Trane RAUC-IOM-15 Installation & Maintenance Instructions Manual

Remote split system units air cooled condensing units and evp chillers

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Remote Split System Units

Air Cooled Condensing Units and

EVP Chillers

Models

"L" and Later Design Sequence

RAUC-C80

RAUC-D10

RAUC-D12

http://www.trane.com

Installation

Operation

Maintenance

Library

Product Section

Product

Model

Literature Type

Sequence

Date

File No.

Supersedes

Since the manufacturer has a policy of continuous product

improvement, it reserves the right to change specifications and

design without notice.

RAUC-IOM-15

Split System Air Conditioning (80 - 120 Tons)

Installation/Operation/Maintenance

SV-UN-S/S-RAUC-IOM-15 03/06

Note: The installation of this equipment must

comply with all National, State, and Local

Codes.

Service Literature

Unitary

RAUC

March 2006

December 2001

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Summary of Contents for Trane RAUC-IOM-15

Page 1 Model RAUC Literature Type Installation/Operation/Maintenance Sequence Date March 2006 File No. SV-UN-S/S-RAUC-IOM-15 03/06 Supersedes December 2001 Remote Split System Units Air Cooled Condensing Units and EVP Chillers Models Note: The installation of this equipment must "L" and Later Design Sequence...
Page 2: About The Manual
About The Manual Literature Change History Overview of Manual RAUC-IOM-15 (March 2006) Note: One copy of this document ships inside the Manual reissued due to minor corrections: Provides Instal- control panel of each unit and is customer lation, Operation, and Maintenance instructions for “L” and property.
Page 3: Table Of Contents
Table of Contents Field Installed Control Wiring ......... 31 Section One Controls Using 115 VAC ..........31 About The Manual Controls using 24 VAC ..........31 Literature Change History ..........2 Controls using DC Analog Input/Outputs ....32 Overview of Manual ............2 Economizer Actuator Circuit ........
Page 4: General Information
When ordering replacement parts or requesting service, be sure to refer to the specific model number, serial number, and DL number (if applicable) stamped on the unit name- All Trane products are identified by a multiple-character plate. model number that precisely identifies a particular type of unit.
Page 5: Unit Component "Layout" And "Shipwith" Locations
General Information (Continued) Direct-drive, vertical discharge condenser fans are provided with built-in current and overload protection. For “Shipwith” items, refer to the Unit Component “Layout” and “Shipwith” Locations illustration. If low ambient operation is required, low ambient dampers are available as a field or factory installed option. These units may be order with one of the following options: No System Controls (Field provided controls required) Supply Air Temperature Control (VAV applications)
Page 6: Installation
Isolators should be installed to minimize the transmission of vibrations into the building. Refer to the [ ] Notify the appropriate Trane office before installing or re- “Unit Isolation” section for spring or rubber isolator installa- pairing a damaged unit.
Page 7 Installation (Continued) Figure 3-1 Typical Installation Clearances for Single, Multiple or Pit Applications...
Page 8 Figure 3-2A RAUC-C80 Unit Dimensional Data & Recommended Clearances...
Page 9 Figure 3-2A (Continued) RAUC-D10 Unit Dimensional Data & Recommended Clearances...
Page 10 Figure 3-2A (Continued) RAUC-D12 Unit Dimensional Data & Recommended Clearances...
Page 11 Figure 3-2B EVPB-C80 Evaporator Chiller Dimensions...
Page 12 Figure 3-2B (Continued) EVPB-D10 Evaporator Chiller Dimensions...
Page 13 Figure 3-2B (Continued) EVPB-D12 Evaporator Chiller Dimensions...
Page 14 Figure 3-2B (Continued) EVPB-C80 through D12 Chill Water Pipe Stubout Dimensions...
Page 15 Installation (Continued) Table 3-1A Typical Unit Weights & Point Loading Data Unit Operating Unit Weight on Isolator @ Mounting Location Size Material Weight Location 1 5500 6099 6472 1010 7272 1104 1083 1080 1058 7000 1100 1075 1071 1046 8199 1241 1225 1222...
Page 16: Rigging
Installation (Continued) Rigging 1. Elevate the unit (one side at a time) to allow access to the base rail mounting holes. A Rigging illustration and Center-of-Gravity dimensional data table is shown in Figure 3-3. Refer to the typical unit Note: Use solid type blocks, i.e. 4" X 4" wood operating weights table before proceeding.
Page 17: Leveling The Unit
Installation (Continued) Figure 3-4 Typical Spring Isolator Selection & Location Spring Isolator Part Number @ Mounting Location Unit Figure Mat’l. Location 1 RAUC-C80 CP-1-32 CP-1-28 CP-1-32 CP-1-28 CP-1-32 CP-1-28 CP-1-32 CP-1-28 CP-2-27 CP-1-28 CP-1-32 CP-1-28 CP-1-32 CP-1-28 CP-1-32 CP-1-28 RAUC-D10 CP-2-27 CP-1-31 CP-2-27...
Page 18 Installation (Continued) shipping “Tiedown” bolts. To remove the shipping hardware, spacer located between the compressor rails and the follow the procedures below: unit base rail as illustrated in the “Tiedown Bolt” detail. 1. At each “Tiedown” location (3 front and 3 rear), remove 2.
Page 19: General Unit Requirements
[ ] Check the unit for shipping damage and material short- Strainer in the solution inlet piping age; file a freight claim and notify Trane office. Balancing valve Flow switch in the solution outlet piping [ ] Verify that the installation location of the unit will provide Chilled solution sensor well and sensor on the chiller the required clearance for proper operation.
Page 20: Field Installed Control Wiring Requirements
Installation (Continued) Field Installed Control Wiring Requirements [ ] Install proper grounding wires to an earth ground. [ ] Install an outside air thermostat in series with the flow 115 Volt Control Wiring (All Units) switch to stop or prevent the unit from operating below the recommended ambient temperatures.
Page 21: Refrigerant Line Components
Installation (Continued) Refrigerant Line Components Thermostatic Expansion Valve (TEV) Trane recommends a balance-ported externally equalized valve in order to maintain satisfactory superheat control Suction line refrigerant components necessary for field down to lower valve loading conditions and to compensate installation in the suction line are a filter (Core Type),...
Page 22 (3) Shutoff Valves - Manual ball valves (10) Frostat (Required for coil freeze protection) (4) Interconnecting Liquid Line Tubing If risers exceed 10 feet, Trane must review the applica- (11) Expansion Valve (One Expansion Valve for each Coil tion Distributor)
Page 23: Refrigerant Piping
The liquid line filter drier should be as close to the sole- noid valve as possible. Note: If Suction Riser Exceeds 50 Feet, Trane Must Review The Application. Note: If The Liquid Line Riser Exceeds 10 Feet,...
Page 24: Evaporator Piping
Installation (Continued) Evaporator Piping Install the TXV directly to the unit liquid connection. Locate the TXV bulb midway between the 90 degrees bends on top of the suction line as illustrated in Figure 3-7A. Secure the bulb to the suction line with two clamps pro- vided by the manufacturer and insulate the bulb.
Page 25: Final Refrigerant Pipe Connections
Installation (Continued) 2. Remove the valve stem cap and place the valve depres- 3. Using the gauge bracket as a template for the self tap- sor (with tubing connected) onto the valve stem and ping screws, mount the gauge bracket approximately 1/ tighten.
Page 26: Leak Testing Procedure
Installation (Continued) the tubing during brazing, sweep an inert gas, such as Trane condensing units are shipped with a Nitrogen hold- dry nitrogen, through the tubing. Nitrogen displaces air in ing charge. If there is no pressure, the unit must be leak the tubing and prevents oxidation of the interior surfaces.
Page 27: Chilled Water Piping
Installation (Continued) Pipe Unions Chilled Water Piping Use pipe unions to simplify disassembly for system service. Use vibration eliminators to prevent transmitting vibrations Evaporator water inlet and outlet types, sizes and locations through the water lines are shown in Figure 3-2B. Refer to the operating GPM pa- rameters listed in Table 3-3 when determining flow and pip- Thermometers ing requirements.
Page 28: Final Water Piping Connections
Installation (Continued) Figure 3-8 Final Water Piping Connections Typical Piping Recommendations 1. All water piping to the system should be flushed thor- oughly before making the final connections. Note: If an acidic commercial flushing solution is used, construct a temporary bypass around the EVP chiller barrel to prevent damage to the internal components of the evaporator.
Page 29: Power Wire Sizing And Protection Device Equations
Installation (Continued) 1. A field supplied disconnect switch must be installed at or 2. Location for the electrical service entrance is illustrated in near the unit in accordance with the National Electrical Figure 3-2. Complete the unit’s power wiring connections Code (NEC latest edition).
Page 31: Field Installed Control Wiring
Installation (Continued) Field Installed Control Wiring loads (OL’s) must be installed as part of the system’s inter- lock circuit to disable the compressors in the event the cir- Before installing any connecting wiring, refer to Figure 3-2 culating pump shuts down or is turned off. for the electrical access locations provided on the unit.
Page 32: Controls Using Dc Analog Input/Outputs
Installation (Continued) Controls using DC Analog Input/Outputs c. Ensure that the wiring between the binary controls and the unit’s termination point does not exceed two and a half (2.5) ohms/conductor for the length of the Before installing any connecting wiring between the unit run.
Page 33: No System Control
Installation (Continued) No System Control ing. The “Fixed-Off” timers are 5 minutes each and they be- gin timing when the circuit for that step of cooling is deacti- vated. The “Fixed-On” timers are 3 minutes each and they Temperature Control Parameters begin timing when the circuit for that step is activated.
Page 34 Installation (Continued) Figure 3-11B Field Connection Diagram for RAUC-D10 & D12 “No System Controls” Application Refer to Wiring Notes on page 35...
Page 35 Installation (Continued) Field Connection Diagram Notes for all System Control Options...
Page 36: Variable Air Volume Control
Installation (Continued) Variable Air Volume Control Locate the thermostat close to the expansion valve bulb on a slightly flattened portion of the suction line. The thermo- (Honeywell W7100A) stat must be securely fastened to the suction line and a field provided thermoconductive grease must be applied In a variable air volume system, the desired space tempera- to the area to ensure good heat transfer.
Page 37 Installation (Continued) Figure 3-13A Field Connection Diagram for RAUC-C80 “Variable Air Volume” Applications Refer to Wiring Notes on Page 35 Diagram continued on next page...
Page 38 Installation (Continued) Figure 3-13B Field Connection Diagram for RAUC-D10 & D12 “Variable Air Volume” Applications Refer to Wiring Notes on Page 35...
Page 39: Evp Chiller Control
Installation (Continued) EVP Chiller Control The descriptions of the following input devices are to ac- quaint the operator with their function as they interface with the Honeywell W7100G controller. Each unit ordered for EVP Chiller applications (digit 9 in the model number), is shipped with the following controls: Note: All wiring must comply with local and EVP Remote Panel w/ W7100G Controller...
Page 40 Installation (Continued) Figure 3-14A Field Connection Diagram for RAUC-C80 “EVP Chiller” Applications Refer to Wiring Notes on page 35 Diagram continued on next page...
Page 41 Installation (Continued) Figure 3-14B Field Connection Diagram for RAUC-D10 & D12 “EVP Chiller” Applications Refer to Wiring Notes on page 35...
Page 42: System Pre-Start Procedures
System Pre-Start Procedures Use the checklist provided below in conjunction with the [ ] Inspect the interior of the unit for tools and debris in “General Unit Requirement” checklist” to ensure that the preparation for starting the unit and complete the remain- unit is properly installed and ready for operation.
Page 43 System Pre-Start Procedures (Continued) pressure in the system to “zero” (0 psig) gauge Figure 4-1 pressure. Repeat this process two or three times Typical Vacuum Pump Hookup during evacuation. Note: It is unlawful to release refrigerant into the atmosphere. When service procedures require working with refrigerants, the service technician must comply with all Federal, State, and local laws.
Page 44: Discharge Air Controller Checkout
LEDs should turn “Off” as the cooling outputs stage “Off”. and the W7100A accessory tool kit (Trane part # TOL-0101 or Honeywell part # 4074EDJ). 13. Immediately readjust the “Setpoint F” dial to 56 F; the LEDs should begin to illuminate again as the cooling out- 1.
Page 45: Discharge Air Sensor Checkout
System Pre-Start Procedures (Continued) 23. Reconnect the economizer leads R, B, W, & Y to the ap- Discharge Air Sensor Checkout propriate terminals on the controller. (Honeywell Sensor) 24. Turn the control circuit switch 1S2, in the unit control 1. Verify that the main power disconnect switch and the panel, and the main power disconnect switch to the control circuit switch 1S2, in the unit control panel, is “OFF”...
Page 46: Economizer Actuator Checkout
The W7100G (6U11) chilled water controller can be “OFF”. checked out using a highly accurate digital volt-ohmmeter, the W7100 accessory tool kit (Trane part # TOL-0101 or 3. At the actuator, disconnect the control wires connected to Honeywell part # 4074EDJ), and the Honeywell 4074EFV Terminals W, R, B, and Y.
Page 47: Chilled Water Sensor Checkout
System Pre-Start Procedures (Continued) Figure 4-4 6. To simulate a call for maximum reset, remove the jumper W7100G Chilled Water Controller from Terminals 6 & 7 and install the 1780 ohm resistor (red leads), from the test kit, across Terminals 6 and 7. 7.
Page 48: Voltage Imbalance
System Pre-Start Procedures (Continued) Voltage Imbalance Electrical Phasing Excessive three phase voltage imbalance between phases Proper electrical phasing can be quickly determined and will cause motors to overheat and eventually fail. The maxi- corrected before starting the unit by using an instrument mum allowable voltage imbalance is 2%.
Page 49: System Start-Up
System Start-Up Sequence of Operation A second economizer “algorithm” within the W7100A is the response time of the controller. The greater the amount of deviation between the discharge air temperature and the VAV W7100A Discharge Air Controller (7U11) economizer control point, i.e., as the temperature strays fur- The discharge air controller used in Variable Air Volume ap- ther from the control point, the response time becomes plications is a Honeywell W7100A.
Page 50: Sequence Of Operation
System Start-Up (Continued) Sequence of Operation Sequence of Operation Thermostatic Expansion Valve Chilled Water Temperature Controller (6U11) The reliability and performance of the refrigeration system The chilled water temperature controller used with EVP is heavily dependent upon proper expansion valve adjust- chiller applications is a Honeywell W7100G.
Page 51: Sequence Of Operation
System Start-Up (Continued) Sequence of Operation Sequence of Operation Condenser Fans Low Ambient Dampers Condenser fan cycling is accomplished through interlocking Low Ambient Dampers are available as a factory installed the fan contactors with liquid line pressure switches (4S7 option or can be field-installed. Dampers are used to extend and 4S8).
Page 52: Low Ambient Damper Adjustment
System Start-Up (Continued) Table 5-1 Low Ambient Damper Adjustment EVP GPM vs Pressure Drop (Factory or Field Installed) Chiller Pressure Drop ** When a unit is ordered with the low ambient option (i.e., GPM* Chiller Size Digit 11 is a “1” in the model number), a damper is factory 80 Ton 100 Ton 120 Ton...
Page 53: System Airflow Measurement
System Start-Up (Continued) System Airflow Measurement Much of the systems performance and reliability is closely COMPRESSOR SERVICE VALVES! associated with, and dependent upon having the proper air- COMPRESSOR SERVICE VALVES MUST BE FULLY flow supplied both to the space that is being conditioned OPENED BEFORE START-UP (SUCTION, DIS- and across the evaporator coil.
Page 54 Note: On many Trane fan/coil units, an access 10. With the compressors operating, slowly open the “Low valve is provided close to the expansion valve bulb Side”...
Page 55 0.05 mg KOH/g if a burnout occurred. Compressor Oil The scroll compressor uses Trane OIL-42 without substi- tution. The appropriate oil charge for a 9 and 10 Ton scroll compressor is 8.5 pints. For a 14 and 15 Ton scroll com- pressor, use 13.8 pints.
Page 56 System Start-Up (Continued) Table 5-5 Compressor Sequence Circuit # 1 % Loaded Circuit # 2 % Loaded % Loaded Unit Control CKT #1 CKT #2 Unit Size Step (1K2) (1K5) (1K1) (1K19) (1K3) (1K6) (1K4) (1K20) 80 Ton 100% 100% 100% 100% 100 Ton...
Page 57 System Start-Up (Continued) Figure 5-5 Typical Scroll Compressor Terminal Block...
Page 58 System Start-up (Continued) Table 5-8 80 Ton Pressure Curve for each Circuit COOLING CYCLE PRESSURE CURVE (Based on Indoor Airflow of 400 CFM / Ton) FULL LOAD 115 F OD Ambient 105 F OD Ambient 95 F OD Ambient 85 F OD Ambient 75 F OD Ambient 65 F OD Ambient SUCTION PRESSURE, PSIG...
Page 59: Final System Setup
System Start-up (Continued) Table 5-8 (Continued) 120 Ton Pressure Curve for each Circuit COOLING CYCLE PRESSURE CURVE (Based on Indoor Airflow of 400 CFM / Ton) FULL LOAD 115 F OD Ambient 105 F OD Ambient 95 F OD Ambient 85 F OD Ambient 75 F OD Ambient 65 F OD Ambient...
Page 60 Set at design full load water Setpoint D T through evaporator. Number of Stages Factory setting - 6 steps Setpoint Freeze Protection 35° F (Contact Trane for alternate Setpoint settings) Load Limit Cut-In = 64° F Setpoint Cut-Out = 56° F...
Page 61: Service & Maintenance
Anytime a compressor is replaced, the oil for each com- pressor within the manifolded set must be replaced. The scroll compressor uses Trane OIL-42 without substi- tution. The appropriate oil charge for a 9 and 10 Ton scroll compressor is 8.5 pints. For a 14 and 15 Ton scroll com- pressor, use 13.8 pints.
Page 62: Fuse Replacement Data
Service & Maintenance (Continued) Fuse Replacement Data Table 6-2 lists the replacement fuses for the control circuit, compressors, and condenser fans. Table 6-2 Fuse Replacement Data Monthly Maintenance [ ] Lubricate the supply fan bearings. Refer to the equip- ment manufacturer for their recommended greases. Before completing the following checks, turn all system con- trol circuit switches to the “Off”...
Page 63: Coil Cleaning
Service & Maintenance (Continued) Coil Cleaning 6. Spray the leaving-airflow side of the coil first; then spray the opposite side of the coil. Allow the cleaning solution to stand on the coil for five minutes. Regular coil maintenance, including annual cleaning, en- hances the unit’s operating efficiency by minimizing: 7.
Page 64: Index
Index Symbols 100 Ton Pressure Curve for each Circuit ......58 Economizer Actuator Circuit Legend ......... 32 See Table 5-8 Economizer Cycle .............. 49 120 Ton Pressure Curve ............ 59 Electrical Service Sizing Data ........... 30 See Table 5-8 See Table 3-5 80 Ton Pressure Curve for each Circuit ......
Page 65 shutoff valves ..............26 silver brazing alloy ............. 25 sizing refrigerant piping ............. 21 Maintenance Log ............... 60 Solenoid Valves ..............21 See Table 5-9 sound and vibration transmission ........16 Maximum allowable pressure drop ......21, 22 SPREX A.C................ 63 maximum allowable voltage imbalance ......
Page 66: Warranty And Liability Clause
WARRANTY AND LIABILITY CLAUSE COMMERCIAL EQUIPMENT RATED 20 TONS AND LARGER AND RELATED ACCESSORIES PRODUCTS COVERED - This warranty* is extended THE WARRANTY AND LIABILITY SET by American Standard Inc. and applies only to com- FORTH HEREIN ARE IN LIEU OF ALL mercial equipment rated 20 Tons and larger and OTHER WARRANTIES AND LIABILITIES, related accessories.

Trane RAUC-IOM-15 Installation & Maintenance Instructions Manual

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