. Mount the unit directly to the concrete pads or footings.

Level the unit using the base rail as a reference.The unit must be level within 1/4-in (6 mm) over the entire length and width. Use shims as necessary to level the unit.

Figure 7. Elastomeric isolator

6.25

5.0

Mounting molded in neoprene

0.50 in

able 6. Isolator specifications

Type Color Ext Max Load (lbs) Max Deflection

RDP-4 Black 61 1500 0.50

RDP-4 Red 62 2250 0.50

RDP-4 Gray 64 4000 0.50

1.60±0.25

1/2 - 13NC - 2B

4.63

0.56 in

3.0

2.75

0.38

Elastomeric Isolators

Note: See unit submittal, or Table 7, p. 17 thru Table 8,

p. 17 for point weights, isolator location and

isolator selections.

1. Secure the isolators to the mounting surface using the mounting slots in the isolator base plate. Do not fully tighten the isolator mounting bolts at this time.

2. Align the mounting holes in the base of the unit with the threaded positioning pins on the top of the isolators.

3. Lower the unit onto the isolators and secure the isolator

4. Level the unit carefully. Fully tighten the isolator mounting

to the unit with a nut.

bolts.

Figure 8. Mounting point locations

2468

Control panel

1357

(a) Quantity of isolators varies with unit. Shorter units will not use

locations 7 and 8. See submittal for actual number required for specific unit.

(a)

16 RTAF-SVX001A-EN

Page 17

Installation Mechanical

Table 7. Point weights

Location

12345678

Tons lb kg lb kg lb kg lb kg lb kg lb kg lb kg lb kg

115 1567 711 1601 726 1496 678 1530 694 937 425 960 435 - - - -

130 1589 721 1623 736 1517 688 1551 704 951 431 973 442 - - - -

150 2342 1062 2386 1082 1420 644 1445 656 1009 457 1025 465 - - - -

170 2294 1041 2332 1058 1557 706 1586 719 940 427 959 435 - - - -

180 2169 984 2658 1206 1621 735 1489 675 1077 488 989 449 - - - -

200 2189 993 2162 974 1734 787 1702 772 923 419 907 411 711 322 699 317

215 2303 1045 2159 979 1761 799 1653 750 901 409 1271 576 673 305 634 287

Table 8. Isolator selections

Location

Tons 1 2345678

115 Red 62 Red 62 Red 62 Red 62 Black 61 Black 61 - -

130 Red 62 Red 62 Red 62 Red 62 Black 61 Black 61 - -

150 Gray 64 Gray 64 Red 62 Red 62 Black 61 Black 61 - -

170 Gray 64 Gray 64 Red 62 Red 62 Black 61 Black 61 - -

180 Gray 64 Gray 64 Red 62 Red 62 Black 61 Black 61 - -

200 Gray 64 Gray 64 Gray 64 Gray 64 Red 62 Red 62 Black 61 Black 61

215 Gray 64 Gray 64 Gray 64 Gray 64 Red 62 Red 62 Black 61 Black 61

RTAF-SVX001A-EN 17

Page 18

Installation Mechanical

Chilled Water Piping Recommendations

Drainage

Locate the unit near a large capacity drain for water vessel drain-down during shutdown or repair. Evaporators are provided with drain connections. A vent on top of evaporator waterbox prevents vacuumby allowing air into evaporator for complete drainage. All local and national codes apply.

Water Treatment

NOTICE:

Proper Water Treatment!

The use of untreated or improperly treated water could

result in scaling, erosion, corrosion, algae or slime. It is recommended that the services of a qualified water treatment specialist be engaged to determine what water treatment, if any, is required.Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water.

Dirt, scale, products of corrosion, and other foreign material will adversely affect heat transfer between the water and system components. Foreign matter in the chilled-water system can also increase pressure drop and consequently, reduce water flow. Proper water treatment must be determined locally, depending on the type of system and local water characteristics.

Evaporator Piping

Evaporator water connections are grooved.

Thoroughly flush allwaterpiping to the unit before making

the final piping connections to the unit. Components and layout will vary slightly, depending on the location of connections and the water sources.

An air vent is located on top of the evaporator at the chiller water inlet. Be sure to provide additional air vents at the highest points in the piping to remove air from the chilled water system. Install necessary pressure gauges to monitor the entering and leaving chilled water pressure.

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

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

NOTICE:

Equipment Damage!

The chilled-water connections to the evaporator are to

be “grooved pipe” type connections. Do not attempt to weld these connections, because the heat generated from welding can cause microscopic and macroscopic fractures on the cast iron water boxes that can lead to premature failure of the water box. An optional grooved pipe stub and coupling is available for welding on flanges.

NOTICE:

Equipment Damage!

If using any commercial flushing/cleaning solution, construct a temporary bypass around the unit to prevent damage to internal components of the evaporator/condenser. Trane assumes no responsibility for equipment damage caused by flushing/cleaning solutions or water-born debris.

18 RTAF-SVX001A-EN

To prevent damage to chilled-water components, do not

allow evaporator pressure (maximum working pressure) to exceed 150 psi (10.5 bar).

A pipe strainer must be installed in theentering water line. Failure to do so can allow waterborne debris to enter the evaporator.

Evaporator Piping Components

Piping components include all devices and controls used to provide proper water system operation and unit operating safety. A typical RTAF evaporator piping is shown below.

Page 19

Figure 9. Evaporator water piping

Installation Mechanical

1 Bypass Valve Pi Pressure Gauge

2 Isolation Valve FT Water Flow Switch

3 Vibration Isolators T1 Evaporator Water Inlet Temperature Sensor

4 Evaporator - End View (2-pass) T2 Evaporator Water Outlet Temperature Sensor

5 Evaporator Waterbox A Isolate unit for initial water loop cleaning

6 Vent B Vent must be installed at the high point of the line

7 Strainer C Drains must be installed at the low point of the line

8 Drain

Entering Chilled Water Piping

• Air vents to bleed the air from the system (to be placed on the highest point)

• Water pressure gauges with shutoff valves

• Vibration eliminators

• Shutoff (isolation) valves

• Thermometers if desired (temperature readings available on chiller controller display)

• Clean-out tees

• Pipe strainer

Leaving Chilled Water Piping

• Air vents to bleed the air from the system (to be placed on the highest point)

• Water pressure gauges with shut off valves

• Vibration eliminators

• Shutoff (isolation) valves

• Thermometers (temperature readingsavailable on the chiller controller display)

• Clean-out tees

• Balancing valve

Waterbox Drains and Vents

RTAF chillers are equipped with two ½” drain connections: one located on each waterbox. Waterboxes also include vent connections to assist in bleeding air from the chilled water loop.These vent connections should not be assumed to be capable of venting attached chilled water piping.

Note: If evaporator will be drained for winter storage, the

heaters must be disconnected to prevent overheating.To drain properly, use pressurized air to ensure all water is removed from the evaporator.

Pressure Gauges

Install field-supplied pressure components as shown in

Table 9, p. 19. Locate pressure gauges or taps in a straight

run of pipe; avoid placing them near elbows.

To read manifold pressure gauges, open one valve and

close the other (depending on the side of the desired reading) to prevent errors resulting from differently calibrated gauges installed at unmatched elevations.

Pressure Relief Valves

Install a water pressure relief valve in the evaporator inlet piping between evaporator and the inlet shutoff valve.

Watervessels with close-coupled shutoff valves have high

RTAF-SVX001A-EN 19

Page 20

Installation Mechanical

potential for hydrostatic pressure buildup on a water temperature increase. Refer to applicable local codes for relief valve installation.

Evaporator Flow Switch

NOTICE:

Equipment Damage!

Flow switch is on a 24V circuit. Do NOT apply 120V to the flow switch. Incorrect voltage application could cause damage to the flow switch.

The flow switch is factory-installed and programmed

based on the operating conditions submitted with the order.The leaving evaporator temperature, fluid type and fluid concentration affect the selected flow switch. If the operating conditions on the job site change, the flow switch may need to be replaced. Contact your localTrane Sales office for more information.

The sensor head includes 3 LEDs, two yellow and one

green.Wait 15 seconds after poweris applied to the sensor before evaluating LEDs for flow status. When wired correctly and flow is established, only the green LED should be lit. Following are the LED indicators:

• Green ON, both yellow OFF — Flow

• Green and outside yellow ON — No Flow

• Center yellow ON continuously — Miswire

• A minimum distance of 5x pipe diameter must be maintained between flow switch and any bends, valves, changes in cross sections, etc.

Figure 10. Proper flow switch indexing

Top V i e w

Flow

Index

The flow switch must have the dot in the shaded area to the left of this line for proper indexing (±90° off Index).

NOTICE:

Equipment Damage!

Incorrect wiring of auxiliary contacts could cause equipment damage.

If using auxiliary flow sensing, both yellow LEDs come on initially when flow is stopped.The center yellow LED will turn off after approximately 7 seconds.The LED indicators are otherwise the same as indicated above.

Indexing Flow Switch

To properly index the flow switch, the following

requirements must be met:

• Dot must be at a position no greater than 90° off Index.

• Torque must be between 22 ft-lb and 74 ft-lb.

20 RTAF-SVX001A-EN

Page 21

Evaporator Waterside

0 100 200 300 400 500 600 700 800 900 1000

Pressure Drop (ft. H2O)

Water Flow (GPM)

215T

200T

180T

170T

150T

130T

115T

Pressure Drop Curves

Figure 11. Evaporator water pressure drop — 2-pass without turbulators

Installation Mechanical

RTAF-SVX001A-EN 21

Page 22

Installation Mechanical

0.0

8.0

16.0

24.0

32.0

40.0

48.0

56.0

64.0

72.0

80.0

88.0

0 100 200 300 400 500 600 700 800 900 1000

Pressure Drop (ft. H2O)

Water Flow (GPM)

215T

200T

180T

170T

150T

130T

115T

Figure 12. Evaporator water pressure drop — 2-pass with turbulators

22 RTAF-SVX001A-EN

Page 23

Freeze Avoidance

One or more of the ambient freeze avoidance methods in

Table 9 must be used to protect the Sintesis™ chiller from

ambient freeze damage.

Table 9. RTAF freeze avoidance methods

Protects to

Method

Water Pump Control AND Heaters

Freeze Inhibitor

Drain Water Circuit Below -4°F

ambient temperature Notes

• Heaters alone will provide low ambient protection down to -4°F (-20°C), but will NOT protect the evaporator from freezing as a result of charge migration. Therefore, it is required that water pump control be used in conjunction with heaters.

• Heaters are factory-installed on the evaporator and water piping and will protect them from freezing.

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

• Tracer™ UC800 controller can start the pump when freezing conditions are detected. For this option the pump must to be controlled by the Sintesis unit and this function must be validated.

• Water circuit valves need to stay open at all times.

• Water pump control and heater combination will protect the evaporator provided power is

Down to -4°F

Varies. See “Low

Evaporator Refrigerant Cutout and Glycol Requirements,” p. 24

available to the pump and the controller. This option will NOT protect the evaporator in the event of a power failure to the chiller unless backup power is supplied to the necessary components.

• When no chiller operation is possible and the pump is already off, UC800 pump control for freeze protection will command the pump to turn: ON if average of the evaporator entering water temperature, the evaporator leaving water temperature, and the evaporator refrigerant pool temperature is less than Low Evaporator Refrigerant Temperature Cutout (LERTC) + 4°F for a period of time. OFF again if the evaporator refrigerant pool temperature rises above the LERTC + 6°F for a period of time.

Note: Time period referenced for ON and Off conditions above is dependent on past running conditions and present temperatures measured.

ON if entering OR leaving water temperature< LWTC for 30°F-sec (1.11°C-sec) OFF again if water temperature > LWTC for 30 min

• Freeze protection can be accomplished by adding sufficient glycol to protect against freezing below the lowest ambient expected.

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

• Shut off the power supply to the unit and to all heaters.

• Purge the water circuit.

• Blow out the evaporator to ensure no liquid is left in the evaporator and water lines.

Installation Mechanical

NOTICE:

Evaporator Damage!

If insufficient concentration or no glycol is used, the evaporator water flow must be controlled by the UC800

AND heaters must be used to avoid catastrophic

damage to the evaporator due to freezing. It is the responsibility of the installing contractor and/or the customer to ensure that a pump will start when called upon by the chiller controls. Even with water pump control, a power loss of as little as 15 minutes under freezing conditions can damage the evaporator. Only the proper addition of freeze inhibitor or complete drainage of the water circuit can ensure no evaporator damage in the event of a power failure.

RTAF-SVX001A-EN 23

Page 24

Installation Mechanical

Low Evaporator Refrigerant Cutout and Glycol Requirements

The table below shows the low evaporator temperature

cutout for different glycol levels.Additional glycol beyond what is required for freeze protection will adversely effect unit performance.The unit efficiency will be reduced and the saturated evaporator temperature willbe reduced.For some operating conditions this effect can be significant.

Always us the applied actualpercent glycol to establish the

Note: Table below should not be interpreted as

suggesting operating ability or performance characteristics at all tabulated glycol percentages. Full unit simulation is required for proper prediction of unit performance for specific operating conditions. For information on specific conditions, contactTrane product support.

low refrigerant cutout and low water temperature cutout setpoints.

Table 10. Low evaporator refrigerant temperature cutout (LERTC) and low water temperature cutout (LWTC)

Ethylene Glycol Propylene Glycol

Glycol

Percentage

(%)

0 32.0 28.6 35.0 0 32.0 28.6 35.0

2 31.0 27.6 34.0 2 31.0 27.6 34.0

4 29.7 26.3 32.7 4 29.9 26.5 32.9

5 29.0 25.6 32.0 5 29.3 25.9 32.3

6 28.3 24.9 31.3 6 28.7 25.3 31.7

8 26.9 23.5 29.9 8 27.6 24.2 30.6

10 25.5 22.1 28.5 10 26.4 23.0 29.4

12 23.9 20.5 26.9 12 25.1 21.7 28.1

14 22.3 18.9 25.3 14 23.8 20.4 26.8

15 21.5 18.1 24.5 15 23.1 19.7 26.1

16 20.6 17.2 23.6 16 22.4 19.0 25.4

18 18.7 15.3 21.7 18 20.9 17.5 23.9

20 16.8 13.4 19.8 20 19.3 15.9 22.3

22 14.7 11.3 17.7 22 17.6 14.2 20.6

24 12.5 9.1 15.5 24 15.7 12.3 18.7

25 11.4 8.0 14.4 25 14.8 11.4 17.8

26 10.2 6.8 13.2 26 13.8 10.4 16.8

28 7.7 4.3 10.7 28 11.6 8.2 14.6

30 5.1 1.7 8.1 30 9.3 5.9 12.3

32 2.3 -1.1 5.3 32 6.8 3.4 9.8

34 -0.7 -4.1 5.0 34 4.1 0.7 7.1

35 -2.3 -5.0 5.0 35 2.7 -0.7 5.7

36 -3.9 -5.0 5.0 36 1.3 -2.1 5.0

38 -7.3 -5.0 5.0 38 -1.8 -5.0 5.0

40 -10.8 -5.0 5.0 40 -5.2 -5.0 5.0

42 -14.6 -5.0 5.0 42 -8.8 -5.0 5.0

44 -18.6 -5.0 5.0 44 -12.6 -5.0 5.0

45 -20.7 -5.0 5.0 45 -14.6 -5.0 5.0

46 -22.9 -5.0 5.0 46 -16.7 -5.0 5.0

48 -27.3 -5.0 5.0 48 -21.1 -5.0 5.0

50 -32.1 -5.0 5.0 50 -25.8 -5.0 5.0

Solution

Freeze Point

(°F)

Minimum

Recommended

LERTC (°F)

Minimum

Recommended

LWTC (°F)

Glycol

Percentage

(%)

Solution

Freeze Point

(°F)

Minimum

Recommended

LERTC (°F)

Recommended

Minimum

LWTC (°F)

24 RTAF-SVX001A-EN

Page 25

Installation Electrical

General Recommendations

As you review this manual, keep in mind that:

• All field-installed wiring must conform to National Electric Code (NEC) guidelines, and any applicable state and local codes. Be sure to satisfy proper equipment grounding requirements per NEC.

• Compressor motor and unit electrical data (including motor kW, voltage utilization range, rated load amps) is listed on the chiller nameplate.

• All field-installed wiring must be checked for proper terminations, and for possible shorts or grounds.

Note: Always refer to wiring diagrams shipped with

chiller or unit submittal for specific electrical schematic and connection information.

WARNING

Hazardous Voltage w/Capacitors!

Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s literature for allowable waiting periods for discharge of capacitors. Verify with an appropriate voltmeter that all capacitors have discharged.

For additional information regarding the safe discharge of capacitors, see PROD-SVB06A-EN

WARNING

Proper Field Wiring and Grounding Required!

NOTICE:

Use Copper Conductors Only!

Failure to use copper conductors could result in equipment damage as unit terminals are not designed to accept other types of conductors.

Important: To prevent control malfunctions, do not run

low voltage wiring (<30 V) in conduit with conductors carrying more than 30 volts.

Installer-Supplied Components

Power Supply Wiring

NOTICE:

Use Copper Conductors Only!

Failure to use copper conductors could result in equipment damage as unit terminals are not designed to accept other types of conductors.

Cut holes into the sides of the control panel for the appropriately-sized power wiring conduits.The wiring is passed through these conduits and connected to the terminal blocks or circuit breakers.

To provide proper phasing of 3-phase input, see field

wiring drawings for correct wiring. Proper equipment grounds must be provided to each ground connection in the panel.

Control Power Supply

Chiller is provided with controlpower transformer. It isnot necessary to provide additional control power voltage to the unit. No other loads should be connected tothe control power transformer

All units are factory-connected for appropriate labeled

voltages.

Heater Power Supply

The evaporator shell is insulated from ambient air and

protected from freezing for temperatures down to -4°F by shell trace heaters and two thermostatically-controlled immersion heaters, combined with evaporator pump activation throughTracer™ UC800. Whenever the ambient temperature drops below 32°F, the thermostat energizes the heaters and theTracer UC800 activates the pumps. If ambient temperatures below -4°F are expected, contact yourTrane local office.

NOTICE:

Equipment Damage!

Control panel main processor does not verify thermostat operation. A qualified technician must confirm operation of the thermostat to avoid catastrophic damage to the evaporator.

NOTICE:

Equipment Damage!

If evaporator water is drained, evaporator heaters must be disconnected to prevent overheating.

RTAF-SVX001A-EN 25

Page 26

Installation Electrical

Chilled Water Pump Control

NOTICE:

Equipment Damage!

If the microprocessor calls for a pump to start and water does not flow, the evaporator may be damaged catastrophically. It is the responsibility of the installing contractor and/or the customer to ensure that a pump will always be running when called upon by the chiller controls.

An evaporator water pump output relay closes when the

chiller is given a signal to go into the Auto mode of operation from any source.The contact is opened to turn off the pump in the event of most machine level diagnostics to prevent the build up of pump heat.

The relay output is required to operate the Evaporator

Water Pump (EWP) contactor. Contacts should be

compatible with 115/240VAC control circuit. Normally, the EWP relay follows theAUTO mode of the chiller.Whenever the chiller has no diagnostics and is in the AUTO mode, regardless of where the auto command is coming from, the normally open relay is energized. When the chiller exits the AUTO mode, the relay is timed to open in an adjustable (usingTechView) 0 to 30 minutes.The non-

AUTOmodes in which the pumpis stopped, include Reset,

Stop, External Stop, Remote Display Stop, Stopped by

Tracer, Start Inhibited by Low AmbientTemp, and Ice

Building complete.

In general, when there is either a non-latching or latching diagnostic, the EWPrelay is turned off as though there was a zero time delay. Exceptions whereby the relay continues to be energized occur with:

• Low Chilled Water Temperature diagnostic

(non-latching unless also accompanied by an Evap Leaving WaterTemperature Sensor Diagnostic)

• Interrupt Failure diagnostic in which a compressor

continues to draw current even after commanded to have shutdown.

• Loss of Evaporator Water Flow diagnostic (non-

latching) and the unit is in the AUTO mode, after initially having proven evaporator water flow.

Table 11. Pump Relay Operations

Chiller Mode Relay Operation

Auto Instant Close

Ice Building Instant Close

Tracer Override Timed Open

Stop Timed Open

Ice Complete Instant Open

Diagnostics Instant Open

When going from Stop toAuto, the EWP relay is energized

immediately. If evaporator water flow is not established in 20 minutes (for normal transition) or 4 minutes, 15 seconds (for pump commanded ON due to an override safety), the UC800 de-energizes the EWP relay and generates a non-latching diagnostic. If flow returns (e.g. someone else is controlling the pump), the diagnostic is cleared, the EWP is re-energized, and normal control resumed.

If evaporator water flow is lost once it had been established, the EWP relay remains energized and a nonlatching diagnostic is generated. If flow returns, the diagnostic is cleared and the chiller returns to normal operation.

26 RTAF-SVX001A-EN

Page 27

Installation Electrical

Programmable Relays

A programmable relay concept provides for enunciation of

certain events or states of the chiller, selected from a list of likely needs, while only using four physical output relays, as shown in the field wiring diagram.

The four relays are provided (generally with a Quad Relay

Output LLID) as part of the Programmable Relay Option.

The relays contacts are isolated Form C (SPDT), suitable

for use with 120 VAC circuits drawing up to 2.8 amps inductive, 7.2 amps resistive, or 1/3 HP and for 240 VAC circuits drawing up to 0.5 amp resistive.

The list of events/states that can be assigned to the

programmable relays can be found in Table 12. Chiller events/Status description.The relay will be energized when the event/state occurs.

Table 12. Alarm and status relay output configuration

Description

This output is true whenever there is any

Alarm - Latching

Alarm - NonLatching

Alarm

Alarm Ckt 1

Alarm Ckt 2

Unit Limit Mode

Compressor Running

Circuit 1 Running

Circuit 2 Running

Ice Building

Maximum Capacity

active latching shutdown diagnostic that targets the Unit, Circuit, or any of the Compressors on a circuit.

This output is true whenever there is any active non-latching shutdown diagnostic that targets the Unit, Circuit, or any of the Compressors on a circuit.

This output is true whenever there is any active latching or non-latching shutdown diagnostic that targets the Unit, Circuit, or any of the Compressors on a circuit.

This output is true whenever there is any active latching or non-latching shutdown diagnostic that targets Circuit 1, or any of the Compressors on Circuit 1.

This output is true whenever there is any active latching or non-latching shutdown diagnostic that targets Circuit 2, or any of the Compressors on Circuit 2.

This output is true whenever a circuit on the unit has been running in one of the limit modes continuously for the Limit Relay debounce time. A given limit or overlapping of different limits must be in effect continuously for the debounce time prior to the output becoming true. It will become false if no limits are present for the debounce time.

The output is true whenever any compressor is running.

The output is true whenever any compressor of Circuit 1 is running.

The output is true whenever any compressor of Circuit 2 is running.

This output is true when Ice Building status is active.

The output is true whenever the unit has reached maximum capacity continuously for the Max Capacity Relay s time. The output is false when the unit is not at maximum capacity continuously for the filter time.

Table 12. Alarm and status relay output configuration

Description

This relay output is energized any time either the Low Evaporator Water Temperature – Unit Off or the Low Evaporator Temperature Ckt x – Unit Off diagnostics are active. This relay is intended for use as an external interlock for a field engineered and provided solution to mitigate the freeze danger implied by these diagnostics. Generally, this would be used in

Evaporator Water Freeze Avoidance Request

None:

Service request (for Unit, Compressor(s) or water pump):

cases where operation of the evaporator water pump is unacceptable due to the system constraints, (i.e. such as mixing unconditioned warm water with controlled supply water as provided by other parallel chillers. The relay’s output can provide the method to close bypass valves so the circulation becomes local to the evap and excludes the load, or can be used to defeat the evap pump override entirely while initiating an independent source of heat / flow to the evap.

This selection is desirable to provide an easy way for a customer to defeat the effect of the relay, if it has already been wired. For instance, if the relay was normally programmed as an “alarm” relay, and was wired to a claxon, it may be desirable to temporarily defeat the feature without changing wiring.

This relay will be energized when at least one Maintenance alert condition (refer to Service required message specification) occurs, as long as at least one of associated informational diagnostic(s) will be active.

Relay Assignments Using

Tracer TU

Tracer™TU ServiceTool is used to install the

Programmable Relay Option package and assign any of the above lists of events or status to each of the four relays provided with the option.The relays to be programmed are referred to by the relay’s terminal numbers on the LLID board 1K23.

The default assignmentsfor the four availablerelays of the

Programmable Relay option are:

Table 13. Default assignments

Relay

Relay 0 Terminals J2-1, 2, 3 Head Pressure

Relay 1 Terminals J2-4, 5, 6 Limit Mode

Relay 2 Terminals J2-7, 8, 9 Alarm

Relay 3 Terminals J2-10, 11, 12 Compressor Running

If any of the Alarm/Status relays are used, provide electrical power, 115 VAC with fused-disconnect to the panel and wire through the appropriate relays (terminals on 1A10). Provide wiring (switched hot, neutral, and ground connections) to the remote annunciation devices. Do not use power from the chiller’s control panel transformer to power these remote devices. See the field diagrams which are shipped with the unit.

RTAF-SVX001A-EN 27

Page 28

Installation Electrical

Low Voltage Wiring

The remote devices described below require low voltage

wiring. All wiring to and from these remote input devices to the Control Panel must be made with shielded, twisted pair conductors. Be sure to ground the shielding only at the panel.

Important: To prevent control malfunctions, do not run

low voltage wiring (<30 V) in conduit with conductors carrying more than 30 volts.

Emergency Stop

UC800 provides auxiliary control for a customer specified/ installed latching trip out. When this customer-furnished remote contact 6S2 is provided, the chiller will run normally when the contact is closed. When the contact opens, the unit will trip on a manually resettable diagnostic.This condition requires manual reset at the front of the control panel.

Connect low voltage leads to terminal strip locations on 1K2. Refer to the field diagrams that are shipped with the unit.

Silver or gold-plated contacts are recommended.These customer-furnished contacts must be compatible with 24

VDC, 12 mA resistive load.

External Auto/Stop

If the unit requires the external Auto/Stop function, the installer must provide remote contact 6S1.

The chiller will run normally when the contactsare closed.

When either contact opens, the compressor(s), if

operating, will go to the RUN:UNLOAD operating mode and cycle off. Unit operation will be inhibited. Closure of the contacts will permit the unit to return to normal operation.

Field-supplied contacts for all low voltage connections must be compatible with dry circuit 24 VDC for a 12 mA resistive load. Refer to the field diagrams that are shipped with the unit.

Ice Building Option

UC800 provides auxiliary control for a customer specified/ installed contact closure for ice building if so configured and enabled.This output is known as the Ice Building Status Relay. The normally open contact will be closed when ice building is in progress and open when ice building has been normally terminated either through Ice

Termination setpoint being reached or removal of the Ice

Building command.This output is for use with the ice storage system equipment or controls (provided by others) to signal thesystem changesrequired as the chiller mode changes from “ice building” to “ice complete”.

When contact 5K3 is provided, the chiller will run normally

when the contact is open.

UC800 will accept either an isolated contact closure (External Ice Building command) or a Remote

Communicated input (Tracer) to initiate andcommand the Ice Building mode.

UC800 also provides a “Front Panel Ice Termination Setpoint”, settable throughTracer™TU, and adjustable from 20 to 31°F (-6.7 to -0.5°C) in at least 1°F (1°C) increments.

Note: When in the Ice Building mode, and the evaporator

entering water temperature drops below the ice termination setpoint, the chiller terminates the Ice Building mode and changes to the Ice Building Complete Mode.

NOTICE:

Equipment Damage!

Freeze inhibitor must be adequate for the leaving water temperature. Failure to do so will result in damage to system components.

Tracer™TU must also be used to enable or disable Ice

Machine Control.This setting does not prevent theTracer from commanding Ice Building mode.

Upon contact closure, the UC800 will initiate an ice building mode, in which the unit runs fully loaded at all times. Ice building shall be terminated either by opening the contact or based on the entering evaporator water temperature. UC800 will not permit the ice building mode to be reentered until the unit has been switched out of ice building mode (open5K3 contacts) and then switched back into ice building mode (close 5K3 contacts.)

In ice building, all limits (freeze avoidance, evaporator, condenser, current) will be ignored. All safeties will be enforced.

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

Connect leads from 5K3 to the proper terminals of 1K22. See the field diagrams which are shipped with the unit.

Silver or gold-plated contacts are recommended.These customer furnished contacts must be compatible with 24

VDC, 12 mA resistive load.

External Chilled Water Setpoint (ECWS) Option

The UC800 provides inputs that accept either 4-20 mA or

2-10VDC signals to set the external chilled water setpoint (ECWS).This is not a reset function.The input defines the setpoint.This input is primarily used with generic BAS (building automation systems).The chilled water setpoint is set via theTracer AdaptiView™TD7 or through digital communication withTracer (Comm3).

The chilled water setpoint may be changed from a remote

location by sending either a 2-10VDC or 4-20 mA signal to the 1K24, terminals 5 and 6 LLID.The 2-10 VDC and 4-20

28 RTAF-SVX001A-EN

Page 29

Installation Electrical

mA each correspond to a 10 to 65°F (-12 to 18°C) external chilled water setpoint.

The following relationships exist:

Voltage Signal External Water Setpoint

< 1 VDC Invalid

1 VDC to 2 VDC min

2 VDC to 10 VDC min + (max-min)* (Signal-2)/8

10 VDC to 11 VDC max

> 11 VDC Invalid

Current Signal External Water Setpoint

< 2 mA Invalid

2 mA to 4 mA min

4 ma to 20 mA min + (max-min)* (Signal-4)/16

20 mA to 22 mA max

>22 mA Invalid

If the ECWS input develops an open or short, the LLID will report either a very high or verylow value back to the main processor.This will generate an informational diagnostic and the unit will default to using the Front Panel (TD7) Chilled Water Setpoint.

TracerTU ServiceTool is used to set the input signal type

from the factory default of 2-10 VDC to that of 4-20 mA.

TracerTU is also used to install or remove the External

ChilledWater Setpoint option as wellas ameans toenable and disable ECWS.

field installation, or can be used to enable or disable the feature (if installed).

EDLS and ECWS Analog Input Signal Wiring Details:

Both the ECWS and EDLS can be connected and setup as either a 2-10 VDC (factory default), 4-20 mA, or resistance input (also a form of 4-2OmA) as indicated below. Depending on the type to be used, theTracerTU Service

Tool must be used to configure the LLID andthe MP forthe

proper input type that is being used.This is accomplished by a setting change on the Custom Tab of the Configuration View withinTracerTU.

Important: For proper unit operation, BOTH the EDLS

and ECWS settings MUST be the same (2-10

VDC or 4-20mA), even if only one input is to

be used.

The J2-3 and J2-6 terminal is chassis grounded and

terminal J2- 1 and J2-4 can be used to source 12VDC.The ECLS uses terminals J2-2 and J2-3. ECWS uses terminals J2-5 and J2-6. Both inputs are only compatible with high-side current sources.

Figure 13. Wiring examples for EDLS and ECWS

J2-1 & 4 Dual

2-10 VDC, 4-20mA

J2-2 & 5 Analog J2-3 & 6 I/O LLID

External Demand Limit Setpoint (EDLS) Option

Similar to the above, the UC800 also provides for an optional External Demand Limit Setpoint that will accept either a 2-10 VDC (default) or a 4-20 mA signal. The Demand Limit Setting can also be set via theTracer

AdaptiView™TD7 or through digital communication with

Tracer (Comm 3).The arbitration of the various sources of

demand limit is described in the flow charts at the end of this section.The External Demand Limit Setpoint may be changed from a remote location by hooking up the analog input signal to the 1K24 LLIDterminals 2 and 3. Refer to the following paragraph on Analog Input Signal Wiring Details.The following equations apply for EDLS:

Voltage Signal Current Signal

As generated from external source

As processed by UCM

If the EDLS input develops an open or short, the LLID will report either a very high or very low value back to the man processor.This will generate an informational diagnostic and the unit will default to using the Front Panel (Tracer

AdaptiView™TD7) Current Limit Setpoint.

TheTracer™TU ServiceTool must be used to set the input

signal type from the factory default of 2-10 VDC to that of 4-20 mA current.TracerTU must also be used to install or remove the External Demand Limit Setpoint Option for

VDC+0.133*(%)-6.0 mA=0.266*(%)-12.0

%=7.5*(VDC)+45.0 %=3.75*(mA)+45.0

Resister

I = 20/(R + 200)

J2-1 & 4 Dual J2-2 & 5 Analog J2-3 & 6 I/O LLID

Chilled Water Reset (CWR)

UC800 resets the chilled water temperature set point based on either return water temperature, or outdoor air temperature. Return Reset is standard, Outdoor Reset is optional.

The following shall be selectable:

• One of three ResetTypes: None, Return Water Temperature Reset, Outdoor AirTemperature Reset, or

Constant Return WaterTemperature Reset.

• Reset Ratio Set Points.

For outdoor air temperature reset there shall be both positive and negative reset ratio's.

• Start Reset Set Points.

• Maximum Reset Set Points.

RTAF-SVX001A-EN 29

Page 30

Installation Electrical

The equations for each type of reset are as follows:

Return

CWS' = CWS + RATIO (START RESET - (TWE -TWL))

and CWS' > or = CWS

and CWS' - CWS < or = Maximum Reset

Outdoor

CWS' = CWS + RATIO * (START RESET -TOD)

and CWS' > or = CWS

and CWS' - CWS < or = Maximum Reset

where

CWS' is the new chilled water set point or the“reset CWS”

CWS is the active chilled water set point before any reset has occurred, e.g. normally Front Panel, Tracer, or ECWS

RESET RATIO is a user adjustable gain

START RESET is a user adjustable reference

TOD is the outdoor temperature

TWE is entering evap. water temperature

TWL is leaving evap. water temperature

MAXIMUM RESET is a user adjustable limit providing the maximum amount of reset. For all types of reset, CWS' CWS < or = Maximum Reset.

Range Increment

Reset

Type

Return

Outdoor

Reset

Ratio

10 to 120%

80 to 80%

Start

Reset

4 to 30 F 0 to 20 F 1% 1% 50%

(2.2 to

16.7 C)

50 to 130 F

(10 to

54.4 C)

Max

Reset

(0.0 to

11.1 C)

0 to 20 F 1% 1% 10%

(0.0 to

11.1 C)

Units

Factory Default

When any type of CWR is enabled, the MP will step the Active CWS toward thedesired CWS' (based on the above

equations and setup parameters) at a rate of 1 degree F every 5 minutes until the Active CWS equals the desired CWS'.This applies when the chiller is running.

When the chiller is not running, CWS is reset immediately

(within one minute) for Return Reset and at a rate of 1 degree F every 5 minutes for Outdoor Reset.The chiller will start at theDifferential to Start value above a fullyreset CWS or CWS' for both Return and Outdoor Reset.

AFD Drive

TraneTR200 drive is an electronic motor controller that

converts AC mains input into a variable AC waveform output.The frequency and voltage of the output are regulated to control the motor speed or torque.

TR200 drive includes the following features:

• Soft start to minimize inrush current

• Improved harmonic mitigation with DC link reactor

• Integrated power fuse

• Graphical LCD keypad

• Unit Mounted with factory pre-wiring

• ‘Trane Drive Utility’ for configuration and tracking

See Service Manual BAS-SVM01*-EN for more information.

In addition to Return and Outdoor Reset, the MP provides a menu item for the operator to select a Constant Return Reset. Constant Return Reset will reset the leaving water temperature set point so as to provide a constant entering water temperature.The Constant Return Reset equation is the same as the Return Reset equation except on selection of Constant Return Reset, the MP will automatically set Ratio, Start Reset, and Maximum Reset to the following.

RATIO = 100%

START RESET = Design DeltaTemp.

MAXIMUM RESET = Design DeltaTemp.

The equation for Constant Return is then as follows:

CWS' = CWS + 100% (Design DeltaTemp. - (TWE -TWL)) and CWS' > or = CWS

and CWS' - CWS < or = Maximum Reset

30 RTAF-SVX001A-EN

Page 31

Installation Electrical

AFD Drive Installation

The AFD drive is manufactured with a jumper installed

between terminal 12 (+24Vdc source) and terminal 37 (Safe Stop digital input).This jumper must be removed prior to unit operation. See Figure 14 for view of jumperas it would be installed on drive from manufacturer.

NOTICE:

Equipment Damage!

Verify/remove jumper between AFD terminals 12 and

37 before unit operation. Failure to remove jumper could cause equipment damage.

Figure 14. AFD jumper

Jumper between terminals 12 and 37 must be removed prior to unit operation.

AFD Drive Programming

Field replacement drives must be programmed via the keypad interface. Program parameters sequentially by ID values as defined in Table 14 and Table 15, p. 32.

Table 14. Non-compressor specific parameter settings

ID Description Setting

0-03 Region Settings [1] North American

0-20 Display Line 1.1 Small [1612] Motor Voltage

0-24 Display Line 3 Large [1617] Speed (rpm)

0-40 [Hand on] Key on LCP [0] Disabled

0-41 [Off] Key on LCP [0] Disabled

0-60 Main Menu Password 999

0-61 Access to Main Menu w/o Password [1] LCP: Read-only

1-03 Torque Characteristics [0] Compressor Torque

1-21 Motor Power [HP] See Table 15

1-22 Motor Voltage See Table 15

1-23 Motor Frequency 60Hz

Table 14. Non-compressor specific parameter settings

ID Description Setting

1-24 Motor Current See Table 15

1-25 Motor Nominal Speed See Table 15

1-71 Start Delay 0s

1-73 Flying Start [0] Disabled

1-78 Compressor Start Max Speed [Hz] 30Hz

1-79 Compressor Start Max Time to Trip 10s

1-82 Min Speed for Function at Stop [Hz] 10Hz

1-87 Trip Speed Low [Hz] 25Hz

3-02 Minimum Reference 30Hz

3-41 Ramp 1 Ramp Up Time 5s

3-42 Ramp 1 Ramp Down Time 5s

3-82 Starting Ramp Up Time 3s

4-10 Motor Speed Direction [0] Clockwise

4-12 Motor Speed Low Limit [Hz] 30Hz

4-18 Current LImit 116.7%

4-19 Max Output Frequency 61Hz

5-12 Terminal 27 Digital Input [2] Coast Inverse

5-13 Terminal 29 Digital Input [0] No Operation

5-40.0 Function Relay 1 [5] Running

5-40.1 Function Relay 2 [3] Drive Rdy/Rem Ctrl

5-41.0 On Delay, Relay 1 1s

5-41.1 On Delay, Relay 2 1s

5-42.0 Off Delay, Relay 1 1s

5-42.1 Off Delay, Relay 2 1s

6-10 Terminal 53 Low Voltage 2V

6-14 Terminal 53 Low Ref./Feedb. Value 30Hz

6-50 Terminal 42 Output [133] Motor Cur. 4-20mA

14-03 Overmodulation [0] Off

14-10 Mains Failure [4] Kinetic Back-up

14-11 Mains Voltage at Mains Fault See Table 15

14-20 Reset Mode [1] Automatic Reset x 1

14-30 Current Lim Ctrl. Proportional Gain 25%

14-31 Current Lim Ctrl. Integration Time 1s

14-50 RFI Filter [0] Off

14-51 DC Link Compensation [1] On

22-75 Short Cycle Protection [1] Enabled

22-76 Interval Between Starts 60s

RTAF-SVX001A-EN 31

Page 32

Installation Electrical

Table 15. Compressor-specific parameter settings 115 to 215 tons — 60Hz

Parameters L1 L2 M3 M4 N3

ID Description 460V 380V 575V 460V 380V 575V 460V 380V 575V 460V 380V 575V 460V 380V 575V

1-21 Motor Power (hp) 86 86 86 102 102 102 122 122 122 144 144 144 177 177 177

1-22 Motor Voltage (V) 460V 380V 575V 460V 380V 575V 460V 380V 575V 460V 380V 575V 460V 380V 575V

1-24 Motor Current (A) 100A 121A 80A 120A 145A 96A 141A 170A 111A 166A 200A 132A 201A 243A 161A

Motor Nominal

1-25

(a) 400V/50 Hz units use 380V/60 Hz compressor settings.

Speed (rpm)

14-11Voltage at Main

Fault (V)

3461 3460 3461 3459 3466 3461 3502 3505 3503 3494 3494 3494 3494 3495 3493

391V 323V 489V 391V 323V 489V 391V 323V 489V 391V 323V 489V 391V 323V 489V

(a)

Communication Interfaces

LonTalk Interface (LCI-C)

UC800 provides an optional LonTalk®Communication Interface (LCI-C) between the chiller and a Building

Automation System (BAS). An LCI-C LLID shall be used to

provide "gateway" functionality between a LonTalk compatible device and the Chiller.The inputs/outputs include both mandatoryand optional network variables as established by the L

ONMARK

8040.

Note: For more information see ACC-SVN100*-EN.

Functional Chiller Profile

BACnet Interface (BCI-C)

Optional BACnet®Communication Interface for Chillers (BCI-C) is comprised of aTracer UC800 controller with interface software. It is a non-programmable communications module that allows units to communicate on a BACnet communications network.

Note: For more information, see BAS-SVP01*-EN.

Modbus RemoteTerminal Unit Interface

Modicon Communication Bus (Modbus™) enables the chiller controller to communicate as a slave device on a Modbus network. Chiller setpoints, operating modes, alarms and status can be monitored and controlled by a Modbus master device.

Note: For more information, see BAS-SVP01*-EN.

32 RTAF-SVX001A-EN

Page 33

Operating Principles

Refrigerant Circuit

Each unit has two refrigerant circuits, with one rotary screw compressor per circuit. Each refrigerant circuit includes compressor suction and discharge service valves, liquid line shut off valve, removable core filter, liquid line sight glass with moisture indicator, charging port, high pressure and low pressure safety valve and electronic expansion valve. Fully modulating compressor and electronic expansion valve provide variable capacity modulation over the entire operating range.

Refrigerant Cycle

Typical refrigerant cycle is represented on the pressure

enthalpy diagram shown in the figure below. Key state points are indicated on the figure.The cycle for the full load design point is represented in the plot.

Figure 15. Pressure-enthalphy diagram

R-134a

h (btu/lb)

120 140100806040200

600

500

200

P (psia)

100

The chiller uses a shell and tube evaporator design with

refrigerant evaporating onthe shell sideand water flowing inside tubes having enhanced surfaces (states 4 to 1).The suction lines are designed to minimize pressure drop (states 1 to1b) the compressor isa twin-rotor helical rotary compressor designed similarly to the compressors offered in otherTrane screw compressor based chiller (states 1b to 2).The discharge lines include a highly efficient oil separation system that removes 99.8% of the oil from the refrigerant stream going to the heat exchangers (states 2 to 2b). De-superheating, condensing and sub-cooling are accomplished in a microchannel cooled heat exchanger where refrigerant is condensed inside the microchannel (states 2b to 3b). Refrigerant flow through the systemis balanced by an electronic expansion valve (states 3b to 4).

Refrigerant and Oil

Use only R-134a or R-513A as shown on unit nameplate, and selected in unit model number digit 16.

Digit 16 =1 or 3: R-513A

Digits 16 = 2 or 4: R-134a

The Sintesis™ chiller uses environmentally friendly

refrigerants.Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified.The Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.

R-134a and R-513A are medium pressure refrigerants.

They may not be used in any condition that would cause

the chiller to operate in a vacuum without a purge system. Sintesis is not equipped with a purge system.Therefore, the chiller may not be operated in a condition that would result in a saturated condition in the chiller of -15°F (-26°C)

or lower.

Use only the specific POE oil as designated on the unit nameplate.

Compressor and Lube Oil System

The rotary screw compressor is semi-hermetic, direct

drive, with capacity control via an adaptive frequency drive, rolling element bearings, differential refrigerant pressure oil pump and oil heater.The motor is a suction gas cooled, hermetically sealed, two-pole squirrel cage induction motor.

Oil separator is provided separate from the compressor. Oil filtration is provided internal to the compressor. Check valves in the compressor discharge and lube oil system are also provided.

Condenser and Fans

The air-cooled microchannel condenser coils use all

aluminum brazed fin construction.The condenser coil has an integral subcooling circuit.The maximum allowable working pressure of the condenser is 350 psig. Condensers are factory proof and leak tested at 525 psig. Coils can be cleaned with high pressure water.

Direct-drive vertical-discharge airfoil condenser fans are dynamically balanced.The condenser fan motors are permanent magnet motors with integrated drive to provide variable speed fan control for all fans.

RTAF-SVX001A-EN 33

Page 34

Operating Principles

All condenser fan motors are designed with permanently lubricated ball bearings and internal temperature and current overload protection.

Evaporator

The evaporator is a tube-in-shell heat exchanger design

constructed from carbon steel shells and tubesheets with internally and externally finned seamless copper tubes mechanically expanded into the tube sheets.The evaporator is designed,tested and stamped in accordance with the ASME Boiler and Pressure Vessel Code for a refrigerant side working pressure of 200 psig. The evaporator is designed for a water side working pressure of 150 psig.

Standard water connections aregrooved forVictaulic style pipe couplings, with flange style connections optionally available. Waterboxes are only available in a 2 pass configuration and include a vent, drain and fittings for temperature control sensors. A factory installed flow switch is installed on the supply waterbox in the evaporator inlet connection.

Evaporators are insulated with 3/4 inch closed cell insulation.

Evaporator shell heaters and waterbox heaters with thermostat are provided to help protect the evaporator from freezing at ambient temperatures down to

-4°F (-20°C).

Note: A separate field supplied 120V power source is

required to power the evaporator freeze protection. See “Installer-Supplied Components,” p. 25 and

“Freeze Avoidance,” p. 23for more information.

34 RTAF-SVX001A-EN

Page 35

Controls

Overview

Sintesis™ RTAF chillers utilize the following control/ interface components:

• Tracer™ UC800 Controller

• Tracer AdaptiView™TD7 Operator Interface

Figure 16. Wiring locations and connection ports

+ +

234 5

LINK

MBUS

UC800 Specifications

This section covers information pertaining to the UC800

controller hardware.

Wiring and Port Descriptions

Figure 16 illustrates the UC800 controller ports, LEDs,

rotary switches, and wiring terminals.The numbered list following Figure 16 corresponds tothe numbered callouts in the illustration.

VDC

Front View

1. Rotary Switches for setting BACnet®MAC address or MODBUS ID.

2. LINK for BACnet MS/TP, or MODBUS Slave (two terminals, ±). Field wired if used.

3. LINK for BACnet MS/TP, or MODBUS Slave (two terminals, ±). Field wired if used.

4. Machine bus for existing machine LLIDs (IPC3Tracer bus 19.200 baud). IPC3 Bus: used for Comm4 using TCI or LonTalk

5. Power (210 mA at 24 Vdc) and ground terminations (same bus as item 4). Factory wired.

6. Not used.

7. Marquee LED power and UC800 Status indicator (Table 16, p. 36).

8. Status LEDs for the BAS link, MBus link, and IMC link.

9. USB device type B connection for the service tool (TracerTU).

10. The Ethernet connection can only be used with the Tracer AdaptiView display.

11. USB Host (not used).

Bottom View

using LCI-C.

RTAF-SVX001A-EN 35

Page 36

Controls

Communication Interfaces

There are four connections on the UC800 that support the

communication interfaces listed. See Figure 16, p. 35 for the locations of each of these ports.

• BACnet

MS/TP

• MODBUS™ Slave

• LonTalk™ using LCI-C (from the IPC3 bus)

• Comm 4 usingTCI (from the IPC3 bus)

Rotary Switches

There are three rotary switches on the front of the UC800

controller. Use these switches to define a three-digit address when the UC800 is installed in a BACnet or MODBUS system (e.g., 107, 127, etc.).

Note: Valid addresses are 001 to 127 for BACnet and 001

to 247 for MODBUS.

LED Description and Operation

There are 10 LEDs on the front of the UC800. Figure 17

shows the locations of each LED and Table 16 describes their behavior in specific instances.

Figure 17. LED locations

Marquee

LINK MBUS IMC

LINK

ACT

SERVICE

Table 16. LED behavior

LED UC800 Status

Powered. If the Marquee LED is green solid, the

UC800 is powered and no problems exist.

Low power or malfunction. If the Marquee LED is

Marquee LED

LINK, MBUS,

IMC

Ethernet Link

Service

red solid, the UC800 is powered, but there are problems present.

Alarm. The Marquee LED blinks Red when an alarm exists.

The TX LED blinks green at the data transfer rate when the UC800 transfers data to other devices on the link.

The Rx LED blinks yellow at the data transfer rate when the UC800 receives data from other devices on the link.

The LINK LED is solid green if the Ethernet link is connected and communicating.

The ACT LED blinks yellow at the data transfer rate when data flow is active on the link.

The Service LED is solid green when pressed. For qualified service technicians only. Do not use.

Important: Maintain at least 6 inches between low-

voltage (<30V) and high voltage circuits. Failure to do so could result i electrical noise that could distort the signals carried by the low-voltage wiring, including IPC.

Tracer AdaptiViewTD7 Display

Operator Interface

Information is tailored to operators, service technicians, and owners. When operating a chiller, there is specific information you need on a day-to-day basis—setpoints, limits, diagnostic information, and reports. Day-to-day operational information is presented at the display. Logically organized groupsof information— chillermodes of operation, active diagnostics, settings and reports put information conveniently at your fingertips.

Figure 18. TD7 screens

Operator Display Boot Screen Display Loading Data Home Screen, Auto Mode

Main Display Area/Home Screen

All screens appearwithin the main display area (shown as

36 RTAF-SVX001A-EN

location in Table 19).

Page 37

Controls

Home screen: Chiller status information

The home screen (Table 19) provides the most frequently

needed chiller status information on “touch targets” (the entire white rectangularareas) for eachchillercomponent.

Touching any touch target displays a screen containing

more chiller status information related to each component.

Figure 19. Main screen

Table 17. Main screen items

Note: You can also access the Chiller Operating Modes

screen from the chiller status button in the upper left corner of the screen.

Figure 20. Chiller operating modes

Description Resolution Units

Active Chilled Water Setpoint X.X °F /°C

Active Current Limit Setpoint X.X %RLA

Average Motor Current %RLA X.X %RLA

Evap Entering/Leaving Water Temp X.X °F /°C

Cond Entering/Leaving Water Temp X.X °F /°C

Frequency Command X.X Hz

Evaporator Water Flow Status X.X

Condenser Water Flow Status

Viewing Chiller Operating Modes

On the Reports screen, touch Chiller Operating Modes to view the current operating status of the chiller in terms of the top-level operating mode and submodes.

Table 18. Operating modes

Chiller Modes Description

MP Resetting The main processor is going through reset

No chiller sub-modes.

Stopped

Local Stop Chiller is stopped by TD7 Stop button command– cannot be remotely overridden.

Immediate Stop

No Circuits Available The entire chiller is stopped by circuit diagnostics or lockouts that may automatically clear.

Diagnostic Shutdown – Manual Reset The chiller has been shut down on a latching diagnostic that requires manual intervention to reset.

Chilled Water Control

Starting is Inhibited by Low Ambient Temperature

The chiller is not running either circuit and cannot run without intervention. Further information is provided by the sub-mode:

Chiller is stopped by the TD7 Panic Stop (by pressing Stop then Immediate Stop in succession) – previous shutdown was manually commanded to shutdown immediately.

Chiller is running to provide a chilled water temperature per the active chilled water setpoint (may be as arbitrated from various sources). (For cooling only units, this mode may be suppressed.)

The chiller is inhibited based on the outdoor air temperature.

RTAF-SVX001A-EN 37

Page 38

Controls

Table 18. Operating modes (continued)

Chiller Modes Description

Starting is Inhibited by External Source

Power Up Delay Inhibit: min:sec On power up, the chiller will wait for the Power Up Delay Timer to expire.

Run Inhibit

No Circuits Available The entire chiller is stopped by circuit diagnostics or lockouts that may automatically clear.

Ice Building Is Complete

Ice to Normal Transition Inhibit

Start Inhibited by BAS The chiller is stopped by Tracer

Starting is Inhibited by External Source

Diagnostic Shutdown – Auto Reset The entire chiller is stopped by a diagnostic that may automatically clear.

Starting is Inhibited by Low Ambient Temperature

Power Up Delay Inhibit: min:sec

Chilled Water Control

Auto

Waiting For Evap Water Flow

Waiting for A Need to Cool

Chilled Water Control

Waiting to Start

Running

Chilled Water Control

Maximum Capacity The chiller is operating at its maximum capacity.

Capacity Control Softloading The control is limiting the chiller loading due to capacity based softloading settings.

Demand Limit Softloading

Running – Limited

Demand Limit

Demand Limit Softloading

The chiller is inhibited from starting or running by the “external stop” hardwired input.

The chiller is currently being inhibited from starting (and running), but may be allowed to start if the inhibiting or diagnostic condition is cleared. Further information is provided by the submode:

The chiller is inhibited from running as the Ice Building process has been normally terminated on the evaporator entering temperature. The chiller will not start unless the ice building command (hardwired input or Building Automation System command) is removed or cycled.

The chiller is inhibited from running for a brief period of time if it is commanded from active ice building mode into normal cooling mode via the ice building hardwired input or Tracer. This allows time for the external system load to “switchover” from an ice bank to the chilled water loop, and provides for a controlled pull down of the loop’s warmer temperature. This mode is not seen if the ice making is automatically terminated on return brine temperature per the mode below.

or Building Automation System.

The chiller is inhibited from starting or running) by the “external stop” hardwired input.

The chiller is inhibited based on the outdoor air temperature.

On power up, the chiller will wait for the Power Up Delay Timer to expire.

Chiller is running to provide a chilled water temperature per the active chilled water setpoint (may be as arbitrated from various sources). (For cooling only units, this mode may be suppressed.)

The chiller is not currently running but can be expected to start at any moment given that the proper conditions and interlocks are satisfied. Further information is provided by the submode:

The chiller will wait up to 20 minutes in this mode for evaporator water flow to be established per the flow switch hardwired input.

The chiller will wait indefinitely in this mode, for an evaporator leaving water temperature higher than the Chilled Water Setpoint plus some control dead-band.

Chiller is running to provide a chilled water temperature per the active chilled water setpoint (may be as arbitrated from various sources). (For cooling only units, this mode may be suppressed.)

The chiller is not currently running and there is a call for cooling but lead circuit start is delayed by certain interlocks or proofs.

No chiller sub-modes.

The chiller, circuit, and compressor are currently running. Further information is provided by the sub-mode:

Chiller is running to provide a chilled water temperature per the active chilled water setpoint (may be as arbitrated from various sources). (For cooling only units, this mode may be suppressed.)

The chiller is running, and loading of individual compressors may be limited by a gradual filter of the chiller’s softloading demand limit setpoint. The starting demand limit and the settling time of this filter is user adjustable as part of the demand limit softload feature. The mode will be displayed as long as the Demand Limit Softloading is ramping or “settling”.

At least one circuit on the chiller is currently running, but the operation of any of the circuits on the chiller is being actively limited by a chiller level limit. Other sub modes that apply to the Chiller Running top level modes may also be displayed here. Refer to the list of circuit limit modes for circuit limits that will cause display of this Chiller Level Running Limit mode.

The chiller is running and the compressor capacity is unloaded or restricted to load slowly or not at all to keep the chiller from exceeding the demand limit set by the customer.

38 RTAF-SVX001A-EN

Page 39

Controls

Table 18. Operating modes (continued)

Chiller Modes Description

The chiller is still running but shutdown is imminent. The chiller is going through a compressor

Shutting Down

Evaporator Water Pump Off Delay min:sec

Local Stop, Maximum Capacity Chiller is in the process of being stopped by TD7 Stop button command

Misc These sub-modes may be displayed in most of the top level circuit modes.

Manual Evaporator Pump Override The evaporator water pump relay is on due to a manual command.

Diagnostic Evaporator Water Pump Override

Manual Compressor Control Signal Chiller capacity control is being controlled by Operator Display or Service Tool.

Noise Reduction Request

Chilled Water Control These modes are mutually exclusive and they indicate that the chiller is controlling to the active chilled

Ice Building

Evaporator Water Pump X Locked Out Evaporator Water Pump X has been locked out by manual override from TD7 or TU.

Waiting for BAS Communications

run-unload or extended operational pumpdown of the lag circuit/compressor (or all circuits simultaneously).

The evaporator water pump is continuing to run past the shutdown of the compressors, executing the pump off delay timer.

The evaporator water pump relay is on due to a diagnostic.

The Noise Reduction Request feature has been activated. If the unit is running, fans will be running at lower speed.

water setpoint, or the active ice termination setpoint respectively. Chiller is running to provide a chilled water temperature per the active chilled water setpoint (may be as arbitrated from various sources). (For cooling only units, this mode may be suppressed.)

The chiller has not detected communication with the BAS. This mode is only supported by LonTalk systems. Depending on configurations and Setpoint source setting, lack of communication may cause the chiller to shut down and or become inhibited from starting, but if so, the “Starting is Inhibited by BAS” mode will also occur.

Alarms

You can use the display to view alarms and to reset them.

Alarms are communicated to the display immediately

upon detection.

Viewing the Alarms Screen

Touchthe Alarms button in the main menu area (Figure 19,

p. 37) to view the Alarms screen. A table of active alarms

appears that is organized chronologically with the most recent at the top of the list, as shown in Figure 21.This example shows the defaultview, which appears each time you return to the screen.

Note: A page number appears in the lower right corner of

the screen. If a screen contains more than one page, up/down arrows also appear for viewing the other pages

Figure 21. Alarm screen

The Alarms screen is accessible by depressing the Alarms

enunciator. A verbal description will be provided.

A scrollable list of the last active Alarms is presented.

Performing a “Reset Alarms” will reset all active Alarms regardless of type, machine or circuit.The scrollable list will be sorted by time of occurrence.

If a informational warning is present, the “Alarms” key will be present but not flashing. If a Alarm shutdown (normal or immediate) has occurred, the “Alarm” key will display that is flashing. If no Alarms exist, the “Alarm” key will not be present.

Reports

You can use theTracer display to view a variety of reports

and to create and edit a custom report. All reports contain live data that refreshes every 2–5 seconds.

Viewing the Reports Screen

Touch the Reports button in the main menu area (Figure 4)

to view the Reports screen.The Reports screen contains the following buttons:

• Custom Report1

• Custom Report2

• Custom Report3

• Evaporator

• Condenser

• Compressor

• Motor

• About

• Operating Modes

RTAF-SVX001A-EN 39

Page 40

Controls

• Log Sheet

• ASHRAE Chiller Log

Each button links to the report named on the button.

Figure 22. Report screen

Reportstab allows a user to select from a list of reports

The

headings. Each report will generate alist of status itemsas defined in the tables that follow.

Figure 23. Edit custom report screen

Figure 24. Report evaporator screen

Editing a Custom Report

You can edit the custom report by adding, removing, or re-

order data as follows:

1. On the Custom Report screen, touch Edit.The Edit Custom Report screen appears.

2. Add, remove, or re-order as follows:

a. To add an item to the custom report, touch it. It

responds arrows to scroll through the rest of the items that can be added to the custom report.Then touch Add to move the selected item to the box on the right side of the screen.To add all of the remaining items in the left box to the custom report, touch Add All.

b. To remove an itemfrom the custom report, touch it.

It responds by changing to blue.You can use the arrows to scroll through the rest of the items that can be removed fromthe custom report.Then touch Remove to movethe selected item to the box on the left side of the screen.

c. To re-order items in the custom report, touch it. It

responds by changing to blue. Use the arrows to change the order of a highlighted item.

3. To save and view your edited custom report, touch S

ave.

by changing to blue.You can use the

Table 19. Report evaporator screen items

Description Resolution Units

Active Chilled Water Setpoint X.X °F / °C

Evaporator Entering Water Temperature X.X °F / °C

Evaporator Leaving Water Temperature X.X °F / °C

Evaporator Water Flow Status Flow, No Flow Text

Evaporator Water Pump Override Auto, On Text

Evaporator Approach Temperature X.X °F / °C

EXV Position Percent X.X %

Evaporator Refrigerant Pressure XXX.X PSIA/kPa

Evaporator Saturated Rfgt Temp X.X °F / °C

Evaporator Refrigerant Liquid Level X.XX in/mm

40 RTAF-SVX001A-EN

Page 41

Figure 25. Report condenser screen

Table 20. Report condenser screen items

Description Resolution Units

Condenser Entering Water Temperature

Condenser Leaving Water Temperature

Condenser Water Flow Status Flow, No Flow Text

Condenser Water Pump Override Auto, On Text

Condenser Approach Temperature X.X F / C

EXV Position Percent X.X %

Condenser Refrigerant Pressure XXX.X PSIA/kPa

Condenser Saturated Rfgt Temp X.X F / C

Differential Refrigerant Pressure XXX.X PSIA/kPa

Outdoor Air Temperature X.X F / C

X.X F / C

Controls

Table 21. Report compressor screen items

Description Resolution Units

Compressor Running Time XX:XX Hr:Min

Oil Loss Level Sensor Wet, Dry Text

Discharge Temperature X.X °F / °C

Compressor Oil Pressure XXX.X PSIA/kPaA

Evaporator Refrigerant Pressure XXX.X PSIA/kPaA

Condenser Refrigerant Pressure XXX.X PSIA/kPaA

Differential Refrigerant Pressure XXX.X PSIA/kPaA

Frequency Command XX.X Hz

Figure 27. Report motor screen

Figure 26. Report compressor screen

Table 21. Report compressor screen items

Description Resolution Units

Compressor Running Status On, Off Text

Average Motor Current %RLA XX.X% %RLA

Compressor Starts XX Text

RTAF-SVX001A-EN 41

Page 42

Controls

Table 22. Report motor screen items

Description Resolution Units

Active Current Limit Setpoint X.X %RLA

Average Motor Current %RLA X.X %RLA

Starter Motor Current L1 %RLA X.X %RLA

Starter Motor Current L2 %RLA X.X %RLA

Starter Motor Current L3 %RLA X.X %RLA

Starter Motor Current L1 X.X A

Starter Input Voltage AB XXX.X V

Starter Input Voltage BC XXX.X V

Starter Input Voltage CA XXX.X V

Average Motor Current X.X A

Average Phase Voltage XXX.X V

Frequency Command XX.X Hz

Equipment Settings

You can use the TD7 display to monitor and change a variety of equipment settings.

Viewing the Settings Screen

Touch the Settings button in the main menu area (see

Figure 19, p. 37) to view the Settings screen. Equipment

Settings identifies a column of buttons located on the screen (see the outlined column in Figure 28).The buttons are:

• Chiller Settings

• Feature Settings

• Chiller Water Reset

• Manual Control Settings

• Service Settings

Each of these buttons provide access to a screen that contains section provides detailed information about these screens.

Figure 28. Setting screen

additional buttons related to each topic. This

Viewing and Changing Equipment Settings

Each button in the Equipment Settings column on the Settings screen takes you to a menu screen that contains a group of buttons. Each button displays the name of a setting and its current value (Figure 29).Touch any button to view a screen where you can change the setting for the feature shown on the button.

Note: A page number appears in the lower right corner of

the screen. If a screen contains more than one page, up/down arrows also appear for viewing the other pages, as in Figure 29.

Figure 29. Equipment setting screen

(Chiller setting shown)

To change an equipment setting, follow this procedure:

1. Touch one of the button in the Equipment Settings column on the Settingsscreen, such as Chiller Settings.

The corresponding screen appears (in this case, the

Chiller Settings screen).

2. Touchthe button that shows the equipment setting you w

ant to change.A screen that allowsyou tochange the equipment setting appears.There are two types of these screens:

a. For screens with button selections (Figure

touch the button that represents the setting you want.The button becomes shaded, and a Save button appears at the bottom of the screen.

b. For screens with numerical keypads (Figure 31),

touch the appropriate numbers to change the current value.The new value appears above the keypad.

3. Touch Save to complete the change.The current value is

updated in the upper left side of the screen, demonstrating that the change has been communicated to theTracer UC800 controller.The screen you were previously viewing appears.

30),

42 RTAF-SVX001A-EN

Page 43

Controls

Figure 30. Chilled water setpoint screen

Figure 31. Changed chilled water setpoint screen

Keypad features:

• When you enter a new number, the value in the New value field is deleted and replaced with the new entry.

• The backspace (arrow) key deletes the characters you previously

• If the keypad is used to enter a setpoint that is out of range, Save button.

• Keypads that allow negative numbers have positive and

entered.

an error dialog will appear when you touch the

negative number (+/-) keys.

Table 23. Settings screen items

Description Resolution Units

Chiller Settings

Active Chilled Water Setpoint ± XXX.X °F / °C

Active Current Limit Setpoint XXX% %RLA

Active Panel Base Load Cmd On/Auto Text

Active Base Loading Setpoint XXX %

Active Base Loading Command On/Auto Text

Differential to Start XXX.X °F / °C

Differential to Stop XXX.X °F / °C

Setpoint Source (BAS/Ext/FP, Ext/Front Panel, Front Panel)

Evaporator Water Pump Off Delay XX Min

Condenser Pump Prestart Time XX Min

High Evap Water Temp Cutout XXX.X °F / °C

Evaporator Leaving Water Temp Cutout XX.X °F / °C

Low Refrigerant Temperature Cutout XX.X °F / °C

Current Limit Softload Start Point XXX.X %

Current Limit Control Softload Time XXXX Sec

Capacity Control Softload Time XXXX Sec

Local Atmospheric Pressure XXX.X psi/kPa

Power Up Start Delay XXX Min

Feature Settings

External Chilled/Hot Water Setpoint (Enable/Disable)

External Current Limit Setpoint (Enable/Disable)

LCI-C Diagnostic Encoding (Enable/Disable) Text

Chilled Water Reset (Constant, Outdoor, Return, Disable),

Return Reset Ratio XXX %

Return Start Reset XXX.X °F / °C

Return Maximum Reset XXX.X °F / °C

Outdoor Reset Ratio XXX %

Outdoor Start Reset XXX.X °F / °C

Outdoor Maximum Reset XXX.X °F / °C

Mode Overrides

Evap Water Pump (Auto, On) Auto Text

Cond Water Pump (Auto, On) Auto Text

Display Reference

Date Format (mmm dd, yyyy, dd-mmm-yyyy)

Data Separator Text

Time Format (12-hour, 24-hour) 12-hour Text

Unit System (SI, English) English Text

Pressure Units (Absolute, Gauge) Absolute Text

Number Format Text

BAS/Ext/FP Text

Text

Disable Text

mmm dd, yyyy Text

RTAF-SVX001A-EN 43

Page 44

Controls

Display Settings

You can use theTracer AdaptiView display to change the

format of the information that appears on the display, and to clean the touch screen.

Viewing the Settings Screen

Touch the Settings button in the main menu area

(Figure 28, p. 42) to view the Settings screen. Display Settings identifies a column of buttons located on the screen (see Figure 32).The buttons are:

• Display Preferences

• Language

• Date andTime

• Clean Display

Eachbutton provide accessto a screen thatis related to the

ton name.

but

Viewing and Changing Display Preferences

On the Settings screen, touch Display Preferences to view a screen containing these buttons (see Figure 32):

• Date Format

• Date Separator

• Time Format

• Unit System

• Pressure Units

• Number Format

Figure 32. Display preference screen

Figure 33. Date format page

To change the format:

1. Touch the button that shows that format you prefer.

2. Touch Save to confirm your selection and to return to the

Display Preferences screen.

Date Format . Use the Date Format screen to choose

from the following date formats:

• MMDDYYYY (default)

• YYYYMMDD

• DDMMYYYY

Date Separator . Use the Date Separator screen to

choose from the following date formats:

• None

• Slash (default)

• Hyphen

Time Format . Use theTime Format screen to choose

from the following time formats:

• 12 hour (default)

• 24 hour

Units System . Use the Display Units screen to choose

from the following display units:

•SI

• Inch-Pounds (default)

Pressure Units . Use the Pressure Units screen to

Each of the buttons shows the name of a display preference these buttons to view a screen where you can change the format.The button representing the format currently used is shaded (see the “MMDDYYYY” button).

and its format (current value).Touch any of

choose from the following pressure units:

• kPaA (default if “SI” is chosen for display units)

•kPaG

• PSIA (default if “Inch-Pound” is chosen for display units)

• PSIG

Number Format .

• 1000000.0

• 1000000,0

44 RTAF-SVX001A-EN

Page 45

Figure 34. Language page

The language that is currently in use on the display is

expressed as the current value on the Language screen.

The button that displays the current value is shaded (see

the “English” buttoninFigure19as an example).

To change the language:

1. Touch the button that identifies the language you prefer.

2. Touch Save to confirm your selection and to return to the Settings screen.

Controls

To change the date or time:

. Touch the square presenting the attribute you want to

change.The square becomes highlighted.

2. Touch the up or down arrow key on the screen until the desired selection appears. Repeat the process for

your any other attributes you want to change.

3. Touch Save to confirm your selection and return to the

ettings screen.

Cleaning the Display

On the Settings screen, touch Clean Display to disable the

Tracer AdaptiView display screen for 15 seconds so that

you can clean the screen without it responding to touch. During this time, the screen is black with a number in the center that countsdown the seconds.After 15 seconds, the Settings screen re-appears.

Figure 36. Countdown screen

Figure 35. Date and time screen

The current date and time for the display is expressed as

the

current value.The current value appears below the

center line on the screen.

Above the center line, the following date and time

attributes appear:

• Month

• Day

• Year

• Hour

• Minute

• AM/PM

Security Settings

If security if enabled, theTracer AdaptiView display requires that you log in with a four-digit security PIN to make setting changes that are protected by security.This feature prevents unauthorized personnel from doing so.

There are two levels of security, each allowing specific

changes to be made.

You can view all data without logging in.The log-in screen

appears only when you try to change a setting that is protected by security, or when you touch theLog in button from the Settings screen.

Disabling/Enabling Security

TheTracer AdaptiView display gives you the ability to

disable or enable the security feature that allows a user to log in and log out.

To disable security, you must be logged in:

1. From the Settings screen, touch the Security button.

The Security screen appears (Figure 37).

Note: If you are logged out, the Log in screen appears.

2. Touch the Disablebutton.The button becomes shaded.

RTAF-SVX001A-EN 45

Page 46

Controls

3. Touch Save.The Settings screen appears with only the Security button visible.The Log in/Logout button is gone.

To enable security:

. From the Settings screen, touch the Security button.

The Security screen appears (Figure 37).

2. Touch the Enable button.The button becomes shaded.

3. Touch Save.The Settings screen appears with a Log

button, in addition to the Security button.

out

Figure 37. Security screen - disable

Figure 38. Security settings screen

2. Use the keypad to enter your PIN.

a. The PIN is a four-digit number, which was

configured service tool.

b. As you enter the number, the PIN remains hidden

by asterisks.

Note: If you enter an invalid PIN, an error message

appears on the Log in screen.

3. Touch Save.

a. If you viewed the Log in screen from touching Log

on the Settings screen, the Settings screen

in appears with a Log out button on it.

b. If the Log in screen appeared when you tried to

change a setting, you return to that setting screen.

Note: The PIN is valid until 30 minutes of inactivity

passes, or until you log out.

Figure 39. Log in screen

for your system with theTracerTU

Logging Out

To log out:

1. Touch the Log out button. A confirmation screen appears (Figure 40).

2. TouchYes to confirm that you want to log out.The

ettings screen appears with a Log in button on it.

Logging In

There are two levels of security:

• Security Level 1allows users to change a limitedgroup secure settings.The default security PIN is 1111.

• Security Level 2 allows users to change all secure

tings.The default security PIN is 7123.

set

A technician must use theTracerTU service tool to define

different PIN, or to recall a PIN that has been forgotten.

When defining a PIN inTracerTU, the technician enters a

4-digit PIN that corresponds with the desired level of security.

To log in:

1. Touch the Log in button.The Log in screen appears

(Figure 38).

46 RTAF-SVX001A-EN

Figure 40. Log out confirmation screen

Page 47

Controls

Tracer TU

The AdaptiView™TD7 operator interface allows for daily

operational tasks and setpoint changes. However, to adequately service Sintesis chillers,Tracer tool is required. (Non-Trane personnel, contact your local

Trane office for software purchase information.)TracerTU

adds a level of sophistication that improves service technician effectiveness and minimizes chiller downtime.

This portable PC-based service-tool software supports

service and maintenance tasks, and is required for software upgrades, configuration changes and major service tasks.

TracerTU serves as a common interface to allTrane

chillers,and will customize itself based onthe properties of the chiller with which it is communicating.Thus, the service technician learns only one service interface.

The panel bus is easy to troubleshoot using LED sensor

verification. Only the defective device is replaced.Tracer

TU can communicate with individual devices or groups of

devices.

All chiller status, machine configuration settings,

customizable limits, and up to 100 active or historic diagnostics are displayed through the service-tool software interface.

LEDs and their respectiveTracerTU indicators visually confirm the availability of each connected sensor, relay, and actuator.

Figure 41. Tracer TU

TU service

TracerTU is designed to run on a customer’s laptop,

connected to theTracer AdaptiView control panel with a USB cable.Your laptop must meet the following hardware and software requirements:

• 1 GB RAM (minimum)

• 1024 x 768 screen resolution

• CD-ROM drive

• Ethernet 10/100 LAN card

• Available USB 2.0 port

• Microsoft

operating system (32-bit or 64-bit)

Note: TracerTU versions 8.6 and earlier will also

• Microsoft .NET Framework 4.0 or later

Notes:

• TracerTU is designed and validated for this minimum

laptop configuration. Any variation from this configuration may have different results.Therefore, support for TracerTU is limited to only those laptops with the configuration previously specified.

• For more information, see TTU-SVN01*-ENTracerTU Getting Started Guide

Windows®7 Enterprise or Professional

support Windows XP Professional operating system with Service Pack 3 (SP3)

RTAF-SVX001A-EN 47

Page 48

Pre-Start

Upon completion of installation, complete the Sintesis™ RTAF Installation CompletionCheck Sheet andRequest for

Trane Service checklist in chapter “Log and Check Sheets,”

p. 86.

Important: Start-up must be performed byTrane or an

agent ofTrane specifically authorized to perform start-up and warranty of Trane products. Contractor shall provideTrane (or an agent ofTrane specifically authorized to perform start-up) with notice of the scheduled start-up at least two weeks prior to the scheduled start-up.

48 RTAF-SVX001A-EN

Page 49

Start-Up and Shutdown

Important: Initial unit commissioning start-up must be

performed byTrane or an agent of Trane specifically authorized to perform start-up and warranty ofTrane products. Contractor shall provideTrane (or an agent ofTrane specifically authorized to perform start-up) with notice of the scheduled start-up at least two weeks prior to the scheduled start-up.

Unit Start-Up

NOTICE:

Equipment Damage!

Ensure that the compressor and oil sump heaters have been operating properly for a minimum of 24 hours before starting. Failure to do so could result in equipment damage.

If required, once the system has been operating for approximately 30 minutes and has become stabilized, complete the remaining start-up procedures, as follows:

1. Check the evaporator refrigerant pressure and the condenser refrigerant pressure under Refrigerant Report on the AdaptiView ™TD7.The pressures are referenced to sea level (14.6960 psia).

2. Check the EXV sight glasses after sufficient time has elapsed to stabilize the chiller.The refrigerant flow past the sight glasses should be clear. Bubbles in the refrigerant indicate either low refrigerant charge or excessive pressure drop in the liquid line or a stuck open expansion valve. A restriction in the line can sometimes be identified by a noticeable temperature differential between the two sides of the restriction. Frost will often form on the line at this point. Proper refrigerant charges are shown in the General Information Section.

Important: A clear sight glass alone does not mean that

the system is properly charged. Also check system subcooling, liquid level control and unit operating pressures.

If chiller is limited by any limiting conditions, contact local

Trane service organization for more information.

Temporary Shutdown And

Restart

and automatically restart the pump when the unit starts normally.

3. The unit will start normally, provided the following conditions exist:

a. The UC800 receives a call for cooling and the

differential-to-start is above the setpoint.

b. All system operating interlocks and safety circuits

are 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, e.g. seasonal shutdown:

1. Test the unit for refrigerant leaks and repair as necessary.

2. Open the electrical disconnect for the chilled water pump. Lock the switches in the “OPEN” position.

NOTICE:

Equipment Damage!

To prevent pump damage, lock the chilled water pump

disconnects open and verify pump is off before draining water.

3. Close all chilled water supply valves. Drain the water from the evaporator.

4. With the water drained from evaporator, disconnect 115 power from evaporator heaters at terminals 1X4-1 and 1X4-2.

NOTICE:

Equipment Damage!

Applying power to the evaporator heaters when no

water is present could result in damage to heaters.

5. Open the main electrical disconnect and lock in the “OPEN” position.

NOTICE:

Equipment Damage!

Lock the disconnect in the “OPEN” position to prevent accidental start-up and damage to the system when it has been shut down for extended periods.

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

procedure:

1. Press the STOP key on the AdaptiviewTD7. The compressors will continue to operate and an operational pumpdown cycle will be initiated.

2. UC800 pump control will turn off the pump (after a minimum 1 min. delay) when the STOP key is pressed

RTAF-SVX001A-EN 49

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

Page 50

Start-Up and Shutdown

Seasonal Unit Start-Up Procedure

1. Close all valves and re-install the drain plugs in the evaporator.

2. Service the auxiliary equipment according to the startup/maintenance instructions provided by the respective equipment manufacturers.

3. Close the vents in the evaporator chilled water circuits.

4. Open all the valves in the evaporator chilled water circuits.

5. Open all refrigerant valves to verify they are in the open condition.

6. If the evaporator was previously drained, vent and fill the evaporator and chilled water circuit.When all air is removed from the system (including each pass), install the vent plugs in the evaporator water boxes.

7. Check the adjustment and operation of each safety and operating control.

8. Refer to the sequence for daily unit startup for the remainder of the seasonal startup.

System Restart After Extended Shutdown

NOTICE:

Proper Water Treatment!

The use of untreated or improperly treated water in

this equipment could result in scaling, erosion, corrosion, algae or slime. It is recommended that the services of a qualified water treatment specialist be engaged to determine what water treatment, if any, is required.Trane assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water.

4. Close the fused-disconnect switches that provides power to the chilled water pump.

5. Start the evaporator water pump and, while water is circulating, inspect all piping for leakage. Make any necessary repairs before starting the unit.

6. While the water is circulating, adjust the water flows and check the water pressure drops through the evaporator. See water flow rates in “General Data,” p. 10 .

7. Verify proper operation of flow switch on the evaporator waterbox.

8. Stop the water pump.The unit is now ready for startup as described previously.

“Pressure Drop Curves,” p. 21 and

NOTICE:

Equipment Damage!

Ensure that the compressor and oil sump heaters have been operating properly for a minimum of 24 hours before starting. Failure to do so could result in equipment damage.

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

1. Verify that the liquid line service valves, oil line, compressor discharge service valves and suction service valves are open (backseated).

NOTICE:

Compressor Damage!

Catastrophic damage to the compressor will occur if the oil line shut off valve or the isolation valves are left closed on unit start-up.

2. Check the oil sump level.

3. Fill the evaporator water circuit.Vent the system while it is being filled. Open the vent on the top of the evaporator and condenserwhile filling and close when filling is completed.

50 RTAF-SVX001A-EN

Page 51

Sequence of Operation

Start-Up and Shutdown

This section will provide basic information on chiller

operation for common events. With microelectronic controls, ladder diagrams cannot show today’s complex logic, as the control functions are much more involved than older pneumatic or solid state controls.

Adaptive control algorithms canalso complicate the exact

sequence of operations.This section illustrates common control sequences.

Software Operation Overview

The Software Operation Overview shown in Figure 42,

p. 51 is a diagram of the five possible software states.This

diagram can be though of as a state chart, with the arrows and arrow text depicting the transitions between states.

Figure 42. Software operation overviewFigure 42

• The text in the circles is the visible top level operating modes that are displayed onTracer™ AdaptiView.

• The shading of each software state circle corresponds

the shading on the time lines that show the state the

to chiller is in.

There are five generic states that the software can be in:

• Power Up

• Stopped

• Starting

• Running

• Stopping

•

Timelines

• Thetime line indicatesthe upper level operating mode, as it would be viewed on theTracer™ AdaptiView.

• The shading color of the cylinder indicates the

tware state.

sof

• Text inparentheses indicates sub-mode text as viewed

Tracer AdaptiView.

• Text above the time line cylinder is used to illustrate

to the Main Processor. This may include user

inputs input to theTracer AdaptiViewTouch screen, control inputs from sensors, or control inputs from a Generic BAS.

• Boxes indicate control actions such as turning on relays,

or pulsing compressor load or unload

solenoids.

• Smaller cylinders under the main cylinder indicate diagnostic

RTAF-SVX001A-EN 51

checks.

• Text outside a box or cylinder indicates time based functions.

• Solid double arrows indicate fixed timers.

Dashed double arrows indicate variable timers.

Page 52

Start-Up and Shutdown

Power Up Diagram

Figure 43, p. 52 shows the respectiveTD-7 AdaptiView

screens during a power up of the UC800 and display.This process takes 25 secondsfor the UC800 and 90 seconds for the display. On all power ups, the software model always will transition through the 'Stopped' Software state

Figure 43. Sequence of operation: power up diagram

independent of the last mode. If the last mode before power down was 'Auto', the transition from 'Stopped' to 'Starting' occurs, but it is not apparent to the user.

52 RTAF-SVX001A-EN

Page 53

Power Up to Starting

Start-Up and Shutdown

Figure 44, p. 53 diagram shows the timing from a power

up event to energizing the first compressor.The shortest allowable time would be under the following conditions:

• No motor restart inhibit time left from subsequent starts

• Evaporator Water flow occurs quickly with pump on command

• Power up Start Delay set to 0 minutes

Figure 44. Sequence of events: power up to starting

• Need to cool (differential to start) already exists

• Oil level is detected immediately

The above conditions would allow for a minimum power

up to starting the first compressor time of about 45 seconds (variations may exist due to options installed). Note that it is not advisable to start a chiller “cold”, the oil heaters should be in operation for a sufficient length of time prior to first start. Consult the chiller’s IOM for specifics.

RTAF-SVX001A-EN 53

Page 54

Start-Up and Shutdown

Stopped to Starting

Figure 45 shows the timing from a stopped mode to

energizing the first compressor.The shortest allowable time would be under the following conditions:

• No motor restart inhibit time left from subsequent starts

Figure 45. Sequence of events: stopped to starting

• Evaporator Water flow occurs quickly with pump on command

• Need to cool (differential to start) already exists

The above conditions would allow acompressor to start in

about 20 seconds.

54 RTAF-SVX001A-EN

Page 55

Running (Lead Compressor/Circuit Start and Run)

Figure 46 shows a typical start and run sequence for the

lead compressor and its circuit.

Figure 46. Sequence of operation: running (lead compressor/circuit start nd run)

Start-Up and Shutdown

RTAF-SVX001A-EN 55

Page 56

Start-Up and Shutdown

Running (Lag Compressor/Circuit Start and Run)

Figure 47 shows a typical start and run sequence for the

lag compressor and its circuit.

Figure 47. Sequence of operation: running (lag compressor/circuit start nd run)

56 RTAF-SVX001A-EN

Page 57

Satisfied Setpoint

Figure 48 shows the normal transition from Running to

shutting down due to the Evap Leaving water temp falling below the differential to stop setpoint.

Figure 48. Sequence of events: satisfied setpoint

Start-Up and Shutdown

RTAF-SVX001A-EN 57

Page 58

Start-Up and Shutdown

Normal Shutdown to Stopped or Run Inhibit

Figure 49 shows theTransition from Running through a

Normal (friendly) Shutdown.The Dashed lines on the top

Figure 49. Sequence of events: normal shutdown to stopped or run inhibit

attempt to show the final mode if you enter the stop via various inputs.

58 RTAF-SVX001A-EN

Page 59

Immediate Shutdown to Stopped or Run Inhibit

Start-Up and Shutdown

Figure 50 shows the transition from Running through an

Immediate Shutdown.The dashed lineson the top attempt

Figure 50. Sequence of events: immediate shutdown to stopped or run inhibit

to show the final mode if you enter the stop via various inputs.

RTAF-SVX001A-EN 59

Page 60

Start-Up and Shutdown

Ice Making (Running to Ice Making to Running)

Figure 51 shows the transition from normal cooling to Ice

making, back to normal cooling.

Figure 51. Sequence of events: ice making (running to ice making to running)

60 RTAF-SVX001A-EN

Page 61

Ice Making (Auto to Ice Making to Ice Making Complete)

Figure 52 shows the transition fromAuto to Ice making, to

Ice Making Complete.

Figure 52. Sequence of events: ice making (auto to ice making to ice making complete)

Start-Up and Shutdown

RTAF-SVX001A-EN 61

Page 62

Maintenance

WARNING

Hazardous Voltage w/Capacitors!

For additional information regarding the safe discharge of capacitors, see PROD-SVB06A-EN

This section describes the basic chiller preventive

maintenance procedures, and recommends the intervals at which these procedures should be performed. Use of a periodic maintenance program is important to ensure the best possible performance and efficiency from a Sintesis™ chiller.

Use Operator Log (see “Log and Check Sheets,” p. 86)to record an operating history for unit.The log serves as a valuable diagnostic tool for service personnel. By observing trends in operating conditions, an operator can anticipate and prevent problem situations.

If unit does not operate properly during inspections, see

“Diagnostics,” p. 66.

Recommended Maintenance

NOTICE:

Equipment Damage!

Do not use detergents to clean coils. Use clean water only. Use of detergents on coils could cause damage to coils.

Monthly

• Perform all weekly maintenance procedures.

• Record the system subcooling.

• Record the system superheat.

• Make any repairs necessary.

Annual

• Perform all weekly and monthly procedures

• Check the oil level while the unit is off. See “Oil Sump

Level Check,” p. 63.

• Routine changing of the oil is notrequired. Make an

oil analysis to determine the condition of the oil.

• HaveTrane or another qualified laboratory perform a compressor oil analysis to determine system moisture content and acid level.

• Contact a qualified service organizationto leak-test the chiller, to check operating and safety controls, and to inspect electrical components for deficiencies

• Clean and repaint any areas that show signs of corrosion.

• Clean the condenser coils. See “Microchannel

Condenser Coils,” p. 65.

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

Weekly

• At AdaptiView™TD7 orTracer™TU service tool, check pressure for evaporator, condenser and intermediate oil.

• Observe liquid line sight glass on EXV. If liquid line sight glass has bubbles measure the subcooling entering the EXV. Subcooling should always be greater than 10°F.

Important: A clear sight glass alone does not mean that

the system is properly charged. Also check the rest of the system operating conditions.

• Inspect the entire system for unusual operation.

• Inspect the condenser coils for dirt and debris. If the coils are dirty, see

p. 65.

62 RTAF-SVX001A-EN

“Microchannel Condenser Coils,”

NOTICE:

Equipment Damage!

Do not use detergents to clean coils. Use clean water only. Use of detergents on coils could cause damage to coils.

• Clean the air filters in the bottom inlet hoods that extend from the back of the electrical panel.

• Check and tighten all electrical connections as necessary.

Page 63

Maintenance

Refrigerant and Oil Charge Management

Proper oil and refrigerant charge is essential for proper unit operation, unit performances, and environmental protection. Only trained and licensed service personnel should service the chiller.

Table 24 lists baseline measurements for Sintesis™ units

running at AHRI standard operating conditions. If chiller measurements vary significantly from values listed below, problems may exist with refrigerant and oil charge levels. Contact your localTrane office.

Note: Low temperature applications units will have

values that vary from Table 24. Contact your local

Trane office for more information.

Table 24. Typical Sintesis baselines (AHRI conditions)

Measurement Baseline

Evaporator Pressure 50.5 psia

Evaporator Approach 3°F

EXV Position 45% open

Evaporator Fluid delta T - entering 54°F

Evaporator Fluid delta T - leaving 44°F

Discharge Superheat 25°F

Condenser Pressure 195 psia

Subcooling 18°F

Lubrication System

Oil Sump Level Check

Figure 53. Oil sump level check

Oil Level

1 Oil Separator 3 Refrigeration hose

2 Valves 4 Sight Glass

The oil level in the sump can be measured to give an

indication of the system oil charge. Follow the procedures below to measure the level.

1. Run the unit as near to full load as possible for a minimum of 30 minutes. For an accurate reading, 40or more minutes at full load with normal/steady discharge superheat readings and no limits/warnings is recommended. Assessing oil charge after running at minimum or low loads may lead to an inaccurate reading.

2. Cycle the compressor offline.

3. Let the chiller sit (powered, but offline) to allow the oil separator

heater to boil off the refrigerant that may be in the oil separator. An initial assessment of the oil separator level maybe made after 30 minutes of heater ON dwell time, but oil charge adjustments should not be made without allowing the oil heaters to run for a minimum of 4 hours.

RTAF-SVX001A-EN 63

Page 64

Maintenance

Important: Do not operate the unit with the sight glass

service valves opened. Close the valves while running before and after checking the oil level. Oil system function may be affected and level reading will not be accurate during operation if valves are opened during operation.

4. Attach a 3/8” or 1/2” hose with a sightglass in the middle to the oil sump servicevalve (3/8” flare) and the oil separator service valve (3/8” flare). See

p. 63 for valve locations.

Note: Using high pressure rated clear hose with

appropriate fittings can help speed up the process. Hose must be rated to withstand system pressures as found on unit nameplate.

5. After the unit is off line for 30 minutes, move the sightglass along the side of the oil sump.

6. The nominal oil level from the bottom of the oil separator should be approximately 4 inches. Depending on running conditions and oil heater dwell time, some deviation from nominal levels is expected.

Important: If level is less than 1 inch from the bottom of

the oil separator, contact your local Trane office.

Figure 53,

Microchannel Condenser Coils

For proper operation, microchannel condenser coils must be cleaned regularly. Eliminate pollution and other residual material help to extend thelife of thecoils and the unit.

Regular coil maintenance, including annual cleaning, enhances the unit’s operating efficiency by minimizing compressor head pressure and amperage draw.The condenser coil should be cleaned at minimum once each year, or more if the unit is located in a “dirty” or corrosive environment.

Coil Cleaning

NOTICE:

Equipment Damage!

Do not use detergents to clean coils. Use clean water only. Use of detergents on coils could cause damage to coils.

Cleaning with cleansers or detergents is strongly discouraged due to the all-aluminum construction.Water should prove sufficient. Any breach in the tubes can result in refrigerant leaks.

WARNING

Hazardous Voltage w/Capacitors!

For additional information regarding the safe discharge of capacitors, see PROD-SVB06A-EN

1. Disconnect Power to the unit.

WARNING

No Step Surface!

Failure to follow instruction below could result in death or serious injury. Do not walk on the sheet metal drain pan. Walking on the drain pan could cause the supporting metal to collapse, resulting in the operator/ technician to fall.

64 RTAF-SVX001A-EN

Important: Bridging between the main supports

required before attempting to enter the unit. Bridging may consist of multiple 2 by 12 boards or sheet metal grating.

Page 65

2. Use a soft brush or vacuum to remove base debris or surface loaded fibers from both sides of the coil.

Note: When

3. Using a sprayer and water ONLY, clean the coil following

a. Sprayer nozzle pressure should not exceed 580 psi.

b. The maximum source angle should not exceed 25°

c. Spray nozzle should be approximately 1”-3” from

d. Use at least a 15º fan type of spray nozzle.

Figure 54. Sprayer source angle

possible, clean the coil from the opposite direction of normal air flow (inside of unit out) to push debris out.

the guidelines below.

to the face of the coil. See Figure 54. For best results spray the microchannel perpendicular toface of the coil.

the coil surface.

Maintenance

Note: To avoid damage from the spray wand contacting

the coil, make sure the 90º attachment does not come in contact with the tube and fin as abrasion to the coil could result.

RTAF-SVX001A-EN 65

Page 66

Diagnostics

Diagnostic Name (Text) and Source:

Black text is the full-context diagnostic name with few or

no abbreviations. It has no intrinsic length limit. It may be used as a guide for translation, or in ahuman interface that can handle the unlimited length text. It is not currently used in any human interface.

Where diagnostic text is different from full-context

diagnostic name:

• Italicized text is intended for use on the ServiceTool or on the operator Display.

• Underlined text is intended for use on LCI-C.

Diagnostic Name Source: Diagnostics may beshown in

the spec with asource of“xy”. In this case, letter “x” can be either “1” or “2” (signifying which circuit) and letter “y” can be “A” or “B” (signifying which compressor on that circuit).

AffectsTarget: Defines the “target” or what is affected

by the diagnostic. Usually either the entire Chiller, or a particular Circuit or Compressor is affected by the diagnostic (the same one as the source), but in special cases functions aremodified or disabled by the diagnostic. None implies that there is no direct affect to the chiller, sub components or functional operation.

Design Note: TU does not support the display of certain targets on its Diagnostics pages althoughthe functionality implied by this table is supported.Targets such as Evap Pump, Ice Mode, Heat Mode, Chilled Water Reset, External Setpoints etc. – are displayed as simply “Chiller” even though they do not imply a chiller shutdown – only a compromise of the specific feature.

Severity: Defines the severity of the above effect. Immediate means immediate shutdown of the affected portion; for AFD generated diagnostics, Immediate implies immediately de-energized compressor windings, while Immediate (decel)implies controlled deceleration to compressor stop. Normal means normal or friendly shutdown of the affected portion, Special Action means a special action or mode of operation (limp along) is invoked, but without shutdown, and Info means an Informational Note or Warning is generated. Design Note:

TU does not support display of “Special Action”,onits

Diagnostics pages, so that if a diagnostic has a special action defined in the table below, it will be displayed only as “Informational Warning” as long as no circuit or chiller shutdown results. If there is ashutdown and special action defined in the table, then theTU Diagnostics Page display will indicate the shutdown type only.

Persistence: Defines whether or not the diagnostic and its effects are to be manually reset (Latched), or can be either manually or automatically reset when and if the condition returns to normal (Nonlatched).

Active Modes [Inactive Modes]: States the modes or

periods of operation thatthe diagnostic is active in and, as necessary, those modes or periods that it is specifically

“not active” in as an exception to the active modes.The

inactive modes are enclosed in brackets, [ ]. Note that the modes used in this column are internal and not generally annunciated to any of the formal mode displays.

Criteria: Quantitatively defines the criteria used in generating the diagnostic and, if nonlatching, the criteria for auto reset. If more explanation is necessary a hot link to the Functional Specification is used.

Reset Level: Defines the lowest level of manual diagnostic reset command which can clear the diagnostic.

The manual diagnostic reset levels in order of priority are:

Local or Remote. For example, adiagnostic that has a reset level of Remote, can be reset byeither a remote diagnostic reset command or by a local diagnostic reset command.

HelpText: Provides for a brief description of what kind of problems might cause this diagnostic to occur. Both control system component related problems as well as chiller application related problems are addressed (as can possibly be anticipated).These help messages will be updated with accumulated field experience with the chillers.

66 RTAF-SVX001A-EN

Page 67

AFD Diagnostics

Table 25. AFD diagnostics

Diagnostics

Diagnostic Name and Source

AFD Fault - xA Cprsr Immediate NonLatch All

AFD Motor Current Overload - xA

AFD Interrupt Failure - xA

Affects Target Severity Persistence

Circuit Immediate Latch All

Chiller

Immediate Shutdown and Special Action

Latch

Active Modes [Inactive Modes] Criteria

AFD Intended to be OFF

AFD Fault. Numerous drive faults can cause this general fault including High Pressure Cutout for AFD compressors.

Compressor current exceeded overload time vs. trip characteristic. Must trip = 132% RLA, Must hold=125%

Respective AFD is reporting that it is still running the compressor when the MP has commanded the drive/ compressor to be Off. Detection time shall be 10 seconds minimum and 15 seconds maximum. On detection and until the controller is manually reset: this diagnostic shall be active and the alarm relay shall be energized, the Evap Pump Output will be energized, the effected compressor will be continually commanded off, and be unloaded, while a normal stop shall be commanded to all other compressors. For as long as compressor operation continues, the MP shall continue oil return and fan control on the circuit affected.

Reset Level

Local

RTAF-SVX001A-EN 67

Page 68

Diagnostics

Starter Diagnostics

Table 26. Starter diagnostics

Diagnostic Name and Source

Compressor Did Not Accelerate: Shutdown xy

Compressor Did Not Accelerate: Transition xy

Motor Current Overload xy

Over Voltage Chiller Normal NonLatch

Phase Loss xy

Phase Reversal - xy

Power Loss xy

Severe Current Imbalance xy

Starter Comm Loss: Main Processor xy

Starter Contactor Interrupt Failure – xy

Affects Target Severity Persistence

Cprsr Immediate Latch

Cprsr Info Latch Start Mode

Circuit Immediate Latch Cprsr Energized

Cprsr Immediate Latch

Cprsr Immediate NonLatch

Circuit Immediate Latch

Cprsr Immediate Latch All

Chiller

Info and Special Action

Latch

Active Modes [Inactive Modes] Criteria

Acceleration Time Out Action set to Shutdown: Compressor motor

Cprsr Accelerating

Pre-Start and Any Ckt(s) Energzd

Start Sequence and Run modes

Compressor energized to transition command [All Other Times]

All compressor running modes [all compressor starting and non-running modes]

All Running Modes

Starter Contactor not Energized [Starter Contactor Energized]

current did not drop below 85% RLA within the Maximum Acceleration Setting setpoint. Compressor motor de-energized. See Current Overload Protection specification.

The compressor did not come up to speed (fall to <85%RLA) in the allotted time defined by the Maximum Acceleration Timer and a transition was forced (motor put across the line) at that time. This applies to all starter types.

Compressor current exceeded overload time vs. trip characteristic. Must trip = 140% RLA, Must hold=125%, nominal trip 132.5% in 30 seconds

Nom. trip: 60 seconds at greater than 112.5%,  2.5%, Auto Reset at 110% or less for 10 cont secs.

a) No current was sensed on one or two of the current transformer inputs while running or starting (See Nonlatching Power Loss Diagnostic for all three phases lost while running). Must hold = 20% RLA. Must trip = 5% RLA. Time to trip shall be longer than guaranteed reset on Starter Module at a minimum, 3 seconds maximum. Actual design trip point is 10%. The actual design trip time is 2.64 seconds. b) If Phase reversal protection is enabled and current is not sensed on one or more current xformer inputs. Logic will detect and trip in a maximum of 0.3 seconds from compressor start.

A phase reversal was detected on the incoming current. On a compressor startup, the phase reversal logic must detect and trip in a maximum of 0.3 second from compressor start.

The compressor had previously established currents while running and then all three phases of current were lost. Design: Less than 10% RLA, trip in 2.64 seconds. This diagnostic will preclude the Phase Loss Diagnostic and the Transition Complete Input Opened Diagnostic from being called out. To prevent this diagnostic from occurring with the intended disconnect of main power, the minimum time to trip must be greater than the guaranteed reset time of the Starter module. Note: This diagnostic prevents nuisance latching diagnostics due to a momentary power loss – It does not protect motor/compressor from uncontrolled power reapplication. See Momentary Power Loss Diagnostic for this protection. This diagnostic is not active during the start mode before the transition complete input is proven. Thus a random power loss during a start would result in either a “Starter Fault Type 3” or a “Starter Did Not Transition” latching diagnostic.

A 30% Current Imbalance has been detected on one phase relative to the average of all 3 phases for 90 continuous seconds.

The Starter module detected a continual loss of communication with the main processor for greater than the Communications Loss Time bound setpoint.

Detected compressor currents greater than 10% RLA on any or all phases when the compressor was commanded off. Detection time shall be 5 second minimum and 10 seconds maximum. On detection and until the controller is manually reset: generate diagnostic, energize the appropriate alarm relay, continue to energize the Evap Pump Output, continue to command the affected compressor off, fully unload the effected compressor and command a normal stop to all other compressors. For as long as current continues, perform liquid level, oil return, and fan control on the circuit effected.

Reset Level

Local

Remote

Local

Remote

Local

Remote

Local

68 RTAF-SVX001A-EN

Page 69

Table 26. Starter diagnostics (continued)

Diagnostics

Diagnostic Name and Source

Starter Did Not Transition xy

Starter Dry Run Test - xy

Starter Failed to Arm/Start xy

Starter Fault Type I - xy

Starter Fault Type II - xy

Starter Fault Type III - xy

Starter Module Memory Error Type 1

- xy (Starter Mem Err Type 1 - xy)

Starter Module Memory Error Type 2

- xy (Starter Mem Err Type 2 - xy)

Transition Complete Input Opened - xy (Trnsn Compl Input Open xy)

Transition Complete Input Shorted - xy (Trnsn Compl Input Short xy)

Under Voltage

Affects Target Severity Persistence

Cprsr Immediate Latch

Circuit Immediate Latch

Cprsr Immediate Latch All Starter failed to arm or start within the allotted time (15 seconds). Local

Cprsr Immediate Latch

Cprsr Info Latch All

Cprsr Immediate Latch All

Cprsr Immediate Latch

Cprsr Immediate Latch Pre-Start

Chiller Normal NonLatch

[Inactive Modes] Criteria

The Starter Module did not receive a transition complete signal in the

On the first check after transition.

Starter Dry Run Mode

Starting - Y Delta Starters Only

Starting - All types of starters

Starting [Adaptive Frequency Starter Type]

All running modes

Pre-Start and Any Ckt(s) Energzd

designated time from its command to transition. The Must Hold time from the Starter Module transition command is 1 second. The Must Trip time from the transition command is 6 seconds. Actual design is 2.5 seconds. This diagnostic is active only for Y-Delta, Auto-Transformer, Primary Reactor, and X-Line Starters.

While in the Starter Dry Run Mode either 50% Line Voltage was sensed at the Potential Transformers or 10% RLA Current was sensed at the Current Transformers.

This is a specific starter test where 1M(1K1) is closed first and a check is made to ensure that there are no currents detected by the CT's. If currents are detected when only 1M is closed first at start, then one of the other contactors is shorted.

a. This is a specific starter test where the Shorting Contactor (1K3) is individually energized and a check is made to ensure that there are no currents detected by the CT's. If current is detected when only S is energized at Start, then 1M is shorted. b. This test in a. above applies to all forms of starters (Note: It is understood that many starters do not connect to the Shorting Contactor.).

As part of the normal start sequence to apply power to the compressor, the Shorting Contactor (1K3) and then the Main Contactor (1K1) were energized. 1.6 seconds later there were no currents detected by the CT's for the last 1.2 Seconds on all three phases. The test above applies to all forms of starters except Adaptive Frequency Drives.

Checksum on RAM copy of the Starter LLID configuration failed. Configuration recalled from EEPROM.

Checksum on EEPROM copy of the Starter LLID configuration failed. Default configuration loaded into RAM and EEPROM.

The Transition Complete input was found to be opened with the compressor motor running after a successful completion of transition. This is active only for Y-Delta, Auto-Transformer, Primary Reactor, and X-Line Starters. To prevent this diagnostic from occurring as the result of a power loss to the contactors, the minimum time to trip must be greater than the trip time for the power loss diagnostic.

The Transition Complete input was found to be shorted before the compressor was started. This is active for all electromechanical starters.

Nom. trip: 60 seconds at less than 87.5%,  2.8% at 200V  1.8% at 575V, Auto Reset at 90% or greater for 10 cont secs.

Reset Level

Local

Remote

Active Modes

RTAF-SVX001A-EN 69

Page 70

Diagnostics

Main Processor Diagnostics

Table 27. Main processor diagnostics

Diagnostic Name

AFD%RLA Feedback - xA

BAS Communication Lost

BAS Failed to Establish Communication BAS Failed to Establish Comm

Chiller Service Recommended

Compressor Discharge Refrigerant Temperature Sensor - xy

Cprsr Disch Rfgt Temp Sensor xy

Disch Rfgt Temp Sensor - xy

Condenser Refrigerant Pressure Sensor

Condenser Rfgt Pressure Sensor

Cond Rfgt Pressure Sensor

Emergency Stop Feedback Input Emergency Stop

Evap Water Pump 1 Svc Recommended Evap Water Pump 1 Svc Recom

Evap Water Pump 2 Svc Recommended Evap Water Pump 2 Svc Recom

Evaporator Approach Error

Affects Target Severity Persistence

Cprsr Normal Latch All Out-Of-Range Low or Hi or bad LLID Remote

Chiller

Chiller Warning Latch

Cprsr Immediate Latch All Bad Sensor or LLID Remote

Circuit Immediate Latch All Bad Sensor or LLID Remote

Chiller Immediate Latch All

Chiller Info Latch

Circuit Immediate Latch

Info and Special Action

NonLatch All

NonLatch At power-up

Active Modes [Inactive Modes] Criteria

The BAS was setup as “installed” at the MP and the Lontalk LCIC lost communications with the BAS for 15 contiguous minutes after it had been established. Refer to Section on Setpoint Arbitration to determine how setpoints and operating modes may be affected by the comm loss. The chiller follows the value of the Tracer Default Run Command which can be previously written by Tracer and stored nonvolatilely by the MP (either use local or shutdown). Note that this diagnostic is never operational for BacNet Communication interface (BCIC) and only operational with a LonTalk Communication interface (LCIC) if so configured by the BAS or Tracer system.

The BAS was setup as “installed” and the BAS did not communicate with the Lontalk LCIC within 15 minutes after chiller controls power-up. Refer to Section on Setpoint Arbitration to determine how setpoints and operating modes may be affected. Note that this diagnostic is never operational for BacNet Communication interface (BCIC) and only operational with a LonTalk Communication interface (LCIC) if so configured by the BAS or Tracer system.

Service Messages Enabled

Respective circuit running

Chiller service interval time has elapsed. Chiller service is recommended.

EMERGENCY STOP FEEBBACK INPUT is open. An external interlock has tripped. Time to trip from input opening to unit stop shall be 0.1 to 1.0 seconds.

Pump service recommended as service interval hours have elapsed. Remote

The Evaporator approach temperature for the respective circuit (ELWT – Evap Sat Temp Ckt x) is negative by more than 10°F for 1 minute continuously while the circuit / compressor is operating. Either the Evap Leaving Water Temp sensor or Evap Suction Rfgt Pressure Sensor Ckt x is in error.

Reset Level

Remote

Local

Remote

70 RTAF-SVX001A-EN

Page 71

Table 27. Main processor diagnostics (continued)

Active

Diagnostic Name

Evaporator Entering Water Pressure Evap Entering Water Pressure

Evaporator Entering Water Temperature Sensor

Evaporator Entering Water Temp Sensor

Evap Ent Water Temp Sensor

Evaporator Isolation Valve Closed Switch Failure

Evap Isolation Valve Closed Switch Failure

Evap Iso Vlv Closed Sw Fail

Evaporator Isolation Valve Failed To Close

Evap Isolation Valve Failed To Close

Evap Iso Vlv Failed To Close

Evaporator Isolation Valve Failed To Open

Evap Isolation Valve Failed To Open

Evap Iso Vlv Failed To Open

Evaporator Isolation Valve Illegal Switch State

Evap Isolation Valve Illegal Switch State

Evap Iso Vlv Illegal Sw Stat

Evaporator Isolation Valve Open Switch Failure

Evap Isolation Valve Open Switch Failure

Evap Iso Vlv Open Sw Fail

Evaporator Leaving Water Pressure Evap Leaving Water Pressure

Affects Target Severity Persistence

Chiller Info Latch All Bad Sensor or LLID Remote

Chiller Normal Latch All

Circuit Immediate Latch All

Chiller Info Latch All Bad Sensor or LLID Remote

Modes [Inactive Modes] Criteria

Diagnostics

Bad Sensor or LLID. Note: Entering Water Temp Sensor is used in EXV pressure control as well as ice making so it must cause a unit shutdown even if ice or CHW reset is not installed.

Evaporator isolation valve open limit switch state does not match expected value. See Evaporator Isolation Valve spec for details.

Evaporator isolation valve was commanded to close, but limit switches did not make expected changes within allotted time. See Evaporator Isolation Valve spec for details.

Evaporator isolation valve was commanded to open, but limit switches did not make expected changes within allotted time. See Evaporator Isolation Valve spec for details.

Both evaporator isolation valve limit switches were closed at the same time, which should not be possible. Check for limit switch failure or improperly adjusted switch points.

Evaporator isolation valve closed limit switch state does not match expected value. See Evaporator Isolation Valve spec for details.

Reset Level

Remote

Local

RTAF-SVX001A-EN 71

Page 72

Diagnostics

Table 27. Main processor diagnostics (continued)

Active

Diagnostic Name

Evaporator Leaving Water Temperature Sensor

Evaporator Leaving Water Temp Sensor

Evap Leav Water Temp Sensor

Evaporator Pump 1 Fault

Evaporator Pump 2 Fault

Evaporator Refrigerant Pool Temperature Sensor

Evap Rfgt Pool Temp Sensor

Evaporator Refrigerant Pool Temperature Sensor Error Cktx

Evap Rfgt Pool Temp Sensor Error - Cktx

Evap Pool Temp Error Cktx

Evaporator Shell Refrigerant Pressure Sensor

Evaporator Shell Rfgt Pressure Sensor

Evap Shell Rfgt Press Sensor

Evaporator Water Flow (Entering Water Temp)

Evap Water Flow (Entering Water Temp)

Evap Flow (Ent Water Temp)

Affects Target Severity Persistence

Chiller Normal Latch All Bad Sensor or LLID Remote

Immediate

Chiller

Circuit

Circuit Normal Latch All

Chiller Info Latch

or Warning and Special Action

Immediate or Warning and Special Action

Info and Special Action

NonLatch All

Latch All

Latch

Modes [Inactive Modes] Criteria

Ckt Energized [Ckt Not Energized]

Any Ckt Energized [No Ckts Energized]

For systems with no evaporator pump, a single evaporator pump, or a single inverter driving dual evaporator pumps, an immediate shutdown shall be performed. For multiple pump systems, detection of a pump fault will generally cause pump control to switch to the redundant pump. For single inverter, dual pump configuration, switching to the redundant pump can only happen after the fault is cleared. Specific details of special action are described in Evaporator_Water_Pump_Control.doc

Bad Sensor or LLID. Note: The Evap Pool Temp Sensors are used for evaporator freeze protection (running and non-running). Invalidate evaporator pool temperature sensor measurement if this diagnostic is active. If evaporator isolation valves are installed, revert to Evaporator Shell Refrigerant Saturated Temperature for freeze protection functions. If evaporator isolation valves are not installed, revert to Evaporator Saturated Temperature for freeze protection functions.

The evaporator refrigerant pool temperature measurement is larger than the evaporator entering water temperature by more than 4°C (7.2°F) for 5 continuous minutes. There is an ignore time of 2 minutes following circuit startup. The trip criteria is not evaluated (and time above the threshold is not counted) until the ignore time passes. Invalidate evaporator pool temperature sensor measurement if this diagnostic is active. If evaporator isolation valves are installed, revert to Evaporator Shell Refrigerant Saturated Temperature for freeze protection functions. If evaporator isolation valves are not installed, revert to Evaporator Saturated Temperature for freeze protection functions.

Bad Sensor or LLID. Note: The evaporator shell refrigerant pressure sensor is used to avoid high shell pressures, to equalize evaporator and condenser pressure prior to circuit start, and as a backup sensor to the pool temperature sensor.

The entering evaporator water temp fell below the leaving evaporator water temp by more than 2°F for 180 °F-sec, minimum trip time 30 seconds. It can warn of improper flow direction through the evaporator, misbound water temperature sensors, improper sensor installation, partially failed sensors, or other system problems. Note that either entering or leaving water temp sensor or the water system could be at fault.

Reset Level

Remote

Local

Remote

72 RTAF-SVX001A-EN

Page 73

Table 27. Main processor diagnostics (continued)

Active

Diagnostic Name

Evaporator Water Flow Lost Evap Water Flow Lost

Evaporator Water Flow Lost – Pump 1 Evap Water Flow Lost Pump 1

Evaporator Water Flow Lost – Pump 2 Evap Water Flow Lost Pump 2

Evaporator Water Flow Overdue Evap Water Flow Overdue

Evaporator Water Flow Overdue – Pump 1 Evap Wtr Flow Overdue Pump 1

Evaporator Water Flow Overdue – Pump 2 Evap Wtr Flow Overdue Pump 2

Excessive Condenser Pressure

External Chilled Water Setpoint Ext Chilled Wtr Setpt

External Demand Limit Setpoint Ext Demand Limit Setpoint

EXV Pressure Equalization Failed EXV Press Equalization Fail

Heat Recovery Entering Water Temperature Sensor

Heat Recovery Entering Water Temp Sensor

Heat Rcvry Ent Water Temp

Affects Target Severity Persistence

Chiller Immediate NonLatch

Chiller

Chiller Normal NonLatch

Chiller

Circuit Immediate Latch All

Chiller Info Latch All

Circuit Immediate Latch All

Chiller Info Latch All Bad Sensor or LLID Remote

Warning and Special Action

NonLatch All

Modes [Inactive Modes] Criteria

[All Stop modes]

Estab. Evap. Water Flow on going from STOP to AUTO or Evap Pump Override.

Diagnostics

A. The Evaporator water flow switch input was open for more than 6 contiguous seconds (or 15 seconds for thermal dispersion type flow switch). B. This diagnostic does not de-energize the evap pump output. C. 6 seconds of contiguous flow shall clear this diagnostic. (further review needed when implementing thermal dispersion for Pueblo)

For dual evaporator pump configurations only. Evaporator Water Flow Lost diagnostic occurred while Pump 1 was the selected pump. Specific details of special action are described in Evaporator_Water_Pump_Control.doc

For dual evaporator pump configurations only. Evaporator Water Flow Lost diagnostic occurred while Pump 2 was the selected pump. Specific details of special action are described in Evaporator_Water_Pump_Control.doc

Evaporator water flow was not proven within 20 minutes of the Evaporator water pump relay being energized in normal “Stop” to “Auto” transition. If the pump is overridden to “On” for certain diagnostics, the delay on diagnostic callout shall be only 255 seconds. The pump command status will not be effected by this diagnostic in either case.

After the pump request was activated, the evaporator water flow overdue wait time elapsed before water flow was established. Special action is to keep the evap pump request active in a diagnostic override mode. See Evaporator_Water_Pump_Control.doc

The condenser pressure sensor of this circuit has detected a condensing pressure in excess of the design high side pressure as limited by the particular compressor type.

a. Function Not “Enabled”: no diagnostics. b. “Enabled “: Out-Of-Range Low or Hi or bad LLID, set diagnostic, default CWS to next level of priority (e.g. Front Panel SetPoint).

a. Not “Enabled”: no diagnostics. b. “Enabled “: Out-Of-Range Low or Hi or bad LLID, set diagnostic, default CLS to next level of priority (e.g. Front Panel SetPoint.)

EXV Pressure Equalization process failed to meet the equalization criteria within the allotted time.

Reset Level

Remote

RTAF-SVX001A-EN 73

Page 74

Diagnostics

Table 27. Main processor diagnostics (continued)

Active

Diagnostic Name

Heat Recovery Leaving Water Temperature Sensor

Heat Recovery Leaving Water Temp Sensor

Heat Rcvry Leav Water Temp

High Compressor Refrigerant Discharge Temp

- xy

High Cprsr Rfgt Discharge Temp

- xy

High Cprsr Disch Temp xy

High Differential Refrigerant Pressure - xy

High Differential Rfgt Pressure xy

High Diff Rfgt Pressure - xy

High Evaporator Refrigerant Pressure High Evap Rfgt Pressure

High Evaporator Shell Refrigerant Pressure – Circuit 1

High Evap Shell Rfgt Pressure Ckt1

High Evap Shell Press Ckt1

High Evaporator Shell Refrigerant Pressure – Circuit 2

High Evap Shell Rfgt Pressure Ckt2

High Evap Shell Press Ckt2

Affects Target Severity Persistence

Chiller Info Latch All Bad Sensor or LLID Remote

Cprsr Immediate Latch

Cprsr Normal Latch

Chiller Immediate NonLatch All

Chiller Immediate NonLatch All See Circuit 1 description. Remote

Modes [Inactive Modes] Criteria

All [compressor run unload or compressor not running]

Cprsr Energized

The compressor discharge temperature exceeded 199.4F (without oil cooler) or 230ºF (with oil cooler). This diagnostic will be suppressed during Stopping mode or after the compressor has stopped. Note: As part of the Compressor High Temperature Limit Mode (aka Minimum Capacity Limit), the compressor shall be forced loaded as the filtered discharge temperature reaches 190ºF (without oil coolers), or 220ºF (with oil coolers).

GP2 Cprsr: The differential pressure for the respective circuit was above 275 Psid (1890 kPa) for 2 consecutive samples 5 seconds apart.

The evaporator refrigerant pressure of either circuit has risen above 190 psig. The evaporator water pump relay will be de-energized to stop the pump regardless of why the pump is running. The diagnostic will auto reset and the pump will return to normal control when all of the evaporator pressures fall below 185 psig. The primary purpose is to stop the evaporator water pump and its associated pump heat from causing refrigerant side pressures, close to the evaporator relief valve setting, when the chiller is not running, such as could occur with Evap Water Flow Overdue or Evaporator Water Flow Loss Diagnostics.

The evaporator shell refrigerant pressure is installed, is valid, and has risen above 190 psig.

- De-energize evaporator water pump regardless of why the pump is running.

- Open the circuit’s EXV to 20% to allow refrigerant flow to other parts of the chiller, if liquid line refrigerant pressure is less than 170 psig. Return EXV to normal control (allow it to close until needed for circuit operation) if liquid line refrigerant pressure is greater than 175 psig. Automatically clear diagnostic when evaporator shell refrigerant pressure is valid and drops below 180 psig.

- Allow evaporator water pump to return to normal control.

- Return circuit’s EXV to normal control (allow it to close until needed for circuit operation). Primary causes of this diagnostic:

- Evaporator water pump heat transferred to evaporator, either by flow blockage, or by lack of heat dissipation in the water loop in the presence of flow.

- Commissioning unit in high ambient temperature environments.

- Water box heater thermostat failed closed.

Reset Level

Remote

74 RTAF-SVX001A-EN

Page 75

Table 27. Main processor diagnostics (continued)

Active

Diagnostic Name

High Evaporator Water Temperature High Evap Water Temperature

High Motor Winding Temperature – xA High Mtr Windng Temp xA

High Oil Temperature - xyCprsr Immediate Latch

High Pressure Cutout - xy

High Refrigerant Pressure Ratio xy High Rfgt Press Ratio - xy

LCI-C Software Mismatch: Use BAS Tool LCI-C Software Mismatch

Liquid Line Pressure Sensor

Liquid Line Temperature Sensor

Liquid Line Temp Sensor

Loss of Oil for Compressor (Running) Loss of Oil for Cprsr (Run)

Loss of Oil for Compressor (Stopped) Loss of Oil for Cprsr (Stop)

Affects Target Severity Persistence

Chiller

Circuit Immediate Latch All

Cprsr Immediate Latch All

Cprsr Immediate Latch

Chiller Info Nonlatch All

Circuit Normal Latch All

Circuit Normal Latch All Bad Sensor or LLID. Note: This is the subcooled liquid line temp sensor. Remote

Circuit Immediate Latch

Circuit

Info and Special Action

Immediate and Special Action

NonLatch

Latch

Modes [Inactive Modes] Criteria

Only effective if either

1)Evap Wtr Flow Overdue

2)Evap Wtr Flow Loss or

3)Low Evap Rfgt Temp,Unit Off, diagnostic is active.

All [compressor run unload or compressor not running]

Cprsr Energized

Starter Contactor Energized

Compressor Pre-start [all other modes]

Diagnostics

Reset Level

Either the leaving or the entering water temperature exceeded the high evap water temp limit (TU service menu settable –default 105F(65.55C), range 80F(26.67C)-150F(65.55C) for 15 continuous seconds. The evaporator water pump relay will be de-energized to stop the pump but only if it is running due one of the diagnostics listed on the left. The diagnostic will auto reset and the pump will return to normal control when both the entering and leaving temperatures fall 5°F below the trip setting. The primary purpose is to stop the evaporator water pump and its associated pump heat from causing excessive waterside temperatures and waterside pressures when the chiller is not running but the evap pump is on due to either Evap Water Flow Overdue, Evaporator Water Flow Loss, or Low Evap Temp – Unit Off Diagnostics. This diagnostic will not auto clear solely due to the clearing of the enabling diagnostic.

The respective compressor’s motor winding thermostat is detected to be open. The compressor shall stop within 5 seconds of this diagnostic.

The oil temperature entering the compressor exceeded 199.4°F. Remote

A high pressure cutout was detected; trip at 315 ± 5 PSIG. For AFD compressor configurations, the HPC is connected directly to the AFD and the UC800 will get an AFD Fault – xA diagnostic when the HPC is tripped.

The pressure ratio for the respective circuit exceeded 12.3 for 1 contiguous minute while any compressor is running or in service pumpdown. This pressure ratio is a fundamental limitation of the HiVi compressor. The pressure ratio is defined as Pcond (abs)/Pevap(abs).

The neuron software in the LCI-C module does not match the chiller type. Download the proper software into the LCI-C neuron. To do this, use the Rover service tool, or a LonTalk® tool capable of downloading software to a Neuron 3150®.

Bad Sensor or LLID. Note: This is the subcooled liquid line pressure sensor.

In running modes, Oil Loss Level Sensor detects lack of oil in the oil sump feeding the compressor (distinguishing a liquid flow from a vapor flow).

Oil Loss Level Sensor detects a lack of oil in the oil sump feeding the compressor for 90 seconds after EXV preposition is completed (and before EXV equalization, if applicable) on an attempted circuit start. Note: Compressor start is delayed pending oil detection during that time, but not allowed once the diagnostic occurs.

Remote

Local

Remote

Local

RTAF-SVX001A-EN 75

Page 76

Diagnostics

Table 27. Main processor diagnostics (continued)

Active

Diagnostic Name

Low Differential Refrigerant Pressure - xy

Low Differential RfgtPressure xy

Low Diff Rfgt Press - xy

Low Discharge Superheat - xy

Low Evaporator Temp: Circuit 1: Unit Off

Low Evaporator Temp: Ckt 1: Unit Off

Low Evap Temp: Unit Off

Low Evaporator Temp: Circuit 2: Unit Off

Low Evaporator Temp: Ckt 2: Unit Off

Low Evap Temp: Unit Off

Low Evaporator Water Temp (Unit Off) Low Evap Water Temp-Unit Off

Low Evaporator Water Temp (Unit On) Low Evap Water Temp-Unit On

Low Oil Flow - xy Cprsr Immediate Latch

Low Refrigerant Temperature

Affects Target Severity Persistence

Cprsr Immediate Latch

Cprsr Normal Latch

Evap Pump

Evap Pump and Freeze Avoidanc e Request Relay

Chiller

Circuit Immediate Latch

Special Action

Immediate and Special Action

NonLatch

Modes [Inactive Modes] Criteria

Cprsr Energized

Any Running Mode

Unit in Stop Mode, or in Auto Mode and No Ckt's Energzd [Any Ckt Energzd]

Unit in Stop Mode, or in Auto Mode and No Ckt(s) Energzd [Any Ckt Energzd]

Any Ckt[s] Energzd [No Ckt(s) Energzd]

Cprsr Energized and Delta P above 15 Psid

All Ckt Running Modes

The system differential pressure for the respective circuit was below the greater of 25 psid (240.5 kPa) or the pressure ratio listed in the table in GP2 Compressor Type FSpec while the compressor is running for a period of time dependent on the deficit (15 sec ignore time from circuit start) – refer to the Oil Flow Protection specification for the time to trip function.

While Running Normally, the Discharge Superheat was less than the Low Discharge Superheat Setpoint for more than 6500 degree F seconds. At circuit startup, the Discharge Superheat will be ignored for 5 minutes.

The respective circuit’s LERTC Integral was seen to be higher than ½ of its trip value (1,125°F-sec) while the chiller is in the Stop mode, or in Auto mode with no compressors running for at least one minute. The LERTC integral is increased if the Evap Refrigerant Pool Temp is below the value of the Low Evap Rfgt Temp Cutout +4°F. Energize Evap Water Pump and Off-Cycle Freeze Avoidance Request Relay until diagnostic auto resets, then return to normal evap pump control and de-energize the Freeze Avoidance Request. Automatic reset occurs when the respective Evap Rfgt Pool Temp rises 2°F (1.1°C) above the LERTC cutout setting and the Chiller Off LERTC Integral is less than 1/3 of its trip value. This diagnostic even while active, does not prevent operation of either circuit.

Either the entering or leaving evaporator water temp. fell below the leaving water temp cutout setting for 30 degree F seconds while the Chiller is in the Stop mode, or in Auto mode with no compressors running. Energize Freeze Avoidance Request Relay and Evap Water Pump Relay until diagnostic auto resets, then de-energize the Freeze Avoidance Request Relay and return to normal evap pump control. Automatic reset occurs when both temps rise 2°F (1.1°C) above the cutout setting for 5 minutes, or either circuit starts. This diagnostic even while active, does not prevent operation of either circuit.

The evaporator entering or leaving water temperature fell below cutout setpoint for 30 degree F Seconds while the compressor was running. Automatic reset occurs when both of the temperature rises 2°F (1.1°C) above the cutout setting for 2 minutes. This diagnostic shall not deenergize the Evaporator Water Pump Output.

The intermediate oil pressure sensor for this compressor was out of the acceptable pressure range for 15 seconds, while the Delta Pressure was greater than 15 Psid (172.4 kPa).: Acceptable range is 0.50 > (PC-PI) / (PC-PE) for the first 2.5 minutes of operation, and 0.28 > (PC-PI) / (PC-PE) thereafter.

The respective Evaporator Refrigerant Pool Temperature dropped below the Low Refrigerant Temperature Cutout Setpoint for 2250°F-sec (12°F-sec max rate for early circuit startup period) while the circuit was running. The minimum LRTC setpoint is -5°F (18.7 Psia) the point at which oil separates from the refrigerant. The integral is held nonvolatile though power down, is continuously calculated, and can decay or build during the circuit off cycle as conditions warrant.

Reset Level

Remote

Local

Remote

76 RTAF-SVX001A-EN

Page 77

Table 27. Main processor diagnostics (continued)

Active

Diagnostic Name

Low Suction Refrigerant Pressure

Low Suction Rfgt Pressure

Mfr Maintenance Recommended xy Maint Recommended xy

MP: Invalid Configuration

MP: Reset Has Occurred

No Differential Refrigerant Pressure - xy

No Differential Rfgt Pressure xy

No Diff Rfgt Press - xy

Oil Flow Protection Fault xyCprsr Immediate Latch

Oil Pressure Sensor - xy

Oil Temperature Sensor - xy Oil Temp Sensor

- xy

Outdoor Air Temperature Sensor Outdoor Air Temp Sensor

Pumpdown Terminated By Time

Restart Inhibit Invoked - xy Restart Inhibit xy

Software Error 1001: Call Trane Service SW Error 1001Call Trane

Affects Target Severity Persistence

Circuit Immediate Latch

Cprsr Info Latch

None Immediate Latch All MP has an invalid configuration based on the current software installed. Remote

None Info Latch All

Cprsr Immediate Latch

Cprsr Immediate Latch All Bad Sensor or LLID Remote

Cprsr Normal Latch All Bad Sensor or LLID Remote

Chiller Normal Latch All Bad Sensor or LLID. Remote

Circuit Info Latch

Cprsr Info Latch All

All functions

Immediate Latch All

Modes [Inactive Modes] Criteria

Cprsr Prestart and Cprsr Energized

Service Messages Enabled

Compressor running on Circuit

Starter Contactor Energized [all Stop modes]

Service Pumpdown

Diagnostics

a. The Suction Pressure dropped below 10 Psia just prior to compressor start (after EXV preposition). b. During Early Startup Period: the Suction Pressure fell below a pressure equal to Condenser Pressure ÷ 8 but as limited to not less than 6 or greater than10 psia. c. After Early Startup Period expires: The Suction Pressure fell below 16 Psia. (Note: the Early Startup Period is between 1 and 5 min as an inverse function of the Cond Temp measured at time of circuit startup).

Compressor service recommended as service interval hours have elapsed.

The main processor has successfully come out of a reset and built its application. A reset may have been due to a power up, installing new software or configuration. This diagnostic is immediately and automatically cleared and thus can only be seen in the Historic Diagnostic List in Tracer TU.

The system differential pressure was below 7.7 Psid (53 kPa) for 6 seconds after the 11 seconds ignore time relative to cprsr/circuit startup had expired.

The Intermediate Oil Pressure Sensor for this cprsr is reading a pressure either above its respective circuit’s Condenser Pressure by 15 Psia or more, or below its respective Suction Pressure 10 Psia or more for 30 seconds continuously.

Service Pumpdown cycle for this circuit was terminated abnormally due to excessive time (RTAF max Service Pumpdown = 4 min.).

When restart inhibit warning is enabled, the warning exists when unit has been inhibited from starting and is cleared when a start of a compressor is possible (Start-to-Start Timer expires)

A high level software watchdog has detected a condition in which there was a continuous 1 minute period of compressor operation, with neither Evaporator water flow nor a” contactor interrupt failure” diagnostic active. The presence of this software error message suggests an internal software problem has been detected. The events that led up to this failure, if known, should be recorded and transmitted to Trane Controls Engineering.

Reset Level

Local

Remote

Local

Remote

Local

RTAF-SVX001A-EN 77

Page 78

Diagnostics

Table 27. Main processor diagnostics (continued)

Active

Diagnostic Name

Software Error 1002: Call Trane Service SW Error 1002Call Trane

Software Error 1003: Call Trane Service SW Error 1003Call Trane

Starts/Hours Modified Starts/Hours Modified

Suction Refrigerant Pressure Sensor

- xy Suction Pressure Sensor

- xy

Unexpected Starter Shutdown - xy Unexpected Starter Shtdn xy

Very Low Evaporator Rfgt Pressure - xy

Very Low Evap Rfgt Pressure xy

Very Low Evap Rfgt Press xy

Water System Differential Pressure Water System Diff Pressure

Affects Target Severity Persistence

All functions

Cprsr Info NonLatch All

Cprsr Immediate Latch All Bad Sensor or LLID Remote

Cprsr Normal NonLatch

Chiller Immediate Latch All

Chiller Info Latch All Bad Sensor or LLID Remote

Immediate Latch All

Modes [Inactive Modes] Criteria

All Cprsr Running modes, Starting, Running and Preparing to Shutdown

Reported if state chart misalignment in stopped or inactive state occurred while a compressor was seen to be operating and this condition lasted for at least 1 minute (cmprsr operation due to Service Pumpdown or with Contactor Interrupt Failure diagnostic is excluded). The presence of this software error message suggests an internal software problem has been detected. The events that led up to this failure, if known, should be recorded and transmitted to Trane Controls Engineering.

Reported if state chart misalignment occurred inferred from the Capacity Control, Circuit, or Compressor State Machines remaining in the Stopping state for more than 3 minutes. The presence of this software error message suggests an internal software problem has been detected. The events that led up to this failure, if known, should be recorded and transmitted to Trane Controls Engineering.

The current value for the cumulative starts and or hours for the given compressor have been modified by a write override from TU.

The Starter module status reported back that it is stopped when the MP thinks it should be running and no Starter diagnostic exist. This diagnostic will be logged in the active buffer and then automatically cleared. This diagnostic could be caused by intermittent communication problems from the Starter to the MP, or due to misbinding

The respective circuit’s evaporator pressure dropped below 80% of the current Low Evap Refrig Press Cutout setting (see above) or 8 psia, whichever is less, regardless of the running state of the circuit’s compressor. Note: Unlike previous products, even if the circuit associated with the suction pressure sensor is locked out, it will not defeat the protection afforded by this diagnostic.

Reset Level

Local

Remote

Local

78 RTAF-SVX001A-EN

Page 79

Communication Diagnostics

Diagnostics

Notes:

• 1The following communication loss diagnostics will

not occur unless that input or output is required to be present by the particular configuration and installed options for the chiller.

• 2Communication diagnostics (with the exception of

“Excessive Loss of Comm” are named by the Functional Name of the input or output that is no longer being heard from by the Main Processor. Many LLIDs, such as the Quad Relay LLID, have more than

Table 28. Communications diagnostics

Diagnostic Name

Comm Loss: %RLA Indication Output(Vdc) Comm: RLA Output

Comm Loss: Liquid Line Pressure Comm: Liquid Line Pressure

Comm Loss: Oil Temperature - xy Comm: Oil Temp - xy

Comm Loss: AFD Fault Input xA Comm: AFD Fault xA

Comm Loss: AFD Run Command - xA Comm: AFD Run Command - xA

Comm Loss: Auxiliary Setpoint Command Comm: Auxiliary Setpt Cmd

Comm Loss: Chiller Bypass Valve Output Comm: Chiller Bypass Valve

Comm Loss: Compressor Discharge Rfgt Temperature - xy

Comm Loss: Cprsr Disch Rfgt Temp - xy

Comm: Cprsr Disch Temp xy

Comm Loss: Condenser Fan Enable Comm: Cond Fan Enable

Comm Loss: Condenser Fan Enable, Shared Circuit 1&2

Comm Loss: Cond Fan Enbl Shared Ckt1&2

Comm: Cond Fan Enbl Ckt 1&2

Affects Target Severity Persistence

None Info Latch All

Circuit Normal Latch All

Cprsr Normal Latch All

Chiller Info Latch All

Chiller Normal Latch All

Cprsr Normal Latch All

Circuit Normal Latch All

Circuit Info Latch All

one functional output associated with it. A comm loss with such a multiple function board, will generate multiple diagnostics. Refer to the Chiller's wiring diagrams to relate the occurrence of multiple communication diagnostics back to the physical LLID boards that they have been assigned to (bound).

• Communication loss diagnostics shall be timed based on action (target status) and not annunciation on the operator display.

Active Modes [Inactive Modes] Criteria

Continual loss of communication between the MP and the Functional ID has occurred for a 15-30 second period.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

Continual loss of communication between the MP and the Functional ID has occurred for a 15-30 second period.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period. This is an info warning, as it is conceivable that the circuit may run without the center shared fan deck working if there are many other coils/fans on the circuits.

Reset Level

Remote

RTAF-SVX001A-EN 79

Page 80

Diagnostics

Table 28. Communications diagnostics (continued)

Diagnostic Name

Comm Loss: Condenser Refrigerant Pressure

Comm Loss: Condenser Rfgt Pressure

Comm: Cond Rfgt Pressure

Comm Loss: Condenser Refrigerant Tank Valve

Comm Loss: Cond Rfgt Tank Valve

Comm: Cond Rfgt Tank Vlv

Comm Loss: Electronic Expansion Valve Comm: EXV

Comm Loss: Emergency Stop Feedback Input Comm: Emergency Stop

Comm Loss: Energy Meter Pulse Input Comm: Energy Pulse Input

Comm Loss: Evaporator Entering Water Pressure

Comm Loss: Evap Entering Water Pressure

Comm: Evap Ent Water Press

Comm Loss: Evaporator Entering Water Temperature

Comm Loss: Evap Entering Water Temp

Comm: Evap Ent Water Temp

Comm Loss: Evaporator Isolation Valve Close Switch

Comm Loss: Evap Iso Valve Close Switch

Comm: Evap Iso Vlv Close Sw

Comm Loss: Evaporator Isolation Valve Open Switch

Comm Loss: Evap Iso Valve Open Switch

Comm: Evap Iso Vlv Open Sw

Comm Loss: Evaporator Isolation Valve Relay

Comm Loss: Evap Isolation Valve Relay

Comm: Evap Iso Valve Relay

Comm Loss: Evaporator Leaving Water Pressure

Comm Loss: Evap Leaving Water Pressure

Comm: Evap Leav Water Press

Affects Target Severity Persistence

Circuit Immediate Latch All

Circuit Normal Latch All

Chiller Normal Latch All

None Info Latch All

Chiller Info Latch All

Chiller Normal Latch All

Circuit Immediate Latch All

Chiller Info Latch All

Active Modes [Inactive Modes] Criteria

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

Continual loss of communication between the MP and the EXV Step Status has occurred for a 30 second period, OR EXV Steps Maximum Position has not been received. If EXV Steps Maximum Position has not been received, MP will periodically request EXV Steps Maximum Position, since it is only transmitted upon request.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period. Note: Entering Water Temp Sensor is used in EXV pressure control as well as ice making & CHW reset, so it must cause a unit shutdown even if Ice or CHW reset is not installed.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

Reset Level

Remote

80 RTAF-SVX001A-EN

Page 81

Table 28. Communications diagnostics (continued)

Diagnostic Name

Comm Loss: Evaporator Leaving Water Temperature

Comm Loss: Evap Leaving Water Temp

Comm: Evap Leav Water Temp

Comm Loss: Evaporator Pump 1 Fault Input Comm: Evap Pump Fault Input

Comm Loss: Evaporator Pump 2 Fault Input Comm: Evap Pump Fault Input

Comm Loss: Evaporator Pump Inverter 1 Run Command

Comm Loss: Evap Pump Inv 1 Run Command

Comm: Evap Water Pump Relay

Comm Loss: Evaporator Refrigerant Pool Temperature

Comm Loss: Evap Rfgt Pool Temp

Comm: Evap Rfgt Pool Temp

Comm Loss: Evaporator Shell Refrigerant Pressure

Comm Loss: Evap Shell Rfgt Pressure

Comm: Evap Shell Rfgt Press

Comm Loss: Evaporator Water Flow Switch Comm: Evap Water Flow Sw

Comm Loss: Evaporator Water Pump 1 Relay Comm: Evap Wtr Pump Relay x

Comm Loss: Evaporator Water Pump 2 Relay Comm: Evap Water Pump Relay

Comm Loss: Evaporator Water Pump Inverter 1 Fault Input

Comm Loss: Evap Pump Inv 1 Fault Input

Comm: Evap Pump Fault Input

Comm Loss: Evaporator Water Pump Inverter Frequency Input

Comm Loss: Evap Water Pump Inv Freq Input

Comm: Evap Watr Pmp Inv Freq

Affects Target Severity Persistence

Chiller Normal Latch All

Circuit and Chiller

Circuit Normal Latch All

Chiller Immediate Latch All

Chiller Normal Latch All

Special Action and Info

Latch All

Active Modes [Inactive Modes] Criteria

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period. Invalidate evaporator pool temperature sensor measurement if this diagnostic is active. If evaporator isolation valves are installed, revert to Evaporator Shell Refrigerant Saturated Temperature for freeze protection functions. If evaporator isolation valves are not installed, revert to Evaporator Saturated Temperature for freeze protection functions.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

Diagnostics

Reset Level

Remote

RTAF-SVX001A-EN 81

Page 82

Diagnostics

Table 28. Communications diagnostics (continued)

Diagnostic Name

Comm Loss: Evaporator Water Pump Inverter Speed

Comm Loss: Evap Water Pump Inverter Speed

Comm: Evap Water Pump Speed

Comm Loss: Ext Noise Reduction Request Comm: Ext Noise Reduct Input

Comm Loss: External Auto/Stop Comm: External Auto/ Stop

Comm Loss: External Chilled Water Setpoint

Comm Loss: Ext Chilled Water Setpoint

Comm: Ext Chilled Wtr Setpt

Comm Loss: External Ckt Lockout

Comm: Ext Ckt Lockout

Comm Loss: External Demand Limit Setpoint

Comm Loss: Ext Demand Limit Setpoint

Comm: Ext Demand Lim Setpt

Comm Loss: External Ice Building Command Comm: Ext Ice Building Cmd

Comm Loss: Fan Board 1 Relay X Comm: Fan Board 1 Relay X

Comm Loss: Fan Board 2 Relay X Comm: Fan Board 2 Relay X

Comm Loss: Fan Inverter Speed Command Comm: Fan Inverter Speed Cmd

Comm Loss: Fan Inverter Speed Command, Shared Circuit 1 & 2

Comm Loss: Fan Inv Spd Cmd, Shrd Ckt 1&2

Comm: Fan Inv Spd Cmd Ckt 1&2

Comm Loss: Heat Recovery Entering Water Temperature Sensor

Comm Loss: HR Entering Water Temp Sensor

Comm: HR Entering Water Temp

Affects Target Severity Persistence

Chiller Normal Latch All

None Info Latch All

Chiller Normal Latch All

External Chilled Water Setpoint

Circuit

External Demand Limit setpoint

Ice Making Mode

Circuit Normal Latch All

Circuit Info Latch All

Chiller Info Latch All

Special Action

Latch All

Active Modes [Inactive Modes] Criteria

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period. Chiller shall discontinue use of the External Chilled Water Setpoint source and revert to the next higher priority for setpoint arbitration

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period. MP will nonvolatile hold the lockout state (enabled or disabled) that was in effect at the time of comm loss.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period. Chiller shall discontinue use of the External Demand limit setpoint and revert to the next higher priority for Demand Limit setpoint arbitration.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period. Chiller shall revert to normal (non-ice building) mode regardless of last state.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

Continual loss of communication between the MP and the Functional ID has occurred for a 15-30 second period.

Continual loss of communication between the MP and the Functional ID has occurred for a 15-30 second period. This is an info warning, as it is conceivable that the circuit may run without the center shared fan deck working if there are many other coils/fans on the circuits.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

Reset Level

Remote

82 RTAF-SVX001A-EN

Page 83

Table 28. Communications diagnostics (continued)

Diagnostic Name

Comm Loss: Heat Recovery Leaving Water Temperature Sensor

Comm Loss: HR Leaving Water Temp Sensor

Comm: HR Leaving Water Temp

Comm Loss: High Pressure Cutout Switch -

xy Comm Loss: High Pressure Cutout Sw - xy

Comm: High Pres Cutout Sw - xy

Comm Loss: Liquid Line Temperature Comm: Liquid Line Temp

Comm Loss: Local BAS Interface Comm: Local BAS Interface

Comm Loss: Motor RLA Input - xA Comm: Motor RLA Input xA

Comm Loss: Motor Winding Thermostat Compressor 1A

Comm Loss: Motor Winding Tstat Cprsr 1A

Comm: Motor Tstat Cprsr 1A

Comm Loss: Motor Winding Thermostat Compressor 2A

Comm Loss: Motor Winding Tstat Cprsr 2A

Comm: Motor Tstat Cprsr 2A

Comm Loss: Oil Loss Level Sensor Input

Comm: Oil Level Sensor

Comm Loss: Oil Pressure xy Comm: Oil Pressure - xy

Comm Loss: Oil Return Line Solenoid Valve -xy

Comm Loss: Oil Return Solenoid Valve - xy

Comm: Oil Ret Sol Vlv xy

Comm Loss: Outdoor Air Temperature Comm: Outdoor Air Temp

Comm Loss: Programmable Relay Board 1 Comm: Program Relay Board 1

Affects Target Severity Persistence

Chiller Info Latch All

Cprsr Normal Latch All

Circuit Normal Latch All

Chiller Info NonLatch All

Cprsr Normal Latch All

Circuit Normal Latch All

Cprsr Immediate Latch All

Cprsr Normal Latch All

Chiller Normal Latch All

None Info Latch All

Active Modes [Inactive Modes] Criteria

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period Note: The Subcooled Liquid Line Temperature Sensors are used for determination of charge and accurate tonnage predictions

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period. Use last valid BAS setpoints. Diagnostic is cleared when successful communication is established with the LonTalk LLID (LCIC) or BacNet LLID (BCIC).

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

Diagnostics

Reset Level

Remote

RTAF-SVX001A-EN 83

Page 84

Diagnostics

Table 28. Communications diagnostics (continued)

Diagnostic Name

Comm Loss: Programmable Relay Board 2 Comm: Program Relay Board 2

Comm Loss: Slide Valve Load - xy Comm: Slide Valve Load xy

Comm Loss: Slide Valve Unload - xy Comm: Slide Valve Unload - xy

Comm Loss: Speed Command - xA Comm: Speed Command

-xA

Comm Loss: Starter xy Cprsr Immediate Latch All

Comm Loss: Step Load xy Comm: Step Load - xy

Comm Loss: Suction Refrigerant Pressure - xy

Comm Loss: Suction Rfgt Pressure - xy

Comm: Suction Rfgt Press xy

Comm Loss: Water System Differential Pressure

Comm Loss: Water System Diff Pressure

Comm: Water Sys Diff Press

Affects Target Severity Persistence

None Info Latch All

Cprsr Normal Latch All

Cprsr Immediate Latch

Chiller Info Latch All

Active Modes [Inactive Modes] Criteria

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

Continual loss of communication between the MP and the Functional ID has occurred for a 15-30 second period.

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

All [Ckt/ Cprsr lock out]

Continual loss of communication between the MP and the Functional ID has occurred for a 30 second period.

Reset Level

Remote

84 RTAF-SVX001A-EN

Page 85

Wiring

Table 29 provides a list of electrical schematics, field wiring diagrams and connection diagrams for RTAF units. Complete

wiring package is documented in RTAF-SVE001*-EN.A laminated wiring diagram booklet is also shipped with each chiller.

Table 29. RTAF unit wiring drawing numbers

Drawing Number Description

5722-6999 Schematic Diagram 5722-7580 Unit Component Location 5722-7552 Panel Component Location Diagram 2311-3537 Field Wiring Diagram

RTAF-SVX001A-EN 85

Page 86

Log and Check Sheets

The operator log and check sheet are included for use as

appropriate, for installationcompletion verification before Trane start-up is scheduled, and for reference during the Trane start-up.

Where the log or check sheet also exists outside of this

publication as standalone literature, the literature order

number is also listed.

• Sintesis™ Model RTAF Installation Completion Check Sheet and Request forTrane Service (RTAF-ADF001*-EN)

• Operator Log

86 RTAF-SVX001A-EN

Page 87

Sintesis™ RTAF Installation Completion Check Sheet and Request forTrane Service

Important: A copy of this completed form must be submitted to theTrane service agency that will be responsible for the start-

up of the chiller. Start-up will NOT proceed unless applicable items listed in this form have been satisfactorily completed. See unit IOM RTAF-SVX001*-EN for detailed installation instructions.

To: Trane Service Office:

S.O. Number: Serial Numbers: Job/Project Name:

Address:

The following items are being installed and will be completed by:

Important: Start-up must be performed byTrane or an agent of Trane specifically authorized to perform start-up of Trane

products. Contractor shall provide Trane (or an agent ofTrane specifically authorized to perform start-up) with notice of the scheduled start-up at least two weeks prior to the scheduled start-up.

Check boxes if the task is complete or if the answer is “yes.”

1. Chiller

 Installation meets foundation requirements.  In place and piped.  Isolation pads or elastomeric pads installed (optional).

2. Piping

 Water piping flushed before making final connections to the system Chilled water piping connected to:

 Evaporator  Air handling units

 Pumps  Flow switch or flow proving device installed  Strainer installed in entering evaporator water piping and cleaned  Water supply connected to filling system  Systems filled  Pumps run, air bled from system  Relief valve ventilation piping installed (if applicable)  Flow balancing valves installed in leaving chilled water  Gauges, thermometers and air vents installed on both sides of evaporator

3. Wiring

 Wire size per submittal and NEC  Full power available, and within utilization range  External interlocks (flow switch, pumps auxiliary, etc.)  Chilled water pump (connected and tested)  115 Vac power available for service tools (recommended)  All controls installed and connected

4. Testing

 Dry nitrogen available for pressure testing  Trace gas amounts of R-134a or R-513A available for leak testing (if required)

5.  Refrigerant on job site (if nitrogen charge option, model number digit 16=3or4,ischosen)

6.  Systems can be operated under load conditions

7. Heaters  If unit was factory charged (model number digit 16=1or2), energize heater s for 24 hours prior to start up.

Important: It is required that chiller heaters are energized for a minimum of 24 hours prior to start up.

Therefore, chiller should have power for this amount of time beforeTrane Service arrives to do start-up.

 If unit has nitrogen charge (model number digit 16 = 3 or 4), contactTrane Service for unit charging prior to start-up.

RTAF-ADF001A-EN 1

Page 88

8. Owner awareness

 If it is required by local code, is a self-contained breathing apparatus available?  Has the owner been fully instructed on the proper use of refrigerant?  Does the owner have a copy of the MSDS for refrigerant?  Was the owner given a copy of the Refrigerant Handling Guidelines?

Note: Additional time required to properly complete the start-up and commissioning, due to any incompleteness of the

installation, will be invoiced at prevailing rates.

This is to certify that theTrane

equipment has been properly and completely installed, andthat theapplicable items listed above

have been satisfactorily completed.

Checklist completed by: ______________________________________________________________________________________________ Signed: _____________________________________________________________________ Date: _______________________________

In accordance with your quotation and our purchase order number __________________, we will therefore require the presence ofTrane service on this site, for the purpose of start-up and commissioning, by __________________ (date).

Note: Minimum two-week advance notification is required to allow scheduling of the chiller start-up.

Additional comments/instructions: ____________________________________________________________________________________

_____________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________

Note: A copy of this completed from must be submitted to theTrane Service Office that will be responsible for start-up of chiller.

All trademarks referenced in this document are the trademarks of their respective owners.

Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, the

leader in creating and sustaining safe, comfortable and energy efficient environments, Trane offers a broad portfolio of advanced controls and HVAC systems, comprehensive building services, and parts. For more information, visit www.Trane.com.

Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice.

RTAF-ADF001A-EN 05 Jun 2015

(New)

We are committed to using environmentally

conscious print practices that reduce waste.

Page 89

Operator Log

Sintesis™ RTAF Chiller with UC800 Controller - Tracer AdaptiView Reports - Log Sheet

Unit Circuit 1 Circuit 2

Start 15 min 30 min 1 hr Start 15 min 30 min 1 hr Start 15 min 30 min 1 hr

EVAPORATOR

Active Chilled Water Setpoint Entering Water Temperature Leaving Water Temperature Saturated Refrigerant Temperature (°F) Refrigerant Pressure (psia) Approach Temperature (°F) Water Flow Status EXV % Open

CONDENSER

Outdoor Air Temperature Air Flow % Saturated Refrigerant Temperature (°F) Refrigerant Pressure (psia)

COMPRESSORS

Compressor A

Running Status

Starts

Running Time (Hr:Min)

Oil Pressure (psia)

Motor A

Active Demand Limit Setpoint

Average Motor Current (%)

Compressor B (if present)

Running Status

Starts

Running Time (Hr:Min)

Oil Pressure (psia)

Motor B (if present)

Active Demand Limit Setpoint

Average Motor Current (%)

COMMENTS:

Date: Technician: Owner:

RTAF Operator Log Revised: 13 May 2015

Page 90

Page 91

Page 92

Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, the leader in

creating and sustaining safe, comfortable and energy efficient environments,Trane offers a broad portfolio of advanced controls and HVAC systems, comprehensive building services, and parts. For more information, visit www.Trane.com.

Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice.

RTAF-SVX001A-EN 11 June 2015

(NEW)

We are committed to using environmentally

conscious print practices that reduce waste.

Trane Sintesis RTAF Installation, Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual