Installation, Operation, and Maintenance Remote Split System Units and Remote Chillers Air Cooled Condensing Units Models RAUJ-C20 RAUJ-C25 RAUJ-C30 RAUJ-C40 RAUJ-C50 RAUJ-C60 RAUJ-C80 RAUJ-D10 RAUJ-D12 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.
Warnings, Cautions and Notices Warnings, Cautions and Notices. Note that warnings, cautions and notices appear at appropriate intervals throughout this manual. Warnings are provide to alert installing contractors to potential hazards that could result in death or personal injury. Cautions are designed to alert personnel to hazardous situations that could result in personal injury, while notices indicate a situation that could result in equipment or property-damage-only accidents.
Introduction Introduction Overview of Manual Note: One copy of this document ships inside the control panel of each unit and is customer property. It must be retained by the unit's maintenance personnel. This booklet describes proper installation, operation, and maintenance procedures for air cooled systems. By carefully reviewing the information within this manual and following the instructions, the risk of improper operation and/or component damage will be minimized.
Table of Contents Model Number Descriptions . . . . . . . . . . . . . . 6 Controls using 24 VAC . . . . . . . . . . . . . . . .53 General Information . . . . . . . . . . . . . . . . . . . . . 7 Controls using DC Analog Input/Outputs .54 Unit Inspection . . . . . . . . . . . . . . . . . . . . . . 7 Economizer Actuator Circuit . . . . . . . . . . .54 Unit Dimensions & Weights . . . . . . . . . . . . . 10 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 10 No System Control . . . . . . . . .
Adding Preliminary Charge . . . . . . . . . . . 86 Compressor Start-Up (All Systems) . . . . 86 Pressure Curves . . . . . . . . . . . . . . . . . . . . 92 Final System Setup . . . . . . . . . . . . . . . . . 95 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Compressor Operational Sounds . . . . . . 97 Scroll Compressor Failure Diagnosis and Replacement . . . . . . . . . . . . . . . . . . . 97 Fuse Replacement Data . . . . . . . . . . . . .
Model Number Descriptions 20 to 60-Ton Units1 DIGIT 1 — UNIT TYPE R = Condensing Unit 80 to 120-Ton Units1 DIGIT 19 DIGIT 1 — UNIT TYPE R = Remote Condensing Unit A = Air Cooled C = Remote Chiller Evaporator & Install Kit T = Flow Switch (EVP Control Only) DIGIT 3 — AIRFLOW DIGIT 20 DIGIT 3 — AIRFLOW U = Upflow 1 = Spring Isolators 2 = Neoprene Isolators U = Upflow DIGIT 2 — CONDENSER DIGIT 4 — DEVELOPMENT SEQUENCE DIGIT 2 — CONDENSER A = Air-Cooled DIGIT 4 — DEVELOPMENT SEQUENCE J= Third J
General Information Unit Inspection As soon as the unit arrives at the job site • Verify that the nameplate data matches the data on the sales order and bill of lading (including electrical data). • Verify that the power supply complies with the unit nameplate specifications. • Visually inspect the exterior of the unit, including the roof, for signs of shipping damage. • Check for material shortages. Refer to the Component Layout and Ship with Location illustration.
General Information On 80-120 Ton units, the CSHN*** compressors come equipped with a compressor protection device capable of detecting phase reversal, phase loss, and phase unbalance. The compressor protection device uses a Green and Red LED to indicate the compressor status. A solid Green LED denotes a fault free condition; a blinking Red LED indicates an identifiable fault condition. Once a problem has been detected, the power will have to be cycled to clear the reset circuit.
General Information Figure 2. Component layout and ‘ship-with’ locations 20 - 60T units(a) Condenser Fans Condenser Coil Control Panel Lifting Bracket (2/side) Access Panels Compressors Condenser Air Intake “Shipwith” Grills Area (a) 60T unit shown Figure 3.
Unit Dimensions & Weights Unit Clearances Figure 4, p. 10 illustrates the minimum operating and service clearances for either a single, multiple, or pit application. These clearances are the minimum distances necessary to assure adequate serviceability, cataloged unit capacity, and peak operating efficiency. NOTICE: Equipment Damage! Providing less than the recommended clearances could result in condenser coil starvation or recirculation of hot condenser air.
Unit Dimensions & Weights Dimensions Figure 5. 20-Ton air-cooled condensing unit NOTES: 1. SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES. FAN GRILLE 2. LOW AMBIENT DAMPER ONLY COMES WITH SELECTED UNIT . 3. FRONT OF UNIT CLEARANCE 72" . BACK OF UNIT CLEARANCE 72" . LEFT AND RIGHT SIDE OF UNIT CLEARANCE 42". 3/4" X 4 MTG HOLES 4 3 1/2" X 4 KO (115V) 1/2" X 2 KO (115V) 5 3/8" 3 3/8" 2 5/8" 5 5/16" CONTROL PANEL 72 1/2" 4 1/2" FRONT (SEE NOTE 3 FOR ALL MIN.
Unit Dimensions & Weights Figure 6. 20-Ton air-cooled condensing unit (connections) CONTROL PANEL SIDE NOTES: 1. VERIFY WEIGHT, CONNECTION, AND ALL DIMENSION WITH INSTALLER DOCUMENTS BEFORE INSTALLATION 1 5/8" O.D. SUCTION LINE SCALE 1,000 5/8" O.D.
Unit Dimensions & Weights Figure 7. 25- and 30-Ton air-cooled condensing unit NOTES: 1. SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES. 2. LOW AMBIENT DAMPER ONLY COMES WITH SELECTED UNIT . 3. FRONT OF 20 AND 30 UNIT CLEARANCE 72" . BACK OF UNIT CLEARANCE 72”. LEFT AND RIGHT SIDE OF 20 AND 30 UNIT CLEARANCE 42”. FAN GRILLE 3/4" X 4 MTG HOLES 1/2" X 4 KO (115V) 4 3 1/2" X 2 KO (115V) 2 5/8" 5 5/16" 5 3/8" 3 3/8" CONTROL PANEL 4 1/2" 72 1/2" 3 3/8" 88 1/2" 1 3/4" KO LOW VOLTAGE (30V MAX.
Unit Dimensions & Weights Figure 8. 25- and 30-Ton air-cooled condensing unit (connections) CONTROL PANEL SIDE 7/8" O.D. HOT GAS BYPASS (OPTIONAL) COMPRESSORS B A A CONTROL PANEL 7/8" O.D. LIQUID LINE SUCTION LINE Horizontal 25T: 2 1/8” O.D. 30T: 2 1/8” O.D. Vertical 25T: 1 5/8” O.D. 30T: 2 1/8” O.D. SCA LE 1.
Unit Dimensions & Weights Figure 9. 40-Ton air-cooled condensing unit FAN GRILLE NOTES: 3/4" X 6 MTG HOLES 1. SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES. 2. LOW AMBIENT DAMPER ONLY COMES WITH SELECTED UNIT . 3. FRONT AND BACK OF UNIT CLEARANCE 72" . LEFT AND RIGHT SIDE OF UNIT CLEARANCE 42". 6 5 1/2" X 4 KO (115V) 36 1/8" 1/2" X 2 KO (115V) 5 3/8" 3 3/8" 2 5/8" 5 5/16" 4 88 9/16" 3 FRONT (SEE NOTE 3 FOR ALL MIN.
Unit Dimensions & Weights Figure 10. 40-Ton air-cooled condensing unit (connections) NOTES: 1. VERIFY WEIGHT, CONNECTION, AND ALL DIMENSION WITH INSTALLER DOCUMENTS BEFORE INSTALLATION 12" 7/8" O.D. HOT GAS BYPASS (OPTIONAL) 5/8" O.D. LIQUID LINE 7 11/16" 2 7/8" 7 1/4" 16 1/4" SERVICE VALVE (OPTIONAL) 1 5/8" O.D. SUCTION LINE COMPRESSORS 13 3/4" 10 1/4" CONTROL PANEL 4 3/4" VOLTAGE ACCESS CONTROL PANEL SIDE 7/8" O.D.
Unit Dimensions & Weights Figure 11. 50-Ton air-cooled condensing unit NOTES: 1. SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES. 2. LOW AMBIENT DAMPER ONLY COMES WITH SELECTED UNIT . 3. FRONT AND BACK OF UNIT CLEARANCE 72" . LEFT AND RIGHT SIDE OF UNIT CLEARANCE 42". FAN GRILLE 1/2" X 4 KO (115V) 3/4" X 6 MTG HOLES 6 5 1/2" X 2 KO (115V) 2 5/8" 5 5/16" 5 3/8" 3 3/8" CONTROL PANEL 48 7/8" 4 1/2" 3 3/8" 4 3 48 7/8" FRONT (SEE NOTE 3 FOR ALL MIN.
Unit Dimensions & Weights Figure 12. 50-Ton air-cooled condensing unit (connections) NOTES: 1. VERIFY WEIGHT, CONNECTION, AND ALL DIMENSION WITH INSTALLER DOCUMENTS BEFORE INSTALLATION 7/8" O.D. LIQUID LINE 12" 7 11/16" 7/8" O.D, HOT GAS BYPASS (OPTIONAL) 10 13/16" 32 3/4" 41 3/4" SERVICE VALVE (OPTIONAL) 1 5/8" O.D. SUCTION LINE for vertical 2 1/8” O.D. SUCTION LINE for horizontal COMPRESSORS 38 3/4" 29 3/4" 10 13/16" VOLTAGE ACCESS CONTROL PANEL SIDE 7 11/16" 7/8" O.D.
Unit Dimensions & Weights Figure 13. 60-Ton air-cooled condensing unit NOTES: 1. SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES. FAN GRILLE 3/4" X 6 MTG HOLES 2. LOW AMBIENT DAMPER ONLY COMES WITH SELECTED UNIT . 3. FRONT AND BACK OF UNIT CLEARANCE 72" . LEFT AND RIGHT SIDE OF UNIT CLEARANCE 42". 1/2" X 4 KO (115V) 5 6 1/2" X 2 KO (115V) 5 3/8" 3 3/8" 2 5/8" 5 5/16" CONTROL PANEL 48 7/8" 4 1/2" 3 3/8" 4 3 1 3/4" KO LOW VOLTAGE (30V MAX.
Unit Dimensions & Weights Figure 14. 60-Ton air-cooled condensing unit (connections) NOTES: 1. VERIFY WEIGHT, CONNECTION, AND ALL DIMENSION WITH INSTALLER DOCUMENTS BEFORE INSTALLATION 7/8" O.D. LIQUID LINE 12" 7 11/16" 7/8" O.D, HOT GAS BYPASS (OPTIONAL) 10 13/16" 32 3/4" 41 3/4" SERVICE VALVE (OPTIONAL) 2 1/8" O.D. SUCTION LINE COMPRESSORS 38 3/4" 29 3/4" 10 13/16" VOLTAGE ACCESS CONTROL PANEL SIDE 7 11/16" 7/8" O.D.
Unit Dimensions & Weights Figure 15. 80-Ton air-cooled condensing unit NOTES: FAN GRILLE 8 1. SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES. 3/4" X 8 MTG HOLES 2. LOW AMBIENT DAMPER ONLY COMES WITH SELECTED UNIT . 3. FRONT AND BACK OF UNIT CLEARANCE 96" . LEFT AND RIGHT SIDE OF UNIT CLEARANCE 48". 7 1/2" X 4 KO (115V) 72 1/8" 1/2" X 2 KO (115V) 5 3/8" 3 3/8" 2 5/8" 5 5/16" 6 5 4 3 176 11/16" 16" CONTROL PANEL 4 1/2" FRONT (SEE NOTE 3 FOR ALL MIN.
Unit Dimensions & Weights Figure 16. 80-Ton air-cooled condensing unit (connections) 2 1/8" O.D. SUCTION LINE 1 1/8" O.D. LIQUID LINE DETAIL A SERVICE VALUE (OPTIONAL SEE DETAIL A) 46 3/16" NOTES: 1. VERIFY WEIGHT, CONNECTION, AND ALL DIMENSION WITH INSTALLER DOCUMENTS BEFORE INSTALLATION 42 9/16" 14 13/16" 25 1/8" CONTROL PANEL SIDE 2 1/8" O.D .SUCTION LINE SERVICE VALUE (OPTIONAL SEE DETAIL A) COMPRESSOR (6) 1 3/8" HOT GAS BYPASS (OPTIONAL) 1 3/8" O.D.
Unit Dimensions & Weights Figure 17. 100- and 120-Ton air-cooled condensing unit NOTES: 1. SEE CONNECTION DRAWING FOR CONNECTION LOCATION AND SIZES. FAN GRILLE 2. LOW AMBIENT DAMPER ONLY COMES WITH SELECTED UNIT . 3. FRONT AND BACK OF UNIT CLEARANCE 96" . LEFT AND RIGHT SIDE OF UNIT CLEARANCE 48". 3/4" X 8 MTG HOLES 1/2" X 4 KO (115V) 1/2" X 2 KO (115V) 5 3/8" 3 3/8" 2 5/8" 97 5/8" 5 5/16" CONTROL PANEL 4 1/2" 3 3/8" 4" CONDUIT MAIN POWER 29 1/4" 31 1/4" 1 3/4" KO LOW VOLTAGE (30V MAX.
Unit Dimensions & Weights Figure 18. 100- and 120-Ton air-cooled condensing unit (connections) SERVICE VALUE (OPTIONAL SEE DETAIL A) SUCTION LINE 45 7/8" 67 7/16" 2 5/8” O.D. for horizontal 2 1/8” O.D. for vertical SUCTION LINE 39 5/8" 2 5/8” O.D. for horizontal 2 1/8” O.D. for vertical 13 1/16" 18 1/16" 25 1/8" 1 1/8" O.D.
SS-SVX11H-EN REQUIRES FIELD PROVIDED 1/2”X14NPTE STAINLESS STEEL OR PVC PLUG REFRIGERANT CONNECTIONS ARE STAINLESS STEEL AND REQUIRE SPECIAL BRAZE MATERIALS. SEE IOM BRAZE PROCEDURES.
REQUIRES FIELD PROVIDED 1/2”X14NPTE STAINLESS STEEL OR PVC PLUG REFRIGERANT CONNECTIONS ARE STAINLESS STEEL AND REQUIRE SPECIAL BRAZE MATERIALS. SEE IOM BRAZE PROCEDURE.
SS-SVX11H-EN REQUIRES FIELD PROVIDED 1/2”X14NPTE STAINLESS STEEL OR PVC PLUG REFRIGERANT CONNECTIONS ARE STAINLESS STEEL AND REQUIRE SPECIAL BRAZE MATERIALS. SEE IOM BRAZE PROCEDURE. WATER CONNECTIONS ARE GROOVED (VICTAULIC) Figure 21.
REQUIRES FIELD PROVIDED 1/2”X14NPTE STAINLESS STEEL OR PVC PLUG REFRIGERANT CONNECTIONS ARE STAINLESS STEEL AND REQUIRE SPECIAL BRAZE MATERIALS. SEE IOM BRAZE PROCEDURES.
SS-SVX11H-EN REQUIRES FIELD PROVIDED 1/2”X14NPTE STAINLESS STEEL OR PVC PLUG REFRIGERANT CONNECTIONS ARE STAINLESS STEEL AND REQUIRE SPECIAL BRAZE MATERIALS. SEE IOM BRAZE PROCEDURES.
Unit Dimensions & Weights Table 3. Typical unit weights and point loading data 20 - 120 Ton units Weight Tons Model 20 RAUJC20 1548 25 RAUJC25 1598 30 RAUJC30 40 CG Locations Shipping Operating Weight on isolator mounting location (lbs.) X Y Loc. 1 Loc. 2 Loc 3. Loc 4. Loc. 5 Loc. 6 Loc. 7 Loc. 8 1573 40.8 33.0 475.5 383.3 403.2 311.0 --- --- --- --- 1623 40.6 32.8 491.2 399.3 412.2 320.3 --- --- --- --- 1598 1623 40.6 32.8 491.2 399.3 412.2 320.
Unit Dimensions & Weights WARNING Heavy Objects! Figure 25. Rigging and center-of-gravity data 20 - 60 Ton units (L) and rigging and center-ofgravity data 80 - 120 Ton units (R) 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.
Unit Dimensions & Weights Unit Isolation Spring Isolators (20 - 120 Ton units) To minimize unit sound and vibration transmission, one of the following installation methods should be used: 1. Install the unit directly on an isolated (detached) concrete pad or on isolated concrete footings located at each unit load point. 2. Install the optional neoprene or spring isolators at each . Refer to the “Neoprene isolators” or “Spring isolator” section below.
Unit Dimensions & Weights Table 6. Typical neoprene isolator selection & location Isolator Part No. On Mounting Location Tons Model Shipping Weight Operating Weight Loc. 1 Loc. 2 Loc 3. Loc 4. Loc. 5 Loc.
Installation Foundation If the unit is installed at ground level, elevate it above the snow line. Provide concrete footings at each support location or a slab foundation for support. See Table 3, p. 30 for the unit operating and point loading weights when constructing the footing foundation. Anchor the unit to the footings or slab using hold down bolts or isolators. Isolators should be installed to minimize the transmission of vibrations into the building. See section “Unit Isolation,” p.
Installation • Install chiller piping drain with shutoff valve. • Install 1/2” x 14 NPT stainless steel or PVC plug in braze plate chiller body. • Flush the chilled solution piping system, if applicable. • Connect the chilled solution piping to the chiller. Note: The braze plate chiller is intended for indoor application. If a subfreezing location is required, contact Trane for installation precautions required to prevent damage.
Installation • Install an outside air thermostat in series with the flow switch to stop or prevent the unit from operating below the recommended ambient temperatures. • Connect properly sized wiring from the field provided economizer, if applicable, to the master energy controller (MEC) in the unit control panel. EVP Chiller Units EVP Chillers • Install proper grounding wires to an earth ground.
Installation Liquid Line Solenoid Valves Liquid line isolation solenoid valves (one per refrigeration circuit) are required for refrigerant migration control into evaporator during “Off” cycle and should be connected as illustrated in applicable field connection diagram. For recommended components, see latest edition of application guide, SS-APG012-EN.
Installation Access Valves (Ports) The access ports in the liquid line allows the unit to be charged with liquid refrigerant and is used to determine sub-cooling. The access ports in the suction line allow the operating suction pressure to be checked across the suction line filter. These ports are usually a Schrader valve with core. Ball Shutoff Valves Two ball shutoff valves equal to the OD Tubing size for both the liquid line and suction line are required.
Installation Suction Line Piping Table 9. Proper suction line sizing is required to guarantee that oil is returned to the compressor throughout the operating system. Furthermore, the line must be sized so that the pressure drop does not excessively affect capacity or efficiency. To accomplish both, it may be necessary to have two sizes, one for horizontal run and vertical drops, and another for the vertical lifts. The suction line size preselected in Table 9, p.
Installation Note: If the liquid line riser exceeds 10 feet, refer to Tube Size and Component Selection, publication number SS-APG012-EN Table 10. Liquid line interconnecting tubing OD unit connection Capacity (Per Circuit) Recommended field piping OD Horizontal (Per Circuit) OD Vertical (Per Circuit) Note: If risers exceed 10 feet, refer to Tube Size and Component Selection, publication SS-APG012-EN. Typical Field-Installed Evaporator Piping: Dual-Circuit Examples 1.
Installation Figure 29. Intertwined Evaporator Coil with Intertwined Circuiting suction lines (circuit 1) (circuit 2) thermal expansion valves (TXV) liquid line (circuit 2) sight glass solenoid valve liquid line (circuit 1) filter drier distributor Typical Field-Installed EVP Chiller Evaporator Piping NOTICE: Equipment Damage! The braze connections at the heat exchanger are stainless steel. Use 40-45% silver brazing alloy BAg-7 or BAg-29 for copper to steel refrigerant connections at the chiller.
Installation the coil frosting is sensed. The compressor is allowed to operate when the coil temperature rises a few degrees above the frosting condition. This action reduces the overall energy consumption of the system while reliably maintaining system control. Note: Wrap all appropriate pipe threads with Teflon tape before assembly. For more information, refer to the Hot Gas Bypass Engineers Newsletter, ADM-APN007-EN. Note: Do not install the valve depressor without the tubing being connected.
Installation Figure 33. Pressure gauges 80 - 120 Ton units: front view Final Refrigerant Pipe Connections To access the refrigerant pipe connections, remove the louvered side grills. These condensing units are shipped with a Nitrogen holding charge. Install pressure gauges to the appropriate access valve(s) and take a reading. If no pressure is present, refer to the “Leak Testing Procedure” section. If pressure is present, relieve the pressure before attempting to unsweat the “seal” caps.
Installation Note: Use 40 to 45% silver brazing alloy (BAg-7 or BAg28) on dissimilar metals. Use BCup-6 brazing alloy on copper to copper joints. 5. If flux is used, apply it sparingly to the joint. Excessive flux can enter the system which will contaminate the refrigerant system. 6. Apply heat evenly over the length and circumference of the joint to draw the brazing material into the joint by capillary action.
Installation system capacity. Proper water treatment must be determined locally and depends on the type of system and local water characteristics. Neither salt nor brackish water is recommend, use of either will lead to a shortened heat exchanger life. Trane encourages employment of a qualified water treatment specialist, familiar with local water conditions, to assist in the establishment of a proper water treatment program.
Installation BPHE). A field provided blow down valve (recommended) or plug must be installed in strainer cleanout if not present. Table 11. Chiller water pressure drop, Ft H2O Flow GPM Size, Tons 20 25 30 25 3.7 30 5.2 3.2 35 6.9 4.2 40 8.8 5.4 3.1 45 10.9 6.7 3.9 40 50 60 80 3. Beginning from water off, start flow and adjust GPM until the switch trips. If flow rate is below minimum, stop water flow and rotate adjusting screw accordingly.
Installation heat exchanger are also useful for EVP chiller service and shutdown. Water Pressure Gauges. NOTICE: Evaporator Damage! To prevent evaporator damage do not exceed 150 psig evaporator pressure. Install pressure gauge(s) to monitor the entering and leaving chilled water pressure, and strainer condition. Water Shutoff Valves. Provide shutoff valves in the "Supply" and "Return" pipe near the chiller so the gauge(s), thermostats, sensors, strainer, etc., can be isolated during service.
Installation Figure 36. EVP Chiller, Typical Water Piping PIPE CONNECTIONS WATER STRAINER AIR VENTS PRESSURE GAUGE SUPPLY LINE OUTLET UNIONS VIBRATION ELIMINATORS FLOW SWITCH AIR VENTS THERMOMETERS SHUTOFF VALVES GATE VALVES UNIONS VIBRATION ELIMINATORS RETURN LINE (INLET) (SEE NOTE 1) BALANCING VALVE GATE VALVES Notes: 1. Shutoff valves are required for evaporator servicing. 2. Evaporator is shown for illustration purposes only. 3.
Installation Main Unit Power Wiring WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. WARNING Proper Field Wiring and Grounding Required! All field wiring MUST be performed by qualified personnel.
Installation Table 13. Customer connection wire range 80 - 120 Ton units To correctly size the main power wiring for the unit, use the appropriate calculation(s) listed below. Read the load definitions that follow and use Calculation #1 for determining the MCA (Minimum Circuit Ampacity), MOP (Maximum Over current Protection), and RDE (Recommended Dual Element fuse size) for each unit. Use Calculation #2 to determine the DSS (Disconnect Switch Size) for each unit.
Installation Table 14. Electrical service sizing data (20-60 Ton units) Unit Characteristics Condenser Fan Motor Compressor Motor Rec. Dual Allowable Min. Max. Element Electrical Voltage Circuit Overcurrent Fuse 1A/ 2A 1B/2B 1A/2A 1B/2B Model Characteristics Range Amp Protection Size KW NO HP FLA LRA NO RLA RLA LRA LRA 20 Ton 25 Ton 30 Ton 40 Ton 50 Ton 60 Ton 200/60/3XL 180-220 102 125 125 0.9 2 1 4.1 20.7 2 41.4 41.4 267 267 230/60/3XL 208-254 89 110 100 0.9 2 1 4.1 20.
Installation Table 15. Electrical service sizing data (80-120 Ton units) Condenser Fan Motor Unit Characteristics Compressor Motor Rec. Dual Allowable Min. Max. Element 1A/ 1B/ 1C/ 1A/ 1B/ 1C/ Electrical Voltage Circuit Overcurrent Fuse 2A 2B 2C 2A 2B 2C Model Characteristics Range Amp Protection Size KW NO HP FLA LRA NO RLA RLA RLA LRA LRA LRA 80 Ton 100 Ton 120 Ton 200/60/3XL 200/60/3XL 411 450 450 0.9 8 1 4.1 20.7 6 230/60/3XL 230/60/3XL 358 400 400 0.9 8 1 4.1 20.
Installation • Chilled water flow switch wiring (EVP units); • Outside air thermostat wiring (EVP units); • Liquid line solenoid valve(s). Supply Fan Interlock Control options utilizing an Air Handler. The normally open evaporator fan interlock auxiliary contacts and the evaporator fan controls; system On/Off switch, fan starter/contactor, and overloads, must be wired as illustrated in the appropriate interlock connection wiring diagram for the specified application. EVP Flow control (6S58).
Installation Controls using DC Analog Input/Outputs WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. Before installing any connecting wiring between the unit and components utilizing a DC analog input/output signal, refer to Figure 5, p. 11 to Figure 18, p.
Installation Table 18. 80 - 120 Ton unit control panel Table 19. Economizer actuator circuit legend Device Designation Device Designation Parts And Notes MM Modutral Motor M.H. M955, (Up to 3 motors may be controlled as shown. Additional motors must be slaved.) TR Transformer M.H. 13081B; cover mounted EC Enthalpy Control M.H. H2051046 MP Minimum Position Potentiometer M.H.
Installation Figure 39.
Installation Figure 40.
Installation Figure 41.
Installation Figure 42. Field connection diagram notes - RAUJ 80-120 - all system controls 21 SS-SVX11H-EN ISOLATION LIQUID SOLENOID VALVES (6L1, 6L3) ARE REQUIRED FOR CHARGE ISOLATION (PROVIDED & INSTALLED BY THE FIELD). UNLOADING LIQUID SOLENOID VALVES (6L2, 6L4), IF APPLICABLE, ARE PROVIDED & INSTALLED BY THE FIELD.
Installation Variable Air Volume Control (Honeywell W7100A) In a variable air volume system, the desired space temperature is maintained by varying the amount of conditioned air being delivered to the space. As the cooling requirements of the space decreases, less air is delivered to the zone; conversely, as the cooling requirements of the space increases, a greater volume of air is delivered to the zone.
Installation Figure 44. Field connection diagram RAUJ80-120 - variable air volume control 2307-9144 Refer to wiring notes on Figure 42, p. 59.
Installation Discharge Air Sensor (Honeywell 6RT3 or Honeywell 8RT3) Discharge Air Sensor Figure 45. Discharge air sensor assembly Each unit ordered with variable air volume controls (digit 9 in the model number) is shipped with a Honeywell 6RT3 or 8RT3 discharge air sensor. WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized.
Installation Night Setback WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. If night setback operation is desired, connect a set of normally open contacts (field provided) to the appropriate terminals on the terminal board (7TB7), in the unit’s control panel.
Installation Figure 47. Field connection diagram - RAUJ-C20-60 - EVP chiller applications 2307-9122 Refer to wiring notes on Figure 40, p. 57.
Installation Figure 48. Field connection diagram - RAUJ-C80-120 EVP chiller applications 2307-9144 See wiring notes on Figure 42, p. 59.. 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.
Installation WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. For 40 through 60 Ton units, requiring four (4) stages of operation, a 402 ohm resistive jumper must be installed across Terminals 7 & 8 on the controller.
Installation Figure 49. Field connection diagram - RAUJ-20-60 constant volume control applications 2307-9122 Refer to wiring notes on Figure 40, p. 57.
Installation Electronic Zone Thermostat (Honeywell T7067) Each unit ordered with constant volume controls (in the model number) is shipped with a Honeywell T7067 electronic zone thermostat. A Honeywell switching subbase (Q667) is also included. The switching subbase allows the operator to select the “System Mode” of operation, i.e., Cool, Heat, Auto, or Off and the “Fan Mode” of operation, i.e., On or Auto.
Installation Figure 51. Q667 switching subbase & T7067 thermostat terminal identification Table 20.
System Pre-Start Procedures is to facilitate an EVP chiller or air over evaporator application. Before starting the system, verify that the correct pressure switch is connected to the control circuit. See Table 23, p. 91 for the pressure control settings, and the unit wiring diagram that shipped with the unit, for the appropriate connections. Use the checklist provided below in conjunction with the “General Unit Requirement” checklist” to ensure that the unit is properly installed and ready for operation.
System Pre-Start Procedures The lines used to connect pump to the system should be copper and the largest diameter that can practically be used. Using larger line sizes with minimum flow resistance can significantly reduce evacuation time. Rubber or synthetic hoses are not recommended for system evacuation. They have moisture absorbing characteristics which result in excessive rates of evaporation, causing pressure rise during standing vacuum test.
System Pre-Start Procedures Discharge Air Controller Checkout (Honeywell W7100A) Note: The following checkout procedure must be performed in its entirety and in the sequence given. WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
System Pre-Start Procedures 20. Turn the control circuit switch 1S2, in the unit control panel, and the main power disconnect switch to the “OFF” position. Discharge Air Sensor Checkout (Honeywell Sensor) 21. Remove the wires from terminals R, B, W, & Y. 22. Measure the resistance across the following pairs of terminals, and compare the actual resistance readings with the values shown below. W7100 Terminals R-to-W = 226 ohms W7100 Terminals R-to-B = 432 ohms W7100 Terminals R-to-Y = 226 ohms 23.
System Pre-Start Procedures for the condensing unit and the control circuit switch 1S2, in the unit control panel, is “OFF”. 2. Verify that the field provided disconnect switch and/or the control circuit switch for the economizer actuator(s) is “OFF”. 3. At the actuator, disconnect the control wires connected to Terminals W, R, B, and Y. 4. Install a jumper across the actuator terminals R-to-Wto-B. 5.
System Pre-Start Procedures WARNING High Voltage is Present at Terminal Block 1TB1 or Unit Disconnect Switch 1S1! To prevent injury or death form electrocution, it is the responsibility of the technician to recognize this hazard and use extreme care when performing service procedures with the electrical power energized. 11. At the Chilled Water Controller, use a digital voltmeter to verify there is 24 volts AC across terminals TR & TR.
System Pre-Start Procedures Insulate the wires with tape to prevent shorting or grounding during control checkout. 4. Close the main power disconnect switch and turn the control circuit switch 1S2, in the unit control panel, “ON”.
System Pre-Start Procedures Table 21. Zone thermostat (6U37) “voltage output” ramps Figure 57. 6RT1 discharge duct sensor “temperature vs resistance” curve Measured Drop-Out between Voltage(a) Throttling these 1U11 (VDC) Terminals Range 1U11 Function Pull-In Voltage1 (VDC) HEAT 1(a) 4.63 4.0 HEAT 2(a) 5.88 5.25 HEAT 3(a) 7.13 6.50 HEAT 4(a) 8.38 7.75 COOL 1 4.58 - 5.42 3.44 - 4.56 COOL 2 5.43 - 6.34 4.69 - 5.81 COOL 3 6.63 - 7.63 5.90 - 7.10 COOL 4 7.84 - 8.92 7.11 - 8.
System Pre-Start Procedures • VD (reading farthest from average) = 221 The percentage of Imbalance equals: • 100 x[(226 - 221)/226)] = 2.2% • Open the main power disconnect switch or circuit protection switch and remove the phase sequence indicator. The 2.2% imbalance in this example exceeds the maximum allowable imbalance of 2.0%. This much imbalance between phases can equal as much as a 20% current imbalance with a resulting increase in motor winding temperatures that will decrease motor life.
Operating Principals VAV W7100A Discharge Air Controller (7U11) The discharge air controller used in Variable Air Volume applications is a Honeywell W7100A. This microprocessor controller is designed to maintain an average discharge air (D/A) temperature by: 1. monitoring the discharge air temperature sensor; and 2. modulating economizer dampers and sequencing stages of mechanical cooling “On” or “Off”, as required.
Operating Principals Chilled Water Temperature Controller (6U11) The chilled water temperature controller used with EVP chiller applications is a Honeywell W7100G. This microprocessor controller is designed to maintain an average leaving water temperature using an integrating control band concept that matches the required operating capacity to the chiller load. The integral action, unlike “proportional only” type controllers, minimizes the amount of offset from the control setpoint.
Operating Principals Condenser Fans Condenser fan cycling is accomplished through interlocking fan contactors with a combination of compressor contactors and pressure switches (4S7 & 4S8). When the low ambient damper option is applied, ambient thermostats (1S36 & 1S37) are used to provide additional fan cycling control. Figure 61 and Figure 62 illustrate the condenser fan locations with their respective fan and relay designation. Figure 61.
Operating Principals Low Ambient Dampers Low Ambient Dampers are available as a factory installed option or can be field-installed. Dampers are used to extend the operation of these units from the standard operational temperatures to a minimum of 0ºF without hot gas bypass or 10ºF with hot gas bypass. (These values apply when wind speed across the condenser coil is less than 5 m.p.h.). If typical wind speeds are higher than 5 m.p.h., a wind screen around the unit may be required.
Start-Up Low Ambient Damper Adjustment (Factory or Field Installed) When a unit is ordered with the low ambient option (i.e., Digit 11 is a “1” in the model number), a damper is factory installed over the lead condenser fan for each refrigeration circuit. See Figure 61, p. 81 or Figure 62, p. 81 for damper location illustrations for the appropriate unit. For field installation, mount the dampers over the condenser fans at the locations shown in Figure 61, p. 81 or Figure 62, p.
Start-Up 5. Turn the main power disconnect switch or circuit protector switch for the unit to the “On” position. Use this data to assist in calculating a new fan drive if the CFM is not at design specifications. WARNING Rotating Components! An alternate method with less accuracy is to measure the static pressure drop across the evaporator coil.
Start-Up Table 22. Thermal expansion valve manufacturer settings - no bleed(a) Sporlan Standard off the shelf nominal valve settings (90 PSIG air test setting) Valve Superheat, °F CW turns available CCW turns available Superheat change per turn Field adjust for 18°F (DX Field adjust for evap coil) 15°F (EVP only) BBIZE-1-GA BBIZE-1-1/2-GA BBIZE-2-GA BBIZE-3-GA BBIZE-4-GA BBIZE-5-GA BBIZE-6-GA BBIZE-8-GA 2.4°F 2.5 CW — 3.4°F .25 CW .25 CW 1.8°F 3.25 CW 1.
Start-Up Adding Preliminary Charge 1. Leak check must be completed and system evacuated. 2. Verify that oil levels are near or above the top of all compressor sight glasses. WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. 3.
Start-Up WARNING Hazardous Voltage! NOTICE: Compressor Damage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. Improper power phasing will cause compressor to run backwards.
Start-Up Some Motors are Rotating Backwards WARNING Rotating Components! WARNING Hazardous Voltage! During installation, testing, servicing and troubleshooting of this product it may be necessary to work with live and exposed rotating components. Have a qualified or licensed service individual who has been properly trained in handling exposed rotating components, perform these tasks.
Start-Up Figure 63. System charging chart (all units) 700 650 150"lines lines 50" Discharge Pressure, psig 150" lines 600 550 Remove Charge 500 Add Charge Add Charge 450 400 350 300 250 70 80 90 100 110 120 130 140 150 Liquid Line Temp at Outdoor Unit, F f. Subtract the total charge already added from the Table 24, p. 91 charge estimate for condensing unit at the appropriate piping length. Add no more R410A than 1/2 of this difference at a time. g.
Start-Up l. If in step 9. the fan pressure control switches were disabled to allow for charging below 80°F outdoor temperature, disconnect unit power and reconnect the control wiring for these fans at this time. Follow the procedures discussed earlier to confirm proper rotation of these condenser fans. 13. After the unit has been operating for approximately 30 minutes at full load with all condenser fans running, record the operating pressures.
Start-Up Compressor Crankcase Heaters Table 26. Compressor sequence: 20-120 Ton units 7.5 thru 15 Ton CSHD compressors use one 90-watt heater per compressor. 15 and 20 Ton CSHN compressors use one 160-watt heater per compressor. Table 23. Pressure control switch settings Pressure Switch Hi Pressure Lo Pressure Make Break 550 psi 650 psi 78 psi 58 psi Condenser Fan Cycling switch 444 psi 255 psi EVP Lo Pressure 105 psi 82 psi Table 24.
Start-Up Figure 64. Typical compressor locations 20 - 60 Ton units “1B” “1A” “1A” “1B” “2B” “2B” “2A” “1A” “1B” Figure 65. Typical compressor locations 80 - 120T units “2A” “1B” “1A” . To Check Operating Pressures 1. Start the unit and allow the pressures to stabilize. 2. Measure the outdoor air dry bulb temperature (F) entering the condenser coil. 92 250 300 350 400 450 500 550 Discharge pressure, PSIG 5. At point of intersection, read to the left for discharge pressure.
(a) All compressors and condenser fans running SS-SVX11H-EN 250 300 350 400 450 500 95 125 Suc on pressure, PSIG 115 105 125 Suc on pressure, PSIG 115 135 135 145 65F OD 75F OD 85F OD 95F OD 105F OD 145 curve(a) 50T Cooling Cycle Pressure Curve All compressors and condenser fans running 105 (a) All compressors and condenser fans running 550 95 65F OD 75F OD 85F OD 95F OD Figure 68.
(a) All compressors and condenser fans running 94 250 300 350 400 450 500 95 125 Suc on pressure, PSIG 115 105 125 Suc on pressure, PSIG 115 135 135 145 65F OD 75F OD 85F OD 95F OD 105F OD 145 curve(a) 120T Cooling Cycle Pressure Curve All compressors and condenser fans running 105 (a) All compressors and condenser fans running 550 95 65F OD 75F OD 85F OD 95F OD Figure 72.
Start-Up Figure 75.
Start-Up WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury. • Turn the 115 volt control circuit switch 1S2 “Off” and program the Night Setback (NSB) panel (if applicable) for proper unoccupied operation. Refer to the programming instructions for the specific panel.
Maintenance Compressor Operational Sounds The following discussion describes some of the operational sounds of Trane R-410A scroll compressors. These sounds do not affect the operation or reliability of the compressor. At Shutdown: When a Scroll compressor shuts down, the gas within the scroll expands and causes momentary reverse rotation until the discharge check valve closes. This results in a “flutter” type sound.
Maintenance Important: Important: Do not spill compressor oil. Refrigerant oil is detrimental to some roofing materials. Care must be taken to protect the roof from oil leaks or spills. Figure 77. CSHD Do not release refrigerant to the atmosphere! If adding or removing refrigerant is required, the service technician must comply with all federal, state, and local laws. Compressor Start-up Discoloration of the oil indicates that an abnormal condition has occurred.
Maintenance When the compressors are restarted verify that correct oil levels are obtained when all compressors are running in a manifold set. Table 29. Oil charge per compressor Compressor Pints CSHD 110 thru 183 7.0 CSHN 176 thru 250 14.2 Figure 80. Precision suction restrictor Table 30. Torque requirements for rotolock fittings CSHD* 64 +/- 12 ft-lbs CSHN* 100 +/- 10 ft-lbs Note: Always replace gasket when reassembling oil equalizer lines.
Maintenance Table 34. 20-60 Ton unit compressor circuit breakers (460-575 volts) 1A/ 2A 1B / 2B Unit Voltage Dial Setting 20 Ton 460 575 20.8 17.7 20.8 17.7 25 Ton 460 575 20.8 17.7 24.9 21.4 30 Ton 460 575 28.5 25.9 28.5 25.9 40 Ton 460 575 20.8 17.7 20.8 17.7 50 Ton 460 575 22.6 19.1 24.9 21.4 60 Ton 460 575 28.5 25.9 28.5 25.9 Table 35. 80-120 Ton unit compressor circuit breakers (460-575 volts) 1A / 2A 1B / 2B 1C / 2C Unit Voltage 80 Ton 460 575 28.4 22.
Maintenance Fuse Replacement Data Table 36. Fuse replacement selection Unit Size Unit Voltage Fuse Type Fuse Size Condenser Fan Fuse (1F1-1F3 on 20 - 30 Ton) (1F1-1F6 on 40 - 60 Ton) Fuse Description 20-60 Ton 200/230 460/575 380/415 Class RK5 25 Amp 15 Amp Control CKT Fuse 1F7 20 - 30 40 - 60 All Class CC FNQ R 3.2 6.
Maintenance • Inspect unit for unusual conditions (e.g., loose access panels, leaking piping connections, etc.) • When checks are complete, verify all retaining screws are reinstalled in unit access panels. Monthly Maintenance Air Handling Equipment WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized.
Maintenance 1. Remove enough panels from the unit to gain safe access to coils.. WARNING No Step Surface! Do not walk on the sheet metal drain pan. Walking on the drain pan could cause the supporting metal to collapse, resulting in the operator/technician to fall. Failure to follow this recommendation could result in death or serious injury. Important: Bridging between the main supports required before attempting to enter into the unit.
Warranty and Liability Clause COMMERCIAL EQUIPMENT RATED 20 TONS AND LARGER AND RELATED ACCESSORIES PRODUCTS COVERED This warranty* is extended by Trane Inc. and applies only to commercial equipment rated 20 Tons and larger and related accessories.
Wiring Diagrams Note: Published unit wiring diagrams (individual, separate diagrams for unitary product lines) are available via e-Library.
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