Page 1 125-450 ton units (50 Hz) Part No. X39640508-03 Since the Trane Company has a policy of continuous product improvement, it reserves the right to change specifications and designs without notice. The installation and servicing equipment referred to into this book-...
Page 3 EPA handling and EPA certification requirements for regulations: recovery, recycling and reclaiming. reclamation. The Trane Company and others offer 1 Recovery - the act of removing refrigerant from reclamation services for most refrigerants.
Page 4 8 Stay aware of unit enhancements, conversion The Trane Company encourages every effort to refrigerants, compatible parts and manufacturer’s eliminate, if possible, or vigorously reduce the recommendations which will reduce refrigerant...
Page 5 Your personal safety and reliable operation of this compressor may result. machine depend upon strict observance of these precautions. The Trane Company assumes no liability for installation or service procedures CAUTION performed by unqualified personnel.
Page 6 Failure to disconnect all electrical power prior to evacuating refrigerant, or applying power while the refrigerant system is in a vacuum, will damage the compressor motor. RTHC-IOM-1C...
Page 7: Table Of Contents
Contents General Information........1 - 1 Operator Interface - Controls......5 - 1 Literature Change History ......1 - 1 UCP2 Microprocessor Control System ... 5 - 1 Unit Identification - Nameplates ..... 1 - 1 Chiller Module - 1U1 ........5 - 2 Unit Inspection..........
Page 8: Table Of Contents
Maintenance Procedures ........ 9 - 1 Cleaning the Condenser ......... 9 - 1 Cleaning the Evaporator ......... 9 - 1 Compressor Oil..........9 - 1 Oil Sump Level Check ........9 - 2 Removing Compressor Oil......9 - 2 Oil Charging Procedure ........9 - 3 Replacing the Main Oil Filter (Hot Filter)..
Page 9: General Information
Report any apparent damage or material shortage to Unit Nameplates the carrier and make a “unit damage” notation on the The RTHC “unit” nameplate ( Figure 2 shows carrier’s delivery receipt. Specify the extent and type location) is applied to the exterior surface of the of damage found and notify the appropriate Trane starter/control panel.
Page 10: Loose Parts Inventory
If concealed damage is discovered, stop unpacking the shipment. Do not remove damaged Figure 2 and Figure 3 show a typical RTHC unit and material from the receiving location. Take photos its components. Water inlet and outlet openings are of the damage, if possible.
Page 11 Table 1 Model Number for RTHC Chiller Selection Category Description of Selection Model No. Digit 200/60/3 230/60/3 380/60/3 380/50/3 Voltage 400/50/3 415/50/3 460/60/3 575/60/3 None Specials Specials denoted elsewhere Specials not denoted elsewhere Design First Design (Factory Input) 10-11 Sequence...
Page 12 With C/UL Listing Without With Oil Cooler Without With Differential Without Pressure With Transducer RTHC Compressor Model Number (located on compressor nameplate): Ø Number CHHC Ø 1,2,3,4 10, 11 Digit Table 2 Compressor Model Number for RTHC Selection Category Description of Selection Model No.
Page 13 RTHC Starter/Control Panel Model Number: Ø Number RTSC #### Ø 1,2,3,4 5, 6, 7, 8 9 10, 11 Digit Table 3 Starter/Control Panel Model Number for RTHC Selection Category Description of Selection Model No. Digit Panel Series RTSC Rated Load per sales order ####...
Page 14 Table 3 Starter/Control Panel Model Number for RTHC Selection Category Description of Selection Model No. Digit ICS Interface Without Module Summit Communications Tracer Communications Operator Std Clear Language Display Interface Complex Character CLD Module No Specials Specials Specials denoted elsewhere...
Page 15 Figure 2 Component Location for Typical RTHC Unit Disconnect Liquid/Vapor Clear Language Switch Separator Starter/Control Panel Display (CLD) Condenser Water Outlet Gas Pump Evaporator Nameplate Relief Valve Evaporator Condenser Liquid Level Water Inlet Sensor Evaporator Water Inlet NOTE: The evaporator inlets and outlets are located opposite from those on the RTHA and RTHB units.
Page 16 Figure 3 Component Location for Typical RTHC Unit (Back View) Unit Nameplate Compressor (on side of starter/control Oil Separator panel) Discharge Oil Separator Relief Lines Valves Lifting Holes Oil Distribution System Condenser Evaporator Water Outlet Oil Sump (located between condenser and evaporator) 8”...
Page 17: Installation Overview
Installation Overview For convenience, Table 4 summarizes responsibilities that are typically associated with the RTHC chiller installation process. Table 4 Installation Responsibility Chart for RTHC Units Requirement Trane-supplied, Trane-installed Trane-supplied, Field-installed Field-supplied, Field-installed Rigging Safety chains Clevis connectors Lifting beam...
Page 18 Where specified, supply and insulate the q Supply and install condenser water control evaporator and any other portion of the unit, as valve(s) per Trane RLC-EB-4. required, to prevent sweating under normal q Supply and install flow switches or equivalent operating conditions.
Page 19 Table 5 General Data Unit Designator (corresponds to digits 6, 7, 12, 13, 16, 17 of unit model number) D1D1E1 D1F1F2 D1G2G2 D2D2E2 D2F2F3 D2G3G3 Maximum Flow (gpm (l/s)) 1666 (105) 2292 (144) 2221 (140) 1827 (115) 2453 (154) 2531 (154) for 2-pass for 2-pass for 3-pass...
Page 20 149 (3785) 125 (3175) 143 (3632) 125 (3175) 143 (3632) Width (in (mm))* 70 (1778) 65 (1651) 65 (1651) 65 (1651) 65 (1651) Height (in (mm))* 80 (2032) 71 (1803) 71 (1803) 71 (1803) 71 (1803) Evaporator 1 - 12 RTHC-IOM-1C...
Page 21 Unit Designator (corresponds to digits 6, 7, 12, 13, 16, 17 of unit model number) C2G1G1 B1B1B1 B1C1D1 B2B2B2 B2C2D2 Water Storage (gal (l)) 136 (515) 41 (155) 55 (208) 45 (170) 58 (220) Minimum Flow (gpm (l/s)) 558 (35) for 275 (17) for 352 (22) for 319 (20) for...
Page 22 1 - 14 RTHC-IOM-1C...
Page 23: Installation - Mechanical
Installation - Mechanical Storage The Trane Company is not responsible for equipment problems resulting from an improperly designed or If the chiller is to be stored at least one month prior to constructed foundation. installation, observe the following precautions: Vibration Eliminators...
Page 24: Access Restrictions
Refer to “Pressure Relief Valves.” Door clearances for the RTHC units are given in Figure 4 . Refer to the unit submittals for specific “per Make provisions in the equipment room to keep the unit”...
Page 25: Moving And Rigging
Moving and Rigging WARNING The Model RTHC chiller should be moved by lifting at Always use lifting equipment with designated lift points only. Refer to Figure 5 and a capacity exceeding unit lifting Table 8 and Table 7 for typical unit lifting and weight by an adequate safety fac- operating weights.
Page 26 Est. Water Wt 1045 (474) 1791 (812) 948 (430) 1324 (601) 1954 (886) 1004 (455) 1396 (633) 2130 (966) Total Installed Wt 15550 20150 15850 17900 21400 15900 18700 22100 (7055) (9142) (7189) (8119) (9707) (7189) (8482) (10024) 2 - 4 RTHC-IOM-1C...
Page 27: Lifting Procedure
Table 8 Unit Weights (lb (kg)) (see Figure 5 ) Unit Designator (corresponds to digits 6, 7, 12, 13, 16, 17 of unit model number) Location (Point) D3D2E2 D3F2F3 D3G3G3 E3D2E2 E3F2F3 E3G3G3 3841 (1742) 4870 (2209) 5445 (2470) 3906 (1772) 4940 (2241) 5489 (2490) 2880 (1306)
Page 28 Unit Model Number Note: Refer to specific unit location submittals or Figure 5 for weight distribution WARNING To prevent personal injury or equipment damage, refer to Trane RTHC-SB-2 for units that must be disassembled due to limited access. 2 - 6 RTHC-IOM-1C...
Page 29: Isolation Pads
NOTE: The elastomeric pads shipped (as standard) cable fail. are adequate for most installations. For additional details on isolation practices, refer to Trane 5 Connect an anti-rotation strap or cable loosely Engineering Bulletin RLC-EB-3, or consult an between the lifting beam and the threaded acoustical engineer for sound-sensitive installations.
Page 30 9 Remove the shipping brackets from the bottom sides of the oil separator(s) (see Figure 8 ). NOTE: Once shipping bracket(s) is removed, the oil separator is only supported by the discharge line. Shipping Bracket 2 - 8 RTHC-IOM-1C...
Page 31: Unit Leveling
Figure 9 Make water piping connections to the evaporator and Shipping Spacer Removal condenser. Isolate and support piping to prevent stress on the unit. Construct piping according to local Compressor Housing and national codes. Insulate and flush piping before connecting to unit. Use grooved pipe connectors for all water piping connections.
Page 32 10-3/4” (273mm) for 300 psi 9-1/2” (241mm) for 150 psi 10-3/4” (273mm) for 300 psi 26-5/8” (703mm) 11-7/8” (302mm) 8-3/4” (222mm) for 2 Pass 11” (279mm) 2 Pass 2 Pass Connection Configuration (Left or Right Hand) Depends on Water Inlet 2 - 10 RTHC-IOM-1C...
Page 33 Figure 11 C2G1G1, D2G3G3, D1G2G2, D3G3G3, and E3G3G3 Condenser and Evaporator Water Connections - 7-1/4” (184mm) for 150 psi 7-5/8” (194mm) for 300 psi 129-3/4” (3296mm) 9-1/4” (235mm) for 150 psi 10” (254mm) for 300 psi 80” (2032mm) Compressor Cond Evap 28-3/8”...
Page 34 9-1/8” (232mm) for 150 psi Std. 3 Pass 9-1/2” (241mm) for 300 psi 9-1/2” (241mm) for 300 psi 13-5/8” (346mm) 28” (711mm) 7-5/8” (194mm) 9-5/8” (245mm) 2 Pass 2 Pass Connection Configuration (Left or Right Hand) Depends on Water Inlet 2 - 12 RTHC-IOM-1C...
Page 35 Figure 13 C1B2C1, C1B3C2, and C2B3C2 Condenser and Evaporator Water Connections - 7-3/4” (197mm) 97-1/2” (2476mm) 8” (203mm) for 150 psi 8-1/2” (216mm) for 300 psi 71-3/4 (1822mm) Evap Cond Compressor 23-1/2” (597mm) 13-1/2” 6-5/8 (168mm) 9-1/2” (343mm) (241mm) 9-1/4” (235mm) 13-3/8 (340mm) 4-3/4”...
Page 36 8-3/8 (213mm) for 150 psi 107-5/8” (2734mm) 8-1/2” (216mm) for 300 psi Std. 3 Pass 8-3/8” (213mm) for 150 psi 8-1/2” (216mm) for 300 psi 12-7/8” (327mm) 25-1/8” (638mm) 6-7/8” (175mm) 8-7/8” (225mm) 2 Pass 2 Pass 2 - 14 RTHC-IOM-1C...
Page 37 B1C1D1/B2C2D2 Figure 15Condenser and Evaporator Water Connections - 118” (2997mm) 8” (203mm) for 150 psi 8-1/4” (210mm) for 300 psi 70-3/4 (1797mm) Compressor Evap Cond 23-1/2” (597mm) 9-5/8 (245mm) 13-1/2” 4-3/4” (121mm) for 150 psi (343mm) 11-1/2” 13-3/8 (340mm) 5-1/4” (133mm) for 300 psi (292mm) 64-1/2”...
Page 38 23.0 18.75 23.0 18.75 33.5 22.0 23.0 18.75 23.0 18.75 23.0 18.75 23.0 18.75 *Note: Metric Conversion is 6 NPS = 150 mm nominal 8 NPS = 200 mm nominal 10 NPS = 250 mm nominal 2 - 16 RTHC-IOM-1C...
Page 39: Water Pressure Drop Data
Water Pressure Drop Data Condenser Pressure Drop Condenser Pressure Drop 2-Pass, E1 2-Pass, E2 1000 10000 1000 10000 Condenser Pressure Drop Condenser Pressure Drop 2-Pass, F2 2-Pass, F3 1000 10000 1000 10000 Condenser Pressure Drop Condenser Pressure Drop 2-Pass, G2 2-Pass, G3 1000 10000...
Page 40 Water Pressure Drop Data (continued) Condenser Pressure Drop Condenser Pressure Drop 2-Pass, C1 2-Pass, C2 1000 1000 10000 Condenser Pressure Drop Condenser Pressure Drop 2-Pass, F1 2-Pass, E3 1000 10000 1000 10000 Condenser Pressure Drop 2-Pass, G1 1000 10000 2 - 18 RTHC-IOM-1C...
Page 41 Water Pressure Drop Data (continued) Condenser Pressure Drop Condenser Pressure Drop 2-Pass, B1 2-Pass, B2 1000 1000 Condenser Pressure Drop Condenser Pressure Drop 2-Pass, D1 2-Pass, D2 1000 1000 Installation, Operation and Maintenance 2 - 19...
Page 42 Evaporator Pressure Drop Evaporator Pressure Drop 3-Pass, F2 3-Pass, F1 2-Pass, F2 2-Pass, F1 1000 10000 1000 10000 Evaporator Pressure Drop Evaporator Pressure Drop 4-Pass, G2 4-Pass, G3 3-Pass, G2 3-Pass, G3 1000 10000 1000 10000 2 - 20 RTHC-IOM-1C...
Page 43 Water Pressure Drop Data (continued) Evaporator Pressure Drop Evaporator Pressure Drop 3-Pass, B3 3-Pass, D3 2-Pass, B3 2-Pass, D3 1000 10000 1000 10000 Evaporator Pressure Drop Evaporator Pressure Drop 4-Pass, G1 3-Pass, E1 3-Pass, G1 2-Pass, E1 1000 10000 1000 10000 Evaporator Pressure Drop Evaporator Pressure Drop...
Page 44 Water Pressure Drop Data (continued) Evaporator Pressure Drop Evaporator Pressure Drop 3-Pass, C2 3-Pass, C1 1000 10000 1000 10000 2 - 22 RTHC-IOM-1C...
Page 45 Making Grooved Pipe Connections Leaving Chilled Water Piping q Air vents (to bleed air from system) CAUTION q Water pressure gauges with shutoff valves CAUTION: To prevent damage to water piping, do not overtighten con- q Pipe unions nections. q Vibration eliminators (rubber boots) NOTE: Make sure that all piping is flushed and q Shutoff (isolation) valves cleaned prior to starting the unit.
Page 46: Condenser Water Regulating Valve
Cleanout tees Condenser Water Regulating Valve Adjustment q Pipe strainer Refer to Trane RTHC-SB-7 for installation and q Flow switch adjustment of the optional condenser water regulating valve. Leaving condenser water piping. q Air vents (to bleed air from system)
Page 47: Water Pressure Gauges And Thermometers
Valve Valve Pressure Differential Gauge NOTE: Refer to Trane Engineering Bulletin RLC-EB-3 for sound-sensitive applications. Water Pressure Relief Valves To provide chiller protection, install and wire flow switches in series with the water pump interlocks, for both chilled water and condenser water circuits (refer to the Installation Electrical section).
Page 48: Refrigerant Pressure Relief Valve Venting
All relief valve venting is the responsibility of the installing contractor. * Valve is hidden by pipe All RTHC units use evaporator, compressor, and NOTE: Once opened, relief valves tend to leak and condenser pressure relief valves ( Figure 17 ) that must be replaced.
Page 49: Thermal Insulation
Thermal Insulation Table 12 All RTHC units are available with optional factory Pressure Relief Valve Data installed thermal insulation. If the unit is not factory insulated, install insulation over the areas shaded in Rated Figure 18 . Refer to Table 13 for types and quantities Capacity of insulation required.
Page 50 Figure 18 Typical RTHC Insulation Requirements Front View Rear View Table 13 Recommended Insulation Types Location Type Sq. Feet 3/4” wall 3/4” wall 3/4” wall 1 = evaporator and liquid vapor separator 2 = compressor 3 = all components and piping on low side of system (gas pump,...
Page 51: General Recommendations
Hazardous Voltage! Disconnect all Power Supply Wiring electrical power, including remote disconnects before servicing. Fail- Model RTHC chillers are designed according to NEC Article 310-15; therefore, all power supply wiring ure to disconnect power before must be sized and selected accordingly by the servicing can cause severe per- project engineer.
Page 52 (for units with circuit knockout for printer cable breaker or a mechanical 11.75” disconnect and RLA > 445 (298 mm) (10) 7/8” (22 mm) dia knockout for 120 VAC control voltage UCP2 connections 14.12” (359 mm) Starter/Control Panel Evaporator 3 - 2 RTHC-IOM-1C...
Page 53: Other Supply Power Components
Other Supply Power Components disconnect) as follows: Fused Disconnect Switches Phase Seq. Lead 1TB1 Terminal Size fused disconnects in accordance with NEC Black (Phase A) Article 440-22(a). Red (Phase B) Yellow (Phase C) Compressor Motor Phase Sequencing Always verify that proper rotation of the Series R 4 Turn power on by closing the unit supply power compressor is established before the machine is disconnect switch.
Page 54: Application Of Solid-State Starters
Lug Size L1 - L3 means that, whereas most solid-state starters may Connection RLA Range (each phase) be applied “in the line connection”, on the RTHC 000-760 (2) #4-500 MCM chiller each SCR pair is connected in series with a Terminals only...
Page 55 bypass contactor closes. This would result in line voltage dips and dimming of lights whenever the chiller starts, and should be avoided. Following the prescribed selections and control settings will result in reliable chiller starting, while maximizing motor and contactor life. Selections in the following table are based on the following startup ramp.
Page 56 STARTER AND MOTOR TERMI- Figure 18 . NALS REMAIN “HOT” AT HIGH VOLTAGE EVEN WHEN MOTOR AND STARTER ARE “OFF.” Be Certain To Disconnect All Power To The Unit Before Per- forming Any Work In The Starter Panel. 3 - 6 RTHC-IOM-1C...
Page 57 Figure 18 Solid State Starter Connections Bypass Contactor Line Triac "In Phase the Phase" Shunt Trip Circuit Breaker\Disconnect BREAKER OPENED. Note that even a Solid State Starter with its triacs “in the line” represent a similar hazard. Should a person EVEN WHEN THE COMPRESSOR IS NOT contact any of the motor terminals, even with the RUNNING, VOLTAGE IS PRESENT AT THE...
Page 58 Figure 20 Y-D Starter Panel showing cables to compressor motor terminals Figure 21 Solid State Starter Panel showing cables to compressor motor terminals 3 - 8 RTHC-IOM-1C...
Page 59: Module Connections For Interconnecting Wiring
Figure 22 Motor Terminal Junction Box Wiring (Wye Delta Starter) Ground Lugs Current Transformers Module Connections for Interconnecting diagrams in this manual are typical only and may not match the unit. Wiring Whenever a contact closure (binary output) is All connectors can be unplugged or the wires can be referenced, the electrical rating is: removed from the screw assembly.
Page 60 The chiller module (1U1) requires a control voltage Figure 23 contact input (1TB3-14, J26-1) through a flow proving RTHC Electrical Installation Programmable Relays switch (5S1) and an auxiliary contact (5K1 AUX) from the chilled water pump starter that provides proof of flow.
Page 61: Diagnostics
not have a chance to return to the unloaded position Tracer Controlled Contact for the next startup. The options module (1U5) provides a Tracer- controlled relay normally open contact closure output NOTE: A “panic” stop (similar to “emergency” stop) (J18-1, J18-3) and normally closed contact output can be manually commanded using the Clear (J18-2, J18-3).
Page 62 Refer to the instructions supplied with the controlled device for setup. Compressor Percent RLA Output The options module (1U5) provides a 2-10 VDC output (J7-3, J7-4) signal that is proportional to the percent compressor RLA. 3 - 12 RTHC-IOM-1C...
Page 63: General
(application dependent) q related interconnecting piping. General Components of a typical RTHC unit are identified in The Model RTHC units are single-compressor, Figure 24 . helical-rotary type water-cooled liquid chillers. These Figure 24...
Page 64: Refrigeration (Cooling) Cycle
(State Pt. 6). Cycle Description The RTHC chiller maximizes the evaporator heat The refrigeration cycle for the RTHC chiller can be transfer performance while minimizing refrigerant described using the pressure-enthalpy diagram charge requirements. This is accomplished by shown in Figure 25 .
Page 65 Figure 25 Pressure /Enthalpy Curve Liquid Pressure Enthalpy Figure 26 Refrigerant Flow Diagram Liquid/Vapor Separator Compressor Evaporator Oil Separators Condenser Installation, Operation and Maintenance 4 - 3...
Page 66: Compressor Description
Compressor Description Figure 27 RTHC Compressor 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...
Page 67: Oil Management System
Separately housed bearing sets are The compressor is unloaded when the unload provided at each end of both rotors on the RTHC solenoid valve (4L3) is open. Vapor “trapped” within units. The slide valve is located below (and moves along) the rotors.
Page 68 20 psid for systems without an monitors both the 7.7 psid differential switch mounted oil cooler and 35 psid for systems with an oil cooler. between the evaporator and the condenser and the temperature sensors mounted in both the evaporator 4 - 6 RTHC-IOM-1C...
Page 69: Oil Filter
and condenser. If the differential is lower than Lubricant Recovery required, the unit will latch out and may start a “low system differential restart inhibit timer,” if necessary, to cool the rotors. To ensure proper lubrication and minimize refrigerant condensation in the oil sump, a heater is mounted on the side of the oil sump.
Page 70: Oil Cooler
The oil cooler is required on units running at high condensing or low suction temperatures. The high discharge temperatures in these applications increase oil temperatures above the recommended limits for adequate lubrication and reduce the viscosity of the oil. 4 - 8 RTHC-IOM-1C...
Page 71: Ucp2 Microprocessor Control System
This part of the section covers information protection, and optimization functions for the RTHC available to you by pressing each report key followed chiller. All module control elements reside in the by the settings, tests, and diagnostics keys.
Page 72: Chiller Module - 1U1
IPC (inter processor communications) link. The chiller module Inputs and outputs include chilled water system level performs the leaving chilled water temperature and input/output (I/O) such as evaporator and condenser 5 - 2 RTHC-IOM-1C...
Page 73: Stepper Module - 1U3
water temperatures, evaporator and condenser Printer Interface Module - 1U7 water pump control, and general status and alarm The printer interface module provides a pre- relays. Other machine inputs and outputs include formatted chiller log to the printer. The printer compressor load and unload pulse outputs, oil return interface can be programed, via the Clear Language pump control and oil lubrication system control and...
Page 74: Key Functions
The <Next> and <Previous> keys can then be used stroke has been recognized. to scroll from one report item to the next. As the last item is reached, continued scrolling will cause the 5 - 4 RTHC-IOM-1C...
Page 75: Communications And Settings Storage
Note that the <Stop> and <Auto> keys act Communications and Settings Storage immediately and do not require the use of the The individual modules identified earlier in this <Enter> key. section communicate via the InterProcessor Communication (IPC) link. The IPC allows the STOP, AUTO modules to work together to direct overall chiller The chiller will stop when the <Stop>...
Page 76: Custom Report Group - Programming Instructions
See Operator’s Manual To Select Entries cause of the communications problem. Persistent problems should be referred to Trane Service. The report then wraps around to the report heading when <Next> is pressed. Custom Report Group - Programming...
Page 77 Table 15 Sequence Parameter Displayed Standard ASHRAE Report Report Ice Termination Setpoint/Source Reset Chilled Water Setpoint/ Source Evap Entering Water Temp Condenser Entering Water Temp. Condenser Leaving Water Temp Current Limit Setpoint/Source Active Current Limit Setpt/Setting Source Outdoor Air Temp Time/Refrigerant Type Refrigerant Monitor (option only) Saturated Evap Refgt Temp...
Page 78 Unit Is Running Starter Dry Run Capacity Limited By Low Evap Temp Unit is Running Establishing Minimum Capacity Limit * Displays are not in any sequence. Some displays will never appear, depending on options and situation 5 - 8 RTHC-IOM-1C...
Page 79 Chilled Water Setpoint and Source/Evap Leaving The second line displays the fundamental Water Temp (Standard Report) temperature (and its source) upon which the reset is based. This represents the lowest setpoint possible when no reset is applied. Chilled Water Setpoint [source]: xxx.x F Ice Termination Setpoint/Ice Termination Evap Leaving Water Temp:...
Page 80 Press (Next) (Previous) to Continue standard report. If the IPC MSA refrigerant monitor allows you to scan various channels, the following item will be displayed: Refrigerant Monitor: Scanner Channel Y: XXXX PPM [Rfgt Type] 5 - 10 RTHC-IOM-1C...
Page 81 where Y is the channel currently being scanned and Chilled Water Flow Switch Status (ASHRAE XXXX is the refrigerant concentration of that channel. Report) The screen displays the status of the chilled water Saturated Evap Temperature/Compressor flow switch at the input to the UCM. Discharge Temperature (ASHRAE Report) Chilled Water Flow Switch Status: Saturated Evap Rfgt Temp:...
Page 82: Refrigerant Report
Compressor Discharge Temp: xxx.x F small load disturbances are normal. If the liquid level remains at the extremes of its range for a long time, this indicates problems that could damage the compressor or severely reduce performance. 5 - 12 RTHC-IOM-1C...
Page 83: Compressor Report
Compressor Discharge Temperature/Discharge Compressor Report Superheat Report Heading Compressor Discharge Temp: xxx.x F Discharge Superheat: xxx.x F Compressor Hours, Starts & Amps Press (Next) (Previous) to Continue Evaporator and Condenser Approach Temperatures Compressor Line Currents% RLA Evaporator Approach Temp.: xxx.x F Compressor Line Currents -% RLA Condenser Approach Temp.: xxx.x F...
Page 84: Operator Settings
HH:MM xm Mon, XX, XXXX To Change Minute, Press (+) (-) & (Enter) Set Contrast: Press (X) to Save Press (+) (-) To Change Setting Current Time/Date HH:MM xm Mon, XX, XXXX To Change Month, Press (+) (-) & (Enter) 5 - 14 RTHC-IOM-1C...
Page 85 Front Panel Current Limit Setpoint Current Time/Date HH:MM xm Mon, XX, XXXX To Change Day, Press (+) (-) & (Enter) XX Front Panel Current Limit Stpt: xxx% Press (+) (-) to Change Setting Current Time/Date HH:MM xm Mon, XX, XXXX To Change Year, Press (+) (-) &...
Page 86 Possible values of [source] are none (ROM default), service setup screen. The ROM default is 27.0°F “Use Front Panel setpoints,” and “Override Tracer. (-2.8°C). Use default setpoints” for which the Tracer option must be installed. this is a global override that will 5 - 16 RTHC-IOM-1C...
Page 87: Service Settings (Non Password Protected Service Settings Group)
prevent Tracer, External, or Chilled Water Reset heading display appears from asserting control on the chilled water setpoint. Service Settings: Basic Setups Press (Next) (Previous) to Continue Service Settings (Non Password Protected Service Settings Group) Menu Settings Password All service settings are accessed by pressing the <Service Settings>...
Page 88 The choices for [status] are XXX.X (factory default) and XXX. The range of values is 1 to 10°F (0.5 to 5.5°C) in increments of 1 or 0.1°F or C depending on the service setup screen. The factory default is 5°F (2.8°C). 5 - 18 RTHC-IOM-1C...
Page 89 Evap/Cond Pump Off Delay Time increments. The ROM default is 8 hours. This time delay is used to keep the chilled water pump on during the run-unload cycle, after the UCP2 Print on Diagnostic [d/e] has been given the command to stop. This stop Press (+) (-) to Change Setting command could come from the Clear Language Display, Tracer, or External Auto/Stop.
Page 90: Service Settings (Password Protected Field Startup Group)
Restart Inhibit Timer Has Been Cleared pressed within 10 minutes in this password-protected menu, the display returns to the chiller operating mode display of the chiller report, and the password must be entered again to return to this menu. 5 - 20 RTHC-IOM-1C...
Page 91 Field Startup Group Heading When the feature is disabled, the menu setting password display does not appear at the top of each of the settings menus and the menu settings cannot Field Start-up Group Settings be password protected. When the menu setting password feature is enabled, the menu settings “Press (Next) (Previous) to Continue”...
Page 92 If When this setpoint is adjusted below 28.5°F the operating conditions change significantly, check with following is displayed on the second line: “Warning: Trane technical service to see if modifications may Adequate Antifreeze Required.” be required. Condenser Limit Setpoint Design Delta Temperature: xxx.x F...
Page 93 Phase Unbalance Limit Enable Soft Load Current Limit Rate Of Change The UCM provides non-defeatable phase unbalance protection that stops compressor operation with more Soft Load Current Limit Rate: x.x%/min than 30% phase unbalance. If this unbalance limit is Press (+)(-) to Change Setting enabled, the motor will be “limited”...
Page 94: Service Settings (Password Protected Machine Configuration Group)
The ROM default is 14.7 psia. Press (+)(-) to Change Setting Possible values for type are Y Delta (ROM default); X line; solid state, C515 series; solid state, EA series; auto transformer; and primary reactor. For the RTHC 5 - 24 RTHC-IOM-1C...
Page 95 It will trigger a amps as determined during the initial selection manually resettable diagnostic, shutting the unit process. If conditions change, contact Trane down, when the current exceeds a specified time-trip Technical Support for new settings based on the new curve.
Page 96 Y-Delta start sequence or under current limit control of the solid state starter. Maximum Acceleration Timer #1: xx sec Press (+)(-) to Change Setting 5 - 26 RTHC-IOM-1C...
Page 97 Press (+)(-) to Change Setting Possible values for status are installed or not installed (ROM default). Where size(-xx) is the EXV size rating and Trane part Unit Line Voltage number extension in parentheses as follows: This screen only appears if the line voltage sensing Table 20 option is installed.
Page 98 If <Next> or <Previous> is pressed, skip to the next heading item in the menu. If <Enter> is pressed, the following screens are displayed in order: Relay #1: [event] Press (+)(-) to Change Setting 5 - 28 RTHC-IOM-1C...
Page 99 If “delta” is selected, the output voltage will be linear Relay #2: [event] with the endpoints defined by th following two menu Press (+)(-) to Change Setting items: NOTE: this function does not use actual measured pressures, but rather temperature sensor readings Relay #3: [event] and assumes sturated conditions for R134a...
Page 100: Service Settings (Password Protected Refrigerant Monitor Settings Group)
Condition to Turn Alarm Off: “Chilled Water Pump” Auto “Condenser Water Pump” Auto “EXV Control” Auto “Slide Valve Control” Auto “Master Oil Line Solenoid Auto Valve” “Oil Return Fill Solenoid Auto Valve” “Oil Return Drain Solenoid Auto Valve” 5 - 30 RTHC-IOM-1C...
Page 101 Service Tools Group Password Request Condenser Water Flow Switch Status The following screen is not a setpoint. This screen displays the status of the condenser water flow Pswd Reqd to Access Service Tools Group switch status at the input to the UCM. Please Enter Password Condenser Water Flow Switch Status: The service tools password is <+>...
Page 102 Ratchet Open Ratchet (second) X15110743 -01 (200) RTHC “B” Frame Comp -03 (400C) “D” Frame Comp. -04 (300) “C” Frame The sequence is for the valve to close normally for the period indicated, then ratchet for the designated period, open normally for a period,...
Page 103 where mode is Auto (ROM default), Hold, Load, or Note: The dry or wet status is determined by the Unload. chiller module by using a filtered value from the sensor’s A/D input and comparing it to fixed The possible values of Y are “Current,” “Condenser switchpoint levels.
Page 104 PN. Notes: These screens will display a line item for [Module x:] [Software PN] every possible module in an RTHC system. If a [Module y:] [Software PN] module fails during operation, the software revision for that module will still appear on the CLD until after a CLD power down reset.
Page 105 Table 24 General Factory Settings Service Settings (Field Startup ICS Address Group) Power Up Start Delay Time 0 SEC 10 ° F Design Delta Temp Setpt 36 ° F Lvg Wtr Temp Cutout Setpt 32 ° F Low Rfgt Temp Cutout Setpt Condenser Limit Setpt 90% HPC Max.
Page 106 Should a diagnostic occur in Auto mode, the display will automatically go to this menu and display certain messages as explained below and detailed in Section 10, Diagnostics. 5 - 36 RTHC-IOM-1C...
Page 107 password screen, and a screen indicating whether The first active diagnostic screen will be: diagnostics are present: [sn] [diagnostic] Active & Historic Diagnostics (Next) [diagnostic type] Press (Next)(Previous) To Continue The sequence number (sn) will run from 1 through 20 Settings In This Menu Are [status] with the most recent diagnostic numbered “01.”...
Page 108 If the <Enter> key is pressed, the following message is displayed for 4 seconds: Historic Diagnostics Have Been Cleared Diagnostic Report Is Being Reset The display will be reset to the top of the Diagnostic Menu after this message clears. 5 - 38 RTHC-IOM-1C...
Page 109: Unit Start-Up
8QLW 6WDUWXS Daily Unit Start-Up The following status screens will be displayed and require no operator action: NOTE: Unless the UCP2 and building automation system are controlling the chilled water pump, the manual unit start sequence is as follows. Operator Self Test in Progress actions are noted.
Page 110 These limits are discussed in installation, from all starting simultaneously after a the following paragraphs. power interruption or power application. The 6 - 2 RTHC-IOM-1C...
Page 111: Seasonal Unit Start-Up Procedure
After the starting sequence ends, the UCP2 checks period (often done by imposing a current limit) or for a complete starter transition, begins a run unload slows the rate of loading during the initial pull- mode, and energizes the unload solenoid for 30 down (by limiting the loading).
Page 112 6 - 4 RTHC-IOM-1C...
Page 113: Unit Shutdown
8QLW 6KXWGRZQ Daily Unit Shutdown If the unit was manually stopped by the operator when the stop sequence began, the following: The unit will shut down normally in either of two ways: when the cooling requirement is satisfied and when the <Stop> key is pressed. Local Stop: Cannot Be Overridden By Any External Or Remote Device NOTE: The normal shutdown sequence in the...
Page 114 7 - 2 RTHC-IOM-1C...
Page 115: Periodic Maintenance
3HULRGLF 0DLQWHQDQFH q Measure the oil filter pressure drop. Replace oil Overview filter if required. Refer to “Service Procedures”. This section describes preventive maintenance q Measure and log the subcooling and superheat. procedures and intervals for the Series R unit. Use a Refer to Table 26 periodic maintenance program to ensure maximum performance and efficiency of the Series R units.
Page 116: Annual Maintenance
Test vent piping of all relief valves for presence of refrigerant to detect improperly sealed relief valves. Replace any leaking relief valve. q Inspect the condenser tubes for fouling; clean if necessary. Refer to Section 9 “Maintenance Procedures”. 8 - 2 RTHC-IOM-1C...
Page 117 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? Y N Vendor ID #/Model #: Oil separator shipping bolts removed? Y N ______Volts...
Page 118 Comp Phase Currents (Amps) Compressor Phase Voltage Compressor Starts Compressor Running Time MENU ITEMS SETTING Current Time/Date MENU ITEMS SETTING Front Panel Chilled OPERATOR SETTINGS Water Setpt Setting in this menu are Lock Front Panel Current Unlock Limit Setpt 8 - 4 RTHC-IOM-1C...
Page 119 MENU ITEMS SETTING MENU ITEMS SETTING Front Panel Chilled ICS Address Water Setpt Power up start delay Front Panel Current time Limit Setpt Design Delta Temp Chilled Wtr Reset Type Setpt Reset Ratio Lvg Wtr Temp Cutout Setpt Start Reset Setpoint Low Rfgt Cutout Setpt Max Reset Setpoint Condenser Limit Setpt...
Page 120 Not Install High Pressure Cutout Setting Line Voltage Sensing Option Unit Line Voltage Ice Building Option Install Not Install Ext. Setpoint Inputs 4-20 ma 2-10 vdc Tracer Option Install Not Install TCI Option Install Not Install 8 - 6 RTHC-IOM-1C...
Page 121 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) Vendor ID #/Model #: ______Volts _______Amps ______ Hz...
Page 123: Unit Location And Mounting
Installation Checklist for Model RTHB/RTHC 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 124 Energize crankcase heaters. Heaters need to be energized 24 hours before start-up. Confirm that all service and isolation valves are open. Refer to RTHC-SB-1 for RTHC units and RTHB-IOM-1 for the RTHB units. Remove the four compressor shipping stops (snubbers) from under the compressor. (RTHC only) Remove shipping bolts from under the two oil separators (RTHC only) Confirm phase-sequencing “A-B-C”.
Page 125 Chilled water piping connected to: Cooling tower fan rotation checked Series R unit Condenser water pump motor connected (In and out different between RTHB and RTHC, refer to IOM) Air handling units Pump (as applicable) Pumps Power available for vacuum pump (115 VAC)
Page 126 Was the owner given a copy of the MSDS sheet for the refrigerant used in the chiller? Was the owner given a copy of Trane publication “CFC-GUIDE-2, Refrigerant Han- dling Guidelines”? Additional time required to complete the start-up and adjustment due to incompleteness of the installation will be invoiced at prevailing rates.
Page 127 Series R Chiller Test Log Date Sales Order No: Voltage Job Name: Model No: Contract No.: Job Location: Serial No: 15 min. 30 min. 1 hr. MENU ITEMS SETTING run- run- run- OPERATOR SETTINGS MENU ITEM time time time Setting in this menu are Lock CHILLER REPORT Unlock...
Page 128 MENU ITEMS SETTING MENU ITEMS SETTING MENU ITEMS SETTING Differential to start set- Liq. Level Control Pro- Ext. Setpoint Inputs 4-20 ma point portional Gain 2-10 vdc Differential to stop set- Liq. Level Control Inte- Tracer Option Install point gral Reset Time Not Install Evap pump off delay Liq.
Page 129: Cleaning The Condenser
1 Remove the retaining bolts from the water boxes at each end of the condenser. Use a hoist to lift Trane polyolester oil is the approved oil for the RTHC the water boxes. units. Polyolester oil is extremely hygroscopic meaning it readily attracts moisture.
Page 130: Oil Sump Level Check
4 After the unit is off line for 10 minutes move the sightglass along the edge of the condenser 9 - 2 RTHC-IOM-1C...
Page 131: Oil Charging Procedure
Oil Charging Procedure NOTE: The remainder of the oil charge can be charged into the 1/4” service valve located at the It is critical to fill the oil lines feeding the compressor bottom of the sump if a larger connection is when charging a system with oil.
Page 132: Replacing The Gas Pump Oil Filter
500 microns psig. CAUTION: DO NOT add more oil to 8 Charge the oil line back with the amount of oil the system removed. Open the isolation valves to the oil 9 - 4 RTHC-IOM-1C...
Page 133: Refrigerant Charging
Figure 34 Oil Filter Replacement Chart (E,D, C and B Frames) 175/450 Ton RTHC Compressor Oil Filter Replacement Chart D- and E-Frame Normal Press Drop C-Frame Normal Press Drop Max Pressure Drop B-Frame Normal Press Drop Condensing Press - Suction Press (psid)
Page 134 When setting up an ice-making system, the ice (Chilled Water Setpoint (ice-making only) = Ice Termination Setpoint - 6 ° F). termination setpoint is the entering water. Subtract 6 ° F from the setpoint to use Table 31 9 - 6 RTHC-IOM-1C...
Page 135 'LDJQRVWLFV Diagnostic Displays or if diagnostics are present, the following screen appears, Information regarding all active and historic diagnostics, as well as screens to clear diagnostics, can be found in the Diagnostics Group. The Diagnostic Report Follows Diagnostics Group can be accessed at any time by Press (Next) For More pressing the <Diagnostics>...
Page 136 Manual Reset, causes either an immediate or as a pre-start unload period, however, are per- “friendly” shutdown of the chiller to prevent system formed, which will usually allow the compres- sor to start unloaded on the next start. 10 - 2 RTHC-IOM-1C...
Page 137 Be sure that the conditions that caused the diagnostic are The following (Table 32, next page) presents all corrected. If diagnostics recur, call Trane service. possible diagnostics and related causes in alphabetical order by the diagnostic message that If the <Enter>...
Page 138 Maximum Acceleration Timer. Troubleshooting Transition b. The clear language display setups defined “Transition or Bypass” Service Bulletin (The Motor is put as the action when the Maximum Acceleration Timer was exceeded. across the line.) 10 - 4 RTHC-IOM-1C...
Page 139 Diagnostic Diagnostic Shutdown Description Type Action Cause Help Message Condenser Rfgt Friendly Open or Short Check Sensor, Temp Sensor Wiring And Connections Cond Entering Open or Short Check Sensor, Wtr Temp Sensor Wiring And Connections Cond Leaving Wtr Open or Short. Check Sensor, Temp Sensor Wiring And...
Page 140 Check Flow, ° Water Temp: Unit compressor was running for 30 F Seconds. Automatic Reset of the Sensor, Wiring and ° ° MAR diag shall occur 2 F (1.1 C) above the cutout setpoint. Rapid Load Loss 10 - 6 RTHC-IOM-1C...
Page 141 Diagnostic Diagnostic Shutdown Description Type Action Cause Help Message Low Differential Friendly A low differential temperature/pressure condition was detected that Check Condsr Rfgt Pressure lasted for more than 240 continuous seconds. The trip point is 23.8 Water Temp Too psid. Low and EXV Low Differential If the 7.7 psid system differential pressure switch is not open on the...
Page 142 Wiring And (Outdoor Air b. Clear diag. when the resistance returns to normal range. Connections Reset Selected) Outdoor Air Temp None Open or Short Sensor a. Display end of range value. (dashes “-----”) (Outdoor Air not selected.) 10 - 8 RTHC-IOM-1C...
Page 143 Diagnostic Diagnostic Shutdown Description Type Action Cause Help Message Over Voltage Friendly a. Line voltage above + 10% of nominal. (Must hold = + 10% of Check Main Power nominal. Must trip = + 15% of nominal. Reset differential = min. of Supply &...
Page 144 Troubleshooting CT’s. If currents are detected when only 1K1 is closed first at start, Service Bulletin then one of the other contactors is shorted. b. This test applies only to factory installed Y-Delta Closed Transition Starters. 10 - 10 RTHC-IOM-1C...
Page 145 Diagnostic Diagnostic Shutdown Description Type Action Cause Help Message Starter Fault Type Immediate a. This is a specific starter test where the Shorting Contactor (1K3) is individually energized and a check is made to ensure that there Troubleshooting are no currents detected by the CT’s. If current is detected when Service Bulletin only S is energized at Start, then 1K1 is shorted.
Page 146 4%. Time to trip = min. of 1 min. and max. of 5 min.) Design: Nom. trip: 60 seconds at less than 87.5%, ±2.8% at 200V or +/- 1.8% at 575V, Auto Reset at 90% or greater. 10 - 12 RTHC-IOM-1C...
Page 147 :LULQJ 6FKHPDWLFV General Typical field connection diagrams, electrical schematics and connections diagrams for the RTHC units are shown in the following 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.
Page 149 A DIVISION OF FIELD WIRING AMERICAN STANDARD INC. 5-11-99 RTHC THIS DRAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS DRAWN BY CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY DATE SIMILAR TO 12-27-96...
Page 164 A DIVISION OF RTHC AMERICAN STANDARD INC. 5-4-99 COMPONENT LOCATION THIS DRAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS DRAWN BY CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY DATE SIMILAR TO 12-23-96...
Page 167 A DIVISION OF RTHC AMERICAN STANDARD INC. 5-4-99 COMPONENT LOCATION THIS DRAWING IS PROPRIETARY AND SHALL NOT BE COPIED OR ITS DRAWN BY CONTENTS DISCLOSED TO OUTSIDE PARTIES WITHOUT THE WRITTEN CONSENT OF THE TRANE COMPANY DATE SIMILAR TO 12-23-96...

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