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Trane RTHD Troubleshooting Manual

Air and water cooled chillers
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Download this manual See also: User Manual, Installation Operation & Maintenance
Diagnostic
Troubleshooting
Repair
Service Alert
RTHD and RTAC
Control Operation, Setup and
Troubleshooting for RTAC and RTHD Units
with Tracer CH530 Controls
The purpose of this bulletin is to provide control operation and general
troubleshooting information on the RTAC Air Cooled Chillers and RTHD Water
Cooled Chillers with the CH530 controls. It is recommended that the service
technician be familiar with the CH530 operation prior to servicing the
microprocessor.
This bulletin is intended to serve as a supplement to the RTAC and RTHD IOMs,
the installation, operation and maintenance manuel. Subjects covered in this
bulletin are intended to provide more comprehensive information for the RTAC
and RTHD units.
RLC-SVD05A-EN
November 2005

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Summary of Contents for Trane RTHD

  • Page 1 CH530 operation prior to servicing the microprocessor. This bulletin is intended to serve as a supplement to the RTAC and RTHD IOMs, the installation, operation and maintenance manuel. Subjects covered in this bulletin are intended to provide more comprehensive information for the RTAC and RTHD units.
  • Page 2 Trane advocates the responsible handling of all refrigerants— including industry replacements for CFCs such as HCFCs and HFCs. Responsible Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians Refrigerant who handle refrigerants must be certified.

  • Page 3: Table Of Contents

    Check out procedure for RTHD ........
  • Page 4 Is the sensor reading accurately? Gas Pump - RTHD Only ......... . . 59 Gas Pump Checkout Procedure - Unit Off .

  • Page 5: Ch530 Overview

    The starter module provides control of the compressor contactors when starting, running, and stopping the chiller. Starter types include Across the Line (RTAC), Y-Delta and Solid State (RTHD). The starter module provides protection of the compressor in the form of running overload, phase reversal, phase loss, phase imbalance, and momentary power loss.
  • Page 6 CH530 OverviewCH530 Overview • EXV stepper driver • liquid level sensor input • inverter interface • pressure transducer The following is a graphic example of the CH530 architecture. Figure 1. CH530 RLC-SVX05A-EN...

  • Page 7: Ipc Overview And Troubleshooting

    IPC Overview and Troubleshooting The CH530 platform provides a highly modular approach for accommodating the inputs and outputs to control a chiller. The CH530 platform includes discrete devices for each input and output point on the system. For example, the EXV includes the electronics to drive its motor contained within the motor housing.

  • Page 8: Installing A Llid

    IPC Overview and Troubleshooting process requires a LLID to be recognized by activating its service pin or green LED. All LLIDs are constructed with a green LED and associated switch. The switch is a hall-effect sensor, which is activated by a magnetic field of the proper polarity (South Pole).
  • Page 9 Figure 3. Cable and Connector 3 Place the cover and wire over the base and hold in place. Crimp the connector down using the Trane tool or a parallel jaw pliers It is important to apply equal pressure across the jaws of the pliers.

  • Page 10: Procedure For Installing Caps

    IPC Overview and Troubleshooting 4 Inspect finished connector. Make sure the red wire matches up with the red line on the connector. Verify that no wires are twisted in the connector. Figure 5. Finished Connector Procedure for A cap must be installed on the bare end any time the is cut and/or spliced. installing caps.

  • Page 11: Troubleshooting Problems With Multiple Llids

    IPC Overview and Troubleshooting 2 Place a small amount of Locktite 480 in the cap and put the end of the cable in the cap. Refer to Figure Figure 7. : Cap Troubleshooting Troubleshooting bus communication problems can be challenging. It is problems with important to remember that all of the LLIDs communicate on the same two wire multiple LLIDS...
  • Page 12 IPC Overview and Troubleshooting Chiller has multiple loss of communication diagnostics. Using TechView go into binding Reset diagnostics view. Are there devices that are not verified? Check for 24 VAC at J2-1 and J2-2 on the power supply. Refer to Section 3- Check for 24 VDC at J1, J3, J4, Power supply and J11 between pins 1 and 2.
  • Page 13 IPC Overview and Troubleshooting Chiller has multiple loss of communication diagnostics. Using TechView go into binding Reset diagnostics view. Are there devices that are not verified? Check for 24 VAC at J2-1 and J2-2 on the power supply. Refer to Section 3- Check for 24 VDC at J1, J3, J4, Power supply and J11 between pins 1 and 2.

  • Page 14: Power Supply

    Power Supply The CH530 power supply has no communication capabilities. It provides 24VDC to the LLIDs and acts as the trunk for the IPC bus. It is also used as a “central hub” to provide a starting point for up to 5 IPC bus cables. Figure 8.
  • Page 15 Power SupplyPower Supply Table 2. Output Voltage Terminals Voltage +24VDC COMM+ COMM- There is a 3.0 amp fuse (X13110456020) on the power supply. If this fuse is open LED 1 will not be on and there will not be any voltage out. This fuse can be replaced.

  • Page 16: Temperature Sensor

    Temperature Sensor All of the temperature sensors used on CH530 are negative temperature coefficient (NTC) thermistors and located in thermal wells. The thermistors all have a base resistance of 10 kOhms at 77 F (25C). The sensors have a probe range of -40 to 120 F and should have an accuracy of ±...

  • Page 17: Is The Sensor Reading Accurately

    Temperature Sensor brighter. If it doesn’t get brighter, this may indicate a problem with the sensor or the connector. Take a close look at the connector to make sure that all four wires are securely in place. It may be necessary to remove the cap to check for broken or misplaced wires.

  • Page 18: Pressure Transducers

    Pressure Transducers All of the Pressure Transducers used on RTAC and RTHD units are mounted on service valves. Pressure Transducers measure absolute pressure. They have a ± range of 0 to 475 psia with an accuracy of 1.5 psi under steady state conditions.

  • Page 19: Is The Transducer Reading Accurately

    Pressure Transducers all four wires are securely in place. It may be necessary to remove the cap to check for broken or misplaced wires. If there is no problem found with the connector and the transducer will not bind, replace the transducer. Is the transducer All transducers are mounted on service valves.

  • Page 20: Variable Speed Fan Control - Rtac Only

    Variable Speed Fan Control - RTAC Only The Main Processor (MP) is configurable for operation with either 0, 1 or 2 variable speed fans per circuit. Variable speed fans are optional and included on units when the low ambient operation is required. The variable speed fans are standard fans and motors, used with the fixed speed fans, but are driven by the small 1.5 HP inverters that create a variable voltage/frequency, 3 phase output using Pulse Width Modulation (PWM) switching.
  • Page 21 Variable Speed Fan Control - RTAC Only R T A C C o n d e n s e r F a n C o n tro l T e m p e ra tu re 1 5 0 1 4 0 P anic Fa n A dd Line : If C ond enser P re ssu re /T e m pe rature rises above th is line , o ne add ition al fan w ill be a dd ed e ach 5 secon ds ittera tion .

  • Page 22: Inverter Fault Input

    Variable Speed Fan Control - RTAC Only Inverter Fault Input The Variable Speed Condenser Fan Inverter provides a fault indication to the MP through an optically isolated darlington transistor circuit. The transistor is off when the inverter is un-powered or in the fault state, and is on at all times during normal operation.
  • Page 23 TRANEAC INVERTER this LED will remain illuminated for up to 60 seconds while the DC Bus Capacitor Voltage discharges. This LED also indicates that the 5 VDC Supply Voltage on the TRANE AC INVERTER control board is present. Alarm LED. When this red LED is illuminated constantly, it indicates that the motor is overloaded and the drive is about to fault on a motor overload.
  • Page 24 Variable Speed Fan Control - RTAC Only 3 Attempt to start the compressor on the desired circuit. Thirty seconds prior to compressor start, the variable speed fan inverter contactor is energized. Be sure that you can hear the fan contactor pull in. If not, attach an AC voltmeter from FR to ground on the Dual Inverter Interface LLID.
  • Page 25 Variable Speed Fan Control - RTAC Only Note: The output from the compressor LLID is a pulse width modulated signal, 10 volt peak and 10 Hz. fundamental. Its average value can be read with a DC voltmeter. 7 Remove the jumper wire and reconnect connector P1 or P2. While the inverter is still powered, measure the DC voltage between pins F (+) and FR (-) on the Dual Inverter Interface LLID.

  • Page 26: Current Transformers

    Current Transformers Each compressor motor has all three of its line currents monitored by toroid (doughnut) current transformers. These currents are normalized with respect to the Rated Load Amps of the respective compressor and thus are expressed in terms of % RLA and in Amps. The currents are “normalized” through the proper selection of the Current Transformer and the unit configuration.

  • Page 27: Ct And Starter Compressor Current Input Checkout Procedure

    I0x = the phase with the largest difference from Iave. 5 Current Limit. The current limit range for each compressor is 60-120% RLA for RTAC and 40-100% RLA for RTHD. The figure below provides a graphical illustration of the current limit control.
  • Page 28 Refer to the Component Location Drawing in the panel to identify the particular current transformer(s) of interest. Locate the part number/UL tag on the transformer leads and note the Trane part number which identifies the transformers. 4 Utilizing the Schematic Wiring Diagram, locate the termination of the transformer's wiring into the Phoenix plug at the appropriate Starter module at pin header J7.
  • Page 29 Current Transformers 7 If the resistance reading above is out of tolerance, the problem is either with the transformer, its wiring, or the Phoenix connector. First, double check the schematic to be sure you are working the proper lead pair. Then, check the CT resistance at the CT.

  • Page 30: Over/Under Voltage

    Over/Under Voltage The under/over voltage protection is an optional configuration for RTHD and standard for RTAC. The input voltage for the Optional Under/Over Voltage Transformers will be supplied from the incoming (line side of the starter contactors) three phase power connections to the unit. The secondary or these transformer(s) are connected to the Starter module.

  • Page 31: Rthd Chillers

    The transformers will display of the magnitude of these voltages as well as under and over voltage protection, if such is enabled. Check out procedure for RTHD WARNING During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components.
  • Page 32 Over/Under Voltage Table 6. Starter Module Input-to-Line Voltage Conversion Starter Module Input Voltage J5-1,2 J5-3,4 J5-5,6 Incoming Line-to-Line Voltage (Volt AC) (Volt AC) 14.4 14.9 15.4 15.9 16.3 16.8 17.3 17.8 18.3 18.8 19.3 19.8 20.3 20.8 21.3 21.8 22.3 22.8 23.3 23.8...

  • Page 33: Starter Module

    Over/Under Voltage Starter Module 1 Switch the line power off and run a separate 120 VAC control power to the chiller controls. With the controls powered up (Chiller mode set to Stop), measure the common mode input voltages to the Starter module as VDC and verify they fall within the following: Table 7.

  • Page 34: Starter

    Starter CH530 provides compatibility with two types of starters for RTAC and RTHD • X-Line - RTAC only • Y-Delta • Solid State - RTHD only X-Line CH530 provides a “Start” contact closure output for across the line starters. To reduce the risk of starter damage due to the wrong starter type being selected, the Transition Complete input is required to be wired at the starter module.
  • Page 35 Starter Starting Wye Delta With Contactor Integrity Test Energize Stop and Start Relays Confirm Proper Compressor Rotation within 0.3 seconds (Phase Reversal) and > 5% RLA (Phase Loss) Confirm No Transition Complete Signal (Transition Complete Input Shorted) Confirm > 10% RLA Compressor Currents within 1.6 se conds (Starter Fault Type III ) Energize Start and...

  • Page 36: Ydelta Starter Sequence

    Starter YDelta Starter Sequence Starter De-energized Power Flow Figure 15. Y-Delta Starter Sequence Close Start Contactor for 500 Msec. (1K1) Check for No Current (Starter Fault type I) Power Flow Figure 16. Y-Delta Starter Sequence RLC-SVD05A-EN...
  • Page 37 Starter De-energize 1K1 and Energize Shorting Contactor (1K3). Check for No Current (Starter Fault type II) 1 Second. 1K3 Remains Closed. Power Flow Figure 17.Y-Delta Starter Sequence Shorting Contactor (1K3) continues energized. Energize Start Contactor (1K1). Power Flow Figure 18.Y-Delta Starter Sequence RLC-SVD05A-EN...
  • Page 38 Starter Motor Starts in Configuration Power Flow Figure 19.Y-Delta Starter Sequence If 1.6 seconds after 1K1 closed, no current was detected by all three CT´s for the last 1.2 seconds, then ¨Starter Fault Type III¨ is Displayed. Power Flow Figure 20.Y-Delta Starter Sequence RLC-SVD05A-EN...
  • Page 39 Starter When Maximum Phase Current Drops Less Than 85% of Nameplate RLA for 1.5 Seconds Power Flow Figure 21.Y-Delta Starter Sequence 1K4 Is Energized Power Flow Figure 22.Y-Delta Starter Sequence RLC-SVD05A-EN...
  • Page 40 Starter Initiate Transition to Delta Power Flow Figure 23.Y-Delta Starter Sequence Power Flows Though Resistors 100 msec After 1K4 Closes Shorting Contactor 1K3 Opens Power Flow Figure 24.Y-Delta Starter Sequence RLC-SVD05A-EN...
  • Page 41 Starter 260 msec After 2K3 Opens Run Contactor 2K2 Closes Power Flow Figure 25.Y-Delta Starter Sequence Delta configuration almost complete Power Flow Figure 26.Y-Delta Starter Sequence RLC-SVD05A-EN...
  • Page 42 Starter Test Transition Complete Contact-closed and Open 1K4 De-energizing Resistors Power Flow Figure 27.Y-Delta Starter Sequence Motor Running in Delta Configuration Power Flow Figure 28.Y-Delta Starter Sequence RLC-SVD05A-EN...

  • Page 43: Solid State - Rthd Only

    Starter Fault diagnostic shall be called out. The sequence of a Solid State Start is shown in Figure 29 Refer to RTHD-SVD01A-EN for IT Solid State Starter Troubleshooting. Refer to RTHD-SVD02A-EN for RediStart Solid State Starter Troubleshooting. RTHD Sequence of Operation:...

  • Page 44: Compressor Capacity - Rthd

    Design improvements from the original RTHB compressor family were made to accommodate refrigerant 134a. The RTHD compressor varies its capacity with a slide valve. The slide valve is located internal to the compressor and directly controls the compressor's capacity (mass flow rate) through varying the compressor's intake volume.

  • Page 45: Checkout Procedure For The Slide Valve And Load-Unload Solenoids

    Compressor Capacity - RTHD fails open), look like it was stuck “on” when using a voltmeter to test it. Thus it is important to verify that the solenoid coil is continuous and providing a normal load or to connect a known good load, such as a low wattage 115 Volt lamp, to the terminals when testing the outputs.
  • Page 46 Compressor Capacity - RTHD WARNING During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed Live Electrical electrician or other individual who has been properly trained in handling live Components! electrical components perform these tasks.

  • Page 47: Load

    Compressor Capacity - RTHD 3. Place the chiller in ”Auto” mode and provide all necessary interlocks and a load to start the chiller 4. Allow the compressor to start and monitor the compressor currents with a clamp-on type ammeter. Load...

  • Page 48: Compressor Capacity - Rtac

    Compressor Capacity - RTAC The CHHP (GP ) compressor is a “screw” or helical rotor design with two rotors, one directly driven by the motor called the male and the other driven by the lobes of the male called the female. CHHP compressors have a female step load solenoid valve and male load/unload solenoid valves that are utilized for capacity control.

  • Page 49: Checkout Procedure For The Female Step Load Outputs

    Compressor Capacity - RTAC Checkout Procedure for the Female Step Load Outputs A dual triac LLID (1U17, 2U17,) controls the female solenoid valve on the compressor with a 115VAC relay output. Refer to the wiring diagrams in the control panel for the following procedure. WARNING During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components.

  • Page 50: Checkout Procedure For The Slide Valve And Load-Unload Solenoids

    Compressor Capacity - RTAC test it. Thus it is important to verify that the solenoid coil is continuous and providing a normal load or to connect a known good load, such as a low wattage 115 Volt lamp, to the terminals when testing the outputs. Refer to the wiring diagrams in the control panel for the following procedure.
  • Page 51 Compressor Capacity - RTAC 1 Identify the LLID associated with the compressor to be tested (1U16, 1U21, 2U16, 2U21). Disconnect the wires, take care to identify the wires to prevent cross wiring when reconnecting. 2 Install a toggle switch between the Control power HOT to the load and unload leads (previously connected to J3-1 and J2-1).

  • Page 52: Load

    Compressor Capacity - RTAC WARNING During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed Live Electrical electrician or other individual who has been properly trained in handling live Components! electrical components perform these tasks.
  • Page 53 Compressor Capacity - RTAC Table 9. Possible Causes to Loading Problem Recorded Possible Operation Measurement Load Unload Hold Operating properly Piston Pressure increase decrease remain constant Amp Draw increase decrease remain constant Stuck piston Piston Pressure increase decrease remain constant Amp Draw remain constant remain constant...

  • Page 54: Electronic Expansion Valve

    Electronic Expansion Valve The Electronic Expansion Valve (EXV) is a flow device which regulates the flow of refrigerant to the evaporator in order to match the compressor capacity. This function increases the part load efficiencies. The EXV is positioned by a 24VDC three phase bipolar stepper motor. The electronics to drive the stepper motor are integral to the motor housing.

  • Page 55: Is The Exv Functioning Properly

    Electronic Expansion Valve the old connector and splice in a new section of cable and a new connector. See Section 2-IPC Overview for instruction on installing a new cap. If the EXV is bound, try to turn the LED on with a magnet. If the light will not turn on, there could be a problem with the EXV.
  • Page 56 Electronic Expansion Valve Figure 36.: Compressor Service View RTAC Figure 37.Manual Override View - RTHD RLC-SVD05A-EN...

  • Page 57: Liquid Level Sensor

    This provides for increased part load efficiencies compared to a fixed orifice device. There are two types of sensors that are used on RTAC and RTHD units. A float type senor with an external LLID was originally used on RTAC and RTHD units. A capacitance based with an internal LLID will soon be used on all units.

  • Page 58: Is The Sensor Reading Accurately

    RTAC- This can be done in TechView in Status View under the Circuit tab or no the DynaView (software version 18 and later only) on the refrigerant tab. RTHD- This can be done in TechView in Status View under the Circuit tab or on the DynaView on the reports tab under evaporator.

  • Page 59: Gas Pump - Rthd Only

    Gas Pump - RTHD Only Residual oil in a falling film evaporator will not immediately be recovered by the oil separators and will eventually log in the evaporator. Oil cannot be returned as oil/liquid droplets pulled up the suction line of the compressor. The oil is instead returned by alternatively filling and draining a small tank with refrigerant from the bottom of the evaporator.

  • Page 60: Gas Pump Checkout Procedure - Unit On

    Gas Pump - RTHD Only Gas Pump Checkout Procedure - Unit On To check the operation of the Gas Pump while the chiller is ON do the following procedure: Note: At least a 50 psi differential must exist between the evaporator and condenser before performing this test.

  • Page 61: Optical Sensor - Rthd Only

    Optical Sensor - RTHD Only The oil level detector is located in the oil sump. The sensor uses infrared light reflected off the inside of a conical prism, back to a detector to sense the difference in refractive index of the prism /oil interface relative to that of the prism/vapor interface.

  • Page 62: Techview Service Tool

    TechView Service Tool Tracer CH530 is a new chiller controller technology developed by Trane for use on large chiller products and is serviced with a PC (laptop)-based tool. Technicians that make any chiller control modification or service any diagnostic with Tracer CH530 must use a laptop running the software application “TechView.

  • Page 63: Laptop Requirements For Ch530

    TechView Service Tool Laptop • Pentium II, III, or higher processor requirements for • 128MB RAM CH530 • 1024x768 resolution • CD-ROM • 56K Modem • 9-pin RS232 serial port connection • 25-pin LPT1 parallel port connection • Windows 2000 •...
  • Page 64 TechView Service Tool Select “Save this program to disk” while downloading the files (do not select “Run this program from its current location”). 4 Remember where you downloaded the files (the “CH530” folder). You will need to locate them to finish the installation process. 5 Proceed to “Main Processor Software Download”...

  • Page 65: Using Techview

    TechView Service Tool Using TechView 1 Connect laptop to the Main Processor using a RS232 serial cable. Refer to Figure Figure 38.TechView Connection 2 A TechView icon has been placed on the computers desktop. Double click on the icon to begin using TechView. Click on Local Connection...
  • Page 66 TechView Service Tool 3 Click on “Help” then “About” to find installed software versions. Figure 40.Installed Software RLC-SVD05A-EN...

  • Page 67: Downloading New Main Processor Software

    TechView Service Tool Downloading New Main Processor Software A new main processor application can be loaded from the Software view. Figure 41 Software View Binding Process Binding is required whenever Binding View shows status icons other than the green smiling face icon in the network status area. If a device is communicating but incorrectly configured, it might not be necessary to replace it.
  • Page 68 TechView Service Tool desired device cannot be selected or if multiple devices are accidentally selected, you can close the manual selection window by clicking on No and repeat the bind function. The typical binding procedure involves: 1 Go into Binding View. Figure 42 Binding View 2 Find the appropriate LLID on the frame or in the control panel.
  • Page 69 TechView Service Tool Watch for the LED to light. Refer to Figure Magnet Figure 43.Panel and Frame Mounted LLIDs 5 When the LED lights, remove the magnet and click on “Yes” . Refer to Table 44 on page 69. Figure 44.Selecting a LLID to bind 6 Confirm that binding took place.

  • Page 70: Binding Symbols

    The chiller configuration can be modified in the Configuration View. This will change the model and CRC number for RTAC units. RTHD units do not have a CRC number. This should only be done after talking with Field Modification in La Crosse or Pueblo Technical Service.
  • Page 71 TechView Service Tool Figure 45.Unit Configuration View for an RTAC Unit RLC-SVD05A-EN...
  • Page 72 TechView Service Tool Figure 46.Unit Configuration View for RTHD Unts RLC-SVD05A-EN...
  • Page 73 RLC-SVD05A-EN...
  • Page 74 Inland A business of American Standard Companies www.trane.com Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. For more information, contact your local Trane office or e-mail us at comfort@trane.com...

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