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Trane R Series Installation Operation & Maintenance

Trane R Series Installation Operation & Maintenance

Helical rotary liquid chillers. 175-450 ton units (60 hz) 125-450 ton units (50 hz)
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See also: Installation Operation & Maintenance , Installation, Operation & Maintenance Manual
© American Standard Inc. 2006
Installation
Operation
Maintenance
Series R
Helical Rotary Liquid Chillers
Models RTHD
175-450 ton units (60 Hz)
125-450 ton units (50 Hz)
November 2006
RTHD-SVX01D-EN

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Summary of Contents for Trane R Series

  • Page 1 Installation Operation Maintenance Series R Helical Rotary Liquid Chillers Models RTHD 175-450 ton units (60 Hz) 125-450 ton units (50 Hz) RTHD-SVX01D-EN November 2006 © American Standard Inc. 2006...
  • Page 2 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 and HCFCs and HFCs.

  • Page 3: Table Of Contents

    Table of Contents General Information..................5 Literature Change History ................. 5 Unit Identification - Nameplates ................ 5 Unit Inspection ....................6 Inspection Checklist ..................6 Loose Parts Inventory ..................6 Unit Description....................6 Model Number Coding System................. 7 Unit Model Number ..................7 Installation Overview..................
  • Page 4 Table of Contents Settings Screen ....................94 Diagnostic Screen ................... 96 TechView ....................97 Minimum PC requirements to install and operate TechView......98 Unit View......................99 Status View ....................100 Setpoint View ....................103 Manual Override View................... 107 Diagnostics View................... 109 Software View....................

  • Page 5: General Information

    General Information Literature Change History RTHD-SVX01D-EN Additional configurations available for 50 hz units. (Nov. 2006) RTHD-SVX01C-EN New control panel design. (May 2005) RTHD-SVX01B-EN New Evap/Cond configuration C2F2F3 and change to minimum flow rates. (June 2004) RTHD-SVX01A-EN New manual describes installation, operation, and maintenance of RTHD units.

  • Page 6: Unit Inspection

    The owner must provide reasonable evidence that the damage did not occur after delivery. • Notify the Trane sales representative and arrange for repair. Do not repair the unit, however, until damage is inspected by the transportation repre- sentative.

  • Page 7: Model Number Coding System

    General Information Model Number Coding System The model numbers for the unit and the compressor are composed of num- bers and letters that represent features of the equipment. Shown in the three tables following are samples of typical unit, compressor, and panel model numbers, followed by the coding system for each.
  • Page 8 General Information Digit 31 -Thermal Insulation Digit 40, 41, 42 Digit 48 No insulation Design RLA (for starter) External Chilled Water & Current Limit Factory insulation cold parts Selection RLA Setpoint None Digit 32 -Sound Attenuator Digit 43 4-20 mA input No insulation Power line connection type 2-10 Vdc input...
  • Page 9 General Information Compressor Model Number (located on compressor nameplate): Table 1 Compressor Model Number Selection Category M/N Digit M/N Code Description of Selection Compressor Series CHHC Semi-Hermetic Heli-Rotor Compressor Design Control Pueblo Compressor Frame B Frame C Frame D Frame E Frame Compressor Capacity Smaller capacity (minor)
  • Page 10 General Information DynaView or EasyView Interface Oil Separator Starter/Control Panel Relief Valves Oil Sump Condenser Water Outlet Evaporator Liquid Level Sensor Gas Pump Condenser Evaporator Water Inlet Water Outlet Figure 2 Component Location for Typical RTHD Unit RTHD-SVX01D-EN...
  • Page 11 General Information Compressor Oil Separators Oil Filter (Cold) Hot Oil Filter is Discharge Line hidden from view. Unit Nameplate Relief Valves (On side of starter/control panel) EXVs Evaporator Water Inlet Condenser Service Valves Oil Sump (With Refrigerant Isolation (The oil distribution system is located between Valve Option Only) the condenser and the evaporator.) Figure 3...

  • Page 12: Installation Overview

    General Information Installation Overview For convenience, Table 2 summarizes responsibilities that are typically asso- ciated with the RTHD chiller installation process. Table 2 Installation Responsibility Chart for RTHD Units Trane-supplied, Trane-supplied, Field-supplied, Requirement Trane-installed Field-installed Field-installed Rigging Safety chains Clevis connectors - Lifting beam...
  • Page 13 • Supply and install condenser water control valve(s) per Trane Engineering Bulletin -Water Cooled Series R  Condenser Water Control. •...
  • Page 14 General Information Table 3 General Data Unit Designator (corresponds to digits 6, 7, 14, 15, 21, 22 of unit model number) D1D1E1 D1F1F2 D1G1G1 D1G2G2 D2D2E2 D2F2F3 D2G3G3 General Refrigerant Type HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a Refrigerant Charge 475 (216) 625 (284) 700 (318)
  • Page 15 General Information Table 4 General Data Unit Designator (corresponds to digits 6, 7, 14, 15, 21, 22 of unit model number) D2G2G1 D3D2E2 D3F2F3 D3G2G1 D3G3G3 E3D2E2 E3F2F3 E3G2G1 E3G3G3 General Refrigerant Type HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a Rfgt Chg (lb (kg))
  • Page 16 General Information Table 5 General Data Unit Designator (corresponds to digits 6, 7, 14, 15, 21, 22 of unit model number) C1D6E5 C1D5E4 C1E1F1 C2D4E4 C2D3E3 General Refrigerant Type HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a Refrigerant Charge (lb (kg)) 490 (222) 490 (222) 525 (238) 490 (222)
  • Page 17 General Information Table 6 General Data Unit Designator (corresponds to digits 6, 7, 14, 15, 21, 22 of unit model number) C2F2F3 B1B1B1 B1C1D1 B2B2B2 B2C2D2 General Refrigerant Type HFC-134a HFC-134a HFC-134a HFC-134a HFC-134a Refrigerant Charge (lb (kg)) 700 (318) 410 (186) 490 ((222) 410 (186)
  • Page 18 General Information RTHD-SVX01D-EN...

  • Page 19: Installation Mechanical

    Trane sales office. NOTE: Pressure will be approximately 20 psig if shipped with the optional nitrogen charge. Location Requirements Noise Considerations Refer to Trane Engineering Bulletin -Series R  Chiller Sound Ratings and • Installation Guide. for sound consideration applications. •...
  • Page 20 NOTE: Required vertical clearance above the unit is 36” (914.4 mm). There should be no piping or conduit located over the compressor motor. If the room configuration requires a variance to the clearance dimensions, contact your Trane sales office representative. 3'-0" (914 mm) Servic e Cl earance 3'-0"...

  • Page 21: Moving And Rigging

    Installation Mechanical NOTE: Maximum clearances are given. Depending on the unit configu- ration, some units may require less clearance than others in the same category. Ventilation The unit produces heat even though the compressor is cooled by the refriger- ant. Make provisions to remove heat generated by unit operation from the equipment room.
  • Page 22 Installation Mechanical = C.G. Figure 5 Unit Weights and Dimensions for Rigging Table 7 Unit Weights (lb (kg)) Location (points) Unit Designator * E3G3G3 5339 4455 4374 5486 (2422) (2021) (1984) (2488) E3G2G1 5158 4304 4226 5300 (2340) (1952) (1917) (2404) E3F2F3 4781...
  • Page 23 Installation Mechanical Table 7 Unit Weights (lb (kg)) Location (points) Unit Designator * D3G3G3 5320 4451 4327 5140 (2413) (2019) (1963) (2331) D3G2G1 5085 4255 4136 5171 (2307) (1930) (1876) (2346) D3F2F3 4737 3563 3722 4797 (2149) (1616) (1688) (2176) D3D2E2 3754 2818...
  • Page 24 Installation Mechanical Table 8 Center of Gravity (in (mm)) Unit Configuration* E3G3G3 30.8 63.81 37.62 (782.32) (1621) (956) E3G2G1 30.8 63.55 38.70 (782.32) (1614) (983) E3F2F3 27.64 63.46 38.33 (702.056 (1612) (974) E3D2E2 25.9 60.05 40.5 (658) (1525) (1029) D3G3G3 30.85 63.48 37.44...

  • Page 25: Lifting Procedure

    Installation Mechanical Lifting Procedure CAUTION Equipment Damage! Never use a forklift to move the unit. The skid is not designed to support the unit at any one point and using a forklift to move the equipment may cause unit damage. Always position the lifting beam so that cables do not contact the unit.
  • Page 26 Installation Mechanical Table 9 Rigging Dimension (mm (in)) Unit Configuration* E3G3G3 3658 3353 1621 (144.02) (132.01) (63.82) (0.79) (26.02) (24.02) E3G2G1 3658 3353 1621 (144.02) (132.01) (63.82) (0.79) (26.02) (24.02) E3F2F3 3658 3353 1612 (144.02) (132.01) (63.46) (1.14) (24.21) (24.02) E3D2E2 3048 2743...
  • Page 27 Installation Mechanical Table 9 Rigging Dimension (mm (in)) Unit Configuration* C1E1F1 3658 3353 1613 (144.02) (132.01) (63.50) (5.08) (24.57) (24.02) C1D5E4 3048 2743 1523 (120.00) (107.99) (59.96) (8.62) (22.99) (24.02) C1D6E5 3048 2743 1524 (120.00) (107.99) (60.00) (8.58) (22.91) (24.02) B2C2D2 3658 3353...
  • Page 28 Installation Mechanical NOTES: 1. LIFTING CABLES (C HAIN S) WIL L N OT BE TH E SAME L EN GTH. ADJUST TO KEEP UNIT L EVEL WHILE L IFTING. 2. ATTACH ANTI-ROLLING C ABL E (CH AIN) AS SHOWN WITHOUT TENSION. NOT AS A LIFTING CABLE, BUT TO PREVENT U NIT FROM ROL LIN G.

  • Page 29: Isolation Pads

    The elastomeric pads shipped (as standard) are adequate for most instal- lations. For additional details on isolation practices, refer to Trane Engineering Bulletin -Series R  Chiller Sound Ratings and Installa- tion Guide., or consult an acoustical engineer for sound-sensitive installa- tions.

  • Page 30: Unit Leveling

    Installation Mechanical 8. The unit is shipped with four spacers (only three on B family) on the com- pressor mount that protect the compressor isolation pads during shipping and in handling. Remove these spacers (Figure 8) before the unit is oper- ated.

  • Page 31: Water Piping

    Installation Mechanical Water Piping Piping Connections CAUTION Equipment Damage! To prevent equipment damage, bypass the unit if using an acidic flushing agent. Make water piping connections to the evaporator and condenser. Isolate and support piping to prevent stress on the unit. Construct piping according to local and national codes.
  • Page 32 Installation Mechanical Figure 9 Condenser and Evaporator Water Connections -BBB RTHD-SVX01D-EN...
  • Page 33 Installation Mechanical Figure 10 Condenser and Evaporator Water Connections - RTHD-SVX01D-EN...
  • Page 34 Installation Mechanical Figure 11 Condenser and Evaporator Water Connections - CEF RTHD-SVX01D-EN...
  • Page 35 Installation Mechanical Figure 12 Condenser and Evaporator Water Connections - CDE/DDE/EDE RTHD-SVX01D-EN...
  • Page 36 Installation Mechanical Figure 13 Condenser and Evaporator Water Connections - DFF/EFF/CFF RTHD-SVX01D-EN...
  • Page 37 Installation Mechanical Figure 14 enser and Evaporator Water Connections - DGG/EGG Cond RTHD-SVX01D-EN...
  • Page 38 Installation Mechanical Table 10 Evaporator and Condenser Data Nom. Compress Conn. or Frame Nominal Connector Size Code Evap Shell Evap. Cond Shell Cond. size (NPS)* (NPS)* (Digit 6,7 Code (Digits Shell Code Shell of Model 14, 15 of Diameter (Digits 21,22 of Diameter No.) Model No.)

  • Page 39: Water Pressure Drop Data

    Installation Mechanical Water Pressure Drop Data Evaporator Pressure D rop G Frame - 3 P ass 1000 1500 2000 2500 3000 Flow (GPM ) Evaporator Pressure D rop G Frame - 4 P ass 1000 1500 2000 Flow (GPM ) RTHD-SVX01D-EN...
  • Page 40 Installation Mechanical Evaporator P ressure D rop F Frame - 2 Pass 1000 1500 2000 2500 3000 Flow (GP M ) Evaporator Pressure D rop F Frame - 3 Pass 1000 1500 2000 Flow (GPM ) RTHD-SVX01D-EN...
  • Page 41 Installation Mechanical Evaporator P ressure D rop E Frame - 2 Pass 1000 1500 2000 Flow (GP M ) Evaporator Pressure D rop E Frame - 3 P ass 1000 1200 1400 Flow (GPM ) RTHD-SVX01D-EN...
  • Page 42 Installation Mechanical Evaporator P ressure D rop D Frame - 2 Pass D4 & D5 1000 1500 2000 2500 Flow (GP M ) Evaporator Pressure D rop D Frame - 3 P ass D4 & D5 1000 1200 1400 Flow (GPM ) RTHD-SVX01D-EN...
  • Page 43 Installation Mechanical Evaporator Pressure D rop C Frame - 2 P ass 1000 1500 Flow (GPM ) Evaporator P ressure D rop C Frame - 3 Pass 1000 Flow (GP M ) RTHD-SVX01D-EN...
  • Page 44 Installation Mechanical Evaporator P ressure D rop B Frame - 3 Pass 1000 Flow (GP M ) Evaporator Pressure D rop B Frame - 2 P ass 1000 1200 1400 Flow (GPM ) RTHD-SVX01D-EN...
  • Page 45 Installation Mechanical C ondenser Pressure D rop G Frame - 2 P ass 1000 1500 2000 2500 3000 Flow (GPM ) C ondenser Pressure D rop F Frame - 2 Pass F1 & F3 1000 1500 2000 Flow (GPM ) RTHD-SVX01D-EN...
  • Page 46 Installation Mechanical C ondenser P ressure D rop E Frame - 2 Pass 1000 1500 Flow (GP M ) C ondenser Pressure D rop D Frame - 2 P ass 1000 Flow (GPM ) RTHD-SVX01D-EN...
  • Page 47 Installation Mechanical C ondenser Pressure D rop B Frame - 2 P ass 1000 Flow (GPM ) Making Grooved Pipe Connections CAUTION Equipment Damage! To prevent damage to water piping, do not overtighten connections. To prevent equipment damage, bypass the unit if using an acidic flushing agent.
  • Page 48 Installation Mechanical “Piping components” include all devices and controls used to provide proper water system operation and unit operating safety. These components and their general locations are given below. Entering Chilled Water Piping • Air vents (to bleed air from system) •...

  • Page 49: Condenser Water Regulating Valve

    Installation Mechanical • Pipe unions • Vibration eliminators (rubber boots) • Shutoff (isolation) valves. One per each pass • Thermometers • Cleanout tees • Pipe strainer • Flow switch Leaving condenser water piping. • Air vents (to bleed air from system) •...

  • Page 50: Water Treatment

    The Trane Company assumes no responsibility for equipment failures which result from untreated or improperly treated water, or saline or brackish water.

  • Page 51: Water Pressure Gauges And Thermometers

    Pressure Differential Gauge Relief Relief Valve Valve Refer to Trane Engineering Bulletin -Series R  Chiller Sound Ratings and Installation Guide for sound-sensitive applications. Figure 15 Typical Thermometer, Valving, and Manifold Pressure Gauge Set-up Water Pressure Relief Valves CAUTION Shell Damage! Install a pressure relief valve in both evaporator and condenser water systems.

  • Page 52: Refrigerant Pressure Relief Valve Venting

    Installation Mechanical Flow switches must stop or prevent compressor operation if either system water flow drops off below the required minimum shown on the pressure drop curves. Follow the manufacturer’s recommendations for selection and installation procedures. General guidelines for flow switch installation are out- lined below.
  • Page 53 Installation Mechanical Relief valve discharge setpoints and capacities rates are given in Table Once the relief valve has opened, it will reclose when pressure is reduced to a safe level. NOTE: Once opened, relief valves may have tendency to leak and must be replaced.

  • Page 54: Thermal Insulation

    Installation Mechanical Table 11 Pressure Relief Valve Data Discharge Rated Capacity Factory Setpoint Number per Relief Valve Field Connection Shell Side Valve Location (psi) of Valves (lba/min.) Pipe Size (in NPT) Connection(in) Evap - G3 78.8 1-1/4 1-5/8 - 12 Cond - B1 48.0 1-5/16 -12...
  • Page 55 Installation Mechanical Figure 17 Typical RTHD Insulation Requirements Table 12 Recommended Insulation Types Location Type Sq. Feet Evaporator 3/4” wall Compressor 3/4” wall All components and piping on low side of system (gas 3/4” wall pump, return oil line, filter from pump) RTHD-SVX01D-EN...
  • Page 56 Installation Mechanical RTHD-SVX01D-EN...

  • Page 57: Installation Electrical

    Model RTHD chillers are designed according to NEC Article 310-15; therefore, all power supply wiring must be sized and selected accordingly by the project engineer. For a complete discussion on the use of conductors, see Trane Engineering Bulletin EB-MSCR-40. Refer to Trane Engineering Bulletin CTV-EB-93 for power wire sizing.
  • Page 58 Installation Electrical Electrical Panel Power Supply Power supply wiring instructions for the starter/control panel are: 1. Run line voltage wiring in conduit to access opening(s) on starter/control panel or pull-box. See CTV-EB-93 for wire sizing and selection information and refer to Table 13 that show typical electrical connection sizes and locations.

  • Page 59: Compressor Motor Phase Sequencing

    Installation Electrical Figure 18 Electrical Installation WARNING Live Electrical Components! During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks.

  • Page 60: Correcting Improper Electrical Phase Sequence

    Installation Electrical phase sequence or phase rotation. This is determined by the direction of rota- tion of the alternator. When rotation is clockwise, phase sequence is usually called “ABC,” when counterclockwise, “CBA.” This direction may be reversed outside the alternator by interchanging any two of the line wires.
  • Page 61 Installation Electrical Terminal Lugs Proper starter/control panel line-side lug sizes are specified on the starter submittals. These lug sizes must be compatible with conductor sizes speci- fied by the electrical engineer or contractor. Appropriate lug sizes are pro- vided. Circuit Breakers and Non-Fused Disconnect Switches (factory installed Option) Units that are ordered with factory installed Circuit Breakers or Non-Fused Disconnect Switches ship with the handle in the control panel.
  • Page 62 Installation Electrical the shaft in all handel positions except RESET/OPEN. To open the enclo- sure door when the breaker is in the ON position, rotate the screw slot on the handle plate counter -clockwise. Verify operation. Table 14 Lug Sizes Device Max.
  • Page 63 Installation Electrical Maximum Fuse/Circuit Breaker Size The maximum fuse/circuit breaker size is equal to 2.25 x the compressor RLA in accordance with UL 1995, para. 36.15.See also NEC 440-22. The recommended dual element (RDE) fuse size is equal to 1.75 x RLA in accordance with NEC Table 430-152.

  • Page 64: Application Of Solid-State Starters

    Installation Electrical Application Of Solid-State Starters The RediStart MX motor starter is a microprocessor-controled started fot induction motors. Viewing Parameter Values Parameter view mode can be entered by: 1. At the default meter display, press the PARAM key to enter parameter mode.
  • Page 65 Installation Electrical WARNING Electrical Shock! Contacting any of the motor terminals, even with the motor off can cause a severe, potentially fatal, shock. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
  • Page 66 Installation Electrical 1 1 B 1 K 4 1 0 A M a i n 8 C 1 0 C 1 2 C P o w e r 1 2 A 1 1 A C T ' s 1 K 1 1 K 3 1 K 2 T o C o n t r o l s...

  • Page 67: Module Connections For Interconnecting Wiring

    Installation Electrical M a i n P o w e r 1 1 C 1 1 C S o l i d N o t e : S S S S t a t e i n s t a l l e d i n C T ' s p a n e l u p s i d e - S t a r t e r...
  • Page 68 Installation Electrical When making field connections, refer to the appropriate field layout, wiring, schematics and controls diagrams that ship with the unit. The diagrams in this manual are typical only and may not match the unit. Whenever a contact closure (binary output) is referenced, the electrical rating At 120 VAC 7.2 amp resistive 2.88 amp pilot duty...
  • Page 69 Installation Electrical Condenser Water Pump Prestart time has been added to help with cold con- denser water problems. In very cold outdoor ambients, the cooling towers sump cold water would reach the chiller some time after the low system dif- ferential pressure protection had run through its ignore time, and result in an immediate shutdown and latching diagnostic.
  • Page 70 Installation Electrical fully reset immediately (within one minute). The chiller will then start at the Differential to Start value above a fully reset CWS or CWS' for Outdoor, Return, and Constant Return Reset. Equations for calculating CWR Equation used to get Degrees of Reset: Outdoor Air: Degrees of Reset = Reset Ratio * (Start Reset - TOD) Return Reset:...
  • Page 71 Installation Electrical Table 15 Chiller Events/Status Descriptions Event/State Description Alarm - Latching This output is true whenever there is any active diagnostic that requires a manual reset to clear, that effects the Chiller, the Circuit, or any of the Compressors on a circuit. This classification does not include informational diagnostics.
  • Page 72 Installation Electrical The CH530 Service Tool (TechView) is used to install and assign any of the above listed events or status to each of the four relays provided with this option. The default assignments for the four available relays are listed below. Table 16 Programable Relays LLID Software...
  • Page 73 % Load = 7.5 * (Vdc Input) + 25 Summit Interface - Optional CH530 provides an optional interface between the chiller and a Trane Summit BAS. A Communications interface LLID shall be used to provide "gateway" functionality between the Chiller and Summit.
  • Page 74 Installation Electrical LonTalk Communication Interface - Optional CH530 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 the LonTalk protocol and the Chiller. Ice Making Contact - Optional CH530 accepts a contact closure input to initiate Ice Building.

  • Page 75: Operating Principles Mechanical

    Refrigeration (Cooling) Cycle The refrigeration cycle of the Series R chiller is conceptually similar to that of other Trane chiller products. It makes use of a shell-and-tube evaporator design with refrigerant evaporating on the shell side and water flowing inside tubes having enhanced surfaces.
  • Page 76 Operating Principles Mechanical Cycle Description The refrigeration cycle for the RTHD chiller can be described using the pres- sure-enthalpy diagram shown in Figure 22. Key State Points are indicated on the figure and are referenced in the discussion following. A schematic of the system showing the refrigerant flow loop as well as the lubricant flow loop is shown in Figure...
  • Page 77 Operating Principles Mechanical As the refrigerant leaves the bottom of the condenser (State Pt. 3), it enters an integral subcooler where it is subcooled before traveling to the electronic expansion valve (State Pt. 4). The pressure drop created by the expansion process vaporizes a portion of the liquid refrigerant.

  • Page 78: Compressor Description

    Operating Principles Mechanical Compressor Description Male Rotor Female Rotor Bearings Suction Unload Solenoid Load Motor Solenoid Housing Rotor Housing Piston Bearing Discharge Housing Housing Check Valve Motor Stator Slide Valve Discharge Unloader Plenum Piston Oil Reclaim Port Discharge Check Valve Primary Mounting Rotor...
  • Page 79 Operating Principles Mechanical The compressor used by the Series R chiller consists of three distinct sec- tions: the motor, the rotors and the bearing housing. Refer to Figure Compressor Motor A two-pole, hermetic, squirrel-cage induction motor directly drives the com- pressor rotors.

  • Page 80: Oil Management System

    Operating Principles Mechanical When both solenoid valves are closed, the present level of compressor load- ing is maintained. On compressor shutdown, the unload solenoid valve is energized. Springs assist in moving the slide valve to the fully-unloaded position, so the unit always starts fully unloaded.
  • Page 81 Operating Principles Mechanical Oil that collects in the oil tank sump is at condensing pressure during com- pressor operation; therefore, oil is constantly moving to lower pressure areas. RTHD Oil System restrictor Compressor Discharge Oil Return Filter Master Oil Line Temperature Oil Pressure Solenoid...
  • Page 82 Operating Principles Mechanical If for any reason oil flow is obstructed because of a plugged oil filter, closed service valve, faulty master solenoid, or other source, the oil pressure trans- ducer will read an excessively high pressure drop in the oil system (relative to the total system pressure) and shut down the chiller.

  • Page 83: Oil Cooler

    Operating Principles Mechanical Lubricant Recovery Despite the high efficiency of the oil separators, a small percentage of oil will get past them, move through the condenser, and eventually end up in the evaporator. This oil must be recovered and returned to the oil sump. The function of active oil return is accomplished by a pressure-actuated pump referred to as the “gas pump.”...
  • Page 84 Operating Principles Mechanical RTHD-SVX01D-EN...

  • Page 85: Operator Interface Controls

    Operator Interface Controls CH530 Communications Overview The Trane CH530 control system that runs the chiller consists of several ele- ments: • The main processor collects data, status, and diagnostic information and communicates commands to the starter module and the LLID (for Low Level Intelligent Device) bus.

  • Page 86: Dynaview Interface

    Operator Interface Controls DynaView Interface The display on DynaView is a 1/4 VGA display with a resistive touch screen and an LED backlight. The display area is approximately 4 inches wide by 3 inches high (102mm x 60mm). Figure 26 DynaView Key Functions In this touch screen application, key functions are determined completely by...

  • Page 87: Display Screens

    Operator Interface Controls Action Buttons Action buttons appear temporarily and provide the user with a choice such as Enter or Cancel. File Folder Tabs File folder tabs are used to select a screen of data. Just like tabs in a file folder, these serve to title the folder/screen selected, as well as provide navi- gation to other screens.

  • Page 88: Keypad/Display Lockout Feature

    Operator Interface Controls The other functions are critical to machine operation. The AUTO and STOP keys are used to enable or disable the chiller. The key selected is in black (reverse video). The chiller will stop when the STOP key is touched and after completing the Run Unload mode.

  • Page 89: Main Screen

    Operator Interface Controls Main Screen The Main screen is a summary of the chiller’s activity.The Main screen is the default screen. After an idle time of 30 minutes the CH530 will display the Main screen with the first data fields. The remaining items (listed in the following table) are viewed by selecting the up/down arrow icons.
  • Page 90 Operator Interface Controls Chiller Operating Modes The machine-operating mode indicates the operational status of the chiller. A sub-screen with additional mode summary information is provided by selec- tion of an additional information icon (>>). The operating mode line will remain stationary while the remaining status items scroll with the up/down arrow keys.
  • Page 91 Operator Interface Controls Table 18 Operating Modes Chiller Modes Description Waiting for BAS Communications This is a transient mode - 15-min. max, and is only possible if the chiller is in the Auto - Remote command mode. After a power up reset, it is necessary to wait for valid communication from a Building Automation System (Tracer) to know whether to run or stay inhibited.
  • Page 92 Operator Interface Controls Table 18 Operating Modes Chiller Modes Description Compressor Restart Inhibit Time The compressor is currently unable to start due to its restart inhibit min:sec timer. A given compressor is not allowed to start until 5 minutes (adj) has expired since its last start. Waiting For EXV Preposition The Chiller will wait for the time it takes the EXV to get to its commanded pre-position prior to starting the compressor.
  • Page 93 Operator Interface Controls Table 18 Operating Modes Chiller Modes Description Capacity Limited by Low Liquid Level The circuit is experiencing low refrigerant liquid levels and the EXV is at or near full open. The compressor will be unloaded to prevent tripping.

  • Page 94: Reports Screen

    Operator Interface Controls Reports Screen The Reports tab allows a user to select from a list of reports headings. Each report will generate a list of status items as defined in the tables that follow. Figure 28. Reports Screen Chiller Log Table 19 Report Screen Items Description...
  • Page 95 Operator Interface Controls Table 19 Report Screen Items Description Resolution Units ± Outdoor Air Temperature XXX.X F / C Compressor Compressor Starts XXXX Integer Compressor Running Time XXXX:XX hr:min System Rfgt Diff Pressure XXX.X psi / kPa Oil Pressure XXX.X psi / kPa ±...

  • Page 96: Settings Screen

    Operator Interface Controls Settings Screen The Settings screen provides the user the ability to adjust settings. The layout provides a list of sub-menus, organized by typical subsystem. Figure 29. Settings Screen Table 20 Settings Screen Items Description Resolution or (Text), Default Units Chiller ±...
  • Page 97 Operator Interface Controls Table 20 Settings Screen Items Description Resolution or (Text), Default Units Outdoor Reset Ratio Percent Outdoor Start Reset XXX.X F / C Outdoor Maximum Reset XXX.X F / C Ext Chilled Water Setpoint (Enable, Disable), Disable Text Ext Current Limit Setpoint (Enable, Disable), Disable Text...

  • Page 98: Diagnostic Screen

    Operator Interface Controls Diagnostic Screen Figure 30. Diagnostics Screen The diagnostic screen is accessible by depressing the Alarms enunciator. A verbal description will be provided. A scrollable list of the last (up to 10) active diagnostics is presented. Per- forming a “Reset Diags” will reset all active diagnostics regardless of type, machine or circuit.

  • Page 99: Techview

    Chillers. Technicians that make any chiller control modification or service any diagnostic with Tracer CH530 must use a laptop running the software application “TechView.” TechView is a Trane application developed to minimize chiller downtime and aid the technicians' understanding of the chiller operation and service requirements.

  • Page 100: Minimum Pc Requirements To Install And Operate Techview

    TechView Minimum PC requirements to install and operate TechView • Pentium II or higher processor • 128Mb RAM • 1024 x 768 resolution of display • 56K modem • 9-pin RS-232 serial connection • Operating system - Windows 2000 • Microsoft Office (MS Word, MS Access, MS Excel) •...

  • Page 101: Unit View

    TechView Unit View Unit view is a summary for the system organized by chiller subsystem. This provides an overall view of chiller operating parameters and gives you an "at-a- glance" assessment of chiller operation. Upon successful Local Connect Tech View will display UNIT VIEW. RTHD Unit View is shown below Figure 31 Unit View...

  • Page 102: Status View

    TechView Status View Status View displays, in real time, all non-setpoint data organized by subsystem tabs. As data changes on the chiller it is automatically updated in Status View Figure 32. Status View RTHD-SVX01D-EN...
  • Page 103 TechView Table 21 Status View Items Text Units Chiller Active Chilled Water Setpoint / Source Temperature Active Current Limit Setpoint / Source Percent RLA Active Base Loading Setpoint / Source Percent Active Ice Termination Setpoint / Source Temperature Evaporator Entering Water Temperature Temperature Evaporator Leaving Water Temperature Temperature...
  • Page 104 TechView Table 21 Status View Items Text Units Compressor Compressor Running Status (On/Off) Compressor Starts Integer Compressor Run Time Hrs:mins Compressor Refrigerant Discharge Temp Temperature Oil Return Gas Fill Solenoid Valve Status (Open/Closed) Oil Return Gas Drain Solenoid Valve Status (Open/Closed) Oil Loss Level Sensor (Dry/Wet)

  • Page 105: Setpoint View

    TechView Setpoint View Setpoint view displays the active setpoints and allows you to make changes. Figure 33 Setpoint View Setpoint List The center of the window displays the scrollable list of setpoint panels. Setpoint Enumeration Panel A setpoint numeric panel contains a label with the setpoint description and a pull-down list showing the active value and the other selections.
  • Page 106 TechView Setpoint Numeric Panel A setpoint numeric panel contains a label with the setpoint description, a Default button, a text field with a unit label, and a slider. The Default button changes the setpoint to the product's factory setting. The text field and slider are updated when the change is complete.
  • Page 107 TechView Table 22 Setpoint View Items (Min, Max), Default Units Setpoint Chiller Front Panel Chilled Water Setpoint (-17.78, 18.33), 6.67 °C Temperature Front Panel Current Limit Setpoint (40, 100), 100 %RLA Percent RLA Front Panel Ice Building Command On/auto Enum Front Panel Ice Termination Setpoint (-6.67, 0.0), -2.78 °C Temperature...
  • Page 108 TechView Table 22 Setpoint View Items (Min, Max), Default Units Setpoint Feature Chilled Water Reset (Constant, Outdoor, Enum Settings Return, Disable), Disable Return Reset Ratio (10, 120), 50 % Percent Return Start Reset (2.22, 16.67), 5.56 °C Diff Temperature Return Max Reset (0.0, 11.11), 2.78 °C Diff Temperature Outdoor Reset Ratio...

  • Page 109: Manual Override View

    TechView Manual Override View Manual Override View is a combined presentation of setpoint (override) and status values. Each manual override item has an "Auto / On" (or Off) for binary control values or an "Auto/Manual" and an analog target value. Additionally, each item has a monitor value that the user will track the effect of an override.
  • Page 110 TechView Table 23 Manuel Override View Description Radio 1 Radio 2 Monitor Value(s): Attribute ID Expansion Valve Auto Manual EXV Position (%) Control Expansion Valve Control Target EXV Position (steps) Evaporator Liquid Level (inches) Evaporator Pump Auto Evap Water Flow Switch Status: Control Chilled Water Pump Relay: Evap Pump Override Time Remaining:...

  • Page 111: Diagnostics View

    TechView Diagnostics View This window lists the active and inactive (history) diagnostics. There can be up to 60 diagnostics, both active and historic. For example, if there were 5 active diagnostics, the possible number of historic diagnostics would be 55. You can also reset active diagnostics here, (i.e., transfer active diagnostics to history and allow the chiller to regenerate any active diagnostics).
  • Page 112 TechView Configuration View Configuration view displays the active configuration and allows you to make changes. Figure 36 Configuration View Configuration View allows you to define the chiller's components, ratings, and configuration settings. These are all values that determine the required installed devices, and how the chiller application is run in the main processor.
  • Page 113 TechView Table 24 Configuration View Items Description Setting Notes Unit Unit Type (MODL) RTHD Type Control Sequence CH530 Chiller Design Sequence** A0, B0, C0, D0, etc. See Nameplate Electronic Expansion Valve - Actuators SNGL (single), DUAL (dual) If COMP=B* then SNGL Evaporator Size B1, B2, C1, C2, D1, D2, D3, D4, D5, E1, F1, F2, G1, G2, G3...
  • Page 114 TechView Table 24 Configuration View Items Description Setting Notes Options Outdoor Air Temperature not installed, installed Ice Building Option not installed, installed w/hdwr, installed w/o hdwr External Chilled Water Setpoint not installed, 2-10 Volts, 4-20 mA External Current Limit Setpoint not installed, 2-10 Volts, 4-20 mA Base Loading not installed, 2-10 Volts, 4-20 mA...

  • Page 115: Software View

    TechView Software View Software view allows you to verify the version of chiller software (MP) currently running on the DynaView and download a new version of chiller software to the DynaView. You can also select up to two available languages to load into the DynaView. Loading an alternate language file allows the DynaView to display its text in the selected alternate language.

  • Page 116: Binding View

    TechView Binding View Binding View allows you to assess the status of the network and all the devices connected as a whole, or the status of individual devices by using status icons and function buttons. Binding View is essentially a table depicting what devices and options are actually discovered on the network bus (and their communication status) versus what is required to support the configuration defined by the feature codes and categories.

  • Page 117: Software Download

    No and repeat the bind function. Software Download Instructions for First Time TechView Users This information can also be found at http://www.trane.com/commercial/ software/tracerch530/. 1. Create a folder called “CH530” on your C:\ drive. You will select and use this folder in subsequent steps so that downloaded files are easy to locate.
  • Page 118 TechView 6. Select the product family. A table with the download link will appear for that product family. 7. Download the main processor software onto your PC in the CH530 folder (please note that this does not install the main processor, it only down- loads the installation utility).

  • Page 119: Unit Start-Up

    Unit Start-up Power Up The Power up chart shows the respective DynaView screens during a power up of the main processor. This process takes from 30 to 50 seconds depend- ing on the number of installed Options. On all power ups, the software model will always transition through the 'Stopped' Software state indepen- dent of the last mode.
  • Page 120 Unit Start-up Figure 40 Power Up to Starting RTHD-SVX01D-EN...

  • Page 121: Stopped To Starting

    Unit Start-up Stopped to Starting: The stopped to starting diagram shows the timing from a stopped mode to energizing the compressor. The shortest allowable time would be under the following conditions: 1. No motor restart inhibit 2. Evaporator and Condenser Water flowing 3.
  • Page 122 Unit Start-up Figure 41 Stopped to Starting RTHD-SVX01D-EN...

  • Page 123: Seasonal Unit Start-Up Procedure

    Unit Start-up Limit Conditions CH530 will automatically limit certain operating parameters during startup and run modes to maintain optimum chiller performance and prevent nui- sance diagnostic trips. These limit conditions are noted in Table Table 25 Limit Conditions The chiller, circuit, and compressor are currently running, but the operation of the chiller/compressor is being actively limited by the controls.
  • Page 124 Unit Start-up Series R Start-up Test Log Job Name Job Location Model # Serial # start date: Sales Order # ship date: Job elevation (ft. above sea level) STARTER DATA: START-UP ONLY Manufacturer Chiller appearance at arrival: Type: (solid state, wye-delta) Compressor shipping bolts removed? Vendor ID #/Model #: Oil separator shipping bolts removed? Y N...
  • Page 125 Unit Start-up Installation Checklist for Model RTHD Series R To:______________________________________________________ Trane Service Company S.O. No.:_________________________________________________Serial No: ___________________________ Job/Project Name:____________________________________________________________________________ RECEIVING Verify that the unit nameplate data corresponds to the ordering information. Inspect the unit for shipping damage and any shortages of materials. Report any damage or shortage to the carrier.
  • Page 126 Unit Start-up Installation Checklist for Model RTHD Series R PRE-START CHECK-OUT Inspect all wiring connections. Connections should be clean and tight. Energize crankcase heaters. Heaters need to be energized 24 hours before start-up. Confirm that all service and isolation valves are open. Refer to RTHD-SVB01A-EN for RTHD units, RTHC- SB-1B for RTHC units and RTHB-IOM-1 for the RTHB units.

  • Page 127: Unit Shutdown

    Unit Shutdown Normal Shutdown to Stopped The Normal Shutdown diagram shows the Transition from Running through a Normal (friendly) Shutdown. The Dashed lines on the top attempt to show the final mode if you enter the stop via various inputs. Figure 42 Normal Shutdown RTHD-SVX01D-EN...

  • Page 128: Seasonal Unit Shutdown

    Unit Shutdown Seasonal Unit Shutdown 1. Perform the normal unit stop sequence using the <Stop> key. NOTE: Do not open the starter disconnect switch. This must remain closed to provide control power from the control power transformer to the oil sump heater.

  • Page 129: Periodic Maintenance

    Periodic Maintenance Overview This section describes preventative maintenance procedures and intervals for the Series R unit. Use a periodic maintenance program to ensure optimal per- formance and efficiency of the Series R units. An important aspect of the chiller maintenance program is the regular com- pletion of the “Series R Operating Log”;...

  • Page 130: Annual Maintenance

    Periodic Maintenance Table 26 Operating Conditions at Full Load Description Condition Evaporator pressure 40-55 psig Condensing pressure 85-120 psig Discharge superheat Subcooling 5-10 EXV percent open 40-50% open in Auto mode All conditions stated above are based on the unit running fully loaded, running at ARI conditions.

  • Page 131: Scheduling Other Maintenance

    Periodic Maintenance • Perform all weekly and monthly maintenance procedures. • Check the refrigerant charge and oil level. Refer to “Maintenance Proce- dures”. Routine oil changing is not necessary on a hermetic system. • Have a qualified laboratory perform an oil analysis to determine system moisture content and acid level NOTE: IMPORTANT: Due to the hygroscopic properties of the POE oil, all oil must be stored in metal containers.
  • Page 132 Periodic Maintenance Chiller Log Run Time Main Tab 15 min 30 min 1 hr Chiller Mode Evap Ent/Lvg Water Temp Cond Ent/Lvg Water Temp Active Chilled Water Setpoint (F) Average Line Current (%RLA) Active Current Limit Setpoint (%RLA) Software Type Software Version Reports Tab Evaporator...
  • Page 133 Periodic Maintenance Settings Settings Tab Chiller Front Panel Chilled Water Setpt (F) Front Panel Current Limit Setpt (RLA) Differential to Start (F) Differential to Stop (F) Setpoint Source Feature Settings Chilled Water Reset Return Reset Ratio Return Start Reset Return Maximum Reset Outdoor Reset Ratio Outdoor Start Reset Outdoor Maximum Reset...
  • Page 134 Periodic Maintenance RTHD-SVX01D-EN...

  • Page 135: Maintenance Procedures

    The Trane Company assumes no responsibility for equipment failures which result from untreated or improperly treated water, saline or brackish water.
  • Page 136 Review mechanical room limitations and determine the safest method or methods of rigging and lifting the waterboxes. 1. Determine the size of chiller being serviced. Refer to Trane Nameplate located on chiller control panel. 2. Select the proper lift connection device from Table 30.
  • Page 137 Maintenance Procedures WARNING OVERHEAD HAZARD! Never stand below or in close proximately to heavy objects while they are suspended from, or being lifted by, a lifting device. Failure to follow these instructions could result in death or serious injuries. 8. Store waterbox in a safe and secure location and position. Do not leave waterbox suspended from lifting device.

  • Page 138: Chemical Cleaning Procedure

    RTHD Safety Hoist Ring RNG01886 M12x1.75 Obtain the required parts from your local Trane Parts Center. Chemical Cleaning Procedure • Scale deposits are best removed by chemical means. Consult a qualified water treatment specialist (i.e., one that knows the local water supply chemical/mineral content) for a recommended cleaning solution suitable for the job.

  • Page 139: Cleaning The Evaporato

    To prevent oil sump heater burnout, open the unit main power disconnect switch before removing oil from the compressor. Trane Polyolester Oil is the approved oil for the RTHD units. Polyolester oil is extremely hygroscopic meaning it readily attracts moisture. The oil can not be stored in plastic containers due to the hygroscopic properties.
  • Page 140 Maintenance Procedures CAUTION Oil Loss! Never operate the compressor with the sightglass service valves opened. Severe oil loss will occur. Close the valves after checking the oil level. The sump is above the condenser and it is possible to drain the oil. 3/8"...

  • Page 141: Removing Compressor Oil

    Maintenance Procedures 6. If the level is below 2”, there is not enough oil in the sump. This can occur from not enough oil in the system or more likely, oil migration to the evap- orator. Oil migration can occur from a low refrigerant charge, gas pump malfunction, etc.

  • Page 142: Replacing The Main Oil Filt E (Hot Filter)

    Maintenance Procedures 6. This will allow the oil to travel from the schrader to the compressor. It takes approximately 2 gallons of oil to fill the lines. 7. After charging the first 2 gallons, de-energize the master solenoid. 8. Open the ball valve just upstream of the schrader connected to the oil pump.

  • Page 143: Replacing The Gas Pump Oil Filter

    Maintenance Procedures 6. Place the cartridge in the nut after filling the bowl with the proper amount of refrigerant oil (see Step 5). Turn the new nut assembly counterclock- wise and tighten securely. 7. Connect manifold gauge set at oil charging valve and evacuate the filter to 500 microns.

  • Page 144: Refrigerant Charging

    Maintenance Procedures 2. Connect the vacuum pump to the 5/8” flare connection on the bottom of the evaporator and/or condenser. 3. To remove all of the moisture from the system and to insure a leak free unit, pull the system down below 500 microns. 4.
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  • Page 147: Diagnostics

    Diagnostics The following diagnostic Table contains all the diagnostics possible. Not all data is available unless TechView is installed. Hex Code: 3 digit hexadecimal code used on all past products to uniquely identify diagnostics. Refer to the database \\SRV-et-data\ucp3\service- tool\databases\servicetool.mdb Diagnostic Name and Source: Name of diagnostic and its source.
  • Page 148 Diagnostics Table 33 Diagnostic List Diagnostic Name and Reset Code Source Severity Persistence Criteria Level BAS Failed to Special The BAS was setup as "installed" and the BAS did Remote Establish not communicate with the MP within 15 minutes Communication after power-up.
  • Page 149 Diagnostics Table 33 Diagnostic List Diagnostic Name and Reset Code Source Severity Persistence Criteria Level Comm Loss: Info Latch Continual loss of communication between the MP Remote Condenser Rfgt and the Functional ID has occurred for a 30 second Pressure Output period.
  • Page 150 Diagnostics Table 33 Diagnostic List Diagnostic Name and Reset Code Source Severity Persistence Criteria Level Comm Loss: Info and NonLatch Continual loss of communication between the MP Remote External Chilled Special and the Functional ID has occurred for a 30 second Water Setpoint Action period.
  • Page 151 Diagnostics Table 33 Diagnostic List Diagnostic Name and Reset Code Source Severity Persistence Criteria Level Comm Loss: Normal Latch Continual loss of communication between the MP Remote Slide Valve Load and the Functional ID has occurred for a 30 second period.
  • Page 152 Diagnostics Table 33 Diagnostic List Diagnostic Name and Reset Code Source Severity Persistence Criteria Level Condenser Water Immediate NonLatch The condenser water flow proof input was open for Remote Flow Lost more than 6 contiguous seconds after flow had been proven.
  • Page 153 Diagnostics Table 33 Diagnostic List Diagnostic Name and Reset Code Source Severity Persistence Criteria Level Excessive Loss of Immediate Latch Loss of comm with 20% or more of the llids Remote Comm configured for the system has been detected. This diagnostic will suppress the callout of all subsequent comm loss diagnostics.
  • Page 154 Diagnostics Table 33 Diagnostic List Diagnostic Name and Reset Code Source Severity Persistence Criteria Level High Pressure Immediate Latch A high pressure cutout was detected; C.O. on rise @ Local Cutout 180 psig, reset @ 135 psig (+/-5 psi on switching tolerance) Note: Pressure relief valve is 200 Psig +- 2% trip at 315 ±...
  • Page 155 Diagnostics Table 33 Diagnostic List Diagnostic Name and Reset Code Source Severity Persistence Criteria Level Low Evaporator Info NonLatch The liquid level sensor is seen to be at or near its low Remote Liquid Level end of range for 80 contiguous minutes while the compressor is running.
  • Page 156 Diagnostics Table 33 Diagnostic List Diagnostic Name and Reset Code Source Severity Persistence Criteria Level MP Application Immediate Latch App software inside the MP failed its own checksum Remote Memory CRC test. Possible causes: application software in the Error MP is not complete - software download to the MP was not completed successfully - or MP hardware problem.
  • Page 157 Diagnostics Table 33 Diagnostic List Diagnostic Name and Reset Code Source Severity Persistence Criteria Level Phase Loss Immediate Latch a) No current was sensed on one or two of the Local current transformer inputs while running or starting (See Nonlatching Power Loss Diagnostic for all three phases lost while running).
  • Page 158 Diagnostics Table 33 Diagnostic List Diagnostic Name and Reset Code Source Severity Persistence Criteria Level Starter Dry Run Immediate Latch While in the Starter Dry Run Mode either 50 % Line Local Test Voltage was sensed at the Potential Transformers or 10 % RLA Current was sensed at the Current Trans- formers.
  • Page 159 Diagnostics Table 33 Diagnostic List Diagnostic Name and Reset Code Source Severity Persistence Criteria Level Starter Module Immediate Latch Checksum on EEPROM copy of the Starter LLID Local Memory Error configuration failed. Factor default values used. Type 2 - Transition Immediate Latch The Transition Complete input is open with the...
  • Page 160 Diagnostics RTHD-SVX01D-EN...

  • Page 161: Wiring Schematics

    Wiring Schematics Typical field connection diagrams, electrical schematics for the RTHD units are shown in this section. NOTE: The drawings in this section are provided for reference only. These diagrams may not reflect the actual wiring of your unit. For specific electrical connection and schematic information, always refer to the wiring diagrams that were shipped with the unit.
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  • Page 184 Stocking Location Inland www.trane.com Trane has a policy of continuous product data and product improvement and reserves For more information contact your local district the right to change design and specifications without notice. Only qualified techni- office or e-mail us at comfort@trane.com cians should perform the installation and servicing of equipment referred to in this bul- letin.

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