Trane R Series Installation Operation & Maintenance
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Trane R Series Installation Operation & Maintenance

Trane R Series Installation Operation & Maintenance

Air-cooled helical-rotary liquid chiller 50 hz 400-1500 kw
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Installation
Operation
Maintenance
Series R™ Air-Cooled Helical-Rotary
Liquid Chiller
Model RTAC 120-400 (50 Hz)
400-1500 kW
RLC-SVX02G-E4

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Summary of Contents for Trane R Series

  • Page 1 Installation Operation Maintenance Series R™ Air-Cooled Helical-Rotary Liquid Chiller Model RTAC 120-400 (50 Hz) 400-1500 kW RLC-SVX02G-E4...

  • Page 2: Table Of Contents

    Neoprene Isolator Installation Drainage Evaporator Grooved Pipe Water Treatment Entering Chilled-Water Piping Leaving Chilled-Water Piping Evaporator Drain Evaporator Flow Proving Device Performance Data Water Pressure Gauges Water Pressure Relief Valves Freeze Protection Refrigerant Cutouts and Glycol Percentages RLC-SVX02G-E4 © 2010 Trane...
  • Page 3 Contents Installation - Electrical General Recommendations Wire Sizing Electrical Data Tables Installer-Supplied Components Power Supply Wiring Control Power Supply Heater Power Supply Water Pump Power Supply Interconnecting Wiring Alarm and Status Relay Outputs (Programmable Relays) Relay Assignments Using TechView Low Voltage Wiring Emergency Stop External Auto/Stop External Circuit Lockout...
  • Page 4 Contents Pre-Start Checkout Installation Checklist General Unit Voltage Power Supply Unit Voltage Imbalance Unit Voltage Phasing Water System Flow Rates Water System Pressure Drop Ch.530 Set-up Unit Startup Procedures Daily Unit Startup General Seasonal Unit Startup Procedure System Restart After Extended Shutdown Unit Shutdown Procedures Temporary Shutdown And Restart Extended Shutdown Procedure...
  • Page 5 Contents Periodic Maintenance Maintenance Procedures Refrigerant Emission Control Refrigerant and Oil Charge Management Charge Isolation in the high or low side of system Filter Replacement Procedure Lubrication System Prelubrication Field Oil Charging Procedure RLC-SVX02G-E4...

  • Page 6: General Information

    72 hours of delivery. Notify the local TRANE sales office at the same time. Loose Parts Inventory Important notice: No shipping Check all the accessories and loose...

  • Page 7: General Data Tables

    General Data SI Units Table G-1 - General Data RTAC 140-200 Standard Size Cooling capacity (5) (6) 491.9 537.3 585.4 648.0 714.5 Power input (7) 170.1 187.8 224.7 244.2 Energy Efficiency Ratio (5) (6) (as Eurovent) kW/kW 2.89 2.86 2.84 2.89 2.93 ESEER (as Eurovent)
  • Page 8 General Data SI Units Table G-2 - General Data RTAC 120-200 High Efficiency Size Cooling capacity (5) (6) 421.9 465.9 513.3 557.3 603.7 669.8 740.1 Power input (7) 137.5 151.4 165.7 182.7 200.3 219.1 238.7 Energy Efficiency Ratio (5) (6) (as Eurovent) kW/kW 3.07 3.08...
  • Page 9 General Data SI Units Table G-3 - General Data RTAC 120-200 Extra Efficiency Size Cooling capacity (5) (6) 426.8 474.7 520.7 566.4 632.8 679.6 747.1 Power input (7) 135.1 149.7 164.8 179.8 198.4 215.7 236.4 Energy Efficiency Ratio (5) (6) (as Eurovent) kW/kW 3.16 3.17...
  • Page 10 General Data SI Units Table G-4 - General Data RTAC 140-200 Low Noise Standard Size Cooling capacity (5) (6) 465.9 508.8 554.5 614.3 677.9 Power input (7) 178.2 196.1 214.9 234.3 254.6 Energy Efficiency Ratio (5) (6) (as Eurovent) kW/kW 2.61 2.58 2.62...
  • Page 11 General Data SI Units Table G-5 - General Data RTAC 120-200 High Efficiency Low Noise Size Cooling capacity (5) (6) 405.0 447.6 493.3 535.5 580.1 643.8 711.3 Power input (7) 155.1 169.8 186.8 204.3 223.8 244.2 Energy Efficiency Ratio (5) (6) (as Eurovent) kW/kW 2.88...
  • Page 12 General Data SI Units Table G-6 - General Data RTAC 120-200 Extra Efficiency Low Noise Size Cooling capacity (5) (6) 412.7 459.2 501.7 548.8 611.8 657.1 718.7 Power input (7) 135.1 149.7 164.8 179.8 198.4 215.7 236.4 Energy Efficiency Ratio (5) (6) (as Eurovent) kW/kW 3.01 3.03...
  • Page 13 General Data SI Units Table G-7 - General Data RTAC 230-400 Standard Size Cooling capacity (5) (6) 769.7 857.9 850.9 947.2 1077.3 1191.6 1322.4 1451.4 Power input (7) 293.6 293.4 330.5 370.2 418.9 458.8 498.4 Energy Efficiency Ratio (5) (6) (as Eurovent) kW/kW 2.93...
  • Page 14 General Data SI Units Table G-8 - General Data RTAC 250-400 High Efficiency Size Cooling capacity (5) (6) 876.9 978.5 1111.8 1227.8 1363.9 1501.3 Power input (7) 289.8 360.2 407.2 446.9 486.9 Energy Efficiency Ratio (5) (6) (as Eurovent) kW/kW 3.03 3.05 3.09...
  • Page 15 General Data SI Units Table G-9 - General Data RTAC 255-400 Extra Efficiency Size Cooling capacity (5) (6) 898.7 998.2 1128.3 1290.0 1388.1 1516.8 Power input (7) 283.5 318.9 355.9 408.2 444.9 481.5 Energy Efficiency Ratio (5) (6) (as Eurovent) kW/kW 3.17 3.13...
  • Page 16 General Data SI Units Table G-10 - General Data RTAC 230-400 Low Noise Standard Size Cooling capacity (5) (6) 728.9 798.1 806.6 897.6 1021.8 1127.2 1252.4 1375.8 Power input (7) 271.9 309.6 306.7 344.6 385.7 478.5 519.6 Energy Efficiency Ratio (5) (6) (as Eurovent) kW/kW 2.68...
  • Page 17 General Data SI Units Table G-11 - General Data RTAC 250-400 High Efficiency Low Noise Size Cooling capacity (5) (6) 838.6 940.9 1068.9 1179.3 1310.1 1442.3 Power input (7) 328.3 368.9 415.6 456.6 498.1 Energy Efficiency Ratio (5) (6) (as Eurovent) kW/kW 2.81 2.87...
  • Page 18 General Data SI Units Table G-12 - General Data RTAC 255-400 Extra Efficiency Low Noise Size Cooling capacity (5) (6) 867.4 966.5 1090.3 1239.7 1334.3 1456.7 Power input (7) 292.1 324.3 363.4 418.8 455.4 495.5 Energy Efficiency Ratio (5) (6) (as Eurovent) kW/kW 2.97 2.98...

  • Page 19: Installation - Mechanical

    Installation - Mechanical Installation Storage Responsibilities Extended storage of the unit prior to installation requires the following Generally, the contractor must do precautionary measures: the following when installing an RTAC unit: 1. Store the unit in a secure area. [ ] Install the unit on a flat 2.

  • Page 20: Special Lifting And Moving Instructions

    Installation - Mechanical Special Lifting and Moving CAUTION Instructions A specific lifting method is 4.This unit must be lifted with the recommended as follows: utmost care. Avoid shock load by lifting slowly and evenly. 1. Lifting points are built into the unit.

  • Page 21: Isolation And Sound Emission

    Installation - Mechanical Figure 4 – Rigging the Unit, Sizes 230-400 Container Pull out Hook Maximum Shipping Weight RTAC Aluminum Copper 7133 3220 7652 8433 230 SE 7133 3220 8031 240 SE 9138 3290 7820 8640 250 SE 9138 3290 8261 9157 250 HE...

  • Page 22: Foundation

    General Data Section for operating weights. After it is in place, the unit must be level within 1/4" [6 mm] over its length and width. Trane is not responsible for equipment problems resulting from an improperly designed or constructed foundation.

  • Page 23: Dimensional Data

    Dimensional Data RLC-SVX02G-E4...
  • Page 24 Installation RLC-SVX02G-E4...
  • Page 25 Installation RLC-SVX02G-E4...
  • Page 26 Installation RLC-SVX02G-E4...
  • Page 27 Installation RLC-SVX02G-E4...
  • Page 28 Dimensional Data RLC-SVX02G-E4...
  • Page 29 Dimensional Data RLC-SVX02G-E4...

  • Page 30: Unit Isolation And Leveling

    Install isolators. shutoff valves on both the entering- Trane assumes no responsibility for and leaving-water lines so that the Lower the unit onto the isolators equipment failures which results...

  • Page 31: Water Treatment

    2. To prevent switch fluttering, [ ] Flow Proving Device Neither salt nor brackish water is remove all air from the water recommended for use in Trane air- system. cooled Series R chillers. Use of CAUTION either will lead to a shortened life to Note: The CH.530 provides a...

  • Page 32: Performance Data

    Performance Data Figure P-18 - Evaporator Water Pressure Drop (SI) RLC-SVX02G-E4...
  • Page 33 Performance Data Figure P-19 - Water Side Pressure Drop (English Units) RLC-SVX02G-E4...

  • Page 34: Water Pressure Gauges

    Installation - Mechanical Water Pressure Gauges Install field-supplied pressure components as shown in Figure 5. Locate pressure gauges or taps in a straight run of pipe; avoid placement near elbows, and so forth. Be sure to install the gauges at the same elevation on each shell if the shells have opposite-end water connections.

  • Page 35: Water Pressure Relief Valves

    1. Additional protection must be to overheat. fitted - contact your Trane Sales It is compulsory to open the heaters Office. switch to protect them from 2. Install heat tape on all water...

  • Page 36: Refrigerant Cutouts And Glycol Percentages

    Installation - Mechanical RLC-SVX02G-E4...
  • Page 37 Installation - Mechanical Chart 3 – Recommended Low Evaporator Refrigerant Cutout (LRTC) and % Glycol for RTAC Chillers Propylene Glycol Ethylene Glycol Low Refrigerant Solution Low Refrigerant Solution Temperature Freeze Temperature Freeze Glycol Cutout °C Point °C Cutout °C Point °C -2.2 -2.2 -2.4...
  • Page 38 Installation - Mechanical Notes for Chart 3: Specials: 1. Solution freeze point is 2.2°C 1. The following constitute a special below operating point saturation that must be calculated by temperature. engineering: • Freeze inhibitor other than 2. LRTC is 2.2°C below freeze point. Ethylene Glycol or Propylene Procedure: Glycol.

  • Page 39: Installation - Electrical

    Installation – Electrical General Recommendations CAUTION WARNING To avoid corrosion and overheating at terminal connections, use copper mono-conductors only. Failure to do The Warning Label shown in Figure so may result in damage to the 6 is displayed on the equipment and equipment.

  • Page 40: Wire Sizing

    Wire Sizing Table J-1 - Customer Wire Selection RTAC 120 - 200 Unit without Unit with Disconnect Switch Disconnect Switch Voltage Wire Selection Size to 400/3/50 Main Terminal Block Wire Selection Size to Disconnect Switch Unit Unit Maximum cable Disconnect Switch Maximum cable size mm²...
  • Page 41 Wire Sizing Table J-2 - Customer Wire Selection RTAC 230 - 400 Unit without Unit with Disconnect Switch Disconnect Switch Voltage Wire Selection Size to 400/3/50 Main Terminal Block Wire Selection Size to Disconnect Switch Unit Unit Maximum cable Disconnect Switch Maximum cable Size Size...

  • Page 42: Electrical Data Tables

    Electrical Data Table E-1 - Electrical Data RTAC 120 - 200 ( 400/3/50) Motor Data Compressor (Each) Fans (Each) (6) Starting Fan fuse Control Maximum Evaporator Amps (4) size (A) (VA) Amps (3) heater Unit Size Quantity cmpr 1 cmpr 2 cmpr 1 cmpr 2 Quantity...
  • Page 43 Electrical Data Table E-1 - Electrical Data RTAC 230 - 400 ( 400/3/50) Compressor (Each) Fans (Each) (6) Maximum Amps (3) Starting Amps (4) Starting amps, Direct on line start (7) Unit cmpr cmpr cmpr cmpr cmpr cmpr cmpr cmpr cmpr cmpr cmpr...
  • Page 44 Electrical Data Table E-2 - Electrical Data RTAC 120 - 200 Unit Wiring (400/3/50) Motor Data Compressor (Each) Unit Starting Starting Amps (2) (7) Power Compressor Short Circuit Number of Power Maximum size Connections Amps (1) Amps (2) Direct on line start Factor (5) Fuse Size (A) Rating (kA)
  • Page 45 Electrical Data Table E-2 - Electrical Data RTAC 120 - 200 Unit Wiring (400/3/50) Motor Data Compressor (Each) Unit Number of Power Maximum Starting Starting Amps (2) (7) Power Compressor Short Circuit size Connections Amps (1) Amps (2) Factor (5) Fuse Size (A) Direct on line start Rating (kA)

  • Page 46: Installer-Supplied Components

    CH530 activates the The type and installation location(s) pumps.. of the fused-disconnect switches must comply with all applicable codes. For temperatures below -29°C, please contact your local Trane sales engineer for advice. RLC-SVX02G-E4...

  • Page 47: Water Pump Power Supply

    Installation – Electrical Table 12 – Pump Relay Operation Water Pump Power Supply Chiller Mode Relay Operation CAUTION Provide power-supply wiring with Auto Instant close Ice Building Instant close fused disconnect switch(es) for the Refer to Freeze Protection section Tracer Override Close chilled-water pump(s).

  • Page 48: Alarm And Status Relay Outputs (Programmable Relays)

    Installation – Electrical Alarm and Status Relay Outputs (Programmable Relays) A programmable relay concept provides for enunciation of certain events or states of the chiller, selected from a list of likely needs, while only using four physical output relays as shown in the field wiring diagram. The four relays are provided (generally with a Quad Relay Output LLID) as part of the Alarm Relay Output.

  • Page 49: Relay Assignments Using Techview

    Installation – Electrical Relay Assignments Using Emergency Stop TechView The CH.530 provides auxiliary control for a customer-specified and The CH.530 Service Tool (TechView) -installed latching tripout. When this is used to assign any of the above customer-furnished remote contact list of events or status to each of the (6S3) is provided, the chiller will run four relays provided.

  • Page 50: External Circuit Lockout

    Installation – Electrical External Circuit Lockout – Ice-Building Option CAUTION Circuit Number 1 and The CH.530 provides auxiliary control for a customer-specified and Circuit Number 2 Freeze inhibitor must be adequate -installed contact closure for ice for the leaving-water temperature. The CH.530 provides auxiliary building, if so configured and Failure to do so will result in...

  • Page 51: Optional External Chilled-Water Set Point (Ecws)

    Installation – Electrical The chilled-water set point may be If the ECWS LLID develops an open Optional External Chilled- changed from a remote location by or short, the LLID will report either a Water Set Point (ECWS): sending either a 2-10 V (dc) or very high or very low value back to The CH.530 provides inputs that 4-20 mA signal to the (A2-1) module.
  • Page 52 Installation – Electrical The following equations apply: For RTAC Units Voltage Signal Current Signal As generated from external source Vdc=0.133*(%)-6.0 mA=0.266*(%)-12.0 As processed by Tracer CH530 % = 7.5*(VDC)+45.0 % = 3.75*(mA)+45.0 As a graph this yields the following: For input signals beyond the 2- 10VDC or 4-20mA range, the end of range value is used.

  • Page 53: Optional Tracer Comm 3 Interface

    Installation – Electrical 6. Connect TechView to the Tracer Optional Tracer Comm 3 Communication Link Connection CH.530 controller. Procedure Interface 7. Look at the Feature tab in 1. Refer to the Tracer installation This option allows the Tracer CH.530 Configuration View-Custom Tab literature to determine proper controller to exchange information in TechView and verify that the...

  • Page 54: Lontalk® Communications Interface For Chillers (Lci-C)

    - 105 ohms at each end for Level 4 between a LonTalk compatible wire device and the chiller. The - 82 ohms at each end for Trane inputs/outputs include both "purple" wire mandatory and optional network variables as established by the •...

  • Page 55: Operating Principles

    Operating Principles Figure 7 – System Schematic 1. Variable-Speed Fan Inverter 15. Discharge Pressure Transducer 30. Oil Return Shutoff (optional) 16. Relief Valve 31. Suction Pressure Transducer 2. EasyView (or DynaView) Interface 17. Heater 32. Suction Isolation Valve (option) 3. To Fans 18.
  • Page 56 Operating Principles Figure 8 – RTAC Oil System CAUTION The RTAC units must only operate with R-134a and Trane OIL 00048E. Key: Refrigerant with small amount of oil Refrigerant and oil mixture (refrigerant vapor and oil) Oil recovery system (liquid refrigerant and oil) Primary oil system 1.

  • Page 57: Pre-Start Checkout

    Pre-Start Checkout Installation Checklist CAUTION CAUTION Complete this checklist as the unit is installed, and verify that all If using an acidic, commercial To avoid corrosion and overheating recommended procedures are flushing solution, construct a at terminal connections, use only accomplished before the unit is temporary bypass around the unit copper conductors.

  • Page 58: General

    If the measured voltage on undervoltage conditions at the treatment, if any, is advisable. Trane any leg is not within the specified compressor motor. warranty specifically excludes range, notify the supplier of the liability of corrosion, erosion, or 2.

  • Page 59: Unit Voltage Imbalance

    Pre-Start Checkout This direction may be reversed Unit Voltage Imbalance CAUTION outside the alternator by Excessive voltage imbalance interchanging any two of the line between the phases of a three- wires. It is this possible interchange Do not interchange any load leads phase system can cause motors to of wiring that makes a phase that are from the unit contactors or...

  • Page 60: Unit Startup Procedures

    (HFC 134a) and for the chilled-water pump. excessive pressure drop in the Trane Oil 0048E. Failure to do so Energize the pump(s) to start liquid line, or an expansion valve may cause compressor damage and water circulation.

  • Page 61: Seasonal Unit Startup Procedure

    Unit Startup Procedures Seasonal Unit Startup CAUTION Procedure 1. Close all valves and reinstall the To prevent damage to the drain plugs in the evaporator. compressor, ensure that all refrigerant valves are open before 2. Service the auxiliary equipment starting the unit. according to the startup and 2.

  • Page 62: Unit Shutdown Procedures

    Unit Shutdown Procedures Temporary Shutdown and CAUTION Restart To shut the unit down for a short Lock the chilled-water pump time, use the following procedure: disconnects open to prevent pump damage. 1. Press the STOP key on the 3. Close all chilled-water supply CH.530.

  • Page 63: Periodic Maintenance

    Periodic Maintenance 3. Have Trane or another qualified General laboratory perform a compressor Perform all maintenance procedures oil analysis to determine system and inspections at the moisture content and acid level. recommended intervals. This will This analysis is a valuable prolong the life of the chiller and diagnostic tool.

  • Page 64: Maintenance Procedures

    Evaporator Temperature) Conservation and emission as gauges, hoses, vacuum reduction can be accomplished by • Low Evaporator-Refrigerant following recommended Trane pumps, and recycling equipment. Temperature Limit operation, maintenance, and service 7. Stay aware of unit enhancements, • Low Refrigerant-Temperature...
  • Page 65 Maintenance Procedures Some symptoms of an oil over- CAUTION charged unit: • Larger-than-normal evaporator Water must be flowing through the approach temperatures (Leaving- evaporator during the entire Water Temperature - Saturated- charging process to avoid freezing Evaporator Temperature) and rupturing of the evaporator •...

  • Page 66: Charge Isolation In The High Or Low Side Of System

    The service tool may include a 8. Remove the remainder of the calculation module that determines charge with the vacuum pump. the proper subcooling for any operating condition (Trane Service Recommendation: Do not pump only). the remaining charge into the high side. This may introduce...
  • Page 67 Maintenance Procedures Table 15 – Charge-Holding Capability on The High Side Normal Circuit *Condenser Charge-Holding Nominal Circuit Charge in Oil Charge Capacity Capacity at 60% full, 35°C ambient Oil Separator Separator (kg) (kg) Level (tons) (liters) 74.8 53.6 21.3 97.70% 74.8 53.6 21.3...

  • Page 68: Filter Replacement Procedure

    7. Remove the old filter element. 8. Inspect the replacement filter element and lubricate the o-ring with Trane OIL 0048E. Note: Do not use mineral oil. It will contaminate the system. 9. Install the new filter element in the filter housing.
  • Page 69 Maintenance Procedures Proper charging of the oil system is Figure 9 – Oil System Schematic critical to the reliability of the compressor and chiller. Too little oil can cause the compressor to run hot and inefficiently. When taken to an extreme, low oil level may result in instant failure of the compressor.

  • Page 70: Prelubrication

    The only issue is that if the schraeder valve is not present on this port, the 7/16 o-ring boss plug normally in this location will have to be replaced by a 7/16- schraeder fitting (Trane part number RLC-SVX02G-E4...

  • Page 71: Field Oil Charging Procedure

    Use only Trane Oil 0048E in the RTAC units to avoid any Note: this procedure can be catastrophic damage to the followed even with the refrigerant compressor or unit.
  • Page 72 Maintenance Procedures If oil was removed to service a WARNING compressor or change the filter follow this procedure: Catastrophic damage to the 1. If the compressor is a new compressor will occur if the oil-line compressor or has been removed shutoff valve or the isolation valves from the system and reworked, are left closed on unit startup.
  • Page 73 Notes RLC-SVX02G-E4...
  • Page 74 Notes RLC-SVX02G-E4...
  • Page 75 Notes RLC-SVX02G-E4...

  • Page 76: Rlc-Svx02G-E4

    Supersedes RLC-SVX02F-E4_0409 Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. Only qualified technicians should perform the installation and servicing of equipment referred to in this publication.

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