Trane RTHD Water-Cooled Chiller Installation, Operation, and Maintenance

Installation, Operation,
and Maintenance
Optimus™ Water-Cooled Chillers
Model RTHD
SAFETY WARNING
Only qualified personnel should install and service the equipment. The installation, starting up, and servicing
of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and
training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or
serious injury. When working on the equipment, observe all precautions in the literature and on the tags,
stickers, and labels that are attached to the equipment.
August 2014
RTHD-SVX01E-EN
Introduction
Read this manual thoroughly before operating or servicing
this unit.
Warnings, Cautions, and Notices
Safety advisories appear throughout this manual as
required. Your personal safety and the proper operation of
this machine depend upon the strict observance of these
precautions.
The three types of advisories are defined as follows:
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
Indicates a potentially hazardous
CAUTIONs situation which, if not avoided, could
result in minor or moderate injury. It
could also be used to alert against
unsafe practices.
WARNING
Proper Field Wiring and Grounding
Required!
Failure to follow code could result in death or serious
injury. All field wiring MUST be performed by qualified
personnel. Improperly installed and grounded field
wiring poses FIRE and ELECTROCUTION hazards. To
avoid these hazards, you MUST follow requirements for
field wiring installation and grounding as described in
NEC and your local/state electrical codes.
WARNING
NOTICE:
Indicates a situation that could result in
equipment or property-damage only
accidents.
WARNING
Personal Protective Equipment (PPE)
Required!
Installing/servicing this unit could result in exposure to
electrical, mechanical and chemical hazards.
•
Before installing/servicing this unit, technicians
MUST put on all PPE required for the work being
undertaken (Examples; cut resistant gloves/sleeves,
butyl gloves, safety glasses, hard hat/bump cap, fall
protection, electrical PPE and arc flash clothing).
ALWAYS refer to appropriate Material Safety Data
Sheets (MSDS)/Safety Data Sheets (SDS) and OSHA
guidelines for proper PPE.
•
When working with or around hazardous chemicals,
ALWAYS refer to the appropriate MSDS/SDS and
OSHA/GHS (Global Harmonized System of
Classification and Labelling of Chemicals) guidelines
for information on allowable personal exposure
levels, proper respiratory protection and handling
instructions.
•
If there is a risk of energized electrical contact, arc, or
flash, technicians MUST put on all PPE in accordance
with OSHA, NFPA 70E, or other country-specific
requirements for arc flash protection, PRIOR to
servicing the unit. NEVER PERFORM ANY
SWITCHING, DISCONNECTING, OR VOLTAGE
TESTING WITHOUT PROPER ELECTRICAL PPE AND
ARC FLASH CLOTHING. ENSURE ELECTRICAL
METERS AND EQUIPMENT ARE PROPERLY RATED
FOR INTENDED VOLTAGE.
Important Environmental Concerns
Scientific research has shown that certain man-made
chemicals can affect the earth’s naturally occurring
stratospheric ozone layer when released to the
atmosphere. In particular, several of the identified
chemicals that may affect the ozone layer are refrigerants
that contain Chlorine, Fluorine and Carbon (CFCs) and
those containing Hydrogen, Chlorine, Fluorine and
Carbon (HCFCs). Not all refrigerants containing these
compounds have the same potential impact to the
environment. Trane advocates the responsible handling of
all refrigerants-including industry replacements for CFCs
such as HCFCs and HFCs.
Important Responsible Refrigerant Practices
Trane believes that responsible refrigerant practices are
important to the environment, our customers, and the air
conditioning industry. All technicians who handle
refrigerants must be certified. The Federal Clean Air Act
(Section 608) sets forth the requirements for handling,
reclaiming, recovering and recycling of certain
refrigerants and the equipment that is used in these
service procedures. In addition, some states or
municipalities may have additional requirements that
must also be adhered to for responsible management of
refrigerants. Know the applicable laws and follow them.
© 2014 Trane All rights reserved
Failure to follow instructions could result in death or
serious injury.
RTHD-SVX01E-EN
Introduction
WARNING
Refrigerant under High Pressure!
System contains oil and refrigerant under high
pressure. Recover refrigerant to relieve pressure before
opening the system. See unit nameplate for refrigerant
type. Do not use non-approved refrigerants, refrigerant
substitutes, or refrigerant additives. Failure to recover
refrigerant to relieve pressure or the use of nonapproved refrigerants, refrigerant substitutes, or
refrigerant additives could result in an explosion which
could result in death or serious injury or equipment
damage.
Factory Warranty Information
Compliance with the following is required to preserve the
factory warranty:
All Unit Installations
Startup MUST be performed by Trane, or an authorized
agent of Trane, to VALIDATE this WARRANTY. Contractor
must provide a two-week startup notification to Trane (or
an agent of Trane specifically authorized to perform
startup).
and the required qualified personnel to operate the
necessary rigging equipment.
Copyright
This document and the information in it are the property of
Trane, and may not be used or reproduced in whole or in
part without written permission. Trane reserves the right
to revise this publication at any time, and to make changes
to its content without obligation to notify any person of
such revision or change.
Trademarks
All trademarks referenced in this document are the
trademarks of their respective owners.
Adaptive Control, Adaptive Frequency, AdaptiSpeed,
AdaptiView, Optimus, System Analyzer, TOPSS, TRACE,
Tracer, Trane and the Trane logo are trademarks or
registered trademarks of Trane in the United States and
other countries. Trane is a business of Ingersoll Rand.
BACnet is a registered trademark of American Society of
Heating, Refrigerating and Air-Conditioning Engineers
(ASHRAE); LONMARK and LonTalk are registered
trademarks of Echelon Corporation; ModBus is a
registered trademark of Schneider Automation Inc.
Additional Requirements for Units Requiring
Disassembly
When a new fully assembled chiller is shipped and
received from our Trane manufacturing location, and, for
any reason, it requires disassembly or partial disassembly
— which could include but is not limited to the evaporator,
condenser, control panel, compressor/motor, or any other
components originally attached to the fully assembled unit
— compliance with the following is required to preserve
the factory warranty:
•
•
•
Trane, or an agent of Trane specifically authorized to
perform startup and warranty of Trane® products, will
perform or have direct onsite technical supervision of
the disassembly and reassembly work.
The installing contractor must notify Trane — or an
agent of Trane specifically authorized to perform
startup and warrant of Trane® products — two weeks in
advance of the scheduled disassembly work to
coordinate the disassembly and reassembly work.
Startup must be performed by Trane or an agent of
Trane specifically authorized to perform startup and
warranty of Trane® products as noted above.
Trane, or an agent of Trane specifically authorized to
perform startup and warranty of Trane® products, will
provide qualified personnel and standard hand tools to
perform the disassembly work at a location specified by
the contractor. The contractor shall provide the rigging
equipment such as chain falls, gantries, cranes, forklifts,
etc. necessary for the disassembly and reassembly work
RTHD-SVX01E-EN
Revision History
RTHD-SVX01E-EN (22 Aug 2014)
•
Optimus implementation to add AFD option, and
change controls to UC800/TD7 and Tracer™ TU.
•
Corrected data for existing RTHD units.
•
Updated warranty information.
RTHD-SVX01D-EN
Additional configurations available for 50 hz units.
RTHD-SVX01C-EN
New control panel design.
RTHD-SVX01B-EN
New Evap/Cond configuration C2F2F3 and change to
minimum flow rates.
RTHD-SVX01A-EN
New manual describes installation, operation, and
maintenance of RTHD units.
3
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings, Cautions, and Notices . . . . . . . . 2
Important Environmental Concerns . . . . . 2
Important Responsible Refrigerant
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Freeze Protection . . . . . . . . . . . . . . . . . . . . . .37
Installation Electrical . . . . . . . . . . . . . . . . . . . . .38
General Recommendations . . . . . . . . . . . . .38
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . .38
Standard Units with Wye-Delta Starter . .38
Units with AFD Option . . . . . . . . . . . . . . . .39
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . 4
Installer-Supplied Components . . . . . . . . . .39
Model Number Description . . . . . . . . . . . . . . . 6
Unit Nameplate . . . . . . . . . . . . . . . . . . . . . . . 6
Fused-disconnect switches or
circuit breakers. . . . . . . . . . . . . . . . . . . . . .39
Compressor Nameplate . . . . . . . . . . . . . . . . 6
Module Connections for Interconnecting
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Model Number Descriptions . . . . . . . . . . . . . . 7
Unit Model Number . . . . . . . . . . . . . . . . . . . . 7
Compressor Model Number . . . . . . . . . . . . 8
AFD Drive (Optional) . . . . . . . . . . . . . . . . . . .46
AFD Drive Installation . . . . . . . . . . . . . . . .46
AFD Drive Programming . . . . . . . . . . . . . .47
General Information . . . . . . . . . . . . . . . . . . . . . 9
Unit Description . . . . . . . . . . . . . . . . . . . . . . . 9
Communications Interface . . . . . . . . . . . . . .49
Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BACnet Interface (BCI-C) . . . . . . . . . . . . . .49
Inspection Checklist . . . . . . . . . . . . . . . . . 14
Loose Parts Inventory . . . . . . . . . . . . . . . 14
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation Requirements . . . . . . . . . . . . . . 15
Dimensions and Weight . . . . . . . . . . . . . . . . . 16
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . 16
Unit Weights . . . . . . . . . . . . . . . . . . . . . . . . . 16
Service Clearances . . . . . . . . . . . . . . . . . . . . 18
Installation Mechanical . . . . . . . . . . . . . . . . . . 19
Location Requirements . . . . . . . . . . . . . . . . 19
Sound Considerations . . . . . . . . . . . . . . . 19
Foundation . . . . . . . . . . . . . . . . . . . . . . . . 19
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . 19
Water Drainage . . . . . . . . . . . . . . . . . . . . . 19
Access Restrictions . . . . . . . . . . . . . . . . . 19
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lifting Procedure . . . . . . . . . . . . . . . . . . . 23
Unit Leveling . . . . . . . . . . . . . . . . . . . . . . . 26
Isolation Pads . . . . . . . . . . . . . . . . . . . . . . 26
Water Piping . . . . . . . . . . . . . . . . . . . . . . . 31
4
LonTalk Interface (LCI-C) . . . . . . . . . . . . . .49
Modbus Remote Terminal Unit Interface .49
Operating Principles . . . . . . . . . . . . . . . . . . . . .50
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Refrigeration Cycle . . . . . . . . . . . . . . . . . . . .50
Refrigeration Circuits . . . . . . . . . . . . . . . . . .50
Compressor and Motor . . . . . . . . . . . . . . . . .50
Evaporator and Condenser . . . . . . . . . . . . .50
Oil Management . . . . . . . . . . . . . . . . . . . . . .51
Unit-Mounted Starter . . . . . . . . . . . . . . . . . .51
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
UC800 Specifications . . . . . . . . . . . . . . . . . .52
Wiring and Port Descriptions . . . . . . . . . .52
Communication Interfaces . . . . . . . . . . . .53
Rotary Switches . . . . . . . . . . . . . . . . . . . . .53
LED Description and Operation . . . . . . . .53
Tracer AdaptiView TD7 Display . . . . . . . . . .53
Operator Interface . . . . . . . . . . . . . . . . . . .53
Main Display Area/Home Screen . . . . . . .54
Viewing Chiller Operating Modes . . . . . .54
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Equipment Settings
. . . . . . . . . . . . . . . . .59
RTHD-SVX01E-EN
Table of Contents
Display Settings . . . . . . . . . . . . . . . . . . . . 61
Refrigerant and Oil Charge Management 77
. . . . . . . . . 61
Maintenance Procedures . . . . . . . . . . . . . . .78
Cleaning the Display . . . . . . . . . . . . . . . . 62
Cleaning the Condenser . . . . . . . . . . . . . .78
Security Settings . . . . . . . . . . . . . . . . . . . 62
Cleaning the Evaporator . . . . . . . . . . . . . .80
Disabling/Enabling Security . . . . . . . . . . 62
Oil Sump Level Check . . . . . . . . . . . . . . . .80
Tracer TU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Optional AFD
Periodic Maintenance and Inspection . . .81
Viewing the Settings Screen
Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Start-Up and Shutdown . . . . . . . . . . . . . . . . . 66
Unit Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . 66
Temporary Shutdown And Restart . . . . . . 66
Extended Unit Shutdown . . . . . . . . . . . . . . 66
Seasonal Unit Start-Up Procedure . . . . . . 66
Sequence of Operation . . . . . . . . . . . . . . . . 67
Software Operation Overview . . . . . . . . . 67
Timelines . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Dashed double arrows indicate variable
timers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Starter Diagnostics . . . . . . . . . . . . . . . . . . . .82
Main Processor Diagnostics . . . . . . . . . . . . .85
Communication Diagnostics . . . . . . . . . . . .90
Operator Display Diagnostics and
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . .93
Log and Check Sheet . . . . . . . . . . . . . . . . . . . .94
Chiller Settings . . . . . . . . . . . . . . . . . . . . . . . . .4
Operator Log . . . . . . . . . . . . . . . . . . . . . . . . . .5
Power Up . . . . . . . . . . . . . . . . . . . . . . . . . 68
Power Up to Starting . . . . . . . . . . . . . . . . 69
Stopped to Starting . . . . . . . . . . . . . . . . . 70
Starting Wye-Delta . . . . . . . . . . . . . . . . . . 70
Starting AFD . . . . . . . . . . . . . . . . . . . . . . . 71
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Satisfied Setpoint . . . . . . . . . . . . . . . . . . . 72
Normal Shutdown to Stopped or
Run Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . 73
Immediate Shutdown to Stopped or
Run Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . 74
Momentary Power Loss . . . . . . . . . . . . . . 74
Ice Making (Running to Ice Making to
Running) . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Ice Making (Auto to Ice Making to
Ice Making Complete) . . . . . . . . . . . . . . . 75
No Load Start . . . . . . . . . . . . . . . . . . . . . . 76
Limit Conditions . . . . . . . . . . . . . . . . . . . . . . 76
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Recommended Maintenance . . . . . . . . . . . 77
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Annual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Scheduling Other Maintenance . . . . . . . 77
RTHD-SVX01E-EN
5
Model Number Description
Nameplates
of typical unit model number and the coding system for
each.
The Optimus™ unit nameplates are applied to the exterior
of the Control Panel. A compressor nameplate is located
on the compressor. When the unit arrives, compare all
nameplate data with ordering, submittal, and shipping
information.
Each position, or group of positions, in the model number
is used to represent a feature. For example, in the first
table, position 08 of the unit model number, Unit Voltage,
contains the letter “F”. An F in this position means that the
unit voltage is 460/60/3.
Unit Nameplate
Unit Model Number. An example of a typical unit
model number (M/N) is:
See Figure 1 for a typical unit nameplate. The unit
nameplate provides the following information:
RTHD UB1F XG0U AB1A 2LAL B1A2 LALA VXQX EXAA
AXY1 76DC XT52 XXXX XXH
•
Unit model and size description.
•
Unit serial number.
•
Identifies unit electrical requirements.
Model number digits are selected and assigned in
accordance with the definitions as listed in “Unit Model
Number,” p. 7.
•
Lists correct operating charges of R-134a and
refrigerant oil.
Compressor Nameplate
•
Lists unit test pressures.
•
Identifies installation, operation and maintenance and
service data literature.
The compressor nameplate provides the following
information:
•
Lists drawing numbers for unit wiring diagrams.
Model Number Coding System
The model numbers for the unit and the compressor are
composed of numbers and letters that represent features
of the equipment. Shown in the following table is a sample
Figure 1.
6
•
Compressor model number. See “Compressor Model
Number,” p. 8.
•
Compressor electrical characteristics.
•
Utilization range.
•
Recommended refrigerant.
Typical unit nameplate
RTHD-SVX01E-EN
Model Number Descriptions
Unit Model Number
Digits 1-4 – Chiller Model
Digits 14,15 – Evaporator
RTHD= Water-Cooled Optimus™ Chiller
B1
B2
C1
C2
D1
D2
D3
D4
D5
D6
E1
F1
F2
G1
G2
G3
Digit 5 – Manufacturing
Location
U
=
Water Chiller Business Unit,
Pueblo, CO USA
Digits 6, 7 – Compressor Frame
B1
B2
C1
C2
D1
D2
D3
E3
=
=
=
=
=
=
=
=
B1 Compressor
B2 Compressor
C1 Compressor
C2 Compressor
D1 Compressor
D2 Compressor
D3 Compressor (50 hz only)
E3 Compressor (50 hz only)
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
B1 Evaporator
B2 Evaporator
C1 Evaporator
C2 Evaporator
D1 Evaporator
D2 Evaporator
D3 Evaporator
D4 Evaporator
D5 Evaporator
D6 Evaporator
E1 Evaporator
F1 Evaporator
F2 Evaporator
G1 Evaporator
G2 Evaporator
G3 Evaporator
Digits 8 – Unit Power Supply
Digit 16 – Evaporator Tube Type
A
C
D
F
H
R
T
U
A =
W =
=
=
=
=
=
=
=
=
200V/60Hz/3Ph power
230V/60Hz/3Ph power
380V/60Hz/3Ph power
460V/60Hz/3Ph power
575V/60Hz/3Ph power
380V/50Hz/3Ph power
400V/50Hz/3Ph power
415V/50Hz/3Ph power
Digit 9 – Specials
X = No Specials
Historical information:
C = Specials denoted elsewhere
S = Specials not denoted elsewhere
Digit 10, 11 – Design Sequence
** =
Factory assigned
Digit 12 – Agency Listing
X
U
=
=
No Agency Listing
UL Listed to US and Canadian
Safety Standard
A = IBC Seismically Rated
B = UL/Canadian and IBC
C = OSHPD Seismically Rated
D = UL/Canadian and OSHPD
Historical information:
3 = CCC - Chinese Compulsory Code
Note: Digit 12 selections A, B, C & D are
special order only.
Digit 13 – Pressure Vessel Code
A
C
D
L
=
=
=
=
ASME Pressure Vessel Code
Canadian Code
Australian Code
Chinese Code-Imported Pressure
Vessel
Historical information:
S = Special
Enhanced fin copper (all fluids)
Enhanced fin copper (water only)
Digit 17 – Evaporator Water Pass
Configuration
2
3
4
=
=
=
2 Pass
3 Pass
4 Pass
Digit 18 – Evaporator Water
Connection
L
R
=
=
Left Hand
Right Hand
Digit 19 – Evaporator
Connection Type
A = Standard Grooved Pipe
Historical information:
S = Special
2
=
2 Pass
Digit 25 – Condenser Water
Connection
L
R
=
=
Left Hand
Right Hand
Digit 26 – Condenser
Connection Type
A
C
S
=
=
=
Standard Grooved Pipe
Marine
Special
Digit 27 – Condenser Waterside
Pressure
L
H
=
=
150 psi (10.5 bar)
300 psi (21 bar)
Digit 28 – Condenser Leaving
Water Temperature
A
=
Standard
Digit 29 – Refrigerant Isolation
Valves
X
V
=
=
No Refrigerant Isolation Valves
With Refrigerant Isolation Valves
Digit 30 – Oil Cooler
X
C
=
=
Without Oil Cooler
With Oil Cooler
Digit 31 – Thermal Insulation
X
Q
=
=
No Insulation
Factory Installed Insulation
Digit 32 – Acoustic Insulation
Digit 20 – Evaporator Water
Side Pressure
X = No Insulation
Historical information:
A = Standard Attenuator
L
H
Digit 33 – Label and Literature
Language
=
=
150 psi (10.5 bar)
300 psi (21 bar)
Digit 21, 22 – Condenser
B1
B2
D1
D2
E1
E2
E3
E4
E5
F1
F2
F3
G1
G2
G3
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
B1 Condenser
B2 Condenser
D1 Condenser
D2 Condenser
E1 Condenser
E2 Condenser
E3 Condenser
E4 Condenser
E5 Condenser
F1 Condenser
F2 Condenser
F3 Condenser
G1 Condenser
G2 Condenser
G3 Condenser
Digit 23 – Condenser Tube Type
A
B
C
D
RTHD-SVX01E-EN
Digit 24 – Condenser Water
Passes
=
=
=
=
Enhanced Fin Copper - 0.028”
Smooth Bore Copper
Smooth Bore CuNi
Enhanced Fin Copper - 0.025”
C
E
F
=
=
=
Spanish
English
French
Digit 34 – Safety Devices
X
=
Standard
Digit 35 – Factory Charge
A
=
B
=
Factory Refrigerant Charge
(R-134a)
Factory Nitrogen Charge
Digit 36 – Shipping Package
A = No Skid (Standard)
B = Shrink Wrap
C = Skid
D = Skid + Shrink Wrap
Historical information:
J = Special
7
Model Number Descriptions
Digit 37 – Flow Switch
Digit 46 – Operator Interface
X
A
B
=
=
=
C
D
=
=
T = Tracer AdaptiView™ TD7 Display
Historical information:
A = DynaView™ - English
B = DynaView - French
C = DynaView - Italian
D = DynaView - Spanish
E = DynaView - German
F = DynaView - Dutch
G = DynaView - Chinese
(traditional)
H = DynaView - Chinese (simple)
J = DynaView - Japanese
K = DynaView - Portugese (Brazil)
L = DynaView - Korean
M = DynaView - Thai
No Flow Switch
Evaporator (NEMA 1)
Evaporator and Condenser
(NEMA 1)
Evaporator (NEMA 4)
Evaporator and Condenser
(NEMA 4)
Digit 38 – Factory Test
X
C
D
=
=
=
Standard Test
Witness Test
Performance Test
Digit 39 – Starter Type
Y
=
Wye-Delta Closed Transition
Starter
V = Premium AFD
Historical information:
A = Solid State Starter
Digits 40 - 42 — Design RLA
(for starter)
*** =
Selection Assigned
Digit 43 – Power Line
Connection Type
A = Terminal Block
B = Mechanical Disconnect Switch
D = Circuit Breaker
F = High Interrupt Circuit Breaker
Historical information:
H = Ground Fault Circuit Breaker
J = Ground Fault High Interrupt
Circuit Breaker
Digit 44 – Max RLA (Starter)
C = 277 max RLA (Unit Mounted)
E = 364 max RLA (Unit Mounted)
Q = 397 max RLA (Unit Mounted)
R = 476 max RLA (Unit Mounted)
T = 598 max RLA (Unit Mounted)
U = 779 max RLA (Unit Mounted)
V = 197 max RLA (Drive and Panel)
W = 241 max RLA (Drive and Panel)
X = 292 max RLA (Drive and Panel)
Y = 367 max RLA (Drive and Panel)
Z = 446 max RLA (Drive and Panel)
1 = 549 max RLA (Drive and Panel)
2 = 176 max RLA (Drive and Panel)
3 = 223 max RLA (Drive and Panel)
4 = 280 max RLA (Drive and Panel)
5 = 335 max RLA (Drive and Panel)
6 = 411 max RLA (Drive and Panel)
7 = 455 max RLA (Drive and Panel)
Historical information - Enclosure Type:
F = NEMA 1 - MRLA207
G = NEMA 1 - MRLA277
H = NEMA 1 - MRLA300
J = NEMA 1 - MRLA364
K = NEMA 1 - MRLA397
L = NEMA 1 - MRLA476
M = NEMA 1 - MRLA500
N = NEMA 1 - MRLA598
P = NEMA 1 - MRLA779
Digit 47 – Digital
Communication Interface
X = None
5 = LCI-C (LonTalk®) Interface
7 = BACnet®
8 = Modbus™ Interface
Historical information:
4 = Tracer™ Comm 4 Interface
Digit 48 – External Water &
Current-Limit Setpoint
X
2
4
=
=
=
None
2–10 Vdc input
4–20 mA input
Digit 49 – External Base Loading
X
2
4
=
=
=
None
2–10 Vdc input
4–20 mA input
Digit 5— Design Control
*
=
B
C
D
E
=
=
=
=
1
2
3
=
=
=
Smaller capacity (minor)
Larger capacity (major)
Special 50 Hz
Digit 8 — Motor Voltage
A
C
D
F
=
=
=
=
H
M
B
G
S
=
=
=
=
=
200V/60Hz/3Ph
230V/60Hz/3Ph
380V/60Hz/3Ph
400/460V- 50/60Hz - 3Ph
used for 380V/50Hz/3Ph
575V/60Hz/3Ph
690V/50Hz/3Ph
525V/50Hz/3Ph
500V/50Hz/3Ph
Special voltage
Digit 9— Design Specials
S
=
None
Ice Making with Relay
Ice Making without Relay
B Frame
C Frame
D Frame
E Frame
Digit 7— Capacity
X
A
B
=
=
=
Factory Assigned
Digit 6— Frame Size
=
=
No specials
All specials denoted by digits
elsewhere
Uncategorized special not
denoted by other digits
Digit 51 – Programmable Relays
Digits 10-11— Design Sequence
X
R
** =
=
=
None
With Programmable Relays
Factory assigned
Digit 52 – Chilled Water Reset
X
=
T
=
Chilled Water Reset Return Water
Chilled Water Reset Outdoor Air Temperature
Digit 53 – Control Outputs
X
D
=
=
P
=
V
=
None
Chiller Differential Pressure &
Percent RLA
Condenser Pressure (% HPC) &
Percent RLA
Condenser Regulating Valve
Control & Percent RLA
Digits 54 – Refrigerant Monitor
Input
X
U
Digit 55 – Condenser Leaving
Hot Water Temp Control
8
CHHC= Positive displacement,
helical rotary (twin screw)
hermetic compressor
0
C
Digit 45 – Under/Over Voltage
Protection
None
With Under/Over Voltage
Protection
Digits 1-4— Compressor Model
Digit 50 – Ice Making
X
A
B
C
D
=
=
Compressor Model
Number
X
H
=
=
=
=
=
=
=
None
100 ppm / 4-20 mA
1000 ppm / 4-20 mA
100 ppm / 2-10 Vdc
1000 ppm / 2-10 Vdc
None
Hot Water Temp Control
RTHD-SVX01E-EN
General Information
Unit Description
The RTHD units are single compressor, helical-rotary type,
water-cooled liquid chillers designed for installation
indoors. Each unit is a completely assembled, hermetic
package that is factory-piped, wired, leak-tested,
dehydrated, charged (optional), and tested for proper
control operation before shipment.
Figure 2 through Figure 4 show typical Optimus™ units
and their components. Water inlet and outlet openings are
covered before shipment. The oil tank is factory charged
with the proper amount of refrigeration oil. The unit can be
factory charged with refrigerant.
Figure 2. Component location — Optimus wye-delta starter (front view)
TD7 Interface
Oil Separator
Control Panel
Relief Valves
Oil Sump
Condenser
Water Outlet
Evaporator
Liquid Level
Sensor
Gas Pump
Evaporator
Water Outlet
Condenser
Water Inlet
Figure 3. Component location - Optimus with AFD (front view)(a)
AFD
(a) Component locations shown in Figure 2 are the same for units with optional AFD.
RTHD-SVX01E-EN
9
General Information
Figure 4. Component location — Optimus (back view)(a)
Oil Separators
Oil Filter (Cold)
Hot Oil Filter is
hidden from view.
Relief Valves
Compressor
Discharge Line
Unit Nameplate
(On side of starter/control panel)
EXVs
Evaporator
Water Inlet
Condenser
Service Valves
(With Refrigerant Isolation
Valve Option Only)
Oil Sump
(The oil distribution system is located between
the condenser and the evaporator.)
(a) Optional AFD is not shown. See Figure 3, p. 9 for location of optional AFD.
10
RTHD-SVX01E-EN
General Information
Table 1.
General Data
Unit Configuration(a)
B1B1B1
B1C1D1
B2B2B2
B2C2D2
C1D5E4
lb
410
490
410
490
490
kg
186
222
186
222
222
C1D6E5
C1E1F1
C2D3E3
490
525
490
222
238
222
GENERAL
Refrigerant Type
Refrigerant Charge
HFC-134a
Oil Type (wye-delta)
OIL48
Oil Charge(b) (wye-delta) gal
L
4.5
4.5
4.5
4.5
6
6
10
6
17
17
17
17
23
23
38
23
Oil Type (AFD)
Oil Charge (AFD)
OIL315
gal
7.5
7.5
7.5
7.5
10
10
11
10
L
28.5
28.5
28.5
28.5
38
38
42
38
gal
41
55
45
58
52
45
82
78
L
155
208
170
220
197
170
310
295
in
8
8
8
8
8
8
8
8
200
EVAPORATOR
Water Storage
Connection size
Min Flow - Water
2-pass
Min Flow - Brine
Maximum Flow
Connection size
Min Flow - Water
3-pass
Min Flow - Brine
Maximum Flow
mm
200
200
200
200
200
200
200
gpm
253
320
288
347
351
293
450
486
l/s
16
18
22
22
21
18
28
31
gpm
303
346
346
375
422
352
487
584
l/s
19
22
22
24
27
22
31
37
gpm
1104
1412
1266
1531
1542
1287
1980
2131
l/s
70
89
80
97
97
81
125
134
in
6
6
6
6
8
8
8
8
mm
150
150
150
150
200
200
200
200
gpm
168
213
192
232
234
196
300
324
l/s
11
13
12
15
15
12
19
20
gpm
200
254
233
276
281
233
357
389
l/s
13
16
15
17
18
15
23
25
gpm
736
941
844
1022
1028
860
1320
1417
l/s
46
59
53
65
65
54
83
89
8
CONDENSER (all are 2-pass)
Connection size
Water Storage
Min Flow - Water
Min Flow - Brine
Max Flow
in
6
6
6
6
8
8
8
mm
150
150
150
150
200
200
200
200
gal
28
31
29
34
32
29
60
47
178
L
106
117
110
129
121
110
226
gpm
193
193
212
212
245
206
375
325
l/s
12
12
13
13
15
13
24
21
gpm
230
230
255
255
295
250
450
390
l/s
15
15
16
16
19
16
28
25
gpm
850
850
935
935
1080
910
1650
1420
l/s
54
54
59
59
68
57
104
90
(a) Unit configuration digits 1, 2 - compressor code (also shown in unit model number digits 6, 7); digits 3, 4 - evaporator code (unit model number digits
14, 15); digits 5, 6 - condenser code (unit model number digits 21, 22).
(b) If oil cooler is installed, add 0.3 gal (1L) to oil charge value given for B compressor family units. Add 1.0 gal (4L) for all other units.
RTHD-SVX01E-EN
11
General Information
Table 2.
General Data
Unit Configuration(a)
C2D4E4
C2F2F3
D1D1E1
D1F1F2
D1G1G1 D1G2G2 D2D2E2
D2F2F3
lb
490
625
475
625
700
700
475
625
kg
222
284
216
284
318
318
216
284
GENERAL
Refrigerant Type
Refrigerant Charge
HFC-134a
Oil Type (wye-delta)
OIL48
Oil Charge(b) (wye-delta) gal
6
10
6
10
11
11
6
10
L
23
38
23
38
42
42
23
38
gal
10
12
9.5
11
13.5
13.5
9.5
11
L
38
45.5
36
42
51
51
36
42
gal
52
107
69
102
136
144
74
107
L
197
405
261
386
515
545
280
405
in
8
10
8
10
-
-
8
10
mm
200
250
200
250
-
-
200
250
gpm
351
604
415
563
-
-
450
604
l/s
21
38
26
36
-
-
28
38
gpm
422
725
498
676
-
-
541
725
l/s
27
46
31
43
-
-
34
46
Oil Type (AFD)
Oil Charge (AFD)
OIL315
EVAPORATOR
Water Storage
Connection size
Min Flow - Water
2-pass
Min Flow - Brine
Maximum Flow
Connection size
Min Flow - Water
3-pass
Min Flow - Brine
Maximum Flow
Connection size
Min Flow - Water
4-pass
Min Flow - Brine
Maximum Flow
gpm
1542
2667
1812
2478
-
-
1980
2667
l/s
97
168
114
156
-
-
125
168
in
8
8
8
8
10
10
8
8
mm
200
200
200
200
250
250
200
200
gpm
234
404
275
376
505
550
300
404
l/s
15
25
17
24
35
35
19
25
gpm
281
487
330
454
606
660
357
487
l/s
18
31
21
29
38
42
23
31
gpm
1028
1780
1206
1655
2218
2413
1320
1780
l/s
65
112
76
104
140
152
83
112
in
-
-
-
-
8
8
-
-
mm
-
-
-
-
200
200
-
-
gpm
-
-
-
-
379
411
-
-
l/s
-
-
-
-
24
26
-
-
gpm
-
-
-
-
454
492
-
-
l/s
-
-
-
-
29
31
-
-
-
gpm
-
-
-
l/s
-
-
-
1666
1807
-
-
105
114
-
-
8
CONDENSER(all are 2-pass)
Connection size
Water Storage
Min Flow - Water
Min Flow - Brine
Max Flow
in
8
8
8
8
8
8
8
mm
200
200
200
200
200
200
200
200
gal
32
61
44
57
79
91
47
61
231
L
121
231
166
216
299
344
178
gpm
245
355
291
355
444
535
316
385
l/s
15
22
18
22
28
34
20
24
gpm
295
460
350
430
530
650
380
460
l/s
19
29
22
27
33
41
24
29
gpm
1080
1700
1280
1560
1960
2360
1390
1700
l/s
68
107
81
98
124
149
88
107
(a) Unit configuration digits 1, 2 - compressor code (also shown in unit model number digits 6, 7); digits 3, 4 - evaporator code (unit model number digits
14, 15); digits 5, 6 - condenser code (unit model number digits 21, 22).
(b) If oil cooler is installed, add 0.3 gal (1L) to oil charge value given for B compressor family units. Add 1.0 gal (4L) for all other units.
12
RTHD-SVX01E-EN
General Information
Table 3.
General Data
Unit Configuration(a)
D2G2G1 D2G3G3 D3D2E2
D3F2F3
D3G2G1 E3D2E2
lb
700
700
475
625
700
kg
318
318
216
284
318
E3F2F3
E3G2G1
475
625
700
216
284
318
GENERAL
Refrigerant Type
Refrigerant Charge
HFC-134a
Oil Type (wye-delta)
OIL48
Oil Charge(b) (wye-delta) gal
11
11
6
10
11
6
10
11
L
42
42
23
38
42
23
38
42
gal
13.5
13.5
9.5
11
13.5
9.5
11
13.5
L
51
51
36
42
51
36
42
51
gal
144
159
74
107
144
74
107
144
L
545
602
280
405
545
280
405
545
Oil Type (AFD)
Oil Charge (AFD)
OIL315
EVAPORATOR
Water Storage
Connection size
Min Flow - Water
2-pass
Min Flow - Brine
Maximum Flow
Connection size
Min Flow - Water
3-pass
Min Flow - Brine
Maximum Flow
Connection size
Min Flow - Water
4-pass
Min Flow - Brine
Maximum Flow
in
-
-
8
10
-
8
10
-
mm
-
-
200
250
-
200
250
-
gpm
-
-
450
604
-
450
604
-
l/s
-
-
28
38
-
28
38
-
gpm
-
-
541
725
-
541
725
-
l/s
-
-
34
46
-
34
46
-
gpm
-
-
1980
2667
-
1980
2667
-
l/s
-
-
125
168
-
125
168
-
in
10
10
8
8
10
8
8
10
mm
250
250
200
200
250
200
200
250
gpm
550
622
300
404
550
300
404
550
l/s
35
39
19
25
35
19
25
35
gpm
660
747
357
487
660
357
487
660
l/s
42
47
23
31
42
23
31
42
gpm
2413
2732
1320
1780
2413
1320
1780
2413
l/s
152
172
83
112
152
83
112
152
in
8
8
-
-
8
-
-
8
mm
200
200
-
-
200
-
-
200
gpm
411
466
-
-
411
-
-
411
l/s
26
29
-
-
26
-
-
26
gpm
492
557
-
-
492
-
-
492
l/s
31
35
-
-
31
-
-
31
gpm
1807
2050
-
-
1807
-
-
1807
l/s
114
129
-
-
114
-
-
114
8
CONDENSER (all are 2-pass)
Connection size
Water Storage
Min Flow - Water
Min Flow - Brine
Max Flow
in
8
8
8
8
8
8
8
mm
200
200
200
200
200
200
200
200
gal
79
97
47
61
79
47
61
79
299
L
299
367
178
231
299
178
231
gpm
444
589
316
385
444
316
385
444
l/s
28
37
20
24
28
20
24
28
gpm
530
710
380
460
530
380
460
530
l/s
33
45
24
29
33
24
29
33
gpm
1960
2600
1390
1700
1960
1390
1700
1960
l/s
124
164
88
107
124
88
107
124
(a) Unit configuration digits 1, 2 - compressor code (also shown in unit model number digits 6, 7); digits 3, 4 - evaporator code (unit model number digits 14, 15); digits 5, 6 condenser code (unit model number digits 21, 22).
(b) If oil cooler is installed, add 0.3 gal (1L) to oil charge value given for B compressor family units. Add 1.0 gal (4L) for all other units.
RTHD-SVX01E-EN
13
Pre-Installation
Inspection
When the unit is delivered, verify that it is the correct unit
and that it is properly equipped.
Inspect all exterior components for visible damage. Report
any apparent damage or material shortage to the carrier
and make a “unit damage” notation on the carrier’s
delivery receipt. Specify the extent and type of damage
found and notify the appropriate Trane Sales Office.
46 psig at 50oF), call a qualified service organization
and the appropriate Trane sales office.
Note: Pressure will be approximately 20 psig if shipped
with the optional nitrogen charge.
Do not proceed with installation of a damaged unit without
sales office approval.
Inspection Checklist
To protect against loss due to damage incurred in transit,
complete the following checklist upon receipt of the unit.
•
Inspect the individual pieces of the shipment before
accepting the unit. Check for obvious damage to the
unit or packing material.
•
Inspect the unit for concealed damage as soon as
possible after delivery and before it is stored.
Concealed damage must be reported within 10 days
after receipt.
•
If concealed damage is discovered, stop unpacking the
shipment. Do not remove damaged material from the
receiving location. Take photos of the damage, if
possible. The owner must provide reasonable
evidence that the damage did not occur after delivery.
•
Notify the carrier’s terminal of the damage
immediately, by phone and by mail. Request an
immediate, joint inspection of the damage with the
carrier and the consignee.
•
Notify the Trane sales representative and arrange for
repair. Do not repair the unit, however, until damage is
inspected by the transportation representative.
Loose Parts Inventory
Check all items against the shipping list. Water vessel drain
plugs, isolation pads, rigging and electrical diagrams,
service literature and the starter/control panel wire pullbox
(required on some starters) are shipped loose in the
control panel.
Storage
If the chiller is to be stored more than one month prior to
installation, observe the following precautions:
•
Do not remove the protective coverings from the
electrical panel.
•
Store the chiller in a dry, vibration-free, secure area.
•
At least every three months, attach a gauge and
manually check the pressure in the refrigerant circuit.
If the refrigerant pressure is below 71 psig at 70oF (or
14
RTHD-SVX01E-EN
Pre-Installation
Installation Requirements
A list of the contractor responsibilities typically associate
with the unit installation process is provided in Table 4.
Table 4.
Installation requirements
Requirement
Trane Supplied,
Trane Installed
Trane Supplied,
Field Onstalled
• Safety chains
• Clevis connectors - Lifting beam
Rigging
Disassembly/
Reassembly
(as required)(a)
• Trane, or an agent
of Trane specifically authorized to perform
start-up of Trane® products (contact
your local Trane
office for pricing)
Isolation
Electrical
Field Supplied,
Field Installed
• Isolation pads
• Circuit breakers or non-fused disconnects • Circuit breaker or non-fused disconnect
(optional)
handle
• Unit-mounted starter
• Temperature sensor (optional outdoor air)
• Flow switches (may be field-supplied)
• Condenser water regulating valve
controller (optional: may be fieldsupplied)
• Flow switches (may be field-supplied)
• Condenser water regulating valve
controller
(optional- may be field-supplied)
Water piping
• Isolation pads
• Circuit breakers or fusible disconnects
(optional)
• Terminal lugs
• Ground connection(s)
• Jumper bars
• BAS wiring (optional)
• IPC wiring
• Control voltage wiring
• High condenser pressure interlock wiring
• Chilled water pump contactor and wiring
• Condenser water pump contactor and
wiring
• Optional relays and wiring
• Thermometers
• Water flow pressure gauges
• Isolation and balancing valves in water
piping
• Vents and drain valves
• Pressure relief valves
(for water boxes as required)
Pressure Relief
• Relief valves
Vent line and flexible connector
Insulation
• Insulation (optional)
Insulation
“Optimus™ RTHD
Installation
Completion Check Sheet
and Request
for Trane Service”
(RLC-ADF005*-EN,
see “Log and Check
Sheet,” p. 94)
Chiller Start-up
Commissioning(b)
• Trane, or an agent of
Trane specifically authorized to
perform start-up of Trane® products
(a) Trane, or an agent of Trane specifically authorized to perform start-up and warranty of Trane® products, will perform or have direct on-site supervision of
the disassembly and reassembly work.
(b) Start-up must be performed by Trane or an agent of Trane specifically authorized to perform start-up and warranty of Trane® products. Contractor shall
provide Trane (or an agent of Trane specifically authorized to perform start-up) with notice of the scheduled start-up at least two weeks prior to the scheduled
start-up.
RTHD-SVX01E-EN
15
Dimensions and Weight
Unit Dimensions
See unit submittals for specific unit dimensions and water
connection locations.
Unit Weights
Table 5.
Weights - standard units (wye-delta starter)
Shipping Weight
Operating Weight
Unit Configuration(a)
lbs
kg
lbs
kg
B1B1B1
9,292
4,215
9,867
4,476
4,787
B1C1D1
9,837
4,462
10,554
B2B2B2
9,402
4,265
10,019
4,545
B2C2D2
9,953
4,515
10,653
4,832
C1D5E4
12,973
5,884
13,673
6,202
C1D6E5
12,780
5,797
13,397
6,077
C1E1F1
14,718
6,676
15,818
7,175
C2D3E3
14,002
6,351
15,044
6,824
C2D4E4
12,972
5,884
13,672
6,201
C2F2F3
16,168
7,334
17,560
7,965
D1D1E1
14,443
6,551
15,385
6,987
D1F1F2
16,187
7,342
17,537
7,955
D1G1G1
18,600
8,437
20,500
9,299
D1G2G2
19,107
8,667
21,065
9,555
D2D2E2
14,562
6,605
15,570
7,062
D2F2F3
16,820
7,629
18,220
8,264
D2G2G1
18,700
8,482
20,700
9,389
D2G3G3
19,508
8,849
21,641
9,816
D3D2E2
14,562
6,605
15,570
7,062
D3F2F3
16,820
7,629
18,220
8,264
D3G2G1
18,650
8,460
20,650
9,367
E3D2E2
14,720
6,677
15,728
7,134
E3F2F3
16,956
7,691
18,356
8,326
E3G2G1
18,800
8,528
20,800
9,435
Notes:
1. All weights +/- 3%
2. Shipping weights include standard 150 psig water boxes, refrigerant charge and oil charge.
3. Operating weights include refrigerant, oil and water charges.
(a) Unit configuration digits 1, 2 - compressor code (also shown in unit model number digits 6, 7); digits 3, 4 - evaporator code (unit
model number digits 14, 15); digits 5, 6 - condenser code (unit model number digits 21, 22).
16
RTHD-SVX01E-EN
Dimensions and Weight
Table 6.
Weights — units with AFD option(a)
Shipping Weight
Unit
Configuration(b)
Operating Weight
AFD D1H Frame
AFD D2H Frame
AFD D1H Frame
AFD D2H Frame
lbs
kg
lbs
kg
lbs
kg
lbs
B1B1B1
9526
4321
-
-
10101
4582
-
kg
-
B1C1D1
10071
4568
-
-
10787
4893
-
-
B2B2B2
9636
4371
-
-
10251
4650
-
-
B2C2D2
10187
4621
-
-
10886
4938
-
-
C1D5E4
13206
5990
13344
6053
13904
6307
14043
6370
C1D6E5
13014
5903
13153
5966
13631
6183
13770
6246
C1E1F1
14949
6781
15088
6844
16801
7621
16940
7684
C2D3E3
14235
6457
14374
6520
15278
6930
15417
6993
C2D4E4
13206
5990
13344
6053
13907
6308
14046
6371
C2F2F3
17055
7736
17194
7799
18446
8367
18585
8430
D1D1E1
-
-
14815
6720
-
-
15756
7147
D1F1F2
-
-
16559
7511
-
-
17910
8124
D1G1G1
-
-
18973
8606
-
-
20873
9468
D1G2G2
-
-
19480
8836
-
-
21438
9724
D2D2E2
-
-
14934
6774
-
-
15944
7232
D2F2F3
-
-
17194
7799
-
-
18594
8434
D2G2G1
-
-
19072
8651
-
-
21074
9559
D2G3G3
-
-
19881
9018
-
-
22013
9985
D3D2E2
-
-
14934
6774
-
-
15944
7232
D3F2F3
-
-
17194
7799
-
-
18594
8434
D3G2G1
-
-
19023
8629
-
-
21023
9536
E3D2E2
-
-
15093
6846
-
-
16100
7303
E3F2F3
-
-
17337
7864
-
-
18728
8495
E3G2G1
-
-
19173
8697
-
-
21173
9604
Notes:
1. All weights +/- 3%
2. Shipping weights include standard 150 psig water boxes, refrigerant charge and oil charge.
3. Operating weights include refrigerant, oil and water charges.
4. AFD frame size determined by unit selection. See submittal for information.
(a) Weights dependent on AFD frame size. D1H frame size used on units with max RLA values 176 - 292 amps (model number digit 44 = V, W,
X, 2, 3 or 4). D2H frame size used with max RLA values of 335 - 549 amps (model number digit 44 = Y, Z, 1, 5, 6 or 7).
(b) Unit configuration digits 1, 2 - compressor code (also shown in unit model number digits 6, 7); digits 3, 4 - evaporator code (unit model number
digits 14, 15); digits 5, 6 - condenser code (unit model number digits 21, 22).
RTHD-SVX01E-EN
17
Dimensions and Weight
Service Clearances
Notes:
•
Required vertical clearance above unit is 36” (914 mm).
There should be no piping or conduit located over the
compressor motor.
•
Maximum clearances are given. Some units
configurations may require less clearance than others
in the same category.
Figure 5.
•
If the room configuration requires a variance to the
clearance dimensions, contact your Trane sales office
representative.
Service clearances(a)
3’-0” (914 mm)
Service Clearance
3’-0” (914mm)
Service Clearance
Tube Removal
Clearance
(Either End)
3’-0” (914mm)
Service Clearance
(Opposite
Tube Removal)
EDE, DDE, CDE, BBB:
108” (2743mm)
EFF, DFF, CEF, BCD:
126” (3200mm)
EGG, DGG, CGG:
130” (3302mm)
36.5” (927mm)
Radius
105° Swing
26.4” (671mm)
Radius
TOP VIEW
3’-0”
(914mm)
Service
Clearance
END VIEW
(a) Optional AFD is not shown. See Figure 3, p. 9 for location of optional AFD.
18
RTHD-SVX01E-EN
Installation Mechanical
Location Requirements
Ventilation must be adequate to maintain an ambient
temperature lower than the following:
Sound Considerations
Wye-Delta Starter Units:
122°F (50°C)
AFD Unit Option:
104°F (40°C)
Note: See Trane Engineering Bulletin Sound Ratings and
Installation Guide Optimus™Water-Cooled Chillers
RLC-PRB015*-EN for sound consideration
applications.
Vent the evaporator, condenser and compressor pressure
relief valves in accordance with all local and national
codes. See Table 10, p. 35
•
Locate the unit away from sound-sensitive areas.
•
Install the isolation pads under the unit. Refer to “Unit
Isolation.”
•
Install rubber vibration isolators in all water piping.
Water Drainage
•
Isolate all pipe hangers and be sure they are not
supported by main structure beams that could
introduce vibration into occupied spaces.
•
Make sure that the piping does not put additional
stress on the unit.
Locate the unit near a large capacity drain for water vessel
drain-down during shutdown or repair. Condensers and
evaporators are provided with drain connections. See “,”
p. 32. All local and national codes apply.
Make provisions in the equipment room to keep the chiller
from being exposed to freezing temperatures (32oF/0oC).
Access Restrictions
Note: Do not use metal braided type eliminators on the
water piping. Metal braided eliminators are not
effective at the frequencies at which the unit will
operate.
Door clearances are given in Figure 5, p. 18. See unit
submittals for specific “per unit” dimensional
information.
•
Use flexible electrical conduit.
•
Seal all wall penetrations.
Rigging
Note: Consult an acoustical engineer for critical
applications.
Foundation
Provide rigid, non-warping mounting pads or a concrete
foundation of sufficient strength and mass to support the
chiller operating weight (including completed piping and
full operating charges of refrigerant, oil and water). See
Table 5, p. 16 and Table 6, p. 17 for unit operating weights.
Place the manufacturer-supplied isolation pad assemblies
under the unit. Once in place, level the chiller within 1/4”
(6.35 mm) over its length and width.
The Trane Company is not responsible for equipment
problems resulting from an improperly designed or
constructed foundation.
Clearances
Provide enough space around the unit to allow the
installation and maintenance personnel unrestricted
access to all service points. Refer to submittal drawings for
the unit dimensions.
See Figure 5, p. 18 for minimum clearances required for
service. In all cases, local codes will take precedence over
these recommendations.
Important:
If unit must be disassembled for
installation, see Engineering Bulletin RTHDSVB02*-EN, Disassembly Procedure,
Optimus Water-Cooled Chillers, for
instructions, including weights and rigging
instruction for components.
The Optimus chiller should be moved by lifting at
designated lift points only. See Table 5, p. 16 and Table 6,
p. 17 for overall unit weights. See Figure 6, p. 20 and
Table 7, p. 20 for typical unit lifting point weights.
WARNING
Heavy Objects!
Ensure that all the lifting equipment used is properly
rated for the weight of the unit being lifted. Each of the
cables (chains or slings), hooks, and shackles used to
lift the unit must be capable of supporting the entire
weight of the unit. Lifting cables (chains or slings) may
not be of the same length. Adjust as necessary for even
unit lift. Other lifting arrangements could cause
equipment or property damage. Failure to follow
instructions above or properly lift unit could result in
unit dropping and possibly crushing operator/
technician which could result in death or serious injury.
Ventilation
The unit produces heat even though the compressor is
cooled by the refrigerant. Make provisions to remove heat
generated by unit operation from the equipment room.
RTHD-SVX01E-EN
19
Installation Mechanical
Figure 6.
Lifting location point weights and dimensions(a)
B
C
= C.G.
X
A
D
Z
Y
(a) Optional AFD is not shown. See Figure 3, p. 9 for location of optional AFD. Lifting weights and center of gravity measurements are shown for both unit
configurations in tables below.
Table 7.
Lifting weights
Location
Wye-Delta Units
Unit Designator(a) Units
B1B1B1
B1C1D1
B2B2B2
B2C2D2
C1D5E4
C1D6E5
C1E1F1
C2D3E3
C2D4E4
C2F2F3
D1D1E1
20
AFD Units
A
B
C
D
A
B
C
D
lb
2495
1969
1901
2928
2565
1969
1900
3092
kg
1132
893
862
1328
1163
893
862
1403
lb
3136
2264
1739
2698
3228
2264
1739
2839
kg
1422
1027
789
1224
1464
1027
789
1288
lb
2522
1996
1926
2958
2591
1995
1927
3123
kg
1144
905
874
1342
1175
905
874
1417
lb
3162
2297
1767
2726
2615
1995
1927
3099
kg
1510
1042
802
1237
1186
905
874
1406
lb
3375
2479
2876
4243
3472
2478
2877
4520
kg
1531
1124
1305
1925
1575
1124
1305
2050
lb
3330
2430
2825
4195
3426
2429
2824
4471
kg
1510
1102
1281
1903
1554
1102
1281
2028
lb
4205
3046
3196
4271
4339
3047
3197
4509
kg
1907
1382
1450
1937
1968
1382
1450
2045
lb
3612
2738
3148
4503
3708
2738
3148
4780
kg
1638
1242
1428
2043
1682
1242
1428
2168
lb
3374
2479
2876
4243
3470
2478
2877
4520
kg
1530
1124
1305
1925
1574
1124
1305
2050
lb
4649
3496
4707
4707
4786
3497
4707
4943
kg
2109
1586
2135
2135
2171
1586
2135
2242
lb
3728
2758
3236
4694
3825
2758
3236
4970
kg
1691
1251
1468
2129
1735
1251
1468
2254
RTHD-SVX01E-EN
Installation Mechanical
Table 7.
Lifting weights (continued) (continued)
Location
Wye-Delta Units
Unit Designator(a) Units
D1F1F2
D1G1G1
D1G2G2
D2D2E2
D2F2F3
D2G2G1
D2G3G3
D3D2E2
D3F2F3
D3G2G1
E3D2E2
E3F2F3
E3G2G1
AFD Units
A
B
C
D
A
B
C
D
lb
4526
3452
3615
4594
4662
3452
3616
4831
kg
2053
1566
1640
2084
2115
1566
1640
2191
lb
4981
4148
4041
5076
5116
4149
4041
5312
kg
2259
1882
1833
2302
2320
1882
1833
2410
lb
5216
4344
4231
5316
5679
4359
4100
5342
kg
2366
1970
1919
2411
2576
1977
1860
2423
lb
3754
2818
3269
4720
3851
2818
3269
4996
kg
1703
1278
1483
2141
1747
1278
1483
2266
lb
4737
3563
3722
4797
4874
3563
4797
5034
kg
2149
1616
2176
2176
2211
1616
2176
2283
5409
lb
5085
4255
4136
5171
5221
4255
4136
kg
2307
1930
1876
2346
2368
1930
1876
2454
lb
5320
4451
4327
5140
5715
4511
4259
5396
kg
2413
2019
1963
2331
2592
2046
1932
2448
lb
3754
2818
3269
4720
3851
2818
3269
4996
kg
1703
1278
1483
2141
1747
1278
1483
2266
lb
4737
3563
3722
4797
4874
3563
3721
5034
kg
2149
1616
1688
2176
2211
1616
1688
2283
5409
lb
5085
4255
4136
5171
5221
4255
4136
kg
2307
1930
1876
2346
2368
1930
1876
2454
lb
3796
2834
3300
4789
3904
2833
3300
5053
kg
1722
1285
1497
2172
1771
1285
1497
2292
lb
4781
3582
3750
4851
5918
3583
3750
5087
kg
2169
1625
1701
2200
2231
1625
1701
2307
lb
5158
4304
4226
5300
5294
4303
4226
5537
kg
2340
1952
1917
2404
2401
1952
1917
2512
(a) Unit designator (digits 6, 7, 14, 15, 21 and 22 of unit model number)
RTHD-SVX01E-EN
21
Installation Mechanical
Table 8.
Center of gravity
Unit
Configuration(a)
Units
X
Wye-Delta Units
Y
Z
X
AFD Units
Y
Z
B1B1B1
in
22.84
58.13
35.59
22.2
56.4
36.0
B1C1D1
B2B2B2
B2C2D2
C1D5E4
C1D6E5
C1E1F1
C2D3E3
C2D4E4
C2F2F3
D1D1E1
D1F1F2
D1G1G1
D1G2G2
D2D2E2
D2F2F3
D2G2G1
D2G3G3
D3D2E2
D3F2F3
D3G2G1
E3D2E2
E3F2F3
E3G2G1
mm
580
1477
904
563
1433
915
in
22.32
58.23
33.65
21.7
57.2
34.1
mm
567
1479
855
552
1454
866
in
22.88
58.11
35.43
22.2
56.4
35.9
mm
581
1476
900
564
1433
911
in
22.4
58.29
33.51
21.0
62.1
33.9
mm
569
1481
851
535
1578
862
in
26.13
59.74
40.08
24.9
59.7
43.0
1093
mm
664
1517
1018
633
1515
in
26.13
59.74
40.08
24.8
59.7
40.6
mm
664
1517
1018
630
1516
1032
in
26.36
63.49
40.95
25.7
64.3
41.4
mm
670
1613
1040
652
1633
1052
in
26.13
59.74
40.08
25.4
59.4
40.6
mm
664
1517
1018
646
1508
1031
in
26.13
59.74
40.08
24.9
59.7
40.6
mm
664
1517
1018
633
1515
1032
39.2
in
27.92
63.47
38.7
30.5
70.7
mm
709
1612
9833
774
1795
995
in
25.91
60
40.47
25.1
59.6
41.0
mm
658
1524
1028
638
1514
1040
in
27.92
63.47
38.7
27.3
64.2
39.2
mm
709
1612
983
693
1631
996
in
30.58
68.56
37.79
29.6
62.1
38.2
mm
777
1741
960
753
1577
971
in
30.77
63.55
37.72
29.6
62.1
38.2
mm
782
1614
958
753
1577
971
in
25.97
59.95
40.31
25.3
59.6
40.8
mm
660
1523
1024
643
1513
1036
in
27.7
63.4
38.14
31.1
72.0
38.6
mm
704
1610
969
789
1829
981
in
30.58
68.56
37.79
30.2
63.0
38.2
mm
777
1741
960
767
1601
971
in
30.85
63.48
37.44
30.2
63.0
38.2
mm
784
1612
951
767
1601
971
in
25.97
59.95
40.31
25.3
59.6
40.8
mm
660
1523
1024
643
1513
1036
in
27.7
63.4
38.14
27.1
64.1
38.6
mm
704
1610
969
687
1628
981
in
30.58
68.56
37.79
30.3
63.2
38.2
mm
777
1741
960
769
1605
971
in
25.9
60.05
40.5
25.3
59.6
41.0
mm
658
1525
1029
642
1513
1041
in
27.64
63.46
38.33
27.0
64.2
38.8
mm
702
1612
974
686
1630
986
in
30.8
63.55
38.70
30.5
64.1
39.1
mm
732
1614
983
776
1628
994
(a) Unit designator (digits 6, 7, 14, 15, 21 and 22 of unit model number).
22
RTHD-SVX01E-EN
Installation Mechanical
Lifting Procedure
Figure 7.
Rigging configuration(a)
A
B
E
C
D
ANTI-R OLL IN G
CABLE
EYELET OR M16 INTERN AL THREAD
ANTI-ROLLING CABL E
F (MIN)
STARTER
 
C ONTROLS
 44 ,5 MM TYP
CON D
EVAP
UN IT MODEL NUMBER LOCATION
(a) Optional AFD is not shown. See Figure 3, p. 9 for location of optional AFD. Rigging information is same for wye-delta or AFD units.
Table 9.
Rigging dimensions
Dimension - in (mm)
Unit
Configuration(a)
Units
A
B
C
D
E
F
B1B1B1
in
120
108
56.97
3.92
21.02
24
mm
3048
2743
1447
97
534
610
in
144
132
58.23
3.74
20.51
24
mm
3658
3353
1479
95
521
610
B1C1D1
B2B2B2
B2C2D2
C1D5E4
C1D6E5
C1E1F1
C2D3E3
C2D4E4
C2F2F3
RTHD-SVX01E-EN
in
120
108
58.11
3.86
21.06
24
mm
3048
2743
1476
98
535
610
in
144
132
58.31
3.66
20.59
24
mm
3658
3353
1481
93
523
610
in
120
108
59.96
8.62
22.99
24
mm
3048
2743
1523
219
584
610
in
120
108
60
8.58
22.91
24
mm
3048
2743
1524
218
582
610
in
144
132
63.50
5.08
24.57
24
mm
3658
3353
1613
129
624
610
in
120
108
59.72
8.86
24.33
24
mm
3048
2743
1517
225
618
610
in
120
108
59.96
8.62
22.99
24
mm
3048
2743
1523
219
584
610
in
144
132
63.4
3.98
24.29
24
mm
3658
3353
1610
101
617
610
23
Installation Mechanical
Table 9.
Rigging dimensions (continued)
Dimension - in (mm)
Unit
Configuration(a)
Units
A
B
C
D
E
F
D1D1E1
in
120
108
60
7.36
24.09
24
mm
3048
2743
1524
187
612
610
in
144
132
63.46
3.9
24.49
24
mm
3658
3353
1612
99
622
610
D1F1F2
D1G1G1
D1G2G2
D2D2E2
D2F2F3
D2G2G1
D2G3G3
D3D2E2
D3F2F3
D3G2G1
E3D2E2
E3F2F3
E3G2G1
in
144
132
63.46
3.9
25.75
24
mm
3658
3353
1612
99
654
610
in
144
132
63.54
3.82
26.02
24
mm
3658
3353
1614
97
661
610
in
120
108
59.96
7.4
24.17
24
mm
3048
2743
1523
188
614
610
in
144
132
63.39
3.98
24.29
24
mm
3658
3353
1610
101
617
610
in
144
132
63.46
3.9
25.75
24
mm
3658
3353
1612
99
654
610
in
144
132
63.46
3.9
25.75
24
mm
3658
3353
1612
99
654
610
in
120
108
60
7.4
24.17
24
mm
3048
2743
1523
188
614
610
in
144
132
63.39
3.98
24.29
24
mm
3658
3353
1610
101
617
610
in
144
132
63.46
3.9
25.75
24
mm
3658
3353
1612
99
654
610
in
120
108
60
4.57
24.09
24
mm
3048
2743
1525
116
612
610
in
144
132
63.46
1.14
24.21
24
mm
3658
3353
1612
29
615
610
in
144
132
63.82
0.79
26
24
mm
3658
3353
1621
20
661
610
(a) Designator corresponds to digits 6, 7, 14, 15, 21 and 22 of model number.
Important:
Rigging dimensions given in Table 9 are
given as a starting point reference. Lifting
cables should be adjusted as necessary for
even unit lift.
WARNING
Improper Unit Lift!
Test lift unit approximately 24 inches to verify proper
center of gravity lift point. To avoid dropping of unit,
reposition lifting point if unit is not level. Failure to
properly lift unit could result in unit dropping and
possibly crushing operator/technician which could
result in death or serious injury and possible
equipment or property-only damage.
WARNING
Risk of Unit Tipping!
Connect an anti-rotation strap between the lifting
beam and compressor before lifting unit. Failure to do
so may result in death or serious injury should a lifting
cable fail.
24
WARNING
Shipping Mounts!
Do not use the threaded holes in the compressor to lift
or assist in lifting the unit. They are not intended for
that purpose and could create a dangerous situation.
Do not remove the wood mounts until the unit is in its
final location. Removal of wood shipping mounts prior
to unit final locating could result in death or serious
injury or equipment damage.
NOTICE:
Equipment Damage!
Never use a forklift to move the unit. The skid is not
designed to support the unit at any one point and
using a forklift to move the equipment may cause unit
damage. Always position the lifting beam so that
cables do not contact the unit. Failure to do so may
result in unit damage.
RTHD-SVX01E-EN
Installation Mechanical
Note: If absolutely necessary, the chiller can be pushed or
pulled across a smooth surface if it is bolted to
wood shipping mounts.
Figure 8.
1. See Table 5, p. 16 or Table 6, p. 17 for unit shipping
weights. See Table 7, p. 20 for weights at each lift
location. See Table 8, p. 22 for center of gravity
information.
Compressor shipping spacers
B family (discharge side)
Compressor Housing
Note: Weights are typical for units with R-134a
charge.
2. When unit is at its final location, remove shipping bolts
that secure unit to wood base mounts.
3. Install clevis connectors in lifting holes provided on the
unit. Attach lifting chains or cables to clevis connectors
as shown in Figure 7, p. 23. Each cable alone must be
strong enough to lift the chiller.
4. Attach cables to lifting beam as shown in Figure 7,
p. 23. See Table 9, p. 23 for rigging dimensions. The
lifting beam crossbar must be positioned so the lifting
cables do not contact unit piping or electrical panel
enclosure.
Remove (1) puck-type spacer
Figure 9.
Compressor shipping spacers
B family (suction side)
Compressor Housing
5. Connect an anti-rotation strap or cable loosely
between the lifting beam and the threaded coupling or
eyelet provided at the top of the compressor. Use an
eyebolt or clevis to secure the strap at the coupling or
eyelet.
Important:
The anti-rotation strap is not a lifting chain,
but a safety device to ensure that the unit
cannot tilt during lifting.
6. Lift from above, or jack the unit per “Alternate Moving
Method,” p. 26. Remove the base mounts.
7.
During final positioning of the unit, place the isolation
pads under the evaporator and condenser tube sheet
supports as shown in Figure 12, p. 26. See “Isolation
Pads,” p. 26 for information on isolation pads.
8. Level the unit as described in “Unit Leveling,” p. 26.
9. The unit is shipped with spacers on the compressor
mount that protect isolation pads during shipping and
handling. Before the unit is operated, remove the
spacers as indicated to prevent excessive noise.
Remove (2) flat washer spacers
• C, D, E Family Compressors:
• Remove (4) puck-type spacer under discharge
side of compressor (see Figure 10).
Figure 10.
Compressor shipping spacers
C, D, E family (discharge side)
• B Family Compressors :
• Remove qty 1 puck-type spacer under discharge
side of compressor (see Figure 8).
Compressor
Housing
• Remove qty 2 flat washer spacers under suction
side of compressor (see Figure 9).
Note: Suction side of compressor WILL float.
Remove (4) puck-type spacers
RTHD-SVX01E-EN
25
Installation Mechanical
10. Remove the shipping brackets from the bottom sides
of the oil separator(s). See Figure 11.
Figure 11.
Oil separator shipping bracket
shell to level the unit. Unit should be level to within 1/
4” (6.35 mm) over its length.
3. Place the level on the evaporator shell tube sheet
support to check side-to-side (front-to-back) level.
Adjust to within 1/4” (6.35 mm) of level front-to-back.
Note: The evaporator MUST be level for optimum heat
transfer and unit performance.
4. Use full-length shims to level the unit.
Alternate Moving Method
Shipping Bracket
Notes:
•
Once shipping bracket(s) is removed, the oil separator
is only supported by the discharge line.
•
Failure to remove oil separator shipping brackets could
result in excessive noise.
If it is not possible to rig from above as shown in Figure 7,
p. 23, the unit may also be moved by jacking each end high
enough to move an equipment dolly under each tube
sheet support. Once securely mounted on the dollies, the
unit may be rolled into position.
Isolation Pads
Notes:
•
The elastomeric pads shipped (as standard) are
adequate for most installations. For additional details
on isolation practices, see Trane Engineering Bulletin
Sound Ratings and Installation Guide
Optimus™Water-Cooled Chillers RLC-PRB015*-EN, or
consult an acoustical engineer for sound-sensitive
installations.
•
Durometer values for isolator pads are a measure of
resilience. See Figure 12.
Unit Leveling
Note: The electrical panel side of the unit is designated as
the “front” of the unit.
1. Check unit level end-to-end by placing a level on the
top surface of the evaporator shell.
2. If there is insufficient surface available on the top of
evaporator shell, attach a magnetic level to bottom of
Figure 12. Isolator pad placement
NOTE: Level unit to 1/4” (6.35 mm)
across width and length
Typical Elastomeric
Isolation Pad
Durometer: 55 +/-10
B
A (hidden leg)
0.31
D
C
Durometer: 50 +/-5
Pads extend the full
width of legs
0.31
26
Durometer: 40 +/-5
0.31
RTHD-SVX01E-EN
Installation Mechanical
Water Pressure Drop Data
Evaporator Pressure Drop
E Frame - 2 Pass
Evaporator Pressure Drop
G Frame - 3 Pass
40
50
G2
45
35
G1
G3
30
Delt-P (Ft H 2O)
Delt-P (Ft H 2O)
40
35
30
25
20
15
E1
25
20
15
10
10
5
5
0
0
0
500
1000
1500
2000
2500
0
3000
500
1000
1500
2000
Flow (GPM)
Flow (GPM)
Evaporator Pressure Drop
E Frame - 3 Pass
Evaporator Pressure Drop
G Frame - 4 Pass
50
70
45
G2
G3
50
E1
40
G1
40
30
20
Delt-P (Ft H 2O)
Delt-P (Ft H 2O)
60
35
30
25
20
15
10
5
10
0
0
0
0
500
1000
1500
2000
200
400
600
800
1000
1200
1400
Flow (GPM)
Flow (GPM)
RTHD-SVX01E-EN
27
Installation Mechanical
Evaporator Pressure Drop
C Frame - 2 Pass
Evaporator Pressure Drop
D Frame - 2 Pass
35
40
35
D1
C2
D4 & D5
D3
D6
25
20
15
10
25
20
15
10
5
5
0
0
0
500
1000
C1
30
Delt-P (Ft H 2O)
30
Delt-P (Ft H 2O)
D2
1500
2000
0
2500
500
Evaporator Pressure Drop
C Frame - 3 Pass
Evaporator Pressure Drop
D Frame - 3 Pass
50
45
40
D4 & D5
D1
D2
D6
C1
45
30
25
20
15
C2
40
D3
Delt-P (Ft H 2O)
35
Delt-P (Ft H 2O)
1500
Flow (GPM)
Flow (GPM)
35
30
25
20
15
10
10
5
5
0
0
0
200
400
600
800
Flow (GPM)
28
1000
1000
1200
1400
0
200
400
600
800
1000
Flow (GPM)
RTHD-SVX01E-EN
Installation Mechanical
Condenser Pressure Drop
G Frame - 2 Pass
Evaporator Pressure Drop
B Frame - 3 Pass
60
45
40
B1
Delt-P (Ft H 2O)
Delt-P (Ft H 2O)
50
B2
35
30
25
20
15
10
G1
G3
40
30
20
10
5
0
0
0
200
400
600
800
0
1000
500
1000
1500
2000
2500
3000
Flow (GPM)
Flow (GPM)
Condenser Pressure Drop
F Frame - 2 Pass
Evaporator Pressure Drop
B Frame - 2 Pass
45
30
F2
40
B1
25
F1 & F3
35
Delt-P (Ft H 2O)
B2
Delt-P (Ft H 2O)
G2
20
15
10
30
25
20
15
10
5
5
0
0
0
200
400
600
800
Flow (GPM)
RTHD-SVX01E-EN
1000
1200
1400
0
500
1000
1500
2000
Flow (GPM)
29
Installation Mechanical
Condenser Pressure Drop
B Frame - 2 Pass
Condenser Pressure Drop
E Frame - 2 Pass
40
40
E1
E5
30
35
E2
E4
E3
25
20
15
Delt-P (Ft H 2O)
Delt-P (Ft H 2O)
35
B1
30
B2
25
20
15
10
10
5
5
0
0
0
500
1000
1500
0
200
400
600
800
1000
Flow (GPM)
Flow (GPM)
Condenser Pressure Drop
D Frame - 2 Pass
45
40
D1
Delt-P (Ft H 2O)
35
D2
30
25
20
15
10
5
0
0
200
400
600
800
1000
Flow (GPM)
30
RTHD-SVX01E-EN
Installation Mechanical
Water Piping
Figure 13. Typical water piping setup
Shutoff
Valves
Isolation
Valves
Shutoff
Valves
Relief
Valve
Relief
Valve
Manifold
Cond Water
Ref Valve
(Opt)
Manifold
Isolation
Valves
Cond
Water
Flow
Evap
Water
Flow
Pressure
Differential
Gauge
Thermometers
Pressure
Differential
Gauge
Thermometers
General
Note: Field piping must be arranged and supported to
avoid stress on the equipment. It is strongly
recommended that the piping contractor provide at
least 3 feet (914 mm) of clearance between the preinstallation piping and the planned location of the
unit. This will allow for proper fit-up upon arrival of
the unit at the installation site. All necessary piping
adjustments can be made at that time. Refer to the
current engineering bulletin for further details on
installation.
•
Flow
Switch
Flow
Switch
Where specified, supply and install valves in the water
piping upstream and downstream of the evaporator
and condenser water boxes, to isolate the shells for
maintenance and to balance/trim the system.
•
Where specified, supply and insulate the evaporator
and any other portion of the unit, as required, to
prevent sweating under normal operating conditions.
Piping Connections
NOTICE:
Equipment Damage!
If using any commercial flushing/cleaning solution,
construct a temporary bypass around the unit to
prevent damage to internal components of the
evaporator/condenser. Trane assumes no responsibility
for equipment damage caused by flushing/cleaning
solutions or water-born debris.
Make water piping connections to the evaporator and
condenser. Isolate and support piping to prevent stress on
the unit. Construct piping according to local and national
codes. Insulate and flush piping before connecting to unit.
•
Supply and install condenser water control valve(s) per
Engineering Bulletin RLC-PRB017*-EN.
•
Supply or locate ship-with flow switches. Install flow
switches or equivalent devices in both the chilled water
and condenser water piping. Wire the flow switches
into the control system as indicated on the electrical
schematics and field wiring diagrams, to ensure that
the unit can only operate when water flow is
established.
•
Supply and install taps for thermometers and pressure
gauges in water piping, adjacent to the inlet and outlet
connections of both the evaporator and the condenser.
•
Supply and install drain valves on each water box.
•
Supply and install vent cocks on each water box.
All water boxes may be reversed end-for-end. See
“Waterbox Removal,” p. 78 for detailed instructions.
•
Where specified, supply and install strainers ahead of
all pumps and automatic modulating valves.
Remove sensors from wells before removing waterbox.
•
Supply and install refrigerant pressure relief piping
from the pressure relief to the atmosphere.
Do not rotate water boxes. See Figure 14, p. 32 through
Figure 16, p. 32 for correct orientation of the water inlet
and outlet.
•
If necessary, supply enough R-134a refrigerant and dry
nitrogen (75 psig) for pressure testing.
Complete the water box switch and replace sensors.
RTHD-SVX01E-EN
Use grooved pipe connectors for all water piping
connections. Evaporator and condenser water inlet and
outlet sizes and locations are shown by the unit submittals.
The designation in the tables corresponds to the
compressor frame code followed by the evaporator shell
code followed by the condenser shell code as given in the
unit model number, digits 6, 7, 14, 15, 21 and 22. Table 1,
p. 11 through Table 3, p. 13 list water connection
information.
Reversing Waterboxes
31
Installation Mechanical
Notes:
•
If water boxes are reversed, be sure to properly rewire
water temperature sensors in control panel.
•
Be certain to replace water boxes right-side-up to
maintain proper baffle orientation. Use new o-rings.
Figure 14. Condenser and evaporator waterboxes - BBB/BCD
OUT
IN
IN
COND
EVAP
2 Pass Evap Connection
Configuration
(left or right hand)
Depending on Water Inlet
Figure 15. Condenser and evaporator waterboxes - CEF/CDE/DDE/EDE/DFF/EFF/CFF
OUT
IN
IN
COND
2 Pass Evap Connection
Configuration
(left or right hand)
Depending on Water Inlet
EVAP
Figure 16. Condenser and evaporator waterboxes - DGG/EGG
OUT
OUT
IN
IN
COND
32
EVAP
3 Pass Evap Connection
Configuration
(left or right hand)
Depending on Water Inlet
RTHD-SVX01E-EN
Installation Mechanical
Making Grooved Pipe Connections
NOTICE:
Equipment Damage!
NOTICE:
Evaporator Damage!
To prevent damage to water piping, do not overtighten
connections. To prevent equipment damage, bypass
the unit if using an acidic flushing agent
To prevent evaporator damage, do not exceed 150 psig
(10.3 bar) evaporator water pressure for standard water
boxes. Maximum pressure for high pressure water
boxes is 300 psig (20.7 bar). Refer to digit 14 of the
Model No. To prevent tube damage, install a strainer in
the evaporator water inlet piping. To prevent tube
corrosion, ensure that the initial water fill has a
balanced pH.
Note: Make sure that all piping is flushed and cleaned
prior to starting the unit.
Vents and Drains
Install pipe plugs in evaporator and condenser water box
drain and vent connections before filling the water
systems.
To drain water, remove vent and drain plugs, install a NPT
connector in the drain connection with a shutoff valve and
connect a hose to it.
Evaporator Piping Components
Note: Make sure all piping components are between the
shutoff valves, so that isolation can be
accomplished on both the condenser and the
evaporator.
Condenser Piping Components
“Piping components” include all devices and controls
used to provide proper water system operation and unit
operating safety. These components and their general
locations are given below.
Entering condenser water piping.
•
Air vents (to bleed air from system)
•
Water pressure gauges with shutoff valves
•
Pipe unions
•
Vibration eliminators (rubber boots)
“Piping components” include all devices and controls
used to provide proper water system operation and unit
operating safety. These components and their general
locations are given below.
•
Shutoff (isolation) valves. One per each pass
•
Thermometers
•
Cleanout tees
Entering Chilled Water Piping
•
Pipe strainer
•
Flow switch
•
Air vents (to bleed air from system)
•
Water pressure gauges with shutoff valves
Leaving condenser water piping.
•
Pipe unions
•
Air vents (to bleed air from system)
•
Vibration eliminators (rubber boots)
•
Water pressure gauges with shutoff valves
•
Shutoff (isolation) valves
•
Pipe unions
•
Thermometers
•
Vibration eliminators (rubber boots)
•
Cleanout tees
•
Shutoff (isolation) valve - one per each pass
•
Pipe strainer
•
Thermometers
•
Flow switch
•
Cleanout tees
•
Balancing valve
•
Pressure relief valve.
Leaving Chilled Water Piping
•
Air vents (to bleed air from system)
•
Water pressure gauges with shutoff valves
•
Pipe unions
•
Vibration eliminators (rubber boots)
•
Shutoff (isolation) valves
•
Thermometers
•
Cleanout tees
•
Balancing valve
•
Pressure relief valve
RTHD-SVX01E-EN
NOTICE:
Condenser Damage!
To prevent condenser damage, do not exceed 150 psig
(10.3 bar) water pressure for standard water boxes.
Maximum pressure for high pressure water boxes is
300 psig (20.7 bar). Refer to digit 18 of the Model No. To
prevent tube damage, install a strainer in condenser
water inlet piping. To prevent tube corrosion, ensure
that the initial water fill has a balanced pH.
33
Installation Mechanical
Condenser Water Regulating Valve
The Condenser Head Pressure Control Option provides for
a 0-10VDC (maximum range - a smaller range is
adjustable) output interface to the customer's condenser
water flow device. The condenser water flow device is
typically a large butterfly type (6" or 8") automatic valve for
200 to 400 Ton chillers.
The following guidelines must be met to ensure adequate
oil circulation throughout the system.
•
The chiller must maintain a 23 psid system pressure
differential at all load conditions in order to ensure
adequate oil circulation.
•
The entering condenser water temperature must be
above 55°F (12.8°C) or between 45°F (7.2°C) and 55°F
(12.8°C) with a 1°F temperature rise per minute to 55°F
(12.8°C).
•
Condenser leaving water temperature must be 17°F
degrees higher than evaporator leaving water
temperature within 2 minutes of startup. A 25°F
differential must be maintained thereafter.
If the above guidelines cannot be met, then some form of
tower water control must be used.
Condenser Water Regulating Valve
Adjustment
A separate Tracer™ TU Settings Menu tab entitled
"Condenser Head Pressure Control - Setup" that is only
visible if the configuration is selected, contains the
following settings and manual overrides for user
adjustments and commissioning all under one tab:
•
"Off State" Output Command (0-10 Vdc 0.1 volt
increments, Default 2.0 Vdc)
•
Output Voltage @ Desired Minimum Flow (Adj: 0 to
10.0 in 0.1 volt increments, Default 2.0 Vdc)
•
Desired Minimum Flow (Adj: 0- 100% of full flow in 1%
intervals, Default 20%)
•
Output Voltage @ Desired Maximum Flow (Adj: 0 to
10.0 in .1 volt increments (or finer), Default 10 Vdc)
•
Actuator Stroke Time (Min to Max Range Time) (Adj: 1
to 1000 seconds, in 1 second increments, Default 30s)
•
Damping Coefficient (adj: 0.1 to 1.8 , in .1 increments,
Default .5)
•
Head Pressure Control Override (enumeration of:
disabled (auto), "off" state, minimum, maximum
(100%),) default :disabled (auto). When this setting is
in "disabled (auto)"
The following setting is found in the Setpoints tab:
•
Condenser Water Pump Prestart Time ( )
Water Treatment
NOTICE:
Proper Water Treatment!
The use of untreated or improperly treated water in a
RTHD chiller could result in scaling, erosion, corrosion,
algae or slime. It is recommended that the services of a
qualified water treatment specialist be engaged to
determine what water treatment, if any, is required.
Trane assumes no responsibility for equipment failures
which result from untreated or improperly treated
water, or saline or brackish water.
Using untreated or improperly treated water in these units
may result in inefficient operation and possible tube
damage. Consult a qualified water treatment specialist to
determine whether treatment is needed.
Water Pressure Gauges and Thermometers
Install field-supplied thermometers and pressure gauges
(with manifolds, whenever practical) as shown in
Figure 13, p. 31. Locate pressure gauges or taps in a
straight run of pipe; avoid placement near elbows, etc. Be
sure to install the gauges at the same elevation on each
shell if the shells have opposite-end water connections.
To read manifolded water pressure gauges, open one
valve and close the other (depending upon the reading
desired). This eliminates errors resulting from differently
calibrated gauges installed at unmatched elevations.
Water Pressure Relief Valves
NOTICE:
Equipment Damage!
Install a pressure relief valve in both evaporator and
condenser water systems. Failure to do so may result in
shell damage.
Install a water pressure relief valve in one of the condenser
and one of the evaporator water box drain connections or
on the shell side of any shutoff valve. Water vessels with
close-coupled shutoff valves have a high potential for
hydrostatic pressure buildup on a water temperature
increase. Refer to applicable codes for relief valve
installation guidelines.
Flow Sensing Devices
Note: The installer must provide flow switches or
differential pressure switches with pump interlocks
to sense system water flow. Flow switch locations
are schematically shown in Figure 13, p. 31.
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). Specific connections and
schematic wiring diagrams are shipped with the unit.
Flow switches must stop or prevent compressor operation
if either system water flow drops off below the required
34
RTHD-SVX01E-EN
Installation Mechanical
minimum shown on the pressure drop curves. Follow the
manufacturer’s recommendations for selection and
installation procedures. General guidelines for flow switch
installation are outlined below.
•
Mount the switch upright, with a minimum of 5 pipe
diameters straight, horizontal run on each side.
•
Do not install close to elbows, orifices or valves.
Relief valve discharge setpoints and capacities rates are
given in Table 10. Once the relief valve has opened, it will
re-close when pressure is reduced to a safe level.
Note: Once opened, relief valves may have tendency to
leak and must be replaced.
Figure 17.
Relief valve location
Note: The arrow on the switch must point in the direction
of the water flow.
•
To prevent switch fluttering, remove all air from the
water system
Note: The UC800 provides a 6-second time delay on the
flow switch input before shutting down the unit on
a loss-of-flow diagnostic. Contact a qualified
service organization if nuisance machine
shutdowns persist.
•
Adjust the switch to open when water flow falls below
nominal. See “General Information,” p. 9, general data
tables for minimum flow recommendations for
specific water pass arrangements. Flow switch
contacts are closed on proof of water flow.
Refrigerant Pressure Relief Valve Venting
Evaporator Shell
* Valve is hidden by pipe
Discharge Pipes
WARNING
Confined Space Hazards!
Do not work in confined spaces where refrigerant or
other hazardous, toxic or flammable gas may be
leaking. Refrigerant or other gases could displace
available oxygen to breathe, causing possible
asphyxiation or other serious health risks. Some gases
may be flammable and or explosive. If a leak in such
spaces is detected, evacuate the area immediately and
contact the proper rescue or response authority. Failure
to take appropriate precautions or to react properly to
such potential hazards could result in death or serious
injury.
Note: Vent pipe size must conform to the ANSI/ASHRAE
Standard 15 for vent pipe sizing. All federal, state,
and local codes take precedence over any
suggestions stated in this manual.
All relief valve venting is the responsibility of the installing
contractor.
All RTHD units use evaporator, compressor, and
condenser pressure relief valves (Figure 17, p. 35) that
must be vented to the outside of the building.
Relief valve connection sizes and locations are shown in
the unit submittals. Refer to local codes for relief valve vent
line sizing information.
NOTICE:
Equipment Damage!
Do not exceed vent piping code specifications. Failure
to comply with specifications may result in capacity
reduction, unit damage and/or relief valve damage.
RTHD-SVX01E-EN
*
*
Condenser Shell
Pressure relief valve discharge capacities will vary with
shell diameter and length and also compressor
displacement. Discharge venting capacity should be
calculated as required by ASHRAE Standard 15-94. Do not
adjust relief valve setting in the field.
Table 10. Pressure Relief Valve Data
Rated
Capacity
Discharge
per Relief
Setpoint Number Valve
Valve
(psi)
of
(lba/
Location
Valves
min.)
Evap - B1
200
1
48.0
Field
Conn
Pipe
Size
(NPT)
Factory
Shell Side
Conn (in)
1
1-5/16 -12
Evap - B2
200
1
48.0
1
1-5/16 -12
Evap -B3
200
1
48.0
1
1-5/16 -12
Evap -C1
200
1
48.0
1
1-5/16 -12
35
Installation Mechanical
Table 10. Pressure Relief Valve Data (continued)
Rated
Capacity
Discharge
per Relief
Setpoint Number Valve
Valve
(psi)
of
(lba/
Location
Valves
min.)
Thermal Insulation
Field
Conn
Pipe
Factory
Size
Shell Side
(NPT) Conn (in)
Evap - C2
200
1
48.0
1
1-5/16 -12
Evap - D1
200
1
48.0
1
1-5/16 -12
Evap - D2
200
1
48.0
1
1-5/16 -12
Evap - D3
200
1
48.0
1
1-5/16 -12
Evap - D4
200
1
48.0
1
1-5/16 -12
Evap - D5
200
1
48.0
1
1-5/16 -12
Evap - D6
200
1
48.0
1
1-5/16 -12
Evap - E1
200
1
48.0
1
1-5/16 -12
Evap - F1
200
1
48.0
1
1-5/16 -12
Evap - F2
200
1
48.0
1
1-5/16 -12
Evap - G1
200
1
78.8
1-1/4
1-5/8 - 12
Evap - G2
200
1
78.8
1-1/4
1-5/8 - 12
Evap - G3
200
1
78.8
1-1/4
1-5/8 - 12
Cond - B1
200
2
48.0
1
1-5/16 -12
Cond - B2
200
2
48.0
1
1-5/16 -12
Cond - D1
200
2
48.0
1
1-5/16 -12
Cond - D2
200
2
48.0
1
1-5/16 -12
Cond - E1
200
2
48.0
1
1-5/16 -12
Cond - E2
200
2
48.0
1
1-5/16 -12
Cond - E3
200
2
48.0
1
1-5/16 -12
Cond - E4
200
2
48.0
1
1-5/16 -12
Cond - E5
200
2
48.0
1
1-5/16 -12
Cond - F1
200
2
48.0
1
1-5/16 -12
Cond - F2
200
2
48.0
1
1-5/16 -12
Cond - F3
200
2
48.0
1
1-5/16 -12
Cond - G1
200
2
48.0
1
1-5/16 -12
Cond - G2
200
2
48.0
1
1-5/16 -12
Cond - G3
200
2
48.0
1
1-5/16 -12
Comp B1/B2*
200
2
78.8
1-1/4
1-5/8 - 12
Comp C1/C2*
200
3
78.8
1-1/4
1-5/8 - 12
Comp D1/D2/D3*
200
3
78.8
1-1/4
1-5/8 - 12
Comp -E3*
200
3
78.8
1-1/4
1-5/8 - 12
* Only used with isolation valve option
36
All Optimus units are available with optional factory
installed thermal insulation. If the unit is not factory
insulated, install insulation over the areas shaded in
Figure 18, p. 36. See Table 11 for types and quantities of
insulation required.
Notes:
•
Liquid line filter, refrigerant charging valves, water
temperature sensors, drain and vent connections
when insulated must remain accessible for service.
•
Use only water-base latex paint on factory-applied
insulation. Failure to do so may result in insulation
shrinkage.
•
Units in environments with higher humidity or very
low leaving water temperature may require thicker
insulation
Figure 18. Typical RTHD insulation requirement
Table 11.
Recommended Insulation Types
Type
Sq. Feet
Evaporator
Location
3/4” wall
90
Compressor
3/4” wall
25
All components and piping on low side of
system (gas pump, return oil line, filter
from pump)
3/4” wall
160
RTHD-SVX01E-EN
Installation Mechanical
Freeze Protection
For unit operation in a low temperature environment,
adequate protection measures must be taken against
freezing. Adjusted settings and recommended ethylene
glycol solution strengths are contained in Table 12 as
follows:
.
Table 12. Low Refrigerant Temperature, Ethylene Glycol, and Freeze Protection Settings
DDE, EDE, CBC(b)
Chilled
Low Rfgt
Water
Leaving
Temp
Setpt Wtr Temp Cutout(c)
(°F)
(°F)(a) Cutout (°F)
DFF, EFF, CDE, BCD, BBB, CFF(b)
Rec %
Solution
Ethylene
Freeze
Glycol
Point (°F)
Low Rfgt
Temp
Cutout(c)
(°F)
Solution
Rec %
Freeze
Ethylene
Point
Glycol
(°F)
DGG, EGG, CEF(b)
Low Rfgt
Temp
Cutout(c)
(°F)
Rec %
Solution
Ethylene
Freeze
Glycol
Point (°F)
40
34
28.6
0
32.0
28.6
0
32.0
28.6
0
32.0
39
33
27.2
2
30.6
27.6
1
31.3
27.9
0
32.0
38
32
25.7
4
29.1
26.5
3
30.1
27.2
2
31.1
37
31
24.2
6
27.6
25.4
5
28.9
26.5
3
30.2
36
30
22.7
8
26.1
24.2
6
27.7
25.7
4
29.3
35
29
21.1
11
24.5
23.0
8
26.4
24.9
6
28.3
34
28
20.2
12
23.6
22.1
10
25.5
24.0
7
27.4
33
27
19.2
13
22.6
21.1
11
24.5
23.0
8
26.4
32
26
18.1
15
21.5
20.1
12
23.5
22.0
10
25.4
31
25
17.0
16
20.4
18.8
14
22.2
20.6
12
24.0
30
24
15.9
17
19.3
17.6
15
21.0
19.3
13
22.7
29
23
14.8
18
18.2
16.6
16
20.0
18.4
14
21.8
28
22
13.6
20
17.0
15.5
17
18.9
17.4
15
20.8
27
21
12.4
21
15.8
14.4
18
17.8
16.4
16
19.8
26
20
11.2
22
14.6
13.3
20
16.7
15.4
17
18.8
25
19
9.9
23
13.3
12.1
21
15.5
14.3
19
17.7
24
18
8.6
24
12.0
10.9
22
14.3
13.2
20
16.6
23
17
7.3
25
10.7
9.7
23
13.1
12.1
21
15.5
22
16
5.9
26
9.3
8.4
24
11.8
10.9
22
14.3
21
15
4.5
27
7.9
7.1
25
10.5
9.7
23
13.1
20
14
3.1
28
6.5
5.8
26
9.2
8.5
24
11.9
19
13
1.6
30
5.0
4.4
27
7.8
7.3
25
10.7
18
12
0.1
31
3.5
3.1
29
6.5
6.0
27
9.4
17
11
-1.4
32
2.0
1.6
30
5.0
4.7
28
8.1
16
10
-2.9
33
0.5
0.2
31
3.6
3.3
29
6.7
15
9
-4.5
33
-1.1
-1.3
32
2.1
2.0
30
5.4
14
8
N/A
34
-2.8
-2.8
33
0.6
0.6
31
4.0
13
7
N/A
35
-4.4
-4.3
34
-0.9
-0.8
32
2.6
12
6
N/A
36
-6.1
N/A
34
-2.5
-2.3
33
1.1
11
5
N/A
37
-7.8
N/A
35
-4.1
-3.8
34
-0.4
10
4
N/A
38
-9.6
N/A
36
-5.7
-5.3
34
-1.9
(a) Column “Chilled Water Setpoint” becomes “Actual Leaving Solution Temperature” for ice-making.
(b) See unit model number digits 6, 14, 21
(c) “N/A” means chiller is not to be applied at leaving evaporator water temperatures, which results in the LRTC setting below those shown in the table.
Example For Ice Making:
Chilled Water Setpoint (std. comfort cooling) = 45°F
Full Load Delta T (across evaporator)= 6°F
Ice Termination Setpoint (entering water temp.) = 26°F
Actual Leaving Solution Temperature = 26 - 6 = 20°F
RTHD-SVX01E-EN
37
Installation Electrical
General Recommendations
As you review this manual, keep in mind that:
• All field-installed wiring must conform to National
Electric Code (NEC) guidelines, and any applicable
state and local codes. Be sure to satisfy proper
equipment grounding requirements per NEC.
• Compressor motor and unit electrical data is listed on
the chiller nameplate.
• All field-installed wiring must be checked for proper
terminations, and for possible shorts or grounds.
• For proper electrical component operation, do not
locate the unit in areas exposed to dust, dirt, corrosive
fumes, or excessive humidity. If any of these
conditions exist, corrective action must be taken.
Notes:
•
•
Always refer to wiring diagrams shipped with chiller or
unit submittal for specific electrical schematic and
connection information.
All conduit must be long enough to allow compressor
and starter removal.
WARNING
Proper Field Wiring and Grounding
Required!
All field wiring MUST be performed by qualified
personnel. Improperly installed and grounded field
wiring poses FIRE and ELECTROCUTION hazards. To
avoid these hazards, you MUST follow requirements
for field wiring installation and grounding as described
in NEC and your local/state electrical codes. Failure to
follow code could result in death or serious injury.
Important:
Electrical Data
Standard Units with Wye-Delta Starter
See “Electrical Data Table Information,” p. 39. Electrical
component sizing should be based on actual jobsite
operating conditions. This factor can be obtained through
the use of TOPSS™.
Table 13. Compressor motor electrical data (60 Hz) —
standard units (wye-delta starter)
Compressor
Code(a)
B1, B2
C1, C2
WARNING
Hazardous Voltage w/Capacitors!
Disconnect all electric power, including remote
disconnects and discharge all motor start/run
capacitors before servicing. Follow proper lockout/
tagout procedures to ensure the power cannot be
inadvertently energized. For variable frequency drives
or other energy storing components provided by Trane
or others, refer to the appropriate manufacturer’s
literature for allowable waiting periods for discharge of
capacitors. Verify with an appropriate voltmeter that all
capacitors have discharged. Failure to disconnect
power and discharge capacitors before servicing could
result in death or serious injury.
Do not allow conduit to interfere with other
components, structural members or
euqipment. Control voltage (115V) wiring in
conduit must be separate from conduit
carrying low voltage (<30V) wiring. To
prevent control malfunctions, do not run
low voltage wiring (<30 V) in conduit with
conductors carrying more than 30 volts.
D1, D2
Voltage
(b)
RLA @
Max
Max kW kW(c)
LRA
LRA
(Wye) (Delta)
200
174
557
970
3103
230
174
484
818
2617
380
174
291
488
1561
460
174
241
400
1280
575
174
193
329
1053
200
249
812
1173
3634
230
249
698
936
2901
380
249
421
558
1727
460
249
349
469
1453
575
249
279
375
1162
200
329
1047
1690
5477
230
329
918
1532
4966
380
329
549
850
2755
460
329
455
730
2366
575
329
367
612
1984
(a) Unit model number digits 6 & 7.
(b) Voltage utilization ranges: 200V (180-220)m 230V (205-254), 380V
(342-418), 460V (414-506), 575V (516-533).
(c) The RLA @ Max k@ is based on the performance of the motor developing
full rated horsepower.
For additional information regarding the safe discharge
of capacitors, see PROD-SVB06A-EN
38
RTHD-SVX01E-EN
Installation Electrical
Units with AFD Option
Table 14. Compressor motor electrical data (50 Hz) —
standard units (wye-delta starter)
Compressor
Code(a)
RLA @
Voltage
Max
(b)
Max kW kW(c)
B1, B2
139
233
391
1229
400
145
233
412
1296
233
428
349
456
1414
400
209
349
480
1488
213
271
349
455
498
711
2303
280
455
748
2424
415
284
455
776
2515
400
415
288
301
306
488
488
488
711
748
776
460V 60 Hz
1544
400
380
Voltage
1348
201
380
E3
148
380
415
D1, D2, D3
LRA
LRA
(Wye) (Delta)
380
415
C1, C2
Table 15. Electrical data - units with AFD
2303
380V 60 Hz
2424
2515
(a) Unit model number digits 6 & 7.
(b) Voltage utilization ranges: 380V (342-418), 400V (360-440), 415V
(374-457).
(c) The RLA @ Max k@ is based on the performance of the motor developing
full rated horsepower.
380V 50 Hz
400V 50 Hz
415V 50 Hz
Electrical Data Table Information
Compressor motor electrical data is provided in Table 13,
p. 38 and Table 14 for each compressor size. Rated load
amperes (RLA), locked rotor wye amperes (LRA) and
expected inrush for the Wye-delta configurations are
shown.
Although the terms “LRA” and “expected inrush” are often
used interchangeably, the distinction applied here is that
LRA is the rated inrush for the motor, but expected inrush
is that allowed by the starter, based on the specific
configuration. Selecting starters in the Wye-delta
configuration lowers expected inrush vs. the Delta (or
“across-the- line”) configuration.
The RLA is based on the motor’s performance when
reaching full rated horsepower. The kW rating of the motor
will equal or exceed the kW requirement indicated by the
TOPSS™ selection program at design conditions. If motor
kW draw at design conditions is less than the kW rating of
the motor, the RLA at design conditions is determined by
multiplying the motor RLA (at the desired voltage) by this
ratio: design kW/ motor kW rating. This calculation is
performed within the computer selection program,
making RLA available as part of the design predictions.
Predicted values include power factor variation from point
to point.
Optimus™ chillers are designed to operate satisfactorily
over a utilization range of ±10 percent of the standard
design voltages: (a) 200V, 230V, 380V, 460V, and 575V for
60 Hertz, 3- phase, and (b) 380V, 400V, 415V for 50 Hertz, 3phase.
RTHD-SVX01E-EN
Applied Range
(Model Number
digits 40-42)
AFD Input
Amps(a)
Estimated
Power Loss
(W)
0 - 176
183
2257
177 - 223
231
2719
224 - 280
291
3622
281 - 335
348
3561
336 - 411
427
4558
412 - 455
516
5703
0 - 197
204
2555
198 - 241
251
2949
242 - 292
304
3764
293 - 367
381
4109
368 - 446
463
5129
447 - 549
567
6663
0 - 197
204
2555
198 - 241
251
2949
242 - 292
304
3764
293 - 367
381
4109
368 - 446
463
5129
447 - 549
567
6663
(a) AFD input amps are shown in the RLA field of the unit nameplate.
Installer-Supplied Components
Customer wiring interface connections are shown in the
electrical schematics and connection diagrams that are
shipped with the unit. The installer must provide the
following components if not ordered with the unit:
•
Power supply wiring (in conduit) for all field-wired
connections.
•
All control (interconnecting) wiring (in conduit) for
field supplied devices.
Fused-disconnect switches or circuit breakers.
Power Supply Wiring
WARNING
Proper Field Wiring and Grounding
Required!
All field wiring MUST be performed by qualified
personnel. Improperly installed and grounded field
wiring poses FIRE and ELECTROCUTION hazards. To
avoid these hazards, you MUST follow requirements
for field wiring installation and grounding as described
in NEC and your local/state electrical codes. Failure to
follow code could result in death or serious injury.
39
Installation Electrical
WARNING
Hazardous Voltage w/Capacitors!
Disconnect all electric power, including remote
disconnects and discharge all motor start/run
capacitors before servicing. Follow proper lockout/
tagout procedures to ensure the power cannot be
inadvertently energized. For variable frequency drives
or other energy storing components provided by Trane
or others, refer to the appropriate manufacturer’s
literature for allowable waiting periods for discharge of
capacitors. Verify with an appropriate voltmeter that all
capacitors have discharged. Failure to disconnect
power and discharge capacitors before servicing could
result in death or serious injury.
For additional information regarding the safe discharge
of capacitors, see PROD-SVB06A-EN
All wiring must comply with local codes and the National
Electrical Code. The installing (or electrical) contractor
must provide and install the system interconnecting
wiring, as well as the power supply wiring. It must be
properly sized and equipped with the appropriate fused
disconnect switches.
The type and installation location(s) of the fused
disconnects must comply with all applicable codes.
NOTICE:
Use Copper Conductors Only!
Unit terminals are not designed to accept other types
of conductors. Failure to use copper conductors could
result in equipment damage.
See Figure 19 for electrical installation panel locations.
All power supply wiring must be sized and selected
accordingly by the project engineer in accordance with
NEC Table 310-16.
Figure 19. Electrical Installation
6.1” x 14.6” (156x370mm)
opening for incoming line voltage
(8) 1/2” conduit knockout
for use with 30 volt wiring
(6) 1/2” conduit and (4) 1-1/4” conduit
knockouts for use with 115 volts wiring
Water Pump Power Supply
Provide power supply wiring with fused disconnect for
both the chilled water and condenser water pumps.
40
RTHD-SVX01E-EN
Installation Electrical
Compressor Motor Phase Sequencing
Always verify that proper rotation of the compressor is
established before the machine is started. Proper motor
rotation requires confirmation of the electrical phase
sequence of the power supply. The motor is internally
connected for clockwise rotation with incoming power
supply phased A, B, C.
Units with Optional AFD.
NOTICE:
Equipment Damage!
Black (Phase A)
L1
Red (Phase B)
L2
Yellow (Phase C)
L3
4. Turn power on by closing the unit supply power
disconnect switch.
5. Read the phase sequence on the indicator. The “ABC”
indicator on the face of the phase indicator will glow if
phase is “ABC”.
WARNING
Hazardous Voltage w/Capacitors!
•
Do not change AFD phase rotation to
counterclockwise.
•
Do not enable phase reversal protection.
Changing default clockwise phase rotation or enabling
phase reversal protection could prevent proper chiller
operation or cause equipment damage.
AFD must be set with phase rotation clockwise (default
from factory), and phase reversal protection DISABLED.
All Units. To confirm the correct phase sequence (ABC),
use a Model 45 Associated Research Phase indicator or
equivalent.
Voltages generated in each phase of a polyphase
alternator or circuit are called phase voltages. In a threephase circuit, three sine wave voltages are generated,
differing in phase by 120 electrical degrees. The order in
which the three voltages of a three-phase system succeed
one another is called phase sequence or phase rotation.
This is determined by the direction of rotation of the
alternator. When rotation is clockwise, phase sequence is
usually called “ABC,” when counterclockwise, “CBA.”
Disconnect all electric power, including remote
disconnects and discharge all motor start/run
capacitors before servicing. Follow proper lockout/
tagout procedures to ensure the power cannot be
inadvertently energized. For variable frequency drives
or other energy storing components provided by Trane
or others, refer to the appropriate manufacturer’s
literature for allowable waiting periods for discharge of
capacitors. Verify with an appropriate voltmeter that all
capacitors have discharged. Failure to disconnect power
and discharge capacitors before servicing could result
in death or serious injury.
For additional information regarding the safe discharge
of capacitors, see PROD-SVB06A-EN
6. If the “CBA” indicator glows instead, open the unit
main power disconnect and switch two line leads on
the line power terminal block (or the unit mounted
disconnect). Reclose the main power disconnect and
recheck phasing.
7.
Reopen the unit disconnect and disconnect the phase
indicator.
This direction may be reversed outside the alternator by
interchanging any two of the line wires. It is this possible
interchange of wiring that makes a phase sequence
indicator necessary if the operator is to quickly determine
the phase rotation of the motor.
Electrical Connections
Correcting Improper Electrical Phase Sequence.
For recommended field connection lug sizes (RTHD
starters) see unit submittal.
Proper compressor motor electrical phasing can be quickly
determined and corrected before starting the unit. If using
an Associated Research Model 45 Phase Sequence
Indicator, follow this procedure:
1. Press the STOP button to insure the unit will not
attempt to start the compressor.
2. Open the electrical disconnect or circuit protection
switch that provides line power to the line power
terminal block in the control panel (or to the unitmounted disconnect).
3. Connect the phase sequence indicator leads to the line
power terminal block (or the unit mounted disconnect)
as follows:
Phase Seq. Lead
RTHD-SVX01E-EN
Proper starter/control panel line-side lug sizes are
specified on the unit submittals. These lug sizes must be
compatible with conductor sizes specified by the electrical
engineer or contractor.
Circuit Breakers and Non-Fused Disconnect
Switches
(Factory Installed Option)
Units that are ordered with factory installed circuit
breakers or non-fused disconnect switches ship with the
handle in the control panel. The handle must be installed
prior to starting the unit.
The operating mechanism is already pre-installed on the
Disconnect/ Circuit Breaker frame.
The hole locations and shafts lengths have already been
cut, and the shaft already installed.
1TB1 Terminal
41
Installation Electrical
WARNING
Hazardous Voltage w/Capacitors!
WARNING
Hazardous Voltage w/Capacitors!
Disconnect all electric power, including remote
disconnects and discharge all motor start/run
capacitors before servicing. Follow proper lockout/
tagout procedures to ensure the power cannot be
inadvertently energized. For variable frequency drives
or other energy storing components provided by Trane
or others, refer to the appropriate manufacturer’s
literature for allowable waiting periods for discharge of
capacitors. Verify with an appropriate voltmeter that all
capacitors have discharged. Failure to disconnect
power and discharge capacitors before servicing could
result in death or serious injury.
Disconnect all electric power, including remote
disconnects and discharge all motor start/run
capacitors before servicing. Follow proper lockout/
tagout procedures to ensure the power cannot be
inadvertently energized. For variable frequency drives
or other energy storing components provided by Trane
or others, refer to the appropriate manufacturer’s
literature for allowable waiting periods for discharge of
capacitors. Verify with an appropriate voltmeter that all
capacitors have discharged. Failure to disconnect
power and discharge capacitors before servicing could
result in death or serious injury.
For additional information regarding the safe discharge
of capacitors, see PROD-SVB06A-EN
For additional information regarding the safe discharge
of capacitors, see PROD-SVB06A-EN
1. Attach the handle and gasket to the enclosure door and
secure with the four bolts, lock washers and nut as
shown in Figure 20. Tighten to 75 in-Lbs.
Note: There is an additional Lexan spacer on the handle,
not shown in the Figure 20. Do not remove.
Figure 20. Handle on door
Important:
WHEN EVACUATING THE CHILLER’S
REFRIGERANT SYSTEM, ALWAYS HAVE
THE MAIN POWER DISCONNECT/CIRCUIT
BREAKER OPENED.
Even when the compressor is not running,
voltage is present at the compressor motor
terminals, providing the potential for
current to flow through a low impedance
path.
NOTICE:
Equipment Damage!
When removing refrigerant for the chiller, both the
condenser and chilled water pump must be operating
to avoid freeze up.
NOTICE:
Motor Damage!
Fully disconnect all power sources before pumpdown
or evacuation procedures and ensure disconnects
cannot be closed while chiller is in a vacuum. Failure to
do so could cause motor damage.
2. Check that when the enclosure door is closed, the
handle interlocks with the shaft in all handle positions
except RESET/OPEN. To open the enclosure door when
the breaker is in the ON position, rotate the screw slot
on the handle plate counter -clockwise. Verify
operation.
42
As the chiller is evacuated below atmospheric pressure,
the dielectric strength (resistance to arcing) of the gaseous
atmosphere is significantly reduced. Because the SCRs are
connected “inside the delta,” three of the motor terminals
are connected directly to the line voltage. An “arc over”
can occur between motor terminals under conditions seen
in the evacuation process. If this occurs the circuit breaker
(or other external protective devices) will trip in response
to high fault currents, and motor damage may also occur.
To avoid motor damage, verify chiller fully disconnected
from all power sources before beginning
pumpdown or evacuation procedures, and use proper
lockout/tagout procedures to make sure the disconnect
cannot be accidentally closed while the chiller is in a
vacuum.
RTHD-SVX01E-EN
Installation Electrical
Module Connections for
Interconnecting Wiring
All connectors can be unplugged or the wires can be
removed from the screw assembly. If an entire plug is
removed, make sure the plug and the associated jack are
marked for proper location identification during
reinstallation.
NOTICE:
Equipment Failure!
Plugs and jacks must be clearly marked before
disconnecting, because specific plugs will fit into other
jacks. Possible damage to equipment may occur if the
plugs are reversed with the jacks.
Interconnecting Wiring (Field Wiring Required)
Important:
Do not turn chiller on or off using the chilled
water pump interlocks.
When making field connections, refer to the appropriate
field layout, wiring, schematics and controls diagrams that
ship with the unit. The diagrams in this manual are typical
only and may not match the unit.
Whenever a contact closure (binary output) is referenced,
the electrical rating is:
7.2 amp resistive
At 120 VAC
2.88 amp pilot duty
1/3 hp, 7.2 FLA, 43.2 LRA
5.0 amp resistive
At 240 VAC
2.0 amp pilot duty
1/3 hp, 3.6 FLA, 21.6 LRA
Whenever a dry contact input (binary input) is referenced,
the electrical rating is 24VDC, 12 mA.
Whenever a control voltage contact input (binary input) is
referenced, the electrical rating is 120 VAC, 5mA.
Note: Connections denoted with an asterisk require the
user to provide an external source of power. The
115V control power transformer is not sized for
additional load.
Chilled Water Pump Control
UC800 has a evaporator water pump output relay that
closes when the chiller is given a signal to go into the Auto
mode of operation from any source. The contact is opened
to turn off the pump in the event of most machine level
diagnostics to prevent the build up of pump heat. To
protect against the build-up of pump heat for those
diagnostics that do not stop and/or start the pump and to
protect against the condition of a bad flow switch, the
pump shall always be stopped when the evaporator
pressure is seen to be close to the Low Side Evaporator
Pressure relief valve setting.
RTHD-SVX01E-EN
Chilled Water Flow Interlock
UC800 has an input that will accept a contact closure from
a proof-of-flow device such as a flow switch. The flow
switch is to be wired in series with the chilled water pump
starter's auxiliary contacts. When this input does not prove
flow within 20 minutes relative to transition from Stop to
Auto modes of the chiller, or if the flow is lost while the
chiller is in the Auto mode of operation, the chiller will be
inhibited from running by a non-latching diagnostic.The
flow switch input shall be filtered to allow for momentary
openings and closings of the switch due to turbulent water
flow. This is accomplished with a 6 seconds filtering time.
The sensing voltage for the condenser water flow switch is
115/240 VAC.
Important:
DO NOT cycle the chiller through starting
and stopping the chilled water pump. This
could cause the compressor to shut down
fully loaded. Use the external stop/start
input to cycle the chiller.
Condenser Water Pump Control
UC800 provides a contact closure output to start and stop
the condenser water pump. If condenser pumps are
arranged in a bank with a common header, the output can
be used to control an isolation valve and/or signal another
device that an additional pump is required.
Condenser Water Pump Prestart time has been added to
help with cold condenser water problems. In very cold
outdoor ambients, the cooling towers sump cold water
would reach the chiller some time after the low system
differential pressure protection had run through its ignore
time, and result in an immediate shutdown and latching
diagnostic. By simply starting the pump earlier, and
allowing mixing of the warmer indoor loop with the
cooling tower's sump, this problem can be avoided.
Condenser Water Flow Interlock
The UC800 shall accept an isolated contact closure input
from a customer installed proof-of-flow device such as a
flow switch and customer provided pump starter auxiliary
contact for interlocking with condenser water flow. The
input shall be filtered to allow momentary openings and
closings of the switch due to turbulent water flow, etc. This
shall be accomplished with a 6 seconds filtering time. The
sensing voltage for the condenser water flow switch is 115/
240 VAC.
On a call for cooling after the restart inhibit timer has timed
out, the UC800shall energize the condenser water pump
relay and then check the condenser water flow switch and
pump starter interlock input for flow confirmation. Startup
of the compressor will not be allowed until flow has
proven.
If flow is not initially established within 1200 seconds (20
minutes) of the condenser pump relay energizing, an
automatically resetting diagnostic "Condenser Water Flow
Overdue" shall be generated which terminates the prestart
mode and de-energizes the condenser water pump relay
43
Installation Electrical
This diagnostic is automatically reset if flow is established
at any later time.
Note: This diagnostic would never automatically reset if
UC800 was in control of the condenser pump
through its condenser pump relay since it is
commanded off at the time of the diagnostic. It
could however reset and allow normal chiller
operation if the pump was controlled from some
external source.
Reset Ratio calculation:
The Reset Ratio on the User Interface is displayed as a
percentage. To use it in the above equation it must be
converted to its decimal form.
Reset Ratio percent / 100 = Reset Ratio decimal
Example of converting Reset Ratio:
If the Reset Ratio displayed on the User Interface is 50%
then use (50/100) = .5 in the equation.
Chilled Water Reset (CWR)
Abbreviations used in equations:
The controller will reset the chilled water temperature
setpoint based on either return water temperature, or
outdoor air temperature. The Return Reset option is
standard, Outdoor Reset is optional.
•
TOD = Outdoor Air Temp
•
TWE = Evap Entering Water Temp
•
TWL = Evap Leaving Water Temp
The following is selectable:
Programmable Relays (Alarm and Status) Optional
•
RESET TYPE Setpoint.
This can be set to: DISABLE, CONSTANT, RETURN or
OUTSIDE AIR. The MP shall not permit more than one
type of reset to be selected.
•
RESET RATIO Setpoints.
For outdoor air temp. reset, both positive and negative
reset ratios will be allowed.
•
START RESET Setpoints.
•
MAXIMUM RESET Setpoints.
The maximum resets shall be with respect to the
chilled water setpoint.
When the chiller is running, if any type of CWR is enabled,
the controller will step the CWS toward the desired CWS'
(based on the below equations and setup parameters) at a
rate of 1 degree F every 5 minutes until the Active CWS
equals the desired CWS'. When the chiller is not running
the CWS will be fully reset immediately (within one
minute). The chiller will then start at the Differential to
Start value above a fully reset CWS or CWS' for Outdoor,
Return, and Constant Return Reset.
Equations for calculating CWR
Equation used to get Degrees of Reset:
Outdoor Air:
Degrees of Reset =
Reset Ratio * (Start Reset - TOD)
Return Reset:
Degrees of Reset =
Reset Ratio * (Start Reset - (TWE - TWL))
Constant Return:
Degrees of Reset =
100% * (Design Delta Temp - (TWE - TWL))
To obtain Active CWS from Degrees of Reset:
Active CWS = Degrees of Reset + Previous CWS
Note: Previous CWS can either be Front Panel, BAS, or
External
44
UC800 provides a flexible alarm or chiller status indication
to a remote location through a hard wired interface to a dry
contact closure. Four relays are available for this function,
and they are provided (generally with a Quad Relay Output
LLID) as part of the Alarm Relay Output Option.
The events/states that can be assigned to the
programmable relays are listed in the following table.
Table 16. Chiller events/status descriptions
Event/State
Description
Alarm - Latching
This output is true whenever there is any active
diagnostic that requires a manual reset to clear,
that affects the Chiller, the Circuit, or any of the
Compressors on a circuit. This classification does
not include informational diagnostics.
This output is true whenever there is any active
diagnostic that could automatically clear, that
affects the Chiller, the Circuit, or any of the
Alarm - Auto Reset Compressors on a circuit. This classification does
not include informational diagnostics. If all of the
auto resetting diagnostics were to clear, this output
would return to a false condition.
Alarm
This output is true whenever there is any
diagnostic effecting any component, whether
latching or automatically clearing. This
classification does not include informational
diagnostics.
Warning
This output is true whenever there is any
informational diagnostic affecting any component,
whether latching or automatically clearing.
This output is true whenever the chiller has been
running in one of the Unloading types of limit
modes (Condenser, Evaporator, Current Limit or
Phase Imbalance Limit) continuously for the last 20
minutes. A given limit or overlapping of different
limits must be in effect continuously for 20 minutes
prior to the output becoming true. It will become
Chiller Limit Mode false, if no Unload limits are present for 1 minute.
The filter prevents short duration or transient
repetitive limits from indicating. The chiller is
considered to be in a limit mode for the purposes
of front panel display and annunciation, only if it is
fully inhibiting loading by virtue of being in either
the "hold" or "forced unload" regions of the limit
control, excluding the "limited loading region".
RTHD-SVX01E-EN
Installation Electrical
Table 16. Chiller events/status descriptions (continued)
Event/State
Description
Compressor
Running
The output is true whenever any compressors are
started or running on the chiller and false when no
compressors are either starting or running on the
chiller.
This status may or may not reflect the true status
of the compressor in Service Pumpdown if such a
mode exists for a particular chiller.
This relay output is energized anytime the chiller is
running in one of the following modes; Ice Making
Mode or Condenser Pressure Limit Control Mode
continuously for the duration specified by the
Chiller Head Relief Relay Filter Time. The Chiller
Head Relief Relay Filter Time is a service setpoint.
The relay output is de-energized anytime the
chiller exits all above modes continuously for the
duration specified by the same Chiller Head Relief
Relay Filter Time.
Chiller Head
Pressure Relief
Request Relay
The UC800 Service Tool (Tracer TU) is used to install and
assign any of the above listed events or status to each of
the four relays provided with this option.
The default assignments for the four available relays are
listed below.
Table 17
Programmable Relays
LLID Name
LLID
Software
Relay
Output
Designation Name
Relay 0
Relay 1
Operating
Status
Programmable
Relay 2
Relays
Relay 3
Soft Loading
Soft loading will prevent the chiller from going to full
capacity during the pull-down period.
The UC800 control system has two soft loading algorithms
running all of the time. hey are capacity control soft
loading and current limit soft loading. These algorithms
introduce the use of a Filtered Chilled Water Setpoint and
a Filtered Current Limit Setpoint. After the compressor has
been started, the starting point of the filtered chilled water
setpoint is initialized to the value of the Evap Leaving
Water Temperature. The filtered current limit setpoint is
initialized to the value of the Current Limit Softload
Starting Percent. These filtered setpoints allow for a stable
pull-down that is user adjustable in duration. They also
eliminate sudden transients due to setpoint changes
during normal chiller operation.
Three settings are used to describe the behavior of soft
loading. The setup for softloading can be done using
Tracer TU.
•
Capacity Control Softload Time: This setting controls
the time constant of the Filtered Chilled Water
Setpoint. It is settable between 0 and 120 min.
•
Current Limit Control Softload Time: This Setting
controls the time constant of the Filtered Current Limit
Setpoint. It is settable between 0 and 120 minutes.
•
Current Limit Softload Starting Percent: This setting
controls the starting point of the Filtered Current Limit
Setpoint. It is adjustable from 40 for RTHD to 100
percent RLA.
Default
Status Relay 4, Head Pressure Relief
J2-1,2,3
Request
Status Relay 3, Chiller Limit Mode
J2-4,5,6
Relay
Chiller Alarm Relay
Status Relay 2,
(latching or
J2-7,8,9
nonlatching)
Status Relay 1, Compressor Running
J2-10,11,12
Relay
Emergency Stop
The UC800 provides auxiliary control for a customer
specified/installed latching trip out. When this customerfurnished remote contact is provided, the chiller will run
normally when the contact is closed. When the contact
opens, the unit will trip off on a manually resettable
diagnostic. This condition requires manual reset at the
chiller switch on the front of the control panel.
External Auto/Stop
If the unit requires the external Auto/Stop function, the
installer must provide leads from the remote contacts to
the proper terminals of the LLID on the control panel.
The chiller will run normally when the contacts are closed.
When the contact opens, the compressor(s), if operating,
will go to the RUN:UNLOAD operating mode and cycle off.
Unit operation will be inhibited. Re-closure of the contacts
will permit the unit to automatically return to normal
operation.
RTHD-SVX01E-EN
Note: A “panic” stop (similar to “emergency” stop) can
be manually commanded by pressing the STOP
button twice in a row, the chiller will immediately
shut down, but without creating a latching
diagnostic.
External Base Loading - Optional
Primarily for process control requirements, base loading
provides for immediate start and loading of a chiller up to
an externally or remotely adjustable current limit setpoint
without regard to differential to start or stop, or to leaving
water temperature control. This allows the flexibility to
prestart or preload a chiller in anticipation of a large load
application. It also allows you to keep a chiller on line
between processes when leaving water temperature
control would normally cycle the unit.
When the base loading option is installed through TD7 it
will be controllable through TD7/Tracer TU, External
Hardware Interface or Tracer (if Tracer is installed). Order
for precedence for all setpoints, TD7/Tracer TU, then
External then Tracer from lowest to highest priority. If one
of the higher priority setpoints drops out due to a bad
sensor or communication loss then base loading shall go
to the next lowest priority of command and setpoint. The
command settings and control setpoints associated with
base loading are explained below.
45
Installation Electrical
Base Loading Control Setpoint
Compressor Percent RLA Output - Optional
This setpoint has three possible sources, an External
Analog Input, TD7/Tracer TU or Tracer.
•
TD7/Tracer TU Base Loading Control Setpoint
UC800 provides a 2-10 Vdc analog output to indicate %RLA
of compressor starter average phase current. The values
of 2 to 10 Vdc correspond to 0 to 120% RLA.
•
The range is 40 - 100% Compressor Load (Max %RLA).
The default is 50%.
AFD Drive (Optional)
•
Tracer Base Loading Control Setpoint
•
The range is 40 - 100% Compressor Load (Max %RLA).
The default is 50%.
•
External Base Loading Setpoint
Trane TR200 drive is an electronic motor controller that
converts AC mains input into a variable AC waveform
output. The frequency and voltage of the output are
regulated to control the motor speed or torque.
This is an Analog Input that sets the base loading setpoint.
This signal can be controlled by either a 2-10Vdc or 4-20ma
Signal based on configuration information. The equations
show the relationship between input and percent
compressor load:
If the input is configured as a 4 - 20 mA:
% Load = 3.75 * (mA Input) + 25
If the input is configured as a 2 - 10 Vdc:
% Load = 7.5 * (Vdc Input) + 25
Ice Making Contact - Optional
UC800 accepts a contact closure input to initiate Ice
Building. When in the ice building mode, the compressor
will be fully loaded (not given a low setpoint) and will
continue to operate until the ice contacts open or the
return water temperature reaches the Ice Termination
Setpoint. If terminated on return setpoint, UC800 will not
allow chiller to restart until ice making contact is opened.
Ice Machine Control - Optional
UC800 provides an output contact closure that can be used
as a signal to the system that ice building is in operation.
This relay will be closed when ice building is in progress
and open when ice building has been terminated by either
UC800 or remote interlock. It is used to signal the system
changes required to convert to and from ice making.
TR200 drive includes the following features:
•
Soft start to minimize inrush current
•
Improved harmonic mitigation with DC link reactor
•
Integrated power fuse
•
Graphical LCD keypad
•
Unit Mounted with factory pre-wiring
•
‘Trane Drive Utility’ for configuration and tracking
See Service Manual BAS-SVM01A-EN for more
information.
AFD Drive Installation
The AFD drive is manufactured with a jumper installed
between terminal 12 (+24Vdc source) and terminal 37
(Safe Stop digital input). This jumper must be removed
prior to unit operation. See Figure 21 for view of jumper as
it would be installed on drive from manufacturer.
NOTICE:
Equipment Damage!
Verify/remove jumper between AFD terminals 12 and
37 before unit operation. Failure to remove jumper
could cause equipment damage.
Figure 21.
AFD jumper
External Chilled Water Setpoint - Optional
UC800 will accept either a 2-10 VDC or a 4-20 mA input (J94, J9-5) signal, to adjust chilled water setpoint remotely.
External Current Limit Setpoint - Optional
UC800 will accept either a 2-10VDC or a 4-20mA input (J711, J7-12) signal to adjust the current limit setpoint from a
remote location.
Percent Condenser Pressure Output - Optional
UC800 provides a 2-10 VDC analog output to indicate
percent High Pressure Cutout (HPC) condenser pressure.
Percent HPC = (Condenser Pressure/High Pressure Cutout
Setpoint)*100
46
Jumper between
terminals 12 and 37
must be removed
prior to unit
operation.
RTHD-SVX01E-EN
Installation Electrical
Important:
• For factory provided AFD units, verify jumper has
been removed.
• For field installed drives, remove jumper shown in
Figure 21.
Table 18. Non-compressor specific parameter settings
ID
Description
Setting
0-03
Region Settings
North American
0-20
Display Line 1.1 Small
DC Link Voltage
0-22
Display Line 1.3
Heatsink Temp.
0-24
Display Line 3 Large
Analog Input 53
NOTICE:
Equipment Damage!
0-40
[Hand on] Key on LCP
Disabled
0-41
[Off] Key on LCP
Disabled
0-60
Main Menu Password
999
•
Do not change AFD phase rotation to
counterclockwise.
0-61
Access to Main Menu w/o Password
Read Only
1-03
Torque Characteristics
Compressor Torque
•
Do not enable phase reversal protection.
1-71
Start Delay
0s
AFD Drive Programming
Changing default clockwise phase rotation or enabling
phase reversal protection could prevent proper chiller
operation or cause equipment damage.
1-73
Flying Start
Disabled
1-78
Compressor Start Max Speed [Hz]
20Hz
1-79
Compressor Start Max Time to Trip
10s
Field replacement drives must be programmed via the
keypad interface. Program non-compressor specific
parameters first in sequential order (Table 18), followed by
compressor specific parameters (see Table 19) in
sequential order.
3-02
Min Reference
30Hz
3-41
Ramp 1 Ramp up Time
10s
3-42
Ramp 1 Ramp Down Time
10s
3-82
Starting Ramp Up Time
5s
4-10
Motor Speed Direction
Clockwise
4-12
Motor Speed Low Limit [Hz]
30Hz
4-18
Current Limit
Max
5-02
Terminal 29 Mode
Output
5-12
Terminal 27 Digital Input
Coast Inverse
5-31
Terminal 29 Digital Output
Alarm
5-40
Function Relay 1
No Operation
RTHD-SVX01E-EN
6-10
Terminal 53 Low Voltage
2V
6-14
Terminal 53 Low Ref./Feedb. Value
30Hz
6-50
Terminal 42 Output
Power 4-20mA
14-00
Switching Pattern
SFAVM
14-01
Switching Frequency
3kHz
14-03
Overmodulation
Off
14-10
Mains Failure
Ctrl. ramp-down
14-12
Function at Mains Imbalance
Derate
14-21
Automatic Restart Time
8s
14-50
RFI Filter
Off
14-51
DC Link Compensation
On
14-60
Function at Over Temperature
Derate
14-61
Function at Inverter Overload
Derate
14-62
Inv. Overload Derate Current
75%
47
Installation Electrical
Table 19. Compressor-specific parameter settings(a)
Parameters
ID
B1/B2 Motor Frame
Description 460/60
C1/C2 Motor Frame
D1/D2/D3/E3 Motor Frame E3 Motor Frame
400/50
380/60
460/60
400/50
380/60
460/60
400/50
380/60
400/50
1-21
Motor Power
(hp)
233
194
233
334
280
334
441
375
441
403
1-22
Motor Voltage
(V)
460
400
380
460
400
380
460
400
380
400
1-23
Motor
Frequency
(Hz)
60
50
60
60
50
60
60
50
60
50
1-24
Motor Current
(A)
241
233
291
349
349
421
455
455
549
488
1-25
Motor Nominal
Speed (rpm)
3512
2921
3512
3531
2938
3531
3535
2943
3535
2943
1-30
Stator
Resistance
(ohms)
0.0303
0.0303
0.0213
0.0201
0.0201
0.0138
0.0122
0.0122
0.0087
0.0122
1-31
Rotor
Resistance
(ohms)
0.0257
0.0257
0.0179
0.0146
0.0146
0.0103
0.0091
0.0091
0.0066
0.0091
1-35
Main
Reactance
(ohms)
5.3684
5.3684
3.9634
3.005
3.005
2.1972
2.8882
2.8882
2.1848
2.8882
1-36
Iron Loss
Resistance
(ohms)
188.388
188.388
142.836
152.612
152.612
116.132
125.549
125.549
90.188
125.549
3-03
Maximum
Reference
(Hz)
60
50
60
60
50
60
60
50
60
50
4-14
Motor Speed
High Limit
(Hz)
60
50
60
60
50
60
60
50
60
50
6-15
Terminal 53
High Ref./
Feedback
Value (Hz)
60
50
60
60
50
60
60
50
60
50
14-11
Voltage at
Main Fault (V)
400
342
342
400
342
342
400
342
342
342
(a) Compressor frame size is shown in model number digits 6 and 7.
48
RTHD-SVX01E-EN
Installation Electrical
Communications Interface
LonTalk Interface (LCI-C)
UC800 provides an optional LonTalk® Communication
Interface (LCI-C) between the chiller and a Building
Automation System (BAS). An LCI-C LLID shall be used to
provide "gateway" functionality between a LonTalk
compatible device and the Chiller. The inputs/outputs
include both mandatory and optional network variables as
established by the LONMARK® Functional Chiller Profile
8040.
Note: For more information see ACC-SVN100*-EN.
BACnet Interface (BCI-C)
Optional BACnet® Communication Interface for Chillers
(BCI-C) is comprised of a Tracer UC800 controller with
interface software. It is a non-programmable
communications module that allows units to
communicate on a BACnet communications network.
Note: For more information, see BAS-SVP01*-EN.
Modbus Remote Terminal Unit Interface
Modicon Communication Bus (Modbus™) enables the
chiller controller to communicate as a slave device on a
Modbus network. Chiller setpoints, operating modes,
alarms and status can be monitored and controlled by a
Modbus master device.
Note: For more information, see BAS-SVP01*-EN.
RTHD-SVX01E-EN
49
Operating Principles
This section describes the overall operating principles of
the Optimus™ water chiller.
General
Optimus units are single-compressor water-cooled liquid
chillers. These units are equipped with unit-mounted
starter/control panels.
The basic components of an Optimus unit are:
•
Unit-mounted panel containing UC800 controller and
input/output LLIDs
•
Helical-rotary compressor
•
Evaporator
•
Electronic expansion valve
•
Water-cooled condenser with integral subcooler
•
Oil supply system
•
Oil cooler (application dependent)
•
Related interconnecting piping
•
AFD (optional)
the compressor to discharge pressure conditions.
Simultaneously, lubricant is injected into the compressor.
An oil management system provides an almost oil-free
refrigerant to the shells to maximize heat transfer
performance, while providing lubrication and rotor
sealing to the compressor. The lubrication system ensures
long compressor life and contributes to quiet operation.
Immediately following the compression process the
lubricant and refrigerant are effectively divided using an
oil separator.
The oil-free refrigerant vapor enters the condenser at State
Pt. 2. Condensing is accomplished in a shell-and-tube heat
exchanger where refrigerant is condensed on the shell
side and water flows internally in the tubes. Cooling tower
water, circulating through the condenser tubes, absorbs
heat from this refrigerant and condenses it.
As the refrigerant leaves the bottom of the condenser
(State Pt. 3), it enters an integral subcooler where it is
subcooled before traveling to the electronic expansion
valve (State Pt. 4). The pressure drop created by the
expansion process vaporizes a portion of the liquid
refrigerant.
Refrigeration Cycle
The refrigeration cycle for the Optimus chiller can be
described using the pressure-enthalpy diagram shown in
Figure 22. Key State Points are indicated on the figure and
are referenced in the discussion following.
The resulting mixture of liquid and gaseous refrigerant
then enters the Evaporator Distribution system (State Pt.
5). The flash gas from the expansion process is internally
routed to compressor suction, and while the liquid
refrigerant is distributed over the tube bundle in the
evaporator.
Figure 22. Pressure/enthalpy curve
Refrigeration Circuits
Liquid
3
4
2
Pressure
1
5
Each unit has a single refrigerant circuit. Each refrigerant
circuit includes compressor suction and discharge service
valves, removable core filter, charging port, and sight
glass. An electronically controlled expansion valve is
provided to maintain variable capacity modulation over
the entire building load and maintain proper refrigerant
flow.
Compressor and Motor
Gas
Enthalpy
The Optimus chiller makes use of a shell-and-tube
evaporator design with refrigerant evaporating on the
shell side and water flowing inside tubes having enhanced
surfaces.Refrigerant vapor leaves the evaporator as
saturated vapor (State Pt. 1).
The refrigerant vapor generated in the evaporator flows to
the suction end of the compressor. The compressor is a
twin-rotor helical rotary type. The refrigerant flows across
the motor, providing the necessary cooling, then enters
the compression chamber. Refrigerant is compressed in
50
Unit is equipped with a semi-hermetic, direct-drive, 3600
rpm 60 Hz (3000 rpm 50 Hz) rotary compressors that
includes a capacity control slide valve, oil sump heater,
and differential pressure refrigerant oil flow system.
Optional AFD provides capacity control with lower speeds.
Four pressure-lubricated rolling element bearing groups
support the rotary assembly. Motor is suction gas-cooled,
hermetically sealed, two-pole squirrel cage induction
motor.
Evaporator and Condenser
Heat exchangers are shell and tube design. Standard tubes
are externally finned, internally enhanced seamless
RTHD-SVX01E-EN
Operating Principles
copper with lands at all tube sheets. All tube sheets are
made of carbon steel. Tubes are mechanically expanded
into tube sheets and mechanically fastened to tube
supports. Evaporator tubes are 1.0- inch (25.4 mm)
diameter and condenser tubes are 0.75-inch (19.05 mm)
diameter. All tubes can be individually replaced.
Shells are carbon steel plate. The evaporator and
condenser are designed, tested, and stamped in
accordance with ASME Code for refrigerant-side/ workingside pressure of 200 psig (13.8 bars).
All water pass arrangements are available with grooved
connections (150 or 300 psig waterside working pressure).
All connections may be either right- or left-handed.
Waterside shall be hydrostatically tested at 1.5X design
working pressure.
Oil Management
The unit is configured with an oil management system that
ensures proper oil circulation throughout the unit. The key
components of the system include an oil separator, oil
filter, oil sump and oil sump heater. An optional oil cooler
is installed when the unit is used for high condensing
temperature or low evaporator temperature conditions
Unit-Mounted Starter
A unit-mounted starter and control panel is provided on
every chiller. Microprocessor-based unit control modules
(Tracer UC800) provide for accurate chilled water control
as well as monitoring, protection and adaptive limit
functions. The “adaptive” nature of the controls
intelligently prevents the chiller from operating outside of
its limits, or compensates for unusual operating
conditions, while keeping the chiller running rather than
simply tripping due to a safety concern. When problems
do occur, diagnostic messages assist the operator in
troubleshooting.
RTHD-SVX01E-EN
51
Controls
Overview
UC800 Specifications
Optimus™ RTHD units utilize the following control/
interface components:
This section covers information pertaining to the UC800
controller hardware.
•
Tracer™ UC800 Controller
•
Tracer AdaptiView™ TD7 Operator Interface
Wiring and Port Descriptions
Figure 23 illustrates the UC800 controller ports, LEDs,
rotary switches, and wiring terminals. The numbered list
following Figure 23 corresponds to the numbered callouts
in the illustration.
Figure 23. Wiring locations and connection ports
+
LINK
2
3
4
+
+
+24
VDC
MBUS
5
6
6
7
8
9
1
10
11
10
11
Front View
1.
Rotary Switches for setting BACnet® MAC address or MODBUS ID.
2.
LINK for BACnet MS/TP, or MODBUS Slave (two terminals, ±). Field wired if used.
Bottom View
3.
LINK for BACnet MS/TP, or MODBUS Slave (two terminals, ±). Field wired if used.
4.
Machine bus for existing machine LLIDs (IPC3 Tracer bus 19.200 baud). IPC3 Bus: used for Comm4 using TCI or LonTalk® using LCI-C.
5.
Power (210 mA at 24 Vdc) and ground terminations (same bus as item 4). Factory wired.
6.
Not used.
7.
Marquee LED power and UC800 Status indicator (Table 20, p. 53).
8.
Status LEDs for the BAS link, MBus link, and IMC link.
9.
USB device type B connection for the service tool (Tracer TU).
10. The Ethernet connection can only be used with the Tracer AdaptiView display.
11. USB Host (not used).
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RTHD-SVX01E-EN
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Communication Interfaces
There are four connections on the UC800 that support the
communication interfaces listed. See Figure 23, p. 52 for
the locations of each of these ports.
• BACnet® MS/TP
• MODBUS™ Slave
• LonTalk™ using LCI-C (from the IPC3 bus)
• Comm 4 using TCI (from the IPC3 bus)
Table 20. LED behavior
LED
Low power or malfunction. If the Marquee LED is
Marquee LED red solid, the UC800 is powered, but there are
problems present.
Alarm. The Marquee LED blinks Red when an alarm
exists.
Rotary Switches
There are three rotary switches on the front of the UC800
controller. Use these switches to define a three-digit
address when the UC800 is installed in a BACnet or
MODBUS system (e.g., 107, 127, etc.).
Note: Valid addresses are 001 to 127 for BACnet and 001
to 247 for MODBUS.
LED Description and Operation
LINK, MBUS,
IMC
The TX LED blinks green at the data transfer rate
when the UC800 transfers data to other devices on
the link.
The Rx LED blinks yellow at the data transfer rate
when the UC800 receives data from other devices on
the link.
Ethernet Link
The LINK LED is solid green if the Ethernet link is
connected and communicating.
The ACT LED blinks yellow at the data transfer rate
when data flow is active on the link.
Service
There are 10 LEDs on the front of the UC800. Figure 24
shows the locations of each LED and Table 20, p. 53
describes their behavior in specific instances.
Important:
Figure 24. LED locations
Marquee
LINK
MBUS
IMC
TX
The Service LED is solid green when pressed. For
qualified service technicians only. Do not use.
Maintain at least 6” between low-voltage
(<30V) and high voltage circuits to prevent
control malfunctions, do not run low
voltage wiring (<30 V) in conduit with
conductors carrying more than 30 volts.
Tracer AdaptiView TD7 Display
Operator Interface
RX
LINK
SERVICE
ACT
UC800 Status
Powered. If the Marquee LED is green solid, the
UC800 is powered and no problems exist.
Information is tailored to operators, service technicians,
and owners. When operating a chiller, there is specific
information you need on a day-to-day basis—setpoints,
limits, diagnostic information, and reports. Day-to-day
operational information is presented at the display.
Logically organized groups of information— chiller modes
of operation, active diagnostics, settings and reports put
information conveniently at your fingertips.
Figure 25. TD7 screens
Operator Display Boot Screen
RTHD-SVX01E-EN
Display Loading Data
Home Screen, Auto Mode
53
Controls
Main Display Area/Home Screen
Viewing Chiller Operating Modes
All screens appear within the main display area (shown as
location in Table 26).
On the Reports screen, touch Chiller Operating Modes to
view the current operating status of the chiller in terms of
the top-level operating mode and submodes.
Home screen: Chiller status information
The home screen (Table 26) provides the most frequently
needed chiller status information on “touch targets” (the
entire white rectangular areas) for each chiller component.
Touching any touch target displays a screen containing
more chiller status information related to each
component.
Note: You can also access the Chiller Operating Modes
screen from the chiller status button in the upper
left corner of the screen.
Figure 27.
Chiller operating modes
Figure 26. Main screen
Table 21. Main screen items
Description
Resolution
Units
Active Chilled Water Setpoint
X.X
°F /°C
Active Current Limit Setpoint
X.X
%RLA
Average Motor Current %RLA
X.X
%RLA
Evap Entering/Leaving Water Temp
X.X
°F /°C
Cond Entering/Leaving Water Temp
X.X
°F /°C
Frequency Command
X.X
Hz
Evaporator Water Flow Status
X.X
Condenser Water Flow Status
Table 22. Operating modes
Chiller Modes
Description
MP Resetting
Stopped
The chiller is not running and cannot run without intervention. Further information is provided
by the sub-mode:
Local Stop
Chiller is stopped by TD7 Stop button command– cannot be remotely overridden.
Immediate Stop
Chiller is stopped by the TD7 Panic Stop (by pressing Stop button twice in succession) – previous shutdown
was manually commanded to shutdown immediately without a run-unload or pumpdown cycle - cannot
be remotely overridden.
Diagnostic Shutdown – Manual Reset The chiller is stopped by a diagnostic that requires manual intervention to reset.
Run Inhibit
The chiller is currently being inhibited from starting (and running*), but may be allowed to start
if the inhibiting or diagnostic condition is cleared. Further information is provided by the submode:
Diagnostic Shutdown – Auto Reset
The entire chiller is stopped by a diagnostic that may automatically clear.
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RTHD-SVX01E-EN
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Table 22. Operating modes (continued)
Chiller Modes
Description
Starting is Inhibited by External
Source
The chiller is inhibited from starting (and running) by the “external stop” hardwired input.
Start Inhibited by BAS
The chiller is inhibited from starting (and running) by command from a Building Automation System via
the digital communication link (com 4 or com 5).
Waiting for BAS Communications
This is a transient mode - 15-min. max, and is only possible if the chiller is in the Auto - Remote command
mode. After a power up reset, it is necessary to wait for valid communication from a Building Automation
System (Tracer) to know whether to run or stay inhibited. Either valid communication will be received from
the Building Automation System (e.g. Tracer), or a communication diagnostic ultimately will result. In the
latter case the chiller will revert to Local control.
Power Up Delay Inhibit
The compressor is currently being inhibited from starting as part of the power up start delay (or staggered
min:sec start) feature. This feature is intended to prevent multiple chillers from all starting simultaneously if power
is restored to all chillers simultaneously.
Low Differential Refrigerant Pressure
Contact your local Trane service office.
Cool-Down Timemin:sec
Auto
The chiller is not currently running but can be expected to start at any moment given that the
proper conditions and interlocks are satisfied. Further information is provided by the submode:
Waiting For Evap Water Flow
The chiller will wait up to 20 minutes in this mode for evaporator water flow to be established per the flow
switch hardwired input.
Waiting for A Need to Cool
The chiller will wait indefinitely in this mode, for an evaporator leaving water temperature higher than the
Chilled Water Setpoint plus the Differential to Start.
Waiting to Start
The chiller is not currently running and there is a call for cooling but start is delayed by certain
interlocks or proofs. Further information is provided by the sub-mode:
Waiting For Cond Water Flow
The chiller will wait up to 20 minutes in this mode for condenser water flow to be established per the flow
switch hardwired input.
Start Inhibited Waiting for Oil
The chiller will wait up to 2 minutes in this mode for oil level to appear in the oil tank.
Condenser Water Pump Pre-Run
Timemin:sec
The chiller will wait up to 30 minutes (user adjustable) in this mode for to allow the condenser water loop
to equalize in temperature
Restart Inhibit min:sec
The compressor is currently unable to start due to its restart inhibit timer. A given compressor is not
allowed to start until 5 minutes (adj) has expired since its last start, once a number of “free starts” have
been used up.
Waiting For EXV Preposition
The Chiller will wait for the time it takes the EXV to get to its commanded pre-position prior to starting
the compressor. This is typically a relatively short delay and no countdown timer is necessary (less than
15 seconds)
Minimum Condenser Watermin:sec
Only possible when Condenser Head Pressure Control option is enabled, this wait may be necessary due
to the Head Pressure control device’s stroke time.
Condenser Water Regulating Control
min:sec
Only possible when Condenser Head Pressure Control option is enabled, this wait may be necessary due
to the Head Pressure control device’s stroke time
Running
The chiller, circuit, and compressor are currently running. Further information is provided by
the sub-mode:
High Discharge Temp Limit
The compressor is running and is being forced loaded to its step load point, without regard to the leaving
water temperature control, to prevent tripping on high compressor discharge temperature.
Base Loaded
Chiller is running in “Base Load” operation where the capacity of the chiller is controlled to maintain a given
current per an adjustable set point. The chiller is forced to run without regard to the chilled water
temperatures and the differential to start and stop
Capacity Control Softloading
The chiller is running, but loading is influenced by a gradual ‘pulldown” filter on the chilled water
temperature setpoint. The settling time of this filter is user adjustable as part of the softload control
feature.
Current Control Softloading
The chiller is running, but loading is influenced by a gradual filter on the current limit setpoint The starting
current and the settling time of this filter is user adjustable as part of the softload control feature.
EXV Controlling Differential Pressure
Liquid level control of the Electronic Expansion Valve has temporarily been suspended. The EXV is being
modulated to control for a minimum differential pressure. This control implies low liquid levels and higher
approach temperatures, but is necessary to provide minimum oil flow for the compressor until the
condenser water loop can warm up to approx 50F.
Chilled Water Control
Unit is running in the Cooling Mode of operation and is attempting to control to the active Chilled Water
Setpoint.
Running – Limited
The chiller, circuit, and compressor are currently running, but the operation of the chiller/
compressor is being actively limited by the controls. Further information is provided by the submode.* See the section below regarding criteria for annunciation of limit modes
RTHD-SVX01E-EN
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Controls
Table 22. Operating modes (continued)
Chiller Modes
Description
Condenser Pressure Limit
The circuit is experiencing condenser pressures at or near the condenser limit setting. Compressors on the
circuit will be unloaded to prevent exceeding the limits.*
Low Evaporator Refrigerant
Temperature Inhibit
The circuit is experiencing saturated evaporator temperatures at or near the Low Refrigerant Temperature
Cutout setting. Compressors on the circuit will be unloaded to prevent tripping. *
Capacity Limited by Low Liquid Level
The circuit is experiencing low refrigerant liquid levels and the EXV is at or near full open. The compressors
on the circuit will be unloaded to prevent tripping.*
Current Limit
The compressor is running and its capacity is being limited by high currents. The current limit setting is
100% RLA (to avoid overcurrent trips) or lower as set by the compressor’s “share” of the active current
limit (demand limit) setting for the entire chiller.*
Phase Unbalance Limit
The compressor is running and its capacity is being limited by excessive phase current unbalance.*
Low Discharge Superheat Limit
This is limit control that acts to prevent chiller shutdown when the discharge superheat approaches the
limit setpoint by reducing the liquid level and unloading the slide valve.
Oil Loss Avoidance
This is limit control that acts to prevent chiller shutdown when the estimated refrigerant flow approaches
the calculated minimum flow by increasing the slide valve capacity and/or VFD frequency
Note: Other normal running modes (see above) may also appear under this top level mode
Shutting Down
The chiller is still running but shutdown is imminent. The chiller is going through a compressor
run-unload. sequence. Shutdown is necessary due to one (or more) of the following sub-modes:
Local Stop
Chiller is in the process of being stopped by TD7 Stop button command
immediate Stop
Chiller is in the process of being stopped by TD7 Panic Stop command
Chiller is in the process of being stopped by a Latching Diagnostic shutdown – Manual Reset is required
Diagnostic Shutdown – Manual Reset
to clear
Diagnostic Shutdown – Auto Reset
Chiller is in the process of being stopped by a Diagnostic shutdown – Automatic clearing of the diagnostic
is possible if condition clears.
Compressor Unloading (min:sec)
The compressor is in its “run – unload” state in which it is being continuously unloaded for 40 sec prior
to shutdown.
Starting is Inhibited by External
Source
Chiller is in the process of being stopped by the External Stop hardwired input
Start Inhibited by BAS
The Chiller is in the process of shutdown due to a command from the Building Automation System (e.g.
Tracer)
Evaporator Water Pump Off Delay
min:sec
Service Override
The Chiller is in a Service Override mode
Service Pumpdown
The chiller, circuit, and compressor is running via a manual command to perform a Service Pumpdown.
Both evap and condenser water pumps are commanded to be running. The EXV is being held wide open,
but the manual liquid line service valve should be closed.
Alarms
You can use the display to view alarms and to reset them.
Alarms are communicated to the display immediately
upon detection.
Figure 28. Alarm screen
Viewing the Alarms Screen
Touch the Alarms button in the main menu area (Figure 26,
p. 54) to view the Alarms screen. A table of active alarms
appears that is organized chronologically with the most
recent at the top of the list, as shown in Figure 28. This
example shows the default view, which appears each time
you return to the screen.
Note: A page number appears in the lower right corner of
the screen. If a screen contains more than one
page, up/down arrows also appear for viewing the
other pages
The Alarms screen is accessible by depressing the Alarms
enunciator. A verbal description will be provided.
A scrollable list of the last active Alarms is presented.
Performing a “Reset Alarms” will reset all active Alarms
56
RTHD-SVX01E-EN
Controls
regardless of type, machine or circuit. The scrollable list
will be sorted by time of occurrence.
If a informational warning is present, the “Alarms” key will
be present but not flashing. If a Alarm shutdown (normal
or immediate) has occurred, the “Alarm” key will display
that is flashing. If no Alarms exist, the “Alarm” key will not
be present.
Reports
You can use the Tracer display to view a variety of reports
and to create and edit a custom report. All reports contain
live data that refreshes every 2–5 seconds.
Viewing the Reports Screen
Touch the Reports button in the main menu area (Figure 4)
to view the Reports screen. The Reports screen contains
the following buttons:
•
Custom Report1
•
Custom Report2
•
Custom Report3
•
Evaporator
•
Condenser
•
Compressor
•
Motor
•
About
•
Operating Modes
•
Log Sheet
•
ASHRAE Chiller Log
Editing a Custom Report
You can edit the custom report by adding, removing, or reorder data as follows:
1. On the Custom Report screen, touch Edit. The Edit
Custom Report screen appears.
2. Add, remove, or re-order as follows:
a. To add an item to the custom report, touch it. It
responds by changing to blue. You can use the
arrows to scroll through the rest of the items that
can be added to the custom report. Then touch Add
to move the selected item to the box on the right
side of the screen. To add all of the remaining items
in the left box to the custom report, touch Add All.
b. To remove an item from the custom report, touch it.
It responds by changing to blue. You can use the
arrows to scroll through the rest of the items that
can be removed from the custom report. Then touch
Remove to move the selected item to the box on the
left side of the screen.
c. To re-order items in the custom report, touch it. It
responds by changing to blue. Use the arrows to
change the order of a highlighted item.
3. To save and view your edited custom report, touch
Save.
Figure 30. Edit custom report screen
Each button links to the report named on the button.
Figure 29. Report screen
Figure 31.
Report evaporator screen
The Reports tab allows a user to select from a list of reports
headings. Each report will generate a list of status items as
defined in the tables that follow.
RTHD-SVX01E-EN
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Controls
Table 23. Report evaporator screen items
Figure 33. Report compressor screen
Description
Resolution
Units
Active Chilled Water Setpoint
X.X
°F / °C
Evaporator Entering Water Temperature X.X
°F / °C
Evaporator Leaving Water Temperature X.X
°F / °C
Evaporator Water Flow Status
Flow, No Flow
Text
Evaporator Water Pump Override
Auto, On
Text
Evaporator Approach Temperature
X.X
°F / °C
EXV Position Percent
X.X
%
Evaporator Refrigerant Pressure
XXX.X
PSIA/kPa
Evaporator Saturated Rfgt Temp
X.X
°F / °C
Evaporator Refrigerant Liquid Level
X.XX
in/mm
Figure 32. Report condenser screen
Table 25. Report compressor screen items
Table 24. Report condenser screen items
Description
Resolution
Condenser Entering Water
Temperature
X.X
Units
Compressor Running Status
On,Off
Text
Average Motor Current %RLA
XX.X%
%RLA
Compressor Starts
XX
Text
Compressor Running Time
XX:XX
Hr:Min
Oil Loss Level Sensor
Wet, Dry
Text
Discharge Temperature
X.X
°F / °C
Discharge Temperature
X.X
°F / °C
Compressor Oil Pressure
XXX.X
PSIA/kPaA
Evaporator Refrigerant Pressure
XXX.X
PSIA/kPaA
Condenser Refrigerant Pressure
XXX.X
PSIA/kPaA
Differential Refrigerant Pressure
XXX.X
PSIA/kPaA
Frequency Command
XX.X
Hz
Figure 34. Report motor screen
F/C
F/C
Condenser Water Flow Status
Flow, No Flow
Text
Condenser Water Pump Override
Auto, On
Text
X.X
F/C
EXV Position Percent
X.X
%
Condenser Refrigerant Pressure
XXX.X
PSIA/kPa
Condenser Saturated Rfgt Temp
X.X
F/C
Differential Refrigerant Pressure
XXX.X
PSIA/kPa
Outdoor Air Temperature
X.X
F/C
58
Resolution
Units
Condenser Leaving Water Temperature X.X
Condenser Approach Temperature
Description
RTHD-SVX01E-EN
Controls
Viewing and Changing Equipment Settings
Table 26. Report motor screen items
Description
Resolution
Units
Active Current Limit Setpoint
X.X
%RLA
Average Motor Current %RLA
X.X
%RLA
Starter Motor Current L1 %RLA
X.X
%RLA
Starter Motor Current L2 %RLA
X.X
%RLA
Starter Motor Current L3 %RLA
X.X
%RLA
Starter Motor Current L1
X.X
A
Starter Motor Current L1
X.X
A
Starter Motor Current L1
X.X
A
Starter Input Voltage AB
XXX.X
V
Starter Input Voltage BC
XXX.X
V
Starter Input Voltage CA
XXX.X
V
Average Motor Current
X.X
A
Average Phase Voltage
XXX.X
V
Frequency Command
XX.X
Hz
Each button in the Equipment Settings column on the
Settings screen takes you to a menu screen that contains
a group of buttons. Each button displays the name of a
setting and its current value (Figure 36). Touch any button
to view a screen where you can change the setting for the
feature shown on the button.
Note: A page number appears in the lower right corner of
the screen. If a screen contains more than one
page, up/down arrows also appear for viewing the
other pages, as in Figure 36.
Figure 36. Equipment setting screen
(Chiller setting shown)
Equipment Settings
You can use the TD7 display to monitor and change a
variety of equipment settings.
Viewing the Settings Screen
Touch the Settings button in the main menu area (see
Figure 26, p. 54) to view the Settings screen. Equipment
Settings identifies a column of buttons located on the
screen (see the outlined column in Figure 35). The buttons
are:
•
Chiller Settings
•
Feature Settings
•
Chiller Water Reset
•
Manual Control Settings
Each of these buttons provide access to a screen that
contains additional buttons related to each topic. This
section provides detailed information about these
screens.
Figure 35. Setting screen
To change an equipment setting, follow this procedure:
1. Touch one of the button in the Equipment Settings
column on the Settings screen, such as Chiller Settings.
The corresponding screen appears (in this case, the
Chiller Settings screen).
2. Touch the button that shows the equipment setting you
want to change. A screen that allows you to change the
equipment setting appears. There are two types of
these screens:
a. For screens with button selections (Figure 37),
touch the button that represents the setting you
want. The button becomes shaded, and a Save
button appears at the bottom of the screen.
b. For screens with numerical keypads (Figure 38),
touch the appropriate numbers to change the
current value. The new value appears above the
keypad.
3. Touch Save to complete the change. The current value
is updated in the upper left side of the screen,
demonstrating that the change has been
communicated to the Tracer UC800 controller. The
screen you were previously viewing appears.
RTHD-SVX01E-EN
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Controls
Figure 37.
Chilled water setpoint screen
Table 27.
Settings screen items
Description
Resolution
Units
± XXX.X
°F / °C
Chiller Settings
Active Chilled Water Setpoint
Figure 38. Changed chilled water setpoint screen
Active Current Limit Setpoint
XXX %
%RLA
Active Panel Base Load Cmd
On/Auto
Text
Active Base Loading Setpoint
XXX
%
Active Base Loading Command
On/Auto
Text
Differential to Start
XXX.X
°F / °C
Differential to Stop
XXX.X
°F / °C
Setpoint Source
BAS/Ext/FP
(BAS/Ext/FP, Ext/Front Panel, Front Panel)
Text
Evaporator Water Pump Off Delay
XX
Min
Condenser Pump Prestart Time
XX
Min
High Evap Water Temp Cutout
XXX.X
°F / °C
Evaporator Leaving Water Temp Cutout
XX.X
°F / °C
Low Refrigerant Temperature Cutout
XX.X
°F / °C
Current Limit Softload Start Point
XXX.X
%
Current Limit Control Softload Time
XXXX
Sec
Capacity Control Softload Time
XXXX
Sec
Local Atmospheric Pressure
XXX.X
psi/kPa
Power Up Start Delay
XXX
Min
Feature Settings
Keypad features:
•
When you enter a new number, the value in the New
value field is deleted and replaced with the new entry.
•
The backspace (arrow) key deletes the characters you
previously entered.
•
If the keypad is used to enter a setpoint that is out of
range, an error dialog will appear when you touch the
Save button.
•
Keypads that allow negative numbers have positive
and negative number (+/-) keys.
External Chilled/Hot Water Setpoint
(Enable/Disable)
Text
External Current Limit Setpoint
(Enable/Disable)
Text
LCI-C Diagnostic Encoding (Enable/Disable)
Text
Chilled Water Reset
(Constant, Outdoor, Return, Disable),
Disable
Text
Return Reset Ratio
XXX
%
Return Start Reset
XXX.X
°F / °C
Return Maximum Reset
XXX.X
°F / °C
Outdoor Reset Ratio
XXX
%
Outdoor Start Reset
XXX.X
°F / °C
Outdoor Maximum Reset
XXX.X
°F / °C
Mode Overrides
Evap Water Pump (Auto, On)
Auto
Text
Cond Water Pump (Auto, On)
Auto
Text
Display Reference
Date Format
(mmm dd, yyyy, dd-mmm-yyyy)
mmm dd, yyyy Text
Data Separator
12-hour
Text
Unit System (SI, English)
English
Text
Pressure Units (Absolute, Gauge)
Absolute
Text
Number Format
60
Text
Time Format (12-hour, 24-hour)
Text
RTHD-SVX01E-EN
Controls
Display Settings
You can use the Tracer AdaptiView display to change the
format of the information that appears on the display, and
to clean the touch screen.
Figure 40. Date format page
Viewing the Settings Screen
Touch the Settings button in the main menu area
(Figure 26, p. 54) to view the Settings screen. Display
Settings identifies a column of buttons located on the
screen (see Figure 39). The buttons are:
•
Display Preferences
•
Language
•
Date and Time
•
Clean Display
Each button provide access to a screen that is related to the
button name.
To change the format:
Viewing and Changing Display Preferences
2. Touch Save to confirm your selection and to return to
the Display Preferences screen.
1. Touch the button that shows that format you prefer.
On the Settings screen, touch Display Preferences to view
a screen containing these buttons (see Figure 29):
Date Format . Use the Date Format screen to choose
•
Date Format
from the following date formats:
•
Date Separator
•
•
Time Format
•
YYYYMMDD
•
Unit System
•
DDMMYYYY
•
Pressure Units
•
Number Format
Date Separator . Use the Date Separator screen to
choose from the following date formats:
Figure 39. Display reference screen
MMDDYYYY (default)
•
None
•
Slash (default)
•
Hyphen
Time Format . Use the Time Format screen to choose
from the following time formats:
•
12 hour (default)
•
24 hour
Units System . Use the Display Units screen to choose
from the following display units:
•
SI
•
Inch-Pounds (default)
Pressure Units . Use the Pressure Units screen to
choose from the following pressure units:
Each of the buttons shows the name of a display
preference and its format (current value). Touch any of
these buttons to view a screen where you can change the
format. The button representing the format currently used
is shaded (see the “MMDDYYYY” button).
•
kPaA (default if “SI” is chosen for display units)
•
kPaG
•
PSIA (default if “Inch-Pound” is chosen for display
units)
•
PSIG
Number Format .
RTHD-SVX01E-EN
•
1000000.0
•
1000000,0
61
Controls
To change the date or time:
Figure 41.
Language page
1. Touch the square presenting the attribute you want to
change. The square becomes highlighted.
2. Touch the up or down arrow key on the screen until the
your desired selection appears. Repeat the process for
any other attributes you want to change.
3. Touch Save to confirm your selection and return to the
Settings screen.
Cleaning the Display
The language that is currently in use on the display is
expressed as the current value on the Language screen.
The button that displays the current value is shaded (see
the “English” buttoninFigure19as an example).
On the Settings screen, touch Clean Display to disable the
Tracer AdaptiView display screen for 15 seconds so that
you can clean the screen without it responding to touch.
During this time, the screen is black with a number in the
center that counts down the seconds. After 15 seconds, the
Settings screen re-appears.
Figure 43. Countdown screen
To change the language:
1. Touch the button that identifies the language you
prefer.
2. Touch Save to confirm your selection and to return to
the Settings screen.
Figure 42. Date and time screen
Security Settings
If security if enabled, the Tracer AdaptiView display
requires that you log in with a four-digit security PIN to
make setting changes that are protected by security. This
feature prevents unauthorized personnel from doing so.
There are two levels of security, each allowing specific
changes to be made.
The current date and time for the display is expressed as
the current value. The current value appears below the
center line on the screen.
Above the center line, the following date and time
attributes appear:
You can view all data without logging in. The log-in screen
appears only when you try to change a setting that is
protected by security, or when you touch the Log in button
from the Settings screen.
Disabling/Enabling Security
The Tracer AdaptiView display gives you the ability to
disable or enable the security feature that allows a user to
log in and log out.
•
Month
•
Day
•
Year
•
Hour
1. From the Settings screen, touch the Security button.
The Security screen appears (Figure 44).
•
Minute
Note: If you are logged out, the Log in screen appears.
•
AM/PM
2. Touch the Disable button. The button becomes shaded.
62
To disable security, you must be logged in:
RTHD-SVX01E-EN
Controls
3. Touch Save. The Settings screen appears with only the
Security button visible. The Log in/Logout button is
gone.
2. Use the keypad to enter your PIN.
To enable security:
a. The PIN is a four-digit number, which was
configured for your system with the Tracer TU
service tool.
1. From the Settings screen, touch the Security button.
The Security screen appears (Figure 44).
b. As you enter the number, the PIN remains hidden
by asterisks.
2. Touch the Enable button. The button becomes shaded.
3. Touch Save. The Settings screen appears with a Log
out button, in addition to the Security button.
Figure 44. Security screen - disable
Note: If you enter an invalid PIN, an error message
appears on the Log in screen.
3. Touch Save.
a. If you viewed the Log in screen from touching Log
in on the Settings screen, the Settings screen
appears with a Log out button on it.
b. If the Log in screen appeared when you tried to
change a setting, you return to that setting screen.
Note: The PIN is valid until 30 minutes of inactivity
passes, or until you log out.
Figure 46. Log in screen
Figure 45. Security settings screen
Logging Out
To log out:
1. Touch the Log out button. A confirmation screen
appears (Figure 47).
Logging In
There are two levels of security:
•
Security Level 1 allows users to change a limited group
of secure settings. The default security PIN is 1111.
•
Security Level 2 allows users to change all secure
settings. The default security PIN is 7123.
2. Touch Yes to confirm that you want to log out. The
Settings screen appears with a Log in button on it.
Figure 47.
Log out confirmation screen
A technician must use the Tracer TU service tool to define
a different PIN, or to recall a PIN that has been forgotten.
When defining a PIN in Tracer TU, the technician enters a
4-digit PIN that corresponds with the desired level of
security.
To log in:
1. Touch the Log in button. The Log in screen appears
(Figure 45).
RTHD-SVX01E-EN
63
Controls
Tracer TU
Tracer™ TU (non-Trane personnel, contact your local
Trane office for software) adds a level of sophistication that
improves service technician effectiveness and minimizes
chiller downtime.TheTracer AdaptiView™ control’s
operator interface is intended to serve only typical daily
tasks. The portable PC-based service-tool software, Tracer
TU, supports service and maintenance tasks. Tracer TU
serves as a common interface to all Trane® chillers, and
will customize itself based on the properties of the chiller
with which it is communicating.Thus, the service
technician learns only one service interface. The panel bus
is easy to troubleshoot using LED sensor verification. Only
the defective device is replaced.Tracer TU can
communicate with individual devices or groups of
devices. All chiller status, machine configuration settings,
customizable limits, and up to 100 active or historic
diagnostics are displayed through the service-tool
software interface. LEDs and their respective Tracer TU
indicators visually confirm the availability of each
connected sensor, relay, and actuator. Tracer TU is
designed to run on a customer’s laptop, connected to the
Tracer AdaptiView control panel with a USB cable.Your
laptop must meet the following hardware and software
requirements:
•
1 GB RAM (minimum)
•
1024 x 768 screen resolution
•
CD-ROM drive
•
Ethernet 10/100 LAN card
•
An available USB 2.0 port
•
Microsoft Windows XP Professional operation system
with Service Pack 3 (SP3) or Windows 7 Enterprise or
Professional operating system (32-bit or 64- bit4.0 or
later.
Note: Tracer TU is designed and validated for this
minimum laptop configuration.Any variation from
this configuration may have different results.
Therefore, support for Tracer TU is limited to only
those laptops with the configuration previously
specified.
Figure 48. Tracer TU
64
RTHD-SVX01E-EN
Pre-Start
Upon completion of installation, complete the Optimus™
RTHD Installation Completion Check Sheet and Request
for Trane Service checklist in chapter “Log and Check
Sheet,” p. 94.
Important:
Start-up must be performed by Trane or an
agent of Trane specifically authorized to
perform start-up and warranty of Trane
products. Contractor shall provide Trane (or
an agent of Trane specifically authorized to
perform start-up) with notice of the
scheduled start-up at least two weeks prior
to the scheduled start-up.
RTHD-SVX01E-EN
65
Start-Up and Shutdown
Important:
Initial unit commissioning start-up must be
performed by Trane or an agent of Trane
specifically authorized to perform start-up
and warranty of Trane products. Contractor
shall provide Trane (or an agent of Trane
specifically authorized to perform start-up)
with notice of the scheduled start-up at least
two weeks prior to the scheduled start-up.
Unit Start-Up
NOTICE:
Equipment Damage!
Ensure that the compressor and oil sump heaters have
been operating properly for a minimum of 24 hours
before starting. Failure to do so could result in
equipment damage.
3. The unit will start normally, provided the following
conditions exist:
a. The UC800 receives a call for cooling and the
differential-to-start is above the setpoint.
b. All system operating interlocks and safety circuits
are satisfied.
Extended Unit Shutdown
4. Perform the normal unit stop sequence using the
<Stop> key.
Note: Do not open starter disconnect switch. This must
remain closed to provide control power from the
control power transformer to the oil sump heater.
5. Verify chilled water and condenser water pumps are
cycled off. If desired, open disconnect switches to the
pumps.
If required, once the system has been operating for
approximately 30 minutes and has become stabilized,
complete the remaining start-up procedures, as follows:
6. Drain condenser piping and cooling tower, if desired.
1. Check evaporator and condenser refrigerant pressures
under Refrigerant Report on the AdaptiView ™TD7. The
pressures are referenced to sea level (14.6960 psia).
8. Verify that the Crank Case heater is working.
2. Check EXV sight glasses after sufficient time has
elapsed to stabilize the chiller. The refrigerant flow past
sight glasses should be clear. Bubbles in the
refrigerant indicate either low refrigerant charge or
excessive pressure drop in the liquid line or a stuck
open expansion valve. A restriction in the line can
sometimes be identified by a noticeable temperature
differential between the two sides of the restriction.
Frost will often form on the line at this point. See
“General Information,” p. 9 for proper refrigerant
charges.
Important:
A clear sight glass alone does not mean that
the system is properly charged. Also check
system subcooling, liquid level control and
unit operating pressures.
If chiller is limited by any limiting conditions, contact local
Trane service organization for more information.
Temporary Shutdown And
Restart
To shut down for a short time, use the following procedure:
1. Press the STOP key on the Adaptiview TD7. The
compressors will continue to operate and an
operational pumpdown cycle will be initiated..
2. UC800 pump control will turn off the pump (after a
minimum 1 min. delay) when the STOP key is pressed
and automatically restart the pump when the unit
starts normally.
66
7.
Remove the drain and vent plugs from the condenser
headers to drain the condenser.
9. Once the unit is secured, perform the maintenance
identified in the following sections.
Seasonal Unit Start-Up Procedure
1. Close all valves and re-install the drain plugs in the
evaporator and condenser heads.
2. Service the auxiliary equipment according to the startup/maintenance instructions provided by the
respective equipment manufacturers.
3. Vent and fill the cooling tower, if used, as well as the
condenser and piping. At this point, all air must be
removed from the system (including each pass). Close
the vents in the evaporator chilled water circuits.
4. Open all valves in the evaporator chilled water circuits.
5. If the evaporator was previously drained, vent and fill
the evaporator and chilled water circuit. When all air is
removed from the system (including each pass), install
the vent plugs in the evaporator water boxes.
NOTICE:
Equipment Damage!
Ensure that the oil sump heaters have been operating
for a minimum of 24 hours before starting. Failure to do
so may result in equipment damage.
6. Check the adjustment and operation of each safety and
operating control.
7.
Close all disconnect switches.
8. Refer to the sequence for daily unit startup for the
remainder of the seasonal startup
RTHD-SVX01E-EN
Start-Up and Shutdown
Sequence of Operation
This section will provide basic information on chiller
operation for common events. With microelectronic
controls, ladder diagrams cannot show today’s complex
logic, as the control functions are much more involved
than older pneumatic or solid state controls.
•
The text in the circles is the visible top level operating
modes that are displayed on Tracer™ AdaptiView.
•
The shading of each software state circle corresponds
to the shading on the time lines that show the state the
chiller is in.
Adaptive control algorithms can also complicate the exact
sequence of operations. This section illustrates common
control sequences.
There are five generic states that the software can be in:
Software Operation Overview
The Software Operation Overview shown in Figure 49 is a
diagram of the five possible software states. This diagram
can be though of as a state chart, with the arrows and
arrow text depicting the transitions between states.
•
Power Up
•
Stopped
•
Starting
•
Running
•
Stopping
•
Figure 49. Software operation overview
RTHD Sequence Of
Operation Overview:
Power
Up
Stopped
Stopped
Run Inhibit
ed
rm
nfi own
o
C utd
Sh
Co Sta r
mm t
and
Auto
Stopping
Auto
Waiting to Start
Starting Compressor
Fast Restart or Satisfied Setpoint
Preparing to Shut Down
Shutting Down
Stop Command or Diagnostic
Sto
pC
om
Dia
gn
os
tic
ma
nd
St
ed
firm
n
Co
Running
art
Running
Running - Limit
Timelines
•
The time line indicates the upper level operating mode,
as it would be viewed on the Tracer™ AdaptiView.
•
•
•
•
The shading color of the cylinder indicates the
software state.
Boxes indicate control actions such as turning on
relays, or pulsing compressor load or unload
solenoids.
•
Text in parentheses indicates sub-mode text as viewed
on Tracer AdaptiView.
Smaller cylinders under the main cylinder indicate
diagnostic checks.
•
Text outside a box or cylinder indicates time based
functions.
•
Solid double arrows indicate fixed timers.
Text above the time line cylinder is used to illustrate
inputs to the Main Processor. This may include user
input to the Tracer AdaptiView Touch screen, control
inputs from sensors, or control inputs from a Generic
BAS.
RTHD-SVX01E-EN
Dashed double arrows indicate variable timers.
67
Start-Up and Shutdown
Power Up
The Power up chart shows the respective TD7 screens
during a power up of the main processor. This process
takes from 30 to 50 seconds depending on the number of
installed Options. On all power ups, the software model
will always transition through the ‘Stopped’ Software
state independent of the last mode. If the last mode before
power down was ‘Auto’, the transition from ‘Stopped’ to
‘Starting’ occurs, but it is not apparent to the user.
Figure 50. Sequence of events: power up diagram
q
p
Operator Display Power Up
Second Trane Logo - Loading
User Interface Template...
Display Ready
Black Screen
Grey Screen
First Trane Logo
Black Screen
10 Sec
Loading Data….
*Display will show
either Auto or Stop
button as “ ac tive”
(depressed) once
it is ready
6/30/2012
18 Seconds
5 Secc 90 second2
27
7oSeconds
SDeicpolnydrseady
15 Sec
15 Seconds
90 seconds to Disp
pllay read
dy
7
0102sec Total to Display Ready
11/16// 2012
1122/11/2012
U14p/ 2and
a0n1d2 Load
o/a1d6/-290
9
y
Operator Display Boot6t /Up
M ileston
ne Descrription
M estoneMDielesscription
Mile
sctroipnteioDnescription
(39 Seconds)
Minimum Time Until 1st Compressor Could Restart
(if “P ower Up Delay Inhibit” s et to 0; Default is 105 sec))
6/14/2012 - 12/10/2012
Starting Sequence
S ee “ P ower Up to
S tarting” S equenc e Diagram
6/12/2012 - 12/11/2012
External
Power
Applied
UC800 Boot Up
Last Mode
Auto*
Booting UC800
(25 Seconds)
6i/s1p6l/a2y01a
2n UC800
Operator D
Display
and
Figure 1 [A
dtaarpttiBooting
S
Bvoieow
tinBgoot Screen]
Start
6/14/2012 7/16/2012
M ilestone
e DM
Milesto
M
esicleispttoin
oen Description
IF
Last Mode
Stop*
6/12/2012 - 12/9/2012
Stopped
12/11//2012
UC800 Fully Operational
IPC Bus Comm Begins
Figure 51.
12/11/2012
Milesttone Description
Remain in
“ S top” indefinitely
until “ A uto”
command- See
“ S topped T o S tarting”
Sequence of events: TD7 screen displays
Operator Display Boot Screen
68
Continue Along Start
Sequence
S ee “ P ower Up
to S tarting”
Display Loading Data
Home Screen, Auto Mode
RTHD-SVX01E-EN
Start-Up and Shutdown
Power Up to Starting
The Power up to starting diagram shows the timing from
a power up event to energizing the compressor. The
shortest allowable time would be under the following
conditions:
•
Power up Start Delay setpoint set to 0 minutes
•
Adjustable Stop to Start Timer set to 5 seconds
•
Need to cool
•
No motor restart inhibit
•
Evaporator and Condenser Water flowing
The above conditions would allow for a minimum power
up to starting compressor time of 95 seconds.
Figure 52. Sequence of events: power up to starting
Last Mode
Was Auto
Power
Applied
Power
Up
UC800
Boot Time
(22 to 32 Sec)
Call for
Cooling
Waiting to
Start
Auto
Confirm Evaporator
Water Flow
(6 Second Filter)
Enforce Restart
Inhibit Timer
(0 to 30 mins)
Waiting
to Start
Confirm Condenser
Water Flow
Enforce Power Up Enforce 'Cond Pmp (6 Second Filter)
Strt Delay'
Start Delay Timer
(0 to 300 Sec)
(0 to 30 mins)
Energize Evaporator
Water Pump Relay
Confirm Evaporator Water
Flow Within 20 minutes
(6 Sec Filter)
Waiting
to Start
Waiting to
Start
Waiting
to Start
Condenser
Water Pump
Pre-Run
Enforce 'Cprsr
Strt Delay'
Confirm Presence of
Oil With Optical Oil
Sensor
(0 to 30 mins)
(0 to 300 Sec)
(0 to 2 mins)
Energize Condenser
Water Pump Relay
Confirm Condenser Water
Flow Within 20 minutes
(6 Sec Filter)
Starting
Compressor
Energize Unload
Solenoid
Pre-Position EXV
Oil Heater always energized
when compressor is de-energized
Overdrive EXV Open
RTHD-SVX01E-EN
69
Start-Up and Shutdown
Stopped to Starting
The stopped to starting diagram shows the timing from a
stopped mode to energizing the compressor. The shortest
allowable time would be under the following conditions:
•
No motor restart inhibit
•
Evaporator and Condenser Water flowing
•
Power up Start Delay Timer has expired
•
Adjustable Stop to Start Timer has expired
•
Need to cool
The above conditions would allow the compressor to start
in 60 seconds.
Figure 53. Sequence of events: stopped to starting
Chiller Mode
Set to Auto
Stopped
Or
Run
Inhibit
Call for
Cooling
Auto
Waiting
to Start
Confirm Evaporator
Water Flow
(6 Second Filter)
Enforce Restart
Inhibit Timer
(0 to 30 mins)
Waiting
to Start
Confirm Condenser
Water Flow
(6 Second Filter)
Enforce 'Cond
Pmp Strt Delay'
(0 to 300 Sec)
Energize Evaporator
Water Pump Relay
Waiting
to Start
Waiting
to Start
Condense r
Water Pump
Pre-Run
Enforce 'Cprsr
Strt Delay'
(0 to 300 Sec)
Starting
Compressor
Waiting
to Start
Confirm Presence of Oil
With Optical Oil Sensor
(0 to 2 mins)
(0 to 30 mins)
Energize Condenser
Water Pump Relay
Confirm Evaporator Water
Flow Within 20 minutes
(6 Sec Filter)
Energize Unload
Solenoid
Confirm Condenser Water
Flow Within 20 minutes
(6 Sec Filter)
Pre-Position EX V
Oil Heater always ene rgized
when compressor is d e energized
Starting Wye-Delta
The Starting Wye-Delta shows the order of operation for this type of starter.
Figure 54. Sequence of events: Starting wye-delta
Energize Stop and Start
Relays
Confirm No Transition Complete Signal
(Transition Complete Input Shorted)
Confirm Proper Compressor Rotation
within 0.3 seconds (Phase Reversal)
and > 5% RLA (Phase Loss)
Confirm > 10% RLA Compressor
Currents within 1.6 se conds
(Starter Fault Type III )
Energize Start and
Stop Relays
When Currents Drop Below 85% RLA + 1 . 5
Seconds, Energize Transition Relay
Confirm No Compressor Currents
(Starter Fault Type I )
De-Energize Shorting
Relay
De-Energize Start and
Stop Relays
Confirm Transition Complete
Input within 2.5 seconds
(Starter Did Not Transition)
Energize Run
Contactor
Energize and Hold
Shorting Relay
De-Energize Transition
Relay
Confirm No Compressor Currents
(Starter Fault Type II )
Starting Compressor
Starter Contactor Integrity Test
Arm/Run Command to Starter Module
70
Starting
Compressor
Starting Compressor
in Wye
Starting Compressor
Compressor
Running
Transition Starter to Delta
Max Accel Timer
(6 to 64 Seconds)
RTHD-SVX01E-EN
Start-Up and Shutdown
Starting AFD
The Starting AFD shows the order of operation for this type of starter.
Figure 55. Sequence of events: Starting AFD
Confirm At Speed Input within
Maximum Acceleration Timer
(Default 7 seconds)
Check for At Speed Input Opened
Energize Stop and Start
Relays
Confirm Individual Phase
Currents are > 10% RLA
within 2.6 seconds
Accelerating
Compressor
(6 to 64 Seconds (Default 7 sec))
(1 Second)
Waiting
To Start
Starting Compressor
Running
Running
Run Command to Starter Module
Running
The Running Diagram shows a typical running sequence.
Figure 56. Sequence of events: running
Starter
Status is
‘Running’
'
Starting
Compressor
Running
Enter
Limit Mode
Running
Running - Limit
Exit
Limit Mode
Running
Running
Run Unload
(15 Seconds)
Hold EXV Pre-position
(6 Seconds)
Energize Unload Solenoid
for 15 Seconds
Modulate Motor
Frequency and Slide Valve
for Capacity Control
Modulate EXV for
Liquid Level Control
Modulate Motor
Frequencye and Slide
Valve for Limit Control
Modulate EXV for
Limit Control
Modulate Motor
Frequency and Slide Valve
for Capacity Control
Modulate EXV for
Liquid Level Control
Hold EXV at Prepostion for
6 Seconds
Enforce All Running Mode Diagnostics
RTHD-SVX01E-EN
71
Start-Up and Shutdown
Satisfied Setpoint
The Satisfied Setpoint diagram shows the normal transition from Running to shutting down due to the Evap Leaving water
temp falling below the differential to stop setpoint.
Figure 57.
Sequence of events: satisfied setpoint
Satisfied Setpoint
Running
Preparing to Shutdown
Shutting Down
Energize Unload Solenoid
(40 Seconds)
Open EXV
(0-20 Seconds)
Energize Unload
Solenoid
Open EXV
Shutting Down
Auto
Close EX V
(20 Seconds)
Close EX V
De-Energize Condenser
Water Pump Relay
Pre-Position EX V
to 38% Open for
Next Start
De-Energize Master Oil
Line Solenoid Valve
Continue to Energize Unload
Solenoid for 60 Mins
Energize Oil Heater
De-Energize
Compressor
Enforce All Running Mode Diagnostics
72
Confirm No Compressor Currents
Within 0 - 30 Seconds
RTHD-SVX01E-EN
Start-Up and Shutdown
Normal Shutdown to Stopped or Run Inhibit
The Normal Shutdown diagram shows the Transition from Running through a Normal (friendly) Shutdown. The Dashed
lines on the top attempt to show the final mode if you enter the stop via various inputs.
Figure 58. Sequence of events: normal shutdown to stopped or run inhibit
EXV Closed and Evap Pump Off Delay Complete
Local Stop
Normal Latching Diagnostic
Normal Non-Latching Diagnostic
Tracer Stop
External Auto-Stop
Running
Preparing
to Shutdown
Energize Unload Solenoid
(40 Seconds)
Energize Unload
Solenoid
Stopped
Run Inhibit
Shutting Down
Open EXV
(0 to 20 Seconds)
De-Energize
Compressor
Shutting Down
Stopped
or
Run Inhibit
Close EX V
(20 Seconds)
Close EX V
Open EXV
De-Energize Condenser
Water Pump Relay
De-Energize Master Oil
Line Solenoid Valve
Energize Unload
Solenoid for 60 mins
Energize Oil Heater
Evap Pump Off Delay Time
(0-30 Minutes)
RTHD-SVX01E-EN
De-Energize Evaporator
Water Pump Relay
73
Start-Up and Shutdown
Immediate Shutdown to Stopped or Run Inhibit
The Immediate Shutdown diagram shows the Transition from Running through an Immediate Shutdown. The Dashed
lines on the top attempt to show the final mode if you enter the stop via various inputs.
Figure 59. Sequence of events: immediate shutdown to stopped or run inhibit
RTHD Sequence of Operation:
Immediate Shutdown to Stopped or Run Inhibit
EXV Closed and Evap
Pump Off Delay Complete
Run Inhibit
Immediate Shutdown Non-Latching Diagnostic
Immediate Shutdown Latching Diagnostic
Front Panel Immediate Shutdown
Running
Shutting Down
Shutting Down
Open EXV (0-20 Seconds)
De-Energize
Condenser Water Pump
Stopped
Shutting Down
Run Inhibit
or
Stopped
Close EXV (20 Seconds)
Close EX V
Energize Unload
Solenoid for 60 mins
De-Energize Evaporator
Water Pump Relay
Evap Pump Off Delay Time (0-30 Minutes)
Open EXV
De-Energize Master Oil
Line Solenoid Valve
Energize Oil Heater
De-Energize
Compressor
Confirm No Compressor Currents
8 Seconds after compressor is de-energiz e d
Momentary Power Loss
The Momentary Power Loss diagram shows how the controls act in a power interruption event that the controls diagnose
as a MPL diagnostic.
Figure 60. Sequence of events: momentary power loss
Momentary Power Loss Detected
Running
Shutting Down
Energize Oil Heater
Energize Unload Solenoid
(40 Seconds)
MPL Cleared and Need to Cool
Waiting to Start
Starting
Cprsr
Establish Cond Water Flow (6 sec Minimu m )
Energize Condenser
Water Pump Relay
Energize Unload
Solenoid
Enforce Power Up Start Delay
(0 to 30 mins)
De-Energize
Compressor
Enforce Restart Inhibit Time r
(0 to 30 mins)
Confirm Condenser Water Flow
Within 20 minutes
(6 Sec Filter)
Enforce Stop to Start Timer
(5 to 200 Seconds)
(30 Second Default)
Confirm No
Compressor Currents
Within 0-30 Seconds
De-Energize Condenser
Water Pump Relay
74
RTHD-SVX01E-EN
Start-Up and Shutdown
Ice Making (Running to Ice Making to Running)
This diagram show the transition from normal cooling to Ice making, back to normal cooling
Figure 61.
Sequence of events: ice making (running to ice making to running)
Ice Making Command:
1. Tracer
2. External
3. Front Panel
Running
Evap Leaving
Water Temp Rises
Above the
Differentail To Stop
Ice Making
Command
Withdrawn
Running
(Ice to Normal Transition)
Running
(Unit is Building Ice)
Running
Running
Ice To Normal Transition Timer
( 0 to 10 Mins)
Open Slide Valve at
Maximum Rate
Close Slide Valve
Ignore Softloading and
Set CLS = 100%
De-Energize Head
Relief Request Relay
Energize Ice Building
Relay
De-Energize Head
Relief Request Relay
Modulate Slide Valve
for LWT Control
Energize Head Relief
Request Relay
Head Relief Request Re lay
Delay ( 1 to 60 Mins)
Enforce All Limits and Running Mode Diagnostics
Ice Making (Auto to Ice Making to Ice Making Complete)
This diagram shows the transition from Auto to Ice making, to Ice Making Complete
Figure 62. Sequence of events: ice making (auto to ice making to ice making complete)
Ice Making Command:
1. Front Panel
2. Tracer
3. External Input
Auto
Starting
Cprsr
Running
(Unit is Building Ice)
Evap Entering Water
Temp Falls Below the
Ice Termination Setpoint
Shutting Down
Close Slide Valve
(40 Seconds)
Shutting
Down
Open EXV
(0 to 20 Sec)
Shutting
Down
Close EX V
(20 Sec)
Open Slide Valve at
Maximum Rate
Close Slide Valve
Ignore Softloading and
Set CLS = 100%
De-Energize Ice
Building Relay
De-Energize Master Oil
Line Solenoid Valve
Energize Ice Building
Relay
De-Energize Head
Relief Request Relay
Energize Oil Heater
Head Relief Request Re lay
Delay (1 to 60 Mins)
Energize Head Relief
Request Relay
Run Inhibit
(Ice
Building
Complete)
De-Energize Condenser
Water Pump Relay
Open EXV then
Close EX V
De-Energize
Compressor
Enforce All Limits and Running Mode Diagnostics
RTHD-SVX01E-EN
Confirm No Compressor Currents
Within 8 Seconds
75
Start-Up and Shutdown
No Load Start
This diagram shows a pre-start sequence with the Start Sequence Type set to 'No Load'.
Figure 63. Sequence of events: no load start
Removal of all of the following:
External Stop
Local Stop
Tracer/BAS Stop
Stopped
Or
Run
Inhibit
Evap Leaving Water
Temp Above the Diff to
Stop
Auto
Waiting
to Start
Confirm Evaporator
Water Flow
(6 Second Filter)
Enforce Restart
Inhibit Timer
(0 to 30 mins)
Enforce 'Cond
Pmp Strt Delay'
(0 to 300 Sec)
Energize Evaporator
Water Pump Relay
Confirm Evaporator Water
Flow Within 20 minutes
seconds (6 Sec Filter)
Waiting
to Start
Confirm Condenser
Water Flow
(6 Second Filter)
Waiting
to Start
Waiting
to Start
Condenser
Water Pump
Pre-Run
Enforce 'Cprsr
Strt Delay'
(0 to 300 Sec)
Waiting
to Start
Starting
Compressor
Confirm Presence of Oil
With Optical Oil Sensor
(0 to 2 mins)
(0 to 30 mins)
Energize Condenser
Water Pump Relay
Confirm Condenser Water
Flow Within 20 minutes
(6 Sec Filter)
Energize Unload
Solenoid
Pre-Position EXV
Oil Heater always energized
when compressor is deenergized
Limit Conditions
UC800 will automatically limit certain operating parameters during startup and run modes to maintain optimum chiller
performance and prevent nuisance diagnostic trips. These limit conditions are noted in Table 28.
Table 28. Limit conditions
Condition
Description
Running- limited
The chiller, circuit, and compressor are currently running, but the operation of the chiller/compressor is being actively
limited by the controls. Further information is provided by the sub-mode.
Condenser Pressure
The circuit is experiencing condenser pressures at or near the condenser limit setting. The compressor will be unloaded
Limit
to prevent exceeding the limits.
Low Evaporator
The circuit is experiencing saturated evaporator temperatures at or near the Low Refrigerant Temperature Cutout setting.
Refrigerant
The compressors will be unloaded to prevent tripping.
Temperature Inhibit
Capacity Limited by
The circuit is experiencing low refrigerant liquid levels and the EXV is at or near full open. The compressor will be unloaded
Low
to prevent tripping.
Liquid Level
Current Limit
The compressor is running and its capacity is being limited by high currents. The current limit setting is 100% RLA (to
avoid overcurrent trips).
Phase Unbalance
Limit
The compressor is running and its capacity is being limited by excessive phase current unbalance.
76
RTHD-SVX01E-EN
Maintenance
WARNING
Hazardous Voltage w/Capacitors!
Disconnect all electric power, including remote
disconnects and discharge all motor start/run
capacitors before servicing. Follow proper lockout/
tagout procedures to ensure the power cannot be
inadvertently energized. Verify with an appropriate
voltmeter that all capacitors have discharged. Failure to
disconnect power and discharge capacitors before
servicing could result in death or serious injury.
For additional information regarding the safe discharge
of capacitors, see PROD-SVB06A-EN
This section describes the basic chiller preventive
maintenance procedures, and recommends the intervals
at which these procedures should be performed. Use of a
periodic maintenance program is important to ensure the
best possible performance and efficiency from a Stealth™
chiller.
•
Measure and log the subcooling and superheat.
•
See “Refrigerant and Oil Charge Management,” p. 77.
If chiller measurements vary significantly from values
listed in Table 29 and Table 30, p. 78, problems may
exist with refrigerant and oil charge levels. Contact
local Trane service.
Annual
Shut down the chiller once each year to check the
following:
•
Perform all weekly and monthly maintenance
procedures.
•
Have a qualified laboratory perform an oil analysis to
determine system moisture content and acid level.
Important:
Due to the hygroscopic properties of the
POE oil, all oil must be stored in metal
containers. The oil will absorb water if
stored in a plastic container.
•
Contact Trane service to leak check the chiller, inspect
safety controls, and inspect electrical components for
deficiencies.
•
Inspect all piping components for leakage and/or
damage. Clean out any in-line strainers.
•
Clean and repaint any areas that show signs of
corrosion.
•
Inspect vent piping of all relief valves for presence of
refrigerant to detect improperly sealed relief valves.
Contact Trane service if unusual conditions are
observed.
•
Inspect the condenser tubes for fouling. Clean if
necessary. See “Cleaning the Condenser,” p. 78.
While the unit is running in stable conditions:
•
Check to make sure that the oil sump heater is working.
•
Log the chiller.
Scheduling Other Maintenance
•
Check evaporator and condenser pressures with
gauges and compare to the reading on the
AdaptiView™ TD7 or Tracer™ TU service too. Pressure
readings should fall within operating ranges specified
in Table 29 and Table 30, p. 78. If chiller measurements
vary significantly from values listed in Table 29 and
Table 30, p. 78, problems may exist with refrigerant
and oil charge levels. Contact local Trane service.
Use an Operator Log (see “Log and Check Sheet,” p. 94) to
record an operating history for unit. The log serves as a
valuable diagnostic tool for service personnel. By
observing trends in operating conditions, an operator can
anticipate and prevent problem situations before they
occur.
If unit does not operate properly during inspections, see
“Diagnostics,” p. 82.
Recommended Maintenance
Weekly
Note: Optimum condenser pressure is dependent on
condenser water temperature, and should
equal saturation pressure of refrigerant at a
temperature 2 to 5°F above that of leaving
condenser water at full load.
Monthly
•
Review operating log.
•
Clean all water strainers in both the chilled and
condensing water piping systems.
RTHD-SVX01E-EN
•
Use a nondestructive tube test to inspect the
condenser and evaporator tubes at 3-year intervals.
Note: It may be desirable to perform tube tests on these
components at more frequent intervals, depending
upon chiller application. This is especially true of
critical process equipment.
•
Depending on chiller duty, contact Trane service
organization to determine when to conduct a complete
examination of the unit to determine the condition of
the compressor and internal components.
Refrigerant and Oil Charge Management
Proper oil and refrigerant charge is essential for proper
unit operation, unit performance, and environmental
protection. Only trained and licensed service personnel
should service the chiller.
Table 29 and Table 30 list baseline measurements for
Optimus units running at AHRI standard operating
77
Maintenance
conditions. If chiller measurements vary significantly from
values listed below, problems may exist with refrigerant
and oil charge levels. Contact Trane service.
Table 29. Operating conditions at full load(a)
Description
Condition
Evaporator pressure
40-55 psig
Condensing pressure
85-120 psig
Discharge superheat
17oF
Subcooling
5-10oF
EXV percent open
40-50% open in Auto mode
(a) All conditions stated above are based on the unit running fully loaded
at AHRI conditions. If full load conditions cannot be met, contact Trane
service.
Mechanical Cleaning Procedure
Mechanical tube cleaning this method is used to remove
sludge and loose material from smooth-bore condenser
tubes.
WARNING
Heavy Objects!
Each of the individual cables (chains or slings) used to
lift the waterbox must be capable of supporting the
entire weight of the waterbox. The cables (chains or
slings) must be rated for overhead lifting applications
with an acceptable working load limit. Failure to
properly lift waterbox could result in death or serious
injury.
Table 30. Operating conditions at minimum load(a)
Description
Condition
Evaporator approach
*less than 7oF (non-glycol applications)
Condensing approach
*less than 7oF
Subcooling
2-3oF
EXV percent open
10-20 % open
*
≅1.0oF for new unit.
(a) Conditions at minimum must be: entering condenser water: 85°F and entering
evaporator water: 55°F
Maintenance Procedures
Cleaning the Condenser
NOTICE:
Proper Water Treatment!
The use of untreated or improperly treated water could
result in scaling, erosion, corrosion, algae or slime. It is
recommended that the services of a qualified water
treatment specialist be engaged to determine what
water treatment, if any, is required. Trane assumes no
responsibility for equipment failures which result from
untreated or improperly treated water, or saline or
brackish water.
Condenser tube fouling is suspect when the “approach”
temperature (i.e., the difference between the refrigerant
condensing temperature and the leaving condenser water
temperature) is higher than predicted.
Standard water applications will operate with less than a
10°F approach. If the approach exceeds 10°F, cleaning the
condenser tubes is recommended.
Note: Glycol in the water system typically doubles the
standard approach.
If the annual condenser tube inspection indicates that the
tubes are fouled, two cleaning methods can be used to rid
the tubes of contaminants.The methods are:
78
WARNING
Heavy Objects!
The proper use and ratings for eyebolts can be found in
ANSI/ASME standard B18.15. Maximum load rating for
eyebolts are based on a straight vertical lift in a
gradually increasing manner. Angular lifts will
significantly lower maximum loads and should be
avoided whenever possible. Loads should always be
applied to eyebolts in the plane of the eye, not at some
angle to this plane. Failure to properly lift waterbox
could result in death or serious injury.
Waterbox Removal. Review mechanical room
limitations and determine the safest method or methods
of rigging and lifting the waterboxes.
Important:
•
Do not rotate water boxes. See Figure 14, p. 32 through
Figure 16, p. 32 for correct orientation of the water inlet
and outlet.
•
Be certain to replace water boxes right-side-up to
maintain proper baffle orientation. Use new o-rings.
1. Determine the size of chiller being serviced. See unit
nameplate located on chiller control panel.
2. Select the proper lift connection device from Table 33,
p. 79. The rated lifting capacity of the selected lift
connection device must meet or exceed the published
weight of the waterbox found in Table 32, p. 79.
3. Ensure the lift connection device has the correct
connection for the waterbox. Example: thread type
(course/fine, English/metric). Bolt diameter (English/
metric).
4. Properly connect the lift connection device to the
waterbox. See Figure 64. Ensure lift connection device
is securely fastened.
5. Install hoist ring on to the lifting connection on the
waterbox. Torque to 28 ft-lbs (37 Nm).
RTHD-SVX01E-EN
Maintenance
Table 31. RTHD Torque
Figure 64. Waterbox lifting
#ABLES#HAINSOR3LINGS
Evaporator
Condenser
65 ft-lbs (88 Nm)
65 ft-lbs (88 Nm)
Table 32. Waterbox weights
#ONNECTION$EVICE
Waterbox Size(a)
7ATERBOX
Evaporator
6. Disconnect water pipes, if connected.
7.
8. Lift the waterbox away from the shell.
WARNING
Overhead Hazard!
Never stand below or in close proximity to heavy
objects while they are suspended from, or being lifted
by, a lifting device. Do not leave waterbox suspended
from lifting device. Failure to follow these instructions
could result in death or serious injuries.
9. Store waterbox in a safe and secure location and
position.
10. Work a round nylon or brass bristled brush (attached to
a rod) in and out of each of the condenser water tubes
to loosen the sludge.
11. Thoroughly flush the condenser water tubes with clean
water.
Note: To clean internally enhanced tubes, use a bidirectional brush or consult a qualified service
organization for recommendations.
Reassembly. Once service is complete the waterbox
should be reinstalled on the shell following all previous
procedures in reverse. Use new o-rings or gaskets on all
joints after thoroughly cleaning each joint.
•
Condenser
Remove waterbox bolts
Torque waterbox bolt in a star pattern. See Table 31 for
torque values.
RTHD-SVX01E-EN
Weight kg (lbs)
Number
of
Standard
Water Grooved Pipe Marine Style
Passes
Waterbox(b) Waterbox(c)
G
4
164 (361)
NA
G
3
208 (458)
NA
F
3
107 (235)
NA
F
2
107 (235)
NA
D/E
3
91 (201)
NA
D/E
2
110 (243)
NA
B/C
3
76 (167)
NA
B/C
2
91 (201)
NA
B/C
2
73 (160)
NA
G
2
102 (226)
297 (655)
E/F
2
66 (146)
239 (526)
B/D
2
53 (116)
187 (412)
(a) Evaporator size is Digit 14 in the model number. Condenser is Digit 21
in model number.
(b) Lifting connection size M12x1.75.
(c) Lifting connection is a lifting lug. Removable cover has a weight of 138
kg (300 lbs). Lifting lug connection is M12x1.75.
Table 33. Connection devices
Unit
Product
Part Number
RTHD
Safety Hoist Ring
M12x1.75
RNG01886
Obtain the required parts from your local Trane Parts
Center.
Chemical Cleaning Procedure
•
Scale deposits are best removed by chemical means.
Consult a qualified water treatment specialist (i.e., one
that knows the local water supply chemical/mineral
content) for a recommended cleaning solution suitable
for the job. (A standard condenser water circuit is
composed solely of copper, cast iron and steel.)
Improper chemical cleaning can damage tube walls.
All of the materials used in the external circulation system,
the quantity of the solution, the duration of the cleaning
period, and any required safety precautions should be
approved by the company furnishing the materials or
performing the cleaning.
Note: Chemical tube cleaning should always be followed
by mechanical tube cleaning.
79
Maintenance
Cleaning the Evaporator
Since the evaporator is typically part of a closed circuit, it
does not accumulate appreciable amounts of scale or
sludge. However, if cleaning is deemed necessary, use the
same cleaning methods described for the condenser
tubes.
The oil level in the oil sump can be measured to give an
indication of the system oil charge. Follow the procedures
below to measure the level.
1. Run the unit fully unloaded for approximately 20
minutes.
2. Cycle the compressor off line.
Oil Sump Level Check
Running the chiller at minimum load is the best for the
quickest return of oil to the separator and sump.The
machine still needs to sit for approximately 30 minutes
before the level is taken. At minimum load, the discharge
superheat should be highest.The more heat in the oil as it
lays in the sump, the more refrigerant will boil off in the
sump and leave more concentrated oil.
NOTICE:
Equipment Damage!
Never operate the compressor with the sightglass
service valves opened. Severe oil loss will occur. Close
the valves after checking the oil level. The sump is
above the condenser and it is possible to drain the oil.
Figure 65. Determining oil level in sump
6” Sight tube
Std Refrigeration Hose
3. Attach standard refrigeration hose with a sight tube in
the middle to the oil sump drain valve and the
condenser service valve at the top of the condenser.
Using high pressure rated clear hose with appropriate
fittings can help speed up the process.
Note: A shutoff valve at one end of the hose is
recommended to facilitate hose drainage after
oil level check is completed.
4. After the unit is off line for 30 minutes, move the
sightglass along the side of the oil sump.
5. The level should be between 2” and 5” from the
bottom of the oil sump.
Note: If oil levels are not between 2” and 5”, contactTrane
service.
80
RTHD-SVX01E-EN
Maintenance
Optional AFD
Periodic Maintenance and Inspection
AFD periodic maintenance and inspections should be
performed every 1–12 months, depending on operating
environment .
Visual Inspection — Power Removed
WARNING
Hazardous Voltage w/Capacitors!
Disconnect all electric power, including remote
disconnects and discharge all motor start/run
capacitors before servicing. Follow proper lockout/
tagout procedures to ensure the power cannot be
inadvertently energized. For variable frequency drives or
other energy storing components provided by Trane or
others, refer to the appropriate manufacturer’s literature
for allowable waiting periods for discharge of
capacitors. Verify with an appropriate voltmeter that all
capacitors have discharged. Failure to disconnect power
and discharge capacitors before servicing could result in
death or serious injury.
For additional information regarding the safe discharge
of capacitors, see PROD-SVB06A-EN
Operational Inspection — Power Applied
WARNING
Live Electrical Components!
During installation, testing, servicing and
troubleshooting of this product, it may be necessary to
work with live electrical components. Have a qualified
licensed electrician or other individual who has been
properly trained in handling live electrical components
perform these tasks. Failure to follow all electrical
safety precautions when exposed to live electrical
components could result in death or serious injury.
1. Verify the drive cabinet cooling fans are operating. This
should be done from outside the enclosure, by looking
into the cabinet at door and cabinet vents, to avoid
electrical hazards.
Note: The power module fan comes on with power.
Other fans cycle with drive operation.
2. Check historic fault codes using AFD control panel
(LCP).
Note: The AFD control panel is used ONLY for service and
should never be used for machine operation.
1. Ensure the door interlocks are present and working.
3. Check configuration settings and confirm all proper
settings are still present in the controls.
2. Verify the safety ground connections to the door
panels are securely connected.
4. Review the diagnostic history.
3. Inspect power wire cables and devices to assure no
abrasion is occurring from vibrations against chassis
of cabinets, or other edges.
6. Check the UC800 alarm histories for any indications of
operational problems.
4. Ensure the drive interior and exterior is clear of any
dust or debris. Fans, circuit boards, vents etc. must be
clean.
Important:
5. Make Chiller Service report to document all setpoints.
Choke Inspection
As needed, replace the magnetic choke if there is physical
damage (for example, cracks).
Only use a vacuum for cleaning. DO NOT
use compressed air.
5. Inspect the interior of the drive for any signs of
moisture entry or leakage.
6. Visually inspect all drive components and wiring. Look
for signs of heat or failure (look for swelled or leaking
capacitors, discolored reactors or inductors, broken
pre-charge resistors, smoke or arc trails on MOVs and
capacitors, etc.).
7.
Closely inspect the motor terminal board for any signs
of leakage, arcing, etc.
8. Check ALL cable/lug/terminal connections inside the
drive enclosure. Ensure all are clean and tight, and not
rubbing against each other anywhere.
RTHD-SVX01E-EN
81
Diagnostics
Diagnostic Name and Source: Name of Diagnostic and
its source. Note that this is the exact text used in the User
Interface and/or Service Tool displays.
Affects Target: Defines the “target” or what is affected
by the diagnostic. Usually either the entire Chiller, or a
particular Circuit or Compressor is affected by the
diagnostic (the same one as the source), but in special
cases functions are modified or disabled by the diagnostic.
None implies that there is no direct affect to the chiller, sub
components or functional operation.
Note: Tracer™ TU does not support the display of certain
targets on its Diagnostics pages although the
functionality implied by this table is supported.
Targets such as Evap Pump, Ice Mode, Heat Mode,
Chilled Water Reset, External Setpoints etc. – are
displayed as simply “Chiller” even though they do
not imply a chiller shutdown – only a compromise
of the specific feature.
Severity: Defines the severity of the above effect.
Immediate means immediate shutdown of the affected
portion, Normal means normal or friendly shutdown of the
affected portion, Special Action means a special action or
mode of operation (limp along) is invoked, but without
shutdown, and Info means an Informational Note or
Warning is generated. Design Note: Tracer TU does not
support display of “Special Action”, on its Diagnostics
pages, so that if a diagnostic has a special action defined
in the table below, it will be displayed only as
“Informational Warning” as long as no circuit or chiller
shutdown results. If there is a shutdown and special action
defined in the table, then the Tracer TU Diagnostics Page
display will indicate the shutdown type only.
Persistence: Defines whether or not the diagnostic and
its effects are to be manually reset (Latched), or can be
either manually or automatically reset when and if the
condition returns to normal (Nonlatched).
Active Modes [Inactive Modes]: States the modes or
periods of operation that the diagnostic is active in and, as
necessary, those modes or periods that it is specifically
“not active” in as an exception to the active modes. The
inactive modes are enclosed in brackets, [ ]. Note that the
modes used in this column are internal and not generally
annunciated to any of the formal mode displays.
Criteria: Quantitatively defines the criteria used in
generating the diagnostic and, if nonlatching, the criteria
for auto reset.
Reset Level: Defines the lowest level of manual
diagnostic reset command which can clear the diagnostic.
The manual diagnostic reset levels in order of priority are:
Local or Remote. For example, a diagnostic that has a reset
level of Remote, can be reset by either a remote diagnostic
reset command or by a local diagnostic reset command.
Starter Diagnostics
Table 34. Starter diagnostics
Diagnostic
Name and
Source
Affects
Target Severity
Active Modes
[Inactive
Persistence Modes]
Criteria
Reset
Level
Local
AFD Drive Fault Chiller
Immediate Latch
All
The AFD Drive Fault Relay is open
At Speed Input
Opened
Chiller
Immediate Latch
All Running Modes
after At Speed
proven
The “At Speed” input was found to be opened with the
compressor motor running after successfully obtaining
Local
an at speed and bypassed condition. This is active for
AFD
At Speed Input
Shorted
Chiller
Immediate Latch
Pre-Start
The “At Speed” input is shorted before the compressor
Local
was started. This is active for AFD.
Start Mode
The compressor did not come up to speed (get to
<85%RLA) in the allotted time defined by the
Maximum Acceleration Timer and a transition was
forced (motor put across the line) at that time. This
Remote
applies to all starter types. Note: Since RTHD SSS has
no forced transition capability, this info warning can be
followed with a “Compressor did not accelerate fully ”
diagnostic above and an aborted start.
Start Mode
The starter module did not receive an “Up to Speed” or
“End of Ramp” signal from the SSS within 2.5 seconds
Local
after commanding a bypass, or after the maximum
acceleration time had expired, whichever is longer.
This diagnostic only applies to SSS/AFD.
Start Mode
The compressor did not come up to speed (get to
<85%RLA) in the allotted time defined by the
Maximum Acceleration Timer and and the start was
aborted per the starter configuration selected.
Compressor Did
Not Accel:
Chiller
Transition
Compressor Did
Not Accelerate Chiller
Fully
Compressor Did
Not Accelerate: Chiller
Shutdown
82
Info
Latch
Immediate Latch
Immediate Latch
Remote
RTHD-SVX01E-EN
Diagnostics
Table 34. Starter diagnostics (continued)
Diagnostic
Name and
Source
Affects
Target Severity
Active Modes
[Inactive
Persistence Modes]
Criteria
Reset
Level
• Momentary Power Loss option disabled: No effect.
• Momentary Power Loss option enabled: A loss of
power on three line cycles or more was detected.
Remote
Diagnostic is reset in 30 seconds.
Momentary
Power Loss
Chiller
Immediate Nonlatch
All compressor
running and
stopping modes
[all compressor
starting and nonrunning modes]
Motor Current
Overload
Chiller
Immediate Latch
Chiller Energized
Compressor current exceeded overload time vs. trip
characteristic. For A/C products Must trip = 140% RLA, Local
Must hold=125%, nominal trip 132.5% in 30 seconds
All
a. Average of all monitored Line voltages above + 10%
of nominal. [Must hold = + 10 % of nominal. Must trip
= + 15 % of nominal. Reset differential = min. of 2%
and max. of 4%. Time to trip = minimum of 1 min. and Remote
maximum of 5 min.) Design: Nom. trip: 60 seconds at
greater than 112.5%, + or - 2.5%, Auto Reset at 109%
or less.
Over Voltage
Chiller
Normal
NonLatch
Phase Loss
Chiller
Immediate Latch
a) No current was sensed on one or two of the current
transformer inputs while running or starting (See
Nonlatching Power Loss Diagnostic for all three phases
lost while running). Must hold = 20% RLA. Must trip
= 5% RLA. Time to trip shall be longer than guaranteed
Start Sequence and
Local
reset on Starter Module at a minimum, 3 seconds
Run modes
maximum. Actual design trippoint is 10%. The actual
design trip time is 2.64 seconds. b) If Phase reversal
protection is enabled and current is not sensed on one
or more current xformer inputs. Logic will detect and
trip in a maximum of 0.3 second from compressor start.
Phase Reversal
Chiller
Immediate Latch
Compressor
energized to
transition command
[All Other Times]
A phase reversal was detected on the incoming current.
On a compressor startup the phase reversal logic must
Local
detect and trip in a maximum of 0.3 second from
compressor start.
Power Loss
Chiller
Immediate NonLatch
The compressor had previously established currents
while running and then all three phases of current were
lost. Design: Less than 10% RLA, trip in 2.64 seconds.
This diagnostic will preclude the Phase Loss Diagnostic
and the Transition Complete Input Opened Diagnostic
from being called out. To prevent this diagnostic from
occurring with the intended disconnect of main power,
the minimum time to trip must be greater than the
guaranteed reset time of the Starter module. Note:
This diagnostic prevents nuisance latching diagnostics
All compressor
running modes [all due to a momentary power loss – It does not protect
Remote
compressor starting motor/compressor from uncontrolled power
reapplication. See Momentary Power Loss Diagnostic
and non-running
for this protection. This diagnostic will auto reset in 10
modes]
seconds from its occurrence, and is not active during
the start mode before the transition complete input is
proven. This prevents the chiller from cycling due to
some internal starter problem, as the starter would
latch out on either a “Starter Fault Type 3” or a “Starter
Did Not Transition” latching diagnostic. However true
power loss occurring during a start would result in a
misdiagnosis and the chiller would not automatically
recover.
Severe Current
Imbalance
Chiller
Normal
All Running Modes
RTHD-SVX01E-EN
Latch
A 30% current imbalance has been detected on one
phase relative to the average of all 3 phases for 90
continuous seconds.
Local
83
Diagnostics
Table 34. Starter diagnostics (continued)
Diagnostic
Name and
Source
Affects
Target Severity
Starter
Contactor
Chiller
Interrupt Failure
Active Modes
[Inactive
Persistence Modes]
Immediatea
nd Special Latch
Action
Reset
Level
Criteria
Starter Contactor
not Energized
[Starter Contactor
Energized]
Detected compressor currents greater than 10% RLA
on any or all phases when the compressor was
commanded off. Detection time shall be 5 seconds
minimum and 10 seconds maximum. On detection and
until the controller is manually reset: generate
Local
diagnostic, energize the appropriate alarm relay,
continue to energize the Evap and Cond Pump Outputs,
continue to command the affected compressor off, fully
unload the effected compressor. For as long as current
continues, perform liquid level and oil return gas pump
control
Chiller
Immediate Latch
On the first check
after transition.
The Starter Module did not receive a transition
complete signal in the designated time from its
command to transition. The must hold time from the
Starter Module transition command is 1 second. The
Local
Must trip time from the transition command is 6
seconds. Actual design is 2.5 seconds. This diagnostic
is active only for Y-Delta, Auto-Transformer, Primary
Reactor, and X-Line Starters.
Starter Dry Run
Chiller
Test
Immediate Latch
Starter Dry Run
Mode
While in the Starter Dry Run Mode either 50 % Line
Voltage was sensed at the Potential Transformers or 10
Local
% RLA Current was sensed at the Current
Transformers.
Immediate Latch
Starting - Y Delta
Starters Only
This is a specific starter test where 1M(1K1) is closed
first and a check is made to ensure that there are no
currents detected by the CT's. If currents are detected Local
when only 1M is closed first at start, then one of the
other contactors is shorted.
Immediate Latch
a. This is a specific starter test where the Shorting
Contactor (1K3) is individually energized and a check is
made to ensure that there are no currents detected by
Starting All types of the CT's. If current is detected when only S is energized
Local
at Start, then 1M is shorted. b. This test in a. above
starters
applies to all forms of starters (Note: It is understood
that many starters do not connect to the Shorting
Contactor.).
Chiller
Immediate Latch
Starting [AFD
Starter]
As part of the normal start sequence to apply power to
the compressor, the Shorting Contactor (1K3) and then
the Main Contactor (1K1) were energized. 1.6 seconds
Local
later there were no currents detected by the CT's for the
last 1.2 seconds on all three phases. The test above
applies to all forms of starters.
Transition
Complete Input Chiller
Opened
Immediate Latch
All Running Modes
after transition
completed
The Transition Complete input is open with the
compressor motor running after a successful
completion of transition. This is active only for all
electromechanical starters
Local
Transition
Complete Input Chiller
Shorted
Immediate Latch
Pre-Start
The Transition Complete input is shorted before the
compressor was started. This is active for all
electromechanical starters.
Local
All
a. Average of all monitored Line voltages below - 10%
of nominal or the Under/Overvoltage transformer(s)
are not connected. [Must hold = - 10 % of nominal.
Must trip = - 15 % of nominal. Reset differential = min.
Remote
of 2% and max. of 4%. Time to trip = min. of 1 min.
and max. of 5 min.) Design: Nom. trip: 60 seconds at
less than 87.5%, + or - 2.8% at 200V or + or - 1.8%
at 575V, Auto Reset at 90% or greater.
Starter Did Not
Transition
Starter Fault
Type I
Starter Fault
Type II
Starter Fault
Type III
Under Voltage
84
Chiller
Chiller
Chiller
Normal
NonLatch
RTHD-SVX01E-EN
Diagnostics
Main Processor Diagnostics
Table 35. Main processor diagnostics
Diagnostic
Name and
Source
AFD output
power input
Affects
Target Severity
Active Modes
[Inactive
Persistence Modes]
Chiller
NonLatch
BAS
Communication Chiller
Lost
BAS Failed to
Establish
Chiller
Communication
Info
Special
Special
Criteria
Reset
Level
All
Out-Of-Range Low or Hi or bad LLID, set diagnostic, This
Info diagnostic will automatically reset if the input returns
to the normal range.
All
The BAS was setup as "installed" at the MP and the Comm
3 llid lost communications with the BAS for 15 contiguous
minutes after it had been established. Refer to Section on
Setpoint Arbitration to determine how setpoints and
operating modes may be effected by the comm loss. The Remote
chiller follows the value of the Tracer Default Run
Command which can be previously written by Tracer and
stored nonvolatilely by the MP (either use local or
shutdown).
At power-up
The BAS was setup as "installed" and the BAS did not
communicate with the MP within 15 minutes after powerup. Refer to Section on Setpoint Arbitration to determine
Remote
how setpoints and operating modes may be effected.
Note: The original requirement for this was 2 minutes, but
was implemented at 15 minutes for RTAC.
Check Clock
Chiller
Info
Latch
All
The real time clock had detected loss of its oscillator at
some time in the past. Check / replace battery? This
diagnostic can be effectively cleared only by writing a new Remote
value to the chiller’s time clock using the Tracer TU or TD7
“set chiller time” functions.
Compressor
Discharge
Temperature
Sensor
Chiller
Immediate Latch
All
Bad Sensor or LLID
Condenser
Entering Water
Temp Sensor
Chiller
Info and
Special
Action
Latch
All
Bad Sensor or LLID. If chiller running, and condenser water
Remote
regulating valve option installed, force valve to 100% flow.
Condenser
Leaving Water
Temp Sensor
Chiller
Info
Latch
All
Bad Sensor or LLID
Remote
Condenser Rfgt
Pressure
Transducer
Chiller
Normal
Latch
All
Bad Sensor or LLID
Remote
Start and All Run
Modes
The condenser water flow proof input was open for more
than 6 contiguous seconds after flow had been proven.
This diagnostic is automatically cleared once the
Remote
compressor is stopped by a fixed time out of 7 sec. The
Cond Pump shall be commanded off but the Evap pump
command will not be effected.
Estab Cond Water
Flow
Condenser water flow was not proven within 20 minutes of
the condenser pump relay being energized. The Cond
Pump shall be commanded off. Diagnostic is reset with Remote
return of flow (although only possible with external control
of pump)
Immediate Latch
All
a. EMERGENCY STOP input is open. An external interlock
has tripped. Time to trip from input opening to unit stop Local
shall be 0.1 to 1.0 seconds.
Evap Water Flow
(Entering Water Chiller
Temp)
Info
Any Ckt(s)
Energized [No
Ckt(s) Energized]
The entering evaporator water temp fell below the leaving
evaporator water temp. by more than 2?F for 100 ?F-sec.
For falling film evaporators this diagnostic cannot reliably
Remote
indicate loss of flow, but can warn of improper flow
direction through the evaporator, misbound temperature
sensors, or other system problems
Evaporator
Entering Water
Temp Sensor
Info and
Special
Action
Condenser
Chiller
Water Flow Lost
Condenser
Water Flow
Overdue
Chiller
Emergency Stop Chiller
Chiller
RTHD-SVX01E-EN
Immediate NonLatch
Normal
NonLatch
NonLatch
Latch
Remote
Bad Sensor or LLID Normal operation unless CHW Reset is
enabled. If CHW Reset is enabled and either Return or
Constant Return Chilled Water Reset is selected, its effect Remote
will be removed but slew rates on the change will be limited
per the Chilled Water Reset spec.
85
Diagnostics
Table 35. Main processor diagnostics (continued)
Diagnostic
Name and
Source
Affects
Target Severity
Active Modes
[Inactive
Persistence Modes]
Criteria
Reset
Level
Evaporator
Leaving Water
Temp Sensor
Chiller
Normal
Latch
All
Bad Sensor or LLID
Remote
Evaporator
Liquid Level
Sensor
Chiller
Normal
Latch
All
Bad Sensor or LLID
Remote
Evaporator Rfgt
Pressure
Chiller
Transducer
Normal
Latch
All
Bad Sensor or LLID
Remote
Evaporator
Chiller
Water Flow Lost
Evaporator
Water Flow
Overdue
Chiller
External Base
Chiller
Loading Setpoint
External Chilled/
Hot Water
Chiller
Setpoint
External Current
Chiller
Limit Setpoint
High Cprsr Rfgt
Discharge
Temperature
Chiller
High Differential
Refrigerant
Chiller
Pressure
High Evaporator
Chiller
Liquid Level
High Evaporator
Refrigerant
Chiller
Pressure
86
Immediate NonLatch
The Evaporator water flow proof input was open for more
than 6-10 contiguous seconds after flow had been proven.
The pump command status will not be effected. Even
Evap pump
though the pump may be commanded to run in the STOP
commanded “on”
Remote
except for [All Stop modes (pump off delay time), this diagnostic shall not be
called out in the STOP modes. This diagnostic will automodes]
clear on proof of flow (6-10 seconds of continuous flow),
or if chiller is returned to Stop mode.
Normal
NonLatch
Evaporator water flow was not proven within 20 minutes
Estab. Evap. Water of the Evaporator water pump relay being energized. The
Remote
Flow on going from Evap pump command status will not be effected. This
diagnostic will auto-clear on proof of flow (6-10 seconds of
STOP to AUTO.
continuous flow), or if chiller is returned to Stop mode.
NonLatch
All
a. Not "Enabled": no diagnostics. b. "Enabled ": Out-OfRange Low or Hi or bad LLID, set diagnostic, default BLS
to next level of priority (e.g. Front Panel SetPoint. This Info Remote
diagnostic will automatically reset if the input returns to
the normal range.
All
a. Function Not "Enabled": no diagnostics. b. "Enabled ":
Out-Of-Range Low or Hi or bad LLID, set diagnostic,
Remote
default CWS to next level of priority (e.g. Front Panel
SetPoint). This Info diagnostic will automatically reset if
the input returns to the normal range.
All
a. Not "Enabled": no diagnostics. b. "Enabled ": Out-OfRange Low or Hi or bad LLID, set diagnostic, default CLS
to next level of priority (e.g. Front Panel SetPoint. This Info Remote
diagnostic will automatically reset if the input returns to
the normal range.
Info and
Special
Action
Info
Info
NonLatch
NonLatch
Immediate Latch
The compressor discharge temperature exceeded 190?F.
This diagnostic will be suppressed if it occurs during the
All [compressor not compressor run-unload period or after the compressor has
stopped, but a run unload will be terminated early as a
running or during
Remote
result. Note: As part of the Compressor High Temperature
compressor run
Limit Mode (aka Minimum Capacity Limit), the compressor
unload]
shall be forced loaded as the filtered discharge
temperature nears this trip-point.
Normal
Latch
Chiller Energized
Latch
The liquid level sensor is seen to be at or near its high end
of range for 80 contiguous minutes while the compressor
Starter Contactor
is running. (The diagnostic timer will hold, but not clear
Energized [all Stop
Remote
when the circuit is off). Design: 80% or more of bit count
modes]
corresponding to +21.2 mm or more liquid level for 80
minutes)
Normal
Immediate
and Special NonLatch
Action
All
a. The system differential pressure was above 160 Psidtrip immediately (normal shutdown)
b.The diff pressure was above 152 Psid - trip in 1 hour
Remote
The evaporator refrigerant pressure has risen above 190
psig (future use – add “for continuous15 seconds”). The
evaporator water pump relay will be de-energized to stop
the pump regardless of why the pump is running. The
Local
diagnostic will auto reset and the pump will return to
normal control when the evaporator pressures falls below
185 psig. This diagnostic must shutdown the chiller if it is
running.
RTHD-SVX01E-EN
Diagnostics
Table 35. Main processor diagnostics (continued)
Diagnostic
Name and
Source
Affects
Target Severity
High Evaporator
Water
Chiller
Temperature
High Pressure
Cutout
Info and
Special
Action
Active Modes
[Inactive
Persistence Modes]
NonLatch
Criteria
Reset
Level
The leaving water temperature exceeded the high evap
water temp limit (TV service menu settable –default 105F)
for 15 continuous seconds. The evaporator water pump
relay will be de-energized to stop the pump but only if it
Only effective if
is running due one of the diagnostics listed on the right.
either
The diagnostic will auto reset and the pump will return to
1)Evap Wtr Flow
normal control when the temperature falls 5?F below the
Overdue, 2)Evap
trip setting. The primary purpose is to stop the evaporator Local
Wtr Flow Loss, or
water pump and its associated pump heat from causing
3)Low Evap Rfgt
excessive waterside temperatures and waterside
Temp,-Unit Off,
pressures when the chiller is not running but the evap
diagnostic is active.
pump is on due to either Evap Water Flow Overdue,
Evaporator Water Flow Loss , or Low Evap Temp – Unit Off
Diagnostics. This diagnostic will not auto clear solely due
to the clearing of the enabling diagnostic.
A high pressure cutout was detected; C.O. on rise @ 180
psig, reset @ 135 psig (+/-5 psi on switching tolerance)
Note: Pressure relief valve is 200 Psig +- 2% trip at 315
Local
± 5 psi. Note: Other diagnostics that may occur as an
expected consequence of the HPC trip will be suppressed
from annunciation. These include Phase Loss, Power Loss,
and Transition Complete Input Open.
Chiller
Immediate Latch
All
High Refrigerant
Chiller
Pressure Ratio
Immediate Latch
The system pressure ratio exceeded 5.61 for 1 contiguous
Service Pumpdown minute. This pressure ratio is a fundamental limitation of
Remote
the compressor. The pressure ratio is defined as Pcond
Only
(abs)/Pevap(abs).
All
The neuron software in the LCI-C module does not match
the chiller type. Download the proper software into the
LCI-C neuron. To do this, use the Rover service tool, or a Remote
LonTalk® tool capable of downloading software to a
Neuron 3150®.
Immediate Latch
Starter Contactor
Energized
In running modes , Oil Loss Level Sensor detects lack of oil
in the oil tank feeding the compressor (distinguishing a Local
liquid flow from a vapor flow)
Immediate
and Special Latch
Action
Compressor Prestart [all other
modes]
Oil Loss Level Sensor detects a lack of oil in the oil tank
feeding the compressor for 90 seconds after EXV
preposition is completed. Note: Compressor start is
delayed while waiting for oil to be detected.
LCI-C Software
Mismatch: Use
BAS Tool
Chiller
info
Loss of Oil at
Compressor
(Running)
Chiller
Loss of Oil at
Compressor
(Stopped)
Chiller
NonLatch
Local
Low Differential
Refrigerant
Chiller
Pressure
Immediate Latch
Chiller Energized
The system differential pressure was either below 15 Psid
for more than 164 Psid-sec, or below 23.0 Psid for 3000
Psid-sec. The latter integral’s value is not cleared for any
reason including diagnostic trip, manual reset, or power up
reset (ie. Integral is saved nonvolatily on power down). Remote
The integral will decay while circuit is running at a max rate
of –10 PSID, and while stopped at a rate of –0.4 PSID. This
same integral is associated with the operating mode
“Compressor Cool Down”. Also see diagnostic below
Low Discharge
Superheat
Normal
Latch
Any Running Mode
While Running Normally, the Discharge Superheat was less
than 12 degrees F +- 1F for more than 6500 degree F
Remote
seconds.. At startup the UCM shall ignore the Discharge
Superheat for 5 minutes.
NonLatch
The liquid level sensor is seen to be at or near its low end
Starter Contactor
of range for 80 contiguous minutes while the compressor
Remote
Energized [all Stop
is running. Design: 20% or less of bit count corresponding
modes]
to –21.2 mm or less liquid level for 80 minutes)
Chiller
Low Evaporator
Chiller
Liquid Level
Low Evaporator
Refrigerant
Chiller
Pressure
RTHD-SVX01E-EN
Info
Immediate Latch
The Evaporator Refrigerant Pressure dropped below 10
psia just prior to compressor start. The pressure fell below
Chiller Prestart and
10 psia while running but before the 3 minute ignore time Local
Chiller Energized
had expired or fell below 16 Psia after the 3 minute ignore
time had expired.
87
Diagnostics
Table 35. Main processor diagnostics (continued)
Diagnostic
Name and
Source
Affects
Target Severity
Low Evaporator
Refrigerant
Chiller
Temperature
Active Modes
[Inactive
Persistence Modes]
Reset
Level
Criteria
a. The inferred Saturated Evap Refrigerant Temperature
(calculated from suction pressure transducer(s)) dropped
below the Low Refrigerant Temperature Cutout Setpoint
for 450?F-sec (10?F-sec max rate) while the circuit was
running after the ignore period had expired. The integral
is held at zero for the 1 minute ignore time following the
circuit startup and the integral will be limited to never trip
in less than 45 seconds, i.e. the error term shall be
Remote
clamped to 10?F. The minimum LRTC setpoint is -5?F (18.7
Psia) the point at which oil separates from the refrigerant.
b. During the timeout of the trip integral, the unload
solenoid(s) of the running compressors on the circuit, shall
be energized continuously and the load solenoid shall be
off. Normal load/unload operation will be resumed if the
trip integral is reset by return to temps above the cutout
setpoint.
Immediate Latch
All Ckt Running
Modes
Info and
Special
Action
NonLatch
The evap sat temp fell below the water temp cutout setting
while the respective evap liquid level was greater than –
21.2mm for 30 (or 150 begining with rev 08) degree F
Unit in Stop Mode,
seconds while Chiller is in the Stop mode, or in Auto mode
or in Auto Mode and
with no compressors running. Energize Evap Water pump Remote
No Ckt's Energizd
Relay until diagnostic auto resets, then return to normal
[Any Ckt Energizd]
evap pump control. Automatic reset occurs when either
the evap temp rises 2?F (1.1?C) above the cutout setting
or the liquid level falls below –21.2mm for 30 minutes
NonLatch
The leaving Evaporator water temp. fell below the leaving
water temp cutout setting for 30 degree F seconds while
Unit in Stop Mode,
the Chiller is in the Stop mode, or in Auto mode with no
or in Auto Mode and
compressors running. Energize Evap Water pump Relay Remote
No Ckt(s) Energized
until diagnostic auto resets, then return to normal evap
[Any Ckt Energized]
pump control. Automatic reset occurs when the temp rises
2?F (1.1?C) above the cutout setting for 30 minutes.
Immediate
and Special NonLatch
Action
Any Ckt[s]
Energized [No
Ckt(s) Energizd]
The Evaporator water temp. fell below the cutout setpoint
for 30 degree F Seconds while the compressor was
running. Automatic reset occurs when the temperature
Remote
rises 2 ?F (1.1?C) above the cutout setting for 2 minutes.
This diagnostic shall not de-energize the Evaporator Water
Pump Output.
Immediate Latch
Chiller Energized
and Delta P above
15 Psid
The oil pressure was out of the acceptable pressure range
for 15 seconds, while the Delta Pressure was greater than
15 Psid.: Acceptable range is 0.50 or 0.60 > (PC-Po) / (PCLocal
PE) for the first 2.5 minutes of operation, and 0.40 or 0.50
> (PC-Po) / (PC-PE) thereafter. The higher ratios used if the
system DP is less than 23 psid
MP: Could not
Store Starts and None
Hours
Info
Latch
All
MP has determined there was an error with the previous
power down store. Starts and Hours may have been lost for Remote
the last 24 hours.
MP: Invalid
Configuration
Immediate Latch
All
MP has an invalid configuration based on the current
software installed
MP: Non-Volatile
None
Block Test Error
Info
Latch
All
MP has determined there was an error with a block in the
Remote
Non-Volatile memory. Check settings.
MP: Non-Volatile
Memory
None
Reformat
Info
Latch
All
MP has determined there was an error in a sector of the
Non-Volatile memory and it was reformatted. Check
Remote
settings.
All
The main processor has successfully come out of a reset
and built its application. A reset may have been due to a
power up, installing new software or configuration. This
Remote
diagnostic is immediately and automatically cleared and
thus can only be seen in the Historic Diagnostic List in
Tracer TU.
Chiller Energized
The system differential pressure was below 7.7 Psid. The
occurrence of this diagnostic will saturate the above “Low
Remote
Diff Rfgt Press” Integral and invoke the same “Compressor
Cool Down” op mode.
Low Evaporator
Chiller
Temp: Unit Off
Low Evaporator
Water Temp
Chiller
(Unit Off)
Low Evaporator
Water Temp
Chiller
(Unit On)
Low Oil Flow
Chiller
None
Info and
Special
Action
MP: Reset Has
Occurred
Chiller
Info
No Differential
Refrigerant
Pressure
Chiller
Immediate Latch
88
NonLatch
Remote
RTHD-SVX01E-EN
Diagnostics
Table 35. Main processor diagnostics (continued)
Diagnostic
Name and
Source
Affects
Target Severity
Active Modes
[Inactive
Persistence Modes]
Criteria
Reset
Level
Oil Flow
Chiller
Protection Fault
Immediate Latch
The Oil Pressure Transducer for this Chiller is reading a
Starter Contactor
pressure either above its Condenser Pressure by 15 Psia or
Local
Energized [all Stop
more, or below its Evaporator Pressure 10 Psia or more for
modes]
30 seconds continuously.
Oil Pressure
Transducer
Chiller
Normal
Latch
All
Bad Sensor or LLID
Outdoor Air
Temperature
Sensor
Chiller
Info and
Special
Action
Latch
All
Bad Sensor or LLID. This diagnostic will only occur if OA
sensor is configured.OA Chilled water reset will be
Remote
suspended if selected and Tracer OA unavailable.
Refrigerant
Monitor Input
Chiller
Info
NonLatch
All –if installed
Open or Shorted input and the Rfgt Monitor is setup as
installed
Remote
Restart Inhibit
Chiller
Info
NonLatch
All
The Restart Inhibit was invoked on a compressor. This
indicates excessive chiller cycling which should be
corrected.
Remote
Software Error
Number: 1001
Call Trane
Service
Latch – power
All
Immediate down reset is All
functions
reqd
Remote
A high level software watchdog has detected a condition in
which there was a continuous 5 minute period of
compressor operation, with neither chilled water flow nor
a” contactor interrupt failure” diagnostic active. The
Local
occurrence of this software error message suggests an
internal software state chart misalignment has occurred.
The events that led up to this failure, if known, should be
recorded and transmitted to Trane Controls Engineering –
(SW rev 6 and higher)
Starter Failed to
Chiller
Arm/Start
Info
Latch
All
Starter failed to arm or start within the allotted time (2
minutes).
Starter Module
Memory Error
Type 1
Chiller
Info
Latch
All
Checksum on RAM copy of the Starter LLID configuration
Local
failed. Configuration recalled from EEPROM.
Starter Module
Memory Error
Type 2 -
Chiller
Immediate Latch
All
Checksum on EEPROM copy of the Starter LLID
configuration failed. Factor default values used.
Normal
All Cprsr Running
modes, Starting,
Running and
Preparing to
Shutdown
The Starter module status reported back that it is stopped
when it should be running and no Starter diagnostic exists.
NA
This diagnostic will be logged in the active buffer and then
cleared.
Unexpected
Starter
Shutdown
Chiller
RTHD-SVX01E-EN
Nonlatch
Remote
Local
89
Diagnostics
Communication Diagnostics
Notes:
•
The following communication loss diagnostics will not
occur unless that input or output is required to be
present by the particular configuration and installed
options for the chiller.
•
Communication diagnostics (with the exception of
“Excessive Loss of Comm” are named by the
Functional Name of the input or output that is no
longer being heard from by the Main Processor. Many
LLIDs, such as the Quad Relay LLID, have more than
one functional output associated with it. A comm loss
with such a multiple function board, will generate
multiple diagnostics. Refer to the Chiller's wiring
diagrams to relate the occurrence of multiple
communication diagnostics back to the physical LLID
boards that they have been assigned to (bound).
Table 36. Communication diagnostics
Diagnostic Name
Affects
Severity
Active Modes
[Inactive
Persistence Modes]
Criteria
Reset
Level
Excessive Loss of Comm
Chiller
Immediate
Latch
All
Loss of comm with 20% or more of the llids configured
for the system has been detected. This diagnostic will
Remote
suppress the callout of all subsequent comm loss
diagnostics. Check power supply(s) and power
disconnects – troubleshoot LLIDS buss using Tracer TU
Comm Loss: Slide Valve
Unload
Chiller
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Slide Valve
Load
Chiller
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: External Auto/
Chiller
Stop
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Emergency
Stop
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: External Ice
Building Command
Normal
Latch
All
Continual loss of communication between the MP and
the Functional ID has occurred for a 30 second period.
Remote
Chiller shall revert to normal (non-ice building) mode
regardless of last state.
Comm Loss: Ice Building
Status Relay
Normal
Latch
All
Continual loss of communication between the MP and
the Functional ID has occurred for a 30 second period.
Remote
Chiller shall revert to normal (non-ice building) mode
regardless of last state.
Comm Loss: Outdoor Air
Temperature
Info and
Special
Action
Latch
All
Continual loss of communication between the MP and
the Functional ID has occurred for a 30 second period.
Note that if this diagnostic occurs, Chiller shall remove
Remote
any OA Chilled Water Reset, if it was in effect and if
Tracer OA was unavailable. Apply slew rates per Chilled
Water Reset spec
Comm Loss: Evap Leaving
Water Temp
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Evap Entering
Water Temp
Info and
Special
Action
Latch
All
Continual loss of communication between the MP and
the Functional ID has occurred for a 30 second period.
Remote
Chiller shall remove any Return or Constant Return
Chilled Water Reset, if it was in effect. Apply slew rates
per Chilled Water Reset spec.
Comm Loss: Condenser
Leaving Water Temp
Info
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Condenser
Entering Water Temp
Info and
Special
Action
Latch
All
Continual loss of communication between the MP and
the Functional ID has occurred for a 30 second period.
Remote
If chiller running, and condenser water regulating valve
option installed, force valve to 100% flow.
Comm Loss: Cprsr
Discharge Rfgt Temp
Immediate
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Ext Chilled/Hot
Water Setpoint
Info and
Special
Action
All
Continual loss of communication between the MP and
the Functional ID has occurred for a 30 second period.
Remote
Chiller shall discontinue use of the External Chilled
Water Setpoint source and revert to the next higher
priority for setpoint arbitration
90
Chiller
Chiller
Latch
RTHD-SVX01E-EN
Diagnostics
Table 36. Communication diagnostics (continued)
Diagnostic Name
Affects
Severity
Active Modes
[Inactive
Persistence Modes]
Criteria
Reset
Level
Comm Loss: Ext Current
Limit Setpoint
Info and
Special
Action
Latch
All
Continual loss of communication between the MP and
the Functional ID has occurred for a 30 second period.
Chiller shall discontinue use of the External Current Remote
limit setpoint and revert to the next higher priority for
Current Limit setpoint arbitration
Comm Loss: High Pressure
Chiller
Cutout Switch
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Evaporator
Water Flow Switch
Immediate
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Condenser
Water Flow Switch
Chiller
Immediate
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Evaporator
Rfgt Pressure
Chiller
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Condenser
Rfgt Pressure
Chiller
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Oil Pressure
Chiller
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Oil Return Gas
Chiller
Pump Fill
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Oil Return Gas
Chiller
Pump Drain
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Oil Loss Level
Chiller
sensor Input
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Master Oil Line
SV
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Evaporator
Water Pump Relay
Info
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Condenser
Water Pump Relay
Info
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: SSS/AFD Fault
Info
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Info
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Ext Base
Loading Setpoint
Info and
Special
Action
Latch
All
Continual loss of communication between the MP and
the Functional ID has occurred for a 30 second period.
Remote
The external base load setpoint input is removed from
the arbitration to establish the Base LoadingSetpoint.
Comm Loss: Ext Base
Loading Command
Info and
Special
Action
Latch
All
Continual loss of communication between the MP and
the Functional ID has occurred for a 30 second period.
Remote
The external base load input is removed from the
arbitration to enable Base Loading.
Comm Loss: Refrigerant
Monitor Input
Chiller
Comm Loss: Evaporator
Rfgt Liquid Level
Chiller
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Starter
Chiller
Immediate
Latch
All
Continual loss of communication between the MP and
Local
the Functional ID has occurred for a 30 second period.
Comm Loss: Electronic
Expansion Valve 1
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Electronic
Expansion Valve 2
Normal
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Starter Comm Loss: Main
Chiller
Processor
Immediate
Latch
All
Starter has had a loss of communication with the MP for
Local
a 15 second period.
Comm Loss: Local BAS
Interface
Chiller
Info and
Special
Action
Latch
All
Continual loss of communication between the MP and
the Functional ID has occurred for a 30 second period. Remote
Use the last values sent from BAS
Comm Loss: Op Status
Programmable Relays
Chiller
Info
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Compressor %
Chiller
RLA Output
Info
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
RTHD-SVX01E-EN
91
Diagnostics
Table 36. Communication diagnostics (continued)
Diagnostic Name
Affects
Comm Loss: Cond Rfgt
Pressure Output
Active Modes
[Inactive
Persistence Modes]
Criteria
Severity
Normal
Reset
Level
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: Cond Head
Press Cntrl Output
Chiller
Immediate
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: AFD speed
signal output
Chiller
Immediate
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: AFD output
power input
Chiller
Immediate
Latch
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Comm Loss: External Hot
Water Command
Chiller
Info
Warning
Reset
All
Continual loss of communication between the MP and
Remote
the Functional ID has occurred for a 30 second period.
Operator Display Diagnostics and Messages
Table 37.
Operator display diagnostics and messages
Operator Display Message
Description
//Troubleshooting
Communication Lost with UC800
•
•
•
•
Ethernet cable not connected between display and UC800.
UC800 not powered.
UC800 has an invalid configuration – Download a valid configuration
UC800 is in Binding View. When exit Binding View, select ‘Restart’ on this message.
Display Failed to Establish Communication
• Ethernet cable not connected between display and UC800.
• UC800 not powered.
• UC800 just has the backup application running as received from the vendor.
application software.
• UC800 has an invalid configuration – Download a valid configuration
Display is about to Restart
• The display is low on memory, and needs to re-start. Select Yes to restart. Selecting Yes will
not affect the UC800 operation.. Only the Operator Display is reset.
File Not Found
Update UC800 software with Tracer TU.
Download CTV
Screen partially populated.
Valid configuration is not present. Download a configuration.
Auto and Stop button graphics display, no text.
Screen Unresponsive
TU is downloading software. Wait till download is complete.
The Page Cannot be found
• Most likely this UC800 has only the backup application. Download the latest UC 800 software
build.
• This could also mean that the UC800 does not have a valid configuration. Download a
configuration to it.
• Cycle power to the OD and UC800.
• UC could be in binding view. If so, get it out of binding view by navigating to another screen in TU.
UC800 Configuration is Invalid
Update the UC800 configuration with TU.
92
RTHD-SVX01E-EN
Wiring Schematics
Table 38 and Table 39 provide lists of field wiring
diagrams, electrical schematics and connection diagrams
for the Optimus™ units. The complete unit wiring package
is documented in RTHD-SVE01*-EN. A laminated wiring
diagram kit is also shipped with each RTHD unit.
To determine the specific electrical characteristics of a
particular chiller, see the nameplates mounted on the
units.
Table 38. Wiring drawings - wye-delta units
Drawing
Description
2309-7552
Schematic
2309-7553
Schematic
2309-7554
Schematic
2309-7555
Schematic
2309-7564
Component Location
2309-4870
Field Wiring
2309-4869
Field Layout
Table 39. Wiring drawings - AFD units
Drawing
Description
2311-1975
Schematic
2311-1977
Component Location
2311-1976
Field Wiring
2311-0023
Field Layout
RTHD-SVX01E-EN
93
Log and Check Sheet
The operator log and check sheet are included for use as
appropriate, for installation completion verification before
Trane start-up is scheduled, and for reference during the
Trane start-up.
Where the log or check sheet also exists outside of this
publication as standalone literature, the literature order
number is also listed.
•
Optimus™ RTHD Installation Completion Check Sheet
and Request for Trane Service (RLC-ADF005*-EN)
•
Chiller Settings
•
Operator Log
94
RTHD-SVX01E-EN
Optimus™ Model RTHD Chiller Installation Completion Check Sheet
and Request for Trane Service
Important:
A copy of this completed form must be submitted to the Trane service agency that will be responsible for the startup of the chiller. Start-up will NOT proceed unless applicable items listed in this form have been satisfactorily
completed. See unit IOM RTHD-SVX01*-EN for detailed installation instructions.
To:
Trane Service Office:
S.O. Number:
Serial Numbers:
Job/Project Name:
Address:
The following items are being installed and will be completed by:
Important:
Start-up must be performed by Trane or an agent of Trane specifically authorized to perform start-up of Trane®
products. Contractor shall provide Trane (or an agent of Trane specifically authorized to perform start-up) with
notice of the scheduled start-up at least two weeks prior to the scheduled start-up.
Check boxes if the task is complete or if the answer is “yes.”
1. Screw Chiller
 Installation meets foundation requirements.
 In place and piped.
 Isolation pads installed.
2. Piping
Note: See bulletin RLC-PRB015*-EN for piping installation considerations affecting sound.
Chilled water piping connected to:
 Evaporator
 Air handling units
 Pumps
 Flow switch or flow proving device installed (if not factory provided)
 Strainer installed and cleaned
Condenser and heat recovery condenser (as applicable) piping connected to:
 Condenser
 Pumps
 Flow switch or flow proving device installed (if not factory provided)
 Cooling tower
 Heating loop (as applicable)
 Make-up water connected to cooling tower
 Water supply connected to filling system
 Systems filled
 Pumps run, air bled from system
 Strainer installed in entering water piping (evaporator and condenser) and cleaned
 Relief valve ventilation piping installed (if applicable)
3. Flow balancing valves installed
 Leaving chilled water
 Leaving condenser water
 Proper porting to measure flow and balance
 Optional heat recovery or auxiliary condenser water (if applicable)
4. Gauges, thermometers, and air vents
 Installed on both sides of evaporator
 Installed on both sides of condenser and heat recovery condenser (as applicable)
5. Wiring
 Wire size per submittal and NEC
 Full power available
 External interlocks (flow switch, pumps auxiliary, etc.)
RLC-ADF005A-EN
1






Chilled water pump (connected and tested)
Condenser water pump (connected and tested)
Cooling tower fan rotation checked
Heat recovery condenser water pump (as applicable)
115 Vac power available for service tools as required
All controls installed and connected
6. Testing
 Dry nitrogen available for pressure testing
 Trace gas amounts of R-134a available for leak testing, if necessary
7.  Refrigerant on job site
8.  Systems can be operated under all actual load conditions
9. Equipment room
 Does the equipment room have a refrigerant monitor/sensor capable of monitoring and alarming within the allowable
exposure level of the refrigerant?
 Does the installation have properly placed and operating audible and visual refrigerant alarms?
 Does the equipment room have proper mechanical ventilation?
 If it is required by local code, is a self-contained breathing apparatus available?
10. Owner awareness
 Has the owner been fully instructed on the proper use of refrigerant?
 Does the owner have a copy of the MSDS for refrigerant?
 Was the owner given a copy of the Refrigerant Handling Guidelines?
Note: Additional time required to properly complete the start-up and commissioning, due to any incompleteness of the
installation, will be invoiced at prevailing rates.
This is to certify that the Trane® equipment has been properly and completely installed, and that the applicable items listed above
have been satisfactorily completed.
Important: It is required that the chiller heaters are energized for a minimum of 24 hours prior to start up. Therefore, the chiller
should have power for this amount of time before Trane Service arrives to do start-up of the equipment.
Checklist completed by: ______________________________________________________________________________________________
Signed: _____________________________________________________________________
Date: _______________________________
In accordance with your quotation and our purchase order number __________________, we will therefore require the presence
of Trane service on this site, for the purpose of start-up and commissioning, by __________________ (date).
Note: Minimum two-week advance notification is required to allow scheduling of the chiller start-up.
Additional comments/instructions: ____________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
Note: A copy of this completed from must be submitted to the Trane Service Office that will be responsible for start-up of chiller.
Optimus, Trane and the Trane logo are trademarks or registered trademarks of Trane in the United States and other countries.
Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, the
leader in creating and sustaining safe, comfortable and energy efficient environments, Trane offers a broad
portfolio of advanced controls and HVAC systems, comprehensive building services, and parts. For more
information, visit 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.
© 2014 Trane All rights reserved
RLC-ADF005A-EN 20 Aug 2014
We are committed to using environmentally
New
conscious print practices that reduce waste.
Chiller Settings
Settings
Settings Tab
Chiller
Front Panel Chilled Water Setpt (F)
Front Panel Current Limit Setpt (RLA)
Differential to Start (F)
Differential to Stop (F)
Setpoint Source
Feature Settings
Chilled Water Reset
Return Reset Ratio
Return Start Reset
Return Maximum Reset
Outdoor Reset Ratio
Outdoor Start Reset
Outdoor Maximum Reset
Mode Overrides
Evap Water Pump
Cond Water Pump
Expansion Valve Control
Slide Valve Control
Service Pumpdown
Display Settings
Date Format
Date
Time Format
Time of Day
Keypad/Display Lockout
Display Units
Pressure Units
Language Selection
Operator Log
Chiller Log
Run Time
Main Tab
15 min
Chiller Mode
Evap Ent/Lvg Water Temp
Cond Ent/Lvg Water Temp
Active Chilled Water Setpoint (F)
Average Line Current (%RLA)
Active Current Limit Setpoint (%RLA)
Software Type
Software Version
Reports Tab
Evaporator
Evap Entering Water Temperature (F)
Evap Leaving Water Temperature (F)
Evap Sat Rfgt Temp (F)
Evap Rfgt Pressure (psia)
Evap Approach Temp (F)
Evap Water Flow Switch Status
Expansion Valve Position (%)
Expansion Valve Position Steps
Evap Rfgt Liquid Level (in)
Condenser
Cond Entering Water Temperature (F)
Cond Leaving Water Temperature (F)
Cond Sat Rfgt Temp (F)
Cond Rfgt Pressure (psia)
Cond Approach Temp (F)
Cond Water Flow Switch Status
Cond Head Pressure Ctrl Command (%)
Compressor
Compressor Starts
Compressor Run Time
System Rfgt Diff Pressure (psid)
Oil Pressure (psia)
Compressor rfgt Discharge Temp (F)
Discharge Superheat (F)
% RLA L1 L2 L3 (%)
Amps L1 L2 L3 (Amps)
Volts AB BC CA
30 min
1 hr
Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, the leader in
creating and sustaining safe, comfortable and energy efficient environments, Trane offers a broad portfolio of advanced
controls and HVAC systems, comprehensive building services, and parts. For more information, visit 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.
© 2014 Trane All rights reserved
RTHD-SVX01E-EN 22 Aug 2014
We are committed to using environmentally
Supersedes RTHD-SVX01D-EN (01 Nov 2006)
conscious print practices that reduce waste.
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