Trane Rtaaiom3 Manual
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LibraryService Literature Product SectionRefrigeration ProductRotary liquid Chillers – Air-Cooled ModelRTAA Literature TypeInstallation, Operation, Maintenance Sequence3 DateDecember 1991 File No.SV-RF-RLC-RTAA-IOM-3-1291 Supersedes Installation RTAA-IOM-3 Operation Maintenance Since The Trane Company has a policy of continuous product improvement, it reserves the right to change specifications and design without notice. The installation and servicing of the equipment referred in this booklet should be done by qualified, experienced technicians. Air-Cooled Series R ® Rotary Liquid Chillers “CO” and Later Design Sequence Packaged Air-Cooled Chiller, RTAA 130-400 Remote Evaporator Air-Cooled Chiller, RTAA 130-200 Models RTAA-130 RTAA-170 RTAA-240 RTAA-340 RTAA-140 RTAA-185 RTAA-270 RTAA-370 RTAA-155 RTAA-200 RTAA-300 RTAA-400 Part No. X39560468-01
4RTAA-IOM-3 77 Operating Principles - Mechanical 77 General 77 Refrigeration (Cooling) Cycle 77 — Cycle Description 77 — Compressor Description 77 — Compressor Motor 77 — Compressor Rotors 77 — Compressor Loading Sequence 82 Oil System Operation 82 — Overview 82 — Domestic Water Heater 83 — Oil Separator 83 — Compressor Bearing Oil Supply 83 — Compressor Rotor Oil Supply 84 — Slide Valve Movement 84 — Oil Filter 84 —Condenser Fans 87 Operating Principles -Adaptive Control™ Microprocessor Logic87 General 87 Digital Display 93 — Menus 99 — Chiller Switch 100 Menu Function Descriptions and Selection 100 — Selecting Variables and Options 100 — Menu 0 - Operating Display 100 — Menu 1 - Service #1 Display 101 — Menu 2 - Service #2 Display 101 — Menu 3 - Auxiliary Options 102 — Menu 4 - Factory Display #1 104 — Menu 5 - Factory Display #2 105 Operational Features 105 — Entering Evaporator Water Temperature 105 — Current Limit Setpoint 105 — Low Ambient Lockout 105 — Electronic Expansion Valve (EXV) Test 105 — Current Overload Protection 105 — Leaving Chilled Water Temperature Control 106 — Chilled Water Reset (CWR) 107 — Leaving Water Temperature Cutout 107 — Low Refrigerant Temperature Cutout 107 — Low Ambient Temperature Start 107 — Low Refrigerant Temperature Cutout Retry 108 — Auto Lead/Lag 108 — Phase Imbalance Protection 108 —Reverse Rotation Protection 108 DIP Switch Settings 108 Compressor Overload DIP Switches 108 IPC Address 108 — 2-10 VDC/4-20 mA Input for (CWS) and (CLS) 109 Diagnostics and Troubleshooting 109 —Mechanical Control Settings 121 Pre-Start Check-out121 General 122 Unit Voltage Power Supply 122 Unit Voltage Imbalance 123 Unit Voltage Phasing 124 Water System Flow Rates 124 Water System Pressure Drop 124 UCM Set-up 125 Start-up Procedures 125 General 125 System Superheat 125 System Subcooling 129 Unit Shutdown Procedures129 Temporary Shutdown and Restart 129 Extended Shutdown Procedure 130 System Restart After Extended Shutdown 131 Periodic Maintenance131 General 133 Refrigerant Emission Control 133 Weekly Maintenance 134 Monthly Maintenance 134 Annual Maintenance 135 Maintenance135 General 135 Coil Cleaning 135 Chemically Cleaning the Evaporator 135 Domestic Water Heater – Tube Cleaning 136 Water Treatment 136 Oil Separator Level Check
5RTAA-IOM-3 37 Figure 18 Spring Isolator Placement for Typical RTAA Packaged Unit - 130 to 200 Tons 38 Figure 19 Spring Isolator Placement for Typical RTAA Packaged Unit -240 to 400 Tons 39 Figure 20 Spring Isolator Placement for Typical RTAA Outdoor Unit with Remote Evaporator Option 40 Figure 21 Spring Isolator Placement for Typical RTAA Unit with Heat Recovery Domestic Water Heater 41 Figure 22 Suggested Piping for Typical RTAA Evaporator 43 Figure 23 RTAA 130 thru 400 Evaporator Water Pressure Drop 46 Figure 24 Typical Domestic Water Heater Piping 46 Figure 25 RTAA 130 thru 400 Domestic Water Heater Water Pressure Drop 47 Figure 26 Remote Evaporator Installation - No Elevation Difference 48 Figure 27 Remote Evaporator Installation - Condenser and Compressor above Evaporator 49 Figure 28 Restricted Installation -Evaporator is More Than 1’8 Above Base of Outdoor Unit. 49 Figure 29 Restricted Installation -Suction Line is on a Higher Plane than the Outdoor Unit. 50 Figure 30 Refrigerant Circuit Identification 52 Figure 31 Remote Evaporator Piping Example 55 Figure 32 Customer Interconnect Wiring for RTAA Outdoor Unit with Remote Evaporator -130 to 200 Tons 57 Figure 33 Warning Label 58 Figure 34 Typical Field Wiring for RTAA Packaged Unit - 130 to 200 Tons 61 Figure 35 Typical Field Wiring for RTAA Packaged Unit - 240 to 400 Tons List of Illustrations 11 Figure 1 Typical RTAA Packaged Unit - 130 to 200 Tons (Front/side Exterior View) 12 Figure 2 Typical RTAA Packaged Unit - 130 to 200 Tons (Rear/side Exterior View) 13 Figure 3 Typical RTAA Packaged Unit - 240 to 400 Tons (Front/side Exterior View) 14 Figure 4 Typical RTAA Unit (Rear Exterior View) 15 Figure 5 Typical RTAA Unit with Remote Evaporator Option (Rear Exterior View) 18 Figure 6 Remote Evaporator 21 Figure 7 Nameplates 22 Figure 8 Model Number Coding System 26 Figure 9 Dimensions and Clearances for RTAA Packaged Unit - 130 to 200 Tons 27 Figure 10 Dimensions and Clearances for RTAA Packaged Unit - 240 to 300 Tons 28 Figure 11 Dimensions and Clearances for RTAA Packaged Unit - 340 to 400 Tons 29 Figure 12 Dimensions and Clearances for RTAA Outdoor Unit with Remote Evaporator Option 30 Figure 13 Dimensions and Weights for Remote Evaporator 33 Figure 14 Rigging and Lifting Weights for RTAA Packaged Unit - 130 to 200 Tons Including Domestic Water Heater 34 Figure 15 Rigging and Lifting Weights for RTAA Packaged Unit - 240 to 300 Tons 34 Figure 16 Rigging and Lifting Weights for RTAA Packaged Unit - 340 to 400 Tons 35 Figure 17 Rigging and Lifting Weights for RTAA Outdoor Unit with Remote Evaporator Option
6RTAA-IOM-3 64 Figure 36 Typical Field Wiring for Outdoor Unit with Remote Evaporator Option 70 Figure 37 Alarm/Running/Maximum Capacity Contact Outputs 72 Figure 38 Resistor and Potentiometer Arrangement for External Chilled Water Setpoint 73 Figure 39 Resistor and Potentiometer Arrangement for External Current Limit Setpoint 78 Figure 40 Refrigeration System and Control Components - Single Circuit 80 Figure 41 Refrigeration System and Control Components - Duplex Circuit 81 Figure 42 Typical RTAA Compressor 82 Figure 43 RTAA Compressor Oil System Schematic 83 Figure 44 Oil Separator 85 Figure 45 Fan Configurations - RTAA 130 to 200 Ton 15 F Minimum Ambient 86 Figure 46 Fan Configurations - RTAA 130 to 400 Ton 0 F Minimum Ambient 88 Figure 47 RTAA Control Panel - 130 to 200 Tons 89 Figure 48 RTAA Control Panel - 240 to 300 Tons 90 Figure 49 RTAA Control Panel - 340 to 400 Tons 91 Figure 50 RTAA Control Panel - 130 to 200 Tons with Remote Evaporator Option 92 Figure 51 Operator Interface Controls 93 Figure 52 Menu Formats 98 Figure 53 Condition/Diagnostic Codes 107 Figure 54 Low Refrigerant Temperature Cutout Ignore Time 123 Figure 55 Associated Research Model 45 Phase Sequence Indicator126 Figure 56 Unit Sequence of Operation - 240 to 400 Tons 128 Figure 57 Unit Sequence of Operation -130 to 200 Tons 132 Figure 58 Operator’s Log 135 Figure 59 Chemical Cleaning Configuration 137 Figure 60 System Oil Level Specification
7RTAA-IOM-3 16 Table 1 General RTAA Mechanical Specifications 17 Table 2 RTAA Refrigerant Circuit Designations and Capacities 51 Table 3 RTAA Circuit Capacities 51 Table 4 Liquid Line Size for Horizontal and/ or Downflow Lines 51 Table 5 Equivalent Lengths of Non-Ferrous Valves and Fittings 53 Table 6 Suction Line Size for Horizontal and/or Upflow Lines 53 Table 7 Suction Line Size for Horizontal and/or Downflow Lines 56 Table 8 System Refrigerant Charge 56 Table 9 Field-installed Piping Charge 67 Table 10 Electrical Data 70 Table 11 Alarm/Running/Maximum Capacity Relay Output Configurations 70 Table 12 Alarm/Running/Maximum Capacity Menu Settings 72 Table 13 Input Values vs Extended Chilled Water Setpoint Inputs (Ohms) 73 Table 14 Input Values vs External Current Unit Setpoint 102 Table 15 Leaving Fluid Temperature Setpoints 104 Table 16 Compressor Overload DIP Switch Settings 105 Table 17 Compressor(s) Current Limit Setpoint vs. Chiller Current Limit Setpoint (CLS) 110 Table 18 Diagnostic and Troubleshooting Chart List of Tables
9RTAA-IOM-3 Literature Change History RTAA-IOM-3 (October 1991) Original manual. Covers installation, operation, and maintenance of “CO” design sequence RTAA-130 thru RTAA-400 units. Unit Identification When the unit arrives, compare all nameplate data with ordering and shipping information. Unit Inspection When the unit is delivered, verify that it is the correct unit and that it is property equipped. Compare the information which appears on the unit nameplate with the ordering and submittal information. Refer to “Nameplates”. Note: If the Remote Evaporator Option is ordered, the remote evaporator will be shipped in a separate crate. The serial number on the evaporator nameplate must match the serial number on the outdoor unit nameplate. Caution: If the serial numbers on the remote evaporator and the outdoor unit do not match, do not proceed with the installation. Notify the appropriate Trane Sales Office. 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. Do not proceed with installation of a damaged unit without sales off ice 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 15 days. [ ] 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 carrier’s representative. Loose Parts Inventory Check all the accessories and loose parts which are shipped with the unit against shipping list. Included in these items will be water vessel drain plugs, rigging and electrical diagrams, and service literature, which are placed inside the control panel and/or starter panel for shipment. General Information
10RTAA-IOM-3 Commonly Used Acronyms Acronyms used in this manual are defined below. OAT = Outdoor Air Temperature BAS = Building Automation System BCL = Bidirectional Communications Link CAR = Circuit Shutdown, Auto Reset CLS = Current Limit Setpoint CMR = Circuit Shutdown, Manual Reset CWR = Chilled Water Reset CWS = Chilled Water Setpoint DDT = Design Delta-Temperature Setpoint (i.e., the difference between entering and leaving chilled water temperatures) ENT = Entering Chilled Water Temperature EXV = Electronic Expansion Valve FLA = Full Load Amps HGBP = Hot Gas Bypass HVAC = Heating, Ventilating and Air Conditioning IFW = Informational - Warning I/O Input and Output Wiring IPC = Inter-Processor Communications LRA = Locked Rotor Amps Leaving Chilled Water Temperature MAR = Machine Shutdown, Auto Reset MMR = Machine Shutdown, Manual Reset NEC = National Electric Code PCWS = Front Panel Chilled Water Setpoint PFCC = Power Factor Correction Capacitors PSID = Pounds-per-Square-inch Differential (pressure differential) PSIG = Pounds-per-Square-inch (gauge pressure) RAS = Reset Action Setpoint RLA = Rated Load Amps RCWS = Reset Chilled Water Setpoint (CWR) RRS = Reset Reference Setpoint (CWR) SV = Slide Valve Tracer ® = Type of Trane Building Automation System SCI = Serial Communications Interface UCLS = Unit Current Limit Setpoint UCM = Unit Control Module (Microprocessor-based) UCWS= Unit Chilled Water Setpoint Unit Description The 130 thru 400-ton Model RTAA units are helical-rotary type, air-cooled liquid chillers designed for installation outdoors Depending upon rated capacity, the unit will have two, three or four compressors. The compressor circuits are completely assembled, hermetic packages that are factory- piped, wired, leak-tested, dehydrated, and tested for proper control operation before shipment. Note: Packaged units are factory charged with refrigerant and oil. Remote evaporator units are shipped with a holding charge of nitrogen and a partial charge of oil. Figures 1 thru 4 show typical RTAA packaged units and their components. Figures 5 and 6 show a typical RTAA Remote Evaporator outdoor unit and evaporator. Tables 1 and 2 contain general RTAA mechanical specifications. Chilled water inlet and outlet openings are covered for shipment. Each compressor has a separate compressor motor starter. The RTAA series features Trane’s exclusive Adaptive Control ™ logic, which monitors the control variables that govern the operation of the chiller unit. Adaptive Control logic can correct these variables, when necessary, to optimize operational efficiencies, avoid chiller shutdown, and keep producing chilled water. An optional remote display is available to monitor unit operation from a remote location. These units feature two independent refrigerant circuits. Compressor unloaders are solenoid actuated and oil pressure operated. Each refrigerant circuit is provided with filter drier, sight glass, electronic expansion valve, and charging valves. The shell-and-tube type evaporator is manufactured in accordance with ASME standards. Each evaporator is fully insulated and is equipped with water drain and vent connections. Packaged units have heat tape protection to -200 F. Remote evaporators do not have heat tape.