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Installation

Operation

Maintenance

Series R™ Air-Cooled Helical RotaryLiquid Chiller

ModelsRTAD 85 - 125 (50Hz)

RTAD-SVX01A-E4

RTAD-SVX01A-E4©American Standard Inc. 2001

General Information 7

Literature History 7Unit Inspection 7Inspection Checklist 7Loose Parts Inventory 7General Data 8Unit Dimensions 9

Installation - Mechanical 10

Warnings and Cautions 10

Installation Responsibilities 10Nameplates 10Storage 10Location Requirements 10

Setting the Unit 10Isolation and Sound Emission 11Noise Considerations 11Foundation 11Clearances 11Unit Isolation and Leveling 11Neoprene Isolator Installation 11Drainage 12

Evaporator Water Piping 12Evaporator Piping 12Entering Chilled Water Piping 12Leaving Chilled Water Piping 12Evaporator Drain 12Evaporator Flow Switch 12Water Treatment 12Water Pressure Gauges 13Water Pressure Relief Valves 14Freeze Protection 14

RTAD-SVX01A-E4 3

Contents

Contents

Installation - Electrical 15

General Recommendations 15Installer-Supplied Components 16Power Supply Wiring 16

Control Power Supply 17Heater Power Supply 17Water Pump Power Supply 17

Interconnecting Wiring 17Chilled Water Flow (Pump) Interlock 17Chilled Water Pump Control 17

Alarm and Status Relay Outputs (Programmable Relays) 17Low Voltage Wiring 19External Emergency Stop 19External Auto/Stop 19External Circuit Lockout - Circuit 1 and Circuit 2 19Ice Making Option 19External Chilled Water Setpoint (CWS) 20External Current Limit Setpoint (CLS) 20Outdoor Air Temperature Sensor 20Communication Card CSR 21Communication link connection procedure 21

Operating Principles 22

System schematic 22

Pre-Start Checkout 23

Installation Checklist 23Receiving 23Unit Location and Mounting 23Unit Piping 23Electrical Wiring 23General 23Unit Voltage Power Supply 24Unit Voltage Imbalance 24Unit Voltage Phasing 24Water System Flow Rates 25Water System Pressure Drop 25

4 RTAD-SVX01A-E4

Contents

RTAD-SVX01A-E4 5

Unit Start-up Procedures 26

Daily Unit Start-Up 26General 26Seasonal Unit Start-Up Procedure 26System Restart After Extended Shutdown 27

Unit Shutdown Procedures 28

Temporary Shutdown And Restart 28Extended Shutdown Procedure 28

Maintenance 29

General 29Weekly Maintenance 29Monthly Maintenance 29Annual Maintenance 29

Maintenance Procedures 30

Refrigerant Emission Control 30Refrigerant and Oil Charge Management 30R134a Field Charging Procedure 31Refrigerant Charging 31Isolating the Refrigerant in the High Pressure Side 31Isolating the Refrigerant in the Low Pressure Side 32Adding Refrigerant 32Refrigerant Filter Changing Procedure 32Lubrication System 33Oil Charging Procedure 33Factory (initial) Oil Charging Procedure 34Field Oil Charging Procedure 34Evaporator Heat Tape Checkout Procedure 35Safety Recommendations 35Maintenance Contract 35Training 35

6 RTAD-SVX01A-E4

Figure 1 - Typical unit nameplate 7

Figure 2 - Unit dimensions and minimum recommended clearances 9

Figure 3 - Rigging the unit 10

Figure 4 - Evaporator water pressure drop 13

Figure 5 - Suggested piping for typical RTAD evaporator 13

Figure 6 - Warning label 15

Figure 7 - Alarm/Running/Maximum capacity relay output 18

Figure 8 - System/Oil system schematic 22

List of Tables

Table 1 - General Data Standard RTAD units 8

Table 2 - General Data High Efficiency and High Ambient RTAD units 8

Table 3 - General Data High Efficiency Low Noise RTAD units 9

Table 4 - Electrical Data 16

Table 5 - Alarm/Running/Maximum capacity relay output configuration 18

Table 6 - Alarm/Running/Maximum capacity menu setting 18

Table 7 - Input values vs. External chilled-water setpoint 20

Table 8 - Input values vs. External current-limit setpoint 20

Table 9 - Standard refrigerant charge 32

Table 10 - Standard oil charge 33

List of Figures

General Information

Literature HistoryNew manual describes installation,operation, and maintenance of RTADunits.A separate manual, RLC-SVU02A, isavailable for the use andmaintenance of the unit's controls -UCM-CLD.

Unit Inspection

When the unit is delivered, verifythat it is the correct unit and that it isproperty equipped. Compare theinformation which appears on theunit nameplate with the ordering andsubmittal information. A typical unitnameplate is shown in Figure 1.Inspect all exterior components forvisible damage. Report any apparentdamage or material shortage to thecarrier and make a "unit damage"notation on the carrier's deliveryreceipt. Specify the extent and typeof damage found and notify the

appropriate Trane Sales Office. Donot proceed with installation of adamaged unit without sales officeapproval.

Inspection ChecklistTo protect against loss due todamage incurred in transit, completethe following checklist upon receiptof the unit.❏ Inspect the individual pieces of the

shipment before accepting theunit. Check for obvious damage tothe unit or packing material.

❏ Inspect the unit for concealeddamage as soon as possible afterdelivery and before it is stored.Concealed damage must bereported within 15 days.

❏ If concealed damage is discovered,stop unpacking the shipment. Donot remove damaged materialfrom the receiving location. Takephotos of the damage, if possible.

The owner must providereasonable evidence that thedamage did not occur afterdelivery.

❏ Notify the carrier's terminal of thedamage immediately, by phoneand by mail. Request animmediate, joint inspection of thedamage with the carrier and theconsignee.

❏ Notify the Trane salesrepresentative and arrange forrepair. Do not repair the unit,however, until damage isinspected by the carrier'srepresentative.

Loose Parts InventoryCheck all the accessories and looseparts which are shipped with the unitagainst the shipping list. Included inthese items will be water vesseldrain plugs, rigging and electricaldiagrams, and service literature,which are placed inside the controlpanel and/or starter panel forshipment.

Figure 1 - Typical Unit Nameplate

RTAD-SVX01A-E4 7

General Information

General Data

Table 1 - General Data RTAD 085 - 125 StandardSize 85 100 115 125

CompressorQuantity 2 2 2 2Nominal Size (1) (Tons) 40/40 50/50 60/60 70/70Evaporator

Evp. Model EG 120 EG 140 EG 170 EG 200Water Storage (l) 106 270 222 204Min. Flow (l/s) 5.7 6.9 8.2 9.5Max. Flow (l/s) 17.3 20.8 24.6 28.4Condenser

Qty of Coils 2 2 2 2Coil Length (mm) 2743 3658 3658 3658Coil Height (mm) 1575 1575 1575 1575Fin series (fins/ft) 192 192 192 192Number of Rows 3/3 2/2 3/3 3/3Condenser Fans

Quantity (1) 6 6 6 6Diameter (mm) 762 762 762 762Total Air Flow (m3/s) 23.43 28.59 27.04 27.07Nominal RPM 915 915 915 915Tip Speed (m/s) 36.48 36.48 34.48 34.48Motor kW (kW) 1.9 1.9 1.9 1.9Min Starting/Oper Ambient (2)

Std Unit (°C) 7 7 7 7Low Ambient Unit (°C) -18 -18 -18 -18General UnitRefrigerant HFC 134a HFC 134a HFC 134a HFC 134aNo. Of independent

Refrigerant Circuits 2 2 2 2% Min. Load (3) 17 17 17 17Refrigerant Charge (1) (kg) 51 50 69 71Oil Charge (1) (l) 10 12 16 18Operating Weight (kg) 2660 3100 3560 3570Shipping Weight (kg) 2550 2835 3335 3570

Table 2- General Data RTAD 085 - 125 High Efficiency and High AmbientSize 85 100 115 125




Quantity (1) 6 8 8 10Diameter (mm) 762 762 762 762Total Air Flow (m3/s) 27.0 31.2 35.0 39.1Nominal RPM 915 915 915 915Tip Speed (m/s) 36.48 36.48 36.48 36.48Motor kW (kW) 1.9 1.9 1.9 1.9Min Starting/Oper Ambient (2)Std Unit (°C) 7 7 7 7Low Ambient Unit (°C) -18 -18 -18 -18General UnitRefrigerant HFC 134a HFC 134a HFC 134a HFC 134aNo. Of independentRefrigerant Circuits 2 2 2 2% Min. Load (3) 17 17 17 17Refrigerant Charge (1) (kg) 50 69 87 87Oil Charge (1) (l) 10 12 18 18Operating Weight (kg) 3240 3370 3905 4000Shipping Weight (kg) 2975 3145 3700 3800

8 RTAD-SVX01A-E4

General Information

Table 3 - General Data RTAD 085 - 125 High Efficiency Low Noise Size 85 100 115 125




Quantity (1) 6 8 8 10Diameter (mm) 762 762 762 762Total Air Flow (m3/s) 19.25 22.23 24.99 27.83Nominal RPM 730 730 730 730Tip Speed (m/s) 29.1 29.1 29.1 29.1Motor kW (kW) 1.05 1.05 1.05 1.05Min Starting/Oper Ambient (2)

Std Unit (°C) 7 7 7 7Low Ambient Unit (°C) -18 -18 -18 -18General UnitRefrigerant HFC 134a HFC 134a HFC 134a HFC 134aNo. Of independentRefrigerant Circuits 2 2 2 2% Min. Load (3) 17 17 17 17Refrigerant Charge (1) (kg) 50 69 87 87Oil Charge (1) (l) 10 12 18 18Operating Weight (kg) 3340 3470 4005 4100Shipping Weight (kg) 3075 3245 3800(1) Data containing information for two circuits (2) Minimum start-up/operation ambient based on a 2.22 m/s (5mph) wind across the condenser.(3) Percent minimum load is for total machine at 10°C (50F) ambient and 7°C (44F) lealing chilled water temp. Not each individual circuit.

Unit DimensionsFigure 2 - Unit Dimensions and Minimum Recommended Clearances

Unit size Unit Dimensions Minimum clearances

Length Width Height A B C

085 STD/HE 3381 2260 2095 1000 1000 1200100 STD/HE 4300 2260 2095 1000 1000 1200115 STD/HE 5219 2115 2095 1000 1000 1200125 STD/HE 5219 2115 2095 1000 1000 1200

RTAD-SVX01A-E4 9

Installation - Mechanical

Warnings and CautionsWarnings and Cautions appear in

boldface type at appropriate points

in this manual.Warnings are

provided to alert personnel to

potential hazards that can result in

personal injury or death; they do not

replace the manufacturer's

recommendations. Cautions alert

personnel to conditions that could

result in equipment damage.Your

personal safety and reliable

operation of this machine depend

upon strict observance of these

precautions.

Installation Responsibilities Generally, the contractor must do thefollowing when installing an RTADunit:❏ Install unit on a flat foundation,

level (within 1/4" [6 mm] acrossthe length of the unit), and strongenough to support unit loading.

❏ Install unit per the instructionscontained in the Installation-Mechanical and Installation-Electrical sections of this manual.

❏ Install any optional sensors andmake electrical connections at theUCM-CLD.

❏ Where specified, provide andinstall valves in water pipingupstream and downstream ofevaporator water connections toisolate the evaporator formaintenance, and to balance/trimsystem.

❏ Furnish and install flow switchand/or auxiliary contacts to provechilled water flow.

❏ Furnish and install pressuregauges in inlet and outlet piping ofthe evaporator.

❏ Furnish and install a drain valve tothe bottom of the evaporatorwaterbox.

❏ Supply and install a vent cock tothe top of the evaporatorwaterbox.

❏ Furnish and install strainers aheadof all pumps and automaticmodulating valves.

❏ Provide and install field wiring.❏ Install heat tape and insulate the

chilled water lines and any otherportions of the system, as

required, to prevent sweatingunder normal operating conditionsor freezing during low ambienttemperature conditions.

❏ Start unit under supervision of aqualified service technician.

NameplatesThe RTAD outdoor unit nameplates(Figure 1) are applied to the exteriorof the control panel. A compressornameplate is located on eachcompressor.Outdoor Unit Nameplate

The outdoor unit nameplate providesthe following information:• Unit model and size description• Unit serial number• Identifies unit electrical

requirements• Lists correct operating charges of

R-134a and refrigerant oil (TraneOK00048)

• Lists unit test pressuresCompressor Nameplate

The compressor nameplate providesfollowing information:• Compressor model number.• Compressor serial number.

• Compressor electricalcharacteristics.

• Utilization range• Recommended refrigerant

StorageExtended storage of the outdoor unitprior to installation requires thefollowing precautionary measures:• Store the outdoor unit in a secure

area.• At least every three months

(quarterly), check the pressure inthe refrigerant circuits to verify thatthe refrigerant charge is intact. If itis not, contact a qualified serviceorganization and the appropriateTrane sales office.

• Close the discharge and liquid lineisolation valves.

Location RequirementsSetting the Unit

A base or foundation is not requiredif the selected unit location is leveland strong enough to support theunit's operating weight as listed inTables 1,2, and 3.

Figure 3 - Rigging the Unit

Maximum weight

RTAD L A Alumimium Copper

85 STD 3381 mm 4000 mm 2760 kg 3090 kg100-115-125 STD85-100 HE 4300 mm 4000 mm 3670 kg 4110 kg115-125 HE 5219 mm 4000 mm 4100 kg 4655 kg

10 RTAD-SVX01A-E4


Condenser coils and fan dischargemust be kept free of snow or otherobstructions to permit adequateairflow for satisfactory unitoperation.In situations where equipment mustbe installed with less clearance thanrecommended, such as frequentlyoccurs in retrofit and rooftopapplications, restricted airflow iscommon. The Main Processor willdirect the unit to make as muchchilled water as possible given theactual installed conditions. Consultyour Trane sales engineer for moredetails.Note: If the outdoor unitconfiguration requires a variance tothe clearance dimensions, contactyour Trane Sales OfficeRepresentative. Also refer to TraneEngineering Bulletins for applicationinformation on RTAD chillers.

Unit Isolation and Leveling

For additional reduction of soundand vibration, install the optionalneoprene isolators. Construct anisolated concrete pad for the unit orprovide concrete footings at the unitmounting points. Mount the unitdirectly to the concrete pads orfootings. Level the unit using thebase rail as a reference. The unitmust be level within 1/4-in (6 mm)over the entire length. Use shims asnecessary to level the unit.

Neoprene Isolator (optional)

Installation

Refer to submittals for diagrams.1 Secure the isolators to the

mounting surface using themounting slots in the isolator baseplate. DO NOT fully tighten theisolator mounting bolts at thistime.

2 Align the mounting holes in thebase of the unit with the threadedpositioning pins on the top of theisolators.

3 Lower the unit onto the isolatorsand secure the isolator to the unitwith a nut. Maximum isolatordeflection should be 1/4 inch(6 mm).

CAUTION: Refer to nameplate for

unit weight and additional

installation instructions contained

inside the control panel. Other lifting

arrangements may cause equipment

damage or serious personal injury.

Isolation and Sound Emission

The most effective form of isolationis to locate the unit away from anysound sensitive area. Structurallytransmitted sound can be reduced byelastomeric vibration eliminators.Spring isolators are notrecommended. Consult an acousticalengineer in critical soundapplications. For maximum isolationeffect, isolate water lines andelectrical conduit. Wall sleeves andrubber isolated piping hangers canbe used to reduce the soundtransmitted through water piping. Toreduce the sound transmittedthrough electrical conduit, useflexible electrical conduit. State andlocal codes on sound emissionsshould always be considered. Sincethe environment in which a soundsource is located affects soundpressure, unit placement must becarefully evaluated. Sound powerlevels for Trane air-cooled RTADchillers are available on request.

Noise Considerations

Locate the outdoor unit away fromsound sensitive areas. If required,install rubber vibration isolators inall water piping and use flexibleelectrical conduit. Consult anacoustical engineer for criticalapplications. Also refer to TraneEngineering Bulletins for applicationinformation on RTAD chillers.

Foundation

Provide rigid, non-warping mountingpads or a concrete foundation ofsufficient strength and mass tosupport the outdoor unit operatingweight (i.e., including completedpiping, and full operating charges ofrefrigerant, oil and water). Refer toTables 1, 2 and 3 for unit operatingweights. Once in place, the outdoorunit must be level within 1/ 4"(6 mm) over its length and width.

Trane is not responsible forequipment problems resulting froman improperly designed orconstructed foundation.Note: To allow for cleaning under thecondensing coil, it is recommendedthat an opening be left between theunit base and the concrete pad.

Clearances

Refer to Figure 2 for minimumclearances. Provide enough spacearound the outdoor unit to allow theinstallation and maintenancepersonnel unrestricted access to allservice points. Refer to submittaldrawings for the unit dimensions. Aminimum of four feet isrecommended for compressorservice. Provide sufficient clearancefor the opening of control paneldoors. In all cases, local codes whichrequire additional clearances willtake precedence over theserecommendations.

Unobstructed flow of condenser airis essential to maintain chillercapacity and operating efficiency.When determining unit placement,give careful consideration toassuring a sufficient flow of airacross the condenser heat transfersurface. Two detrimental conditionsare possible and must be avoided ifoptimum performance is to beachieved: warm air recirculation andcoil starvation. Warm air recirculationoccurs when discharge air from thecondenser fans is recycled back to hecondenser coil inlet. Coil starvationoccurs when free airflow to (or from)the condenser is restricted. Bothwarm air recirculation and coilstarvation cause reduction in unitefficiency and capacity due to theincreased head pressures. Debris,trash, supplies etc. should not beallowed to accumulate in the vicinityof the unit. Supply air movementmay draw debris into the condensercoil, blocking spaces between coilfins and causing coil starvation.Special consideration should begiven to low ambient units.

RTAD-SVX01A-E4 11


Caution: A pipe strainer must be

installed in the entering water line.

Failure to do so can allow

waterborne debris to enter the

evaporator.

"Piping components" include alldevices and controls used to provideproper water system operation andunit operating safety. Thesecomponents and their generallocations are given below.

Entering Chilled Water

Piping❏ Air vents (to bleed air from

system).❏ Water pressure gauges with

shutoff valves.❏ Vibration eliminators.❏ Shutoff (isolation) valves.

Thermometers (if desired).❏ Clean-out tees.❏ Pipe strainer.Caution: Install strainer in

evaporator water inlet piping. Failure

to do so can result in evaporator

tube damage.

Leaving Chilled Water

Piping❏ Air vents (to bleed air from

system).❏ Water pressure gauges with

shutoff valves. Vibrationeliminators.

❏ Shutoff (isolation) valves.❏Thermometers.❏ Clean-out tees.❏ Balancing valve.❏ Flow SwitchCaution:To prevent evaporator

damage, do not exceed 150 psig

(10.5 bar) evaporator water pressure.

Evaporator DrainA 3/4" drain connection is locatedunder the evaporator shell. This maybe connected to a suitable drain topermit evaporator drainage duringunit servicing. A shutoff valve mustbe installed on the drain line.

Evaporator Flow SwitchSpecific connection and schematicwiring diagrams are shipped withthe unit. Some piping and controlschemes, particularly those using asingle water pump for both chilledand hot water must be analyzed todetermine how and or if a flow-sensing device will provide desiredoperation.Follow the manufacturer'srecommendations for selection andinstallation procedures. Generalguidelines for flow switch installationare outlined below1. Mount the switch upright, with a

minimum of 5 pipe diameters ofstraight horizontal run on eachside. Do not install close toelbows, orifices or valves.

Note: The arrow on the switch mustpoint in the direction of flow.2. To prevent switch fluttering,

remove all air from the watersystem.

Note: The UCM-CLD provides a 6-second time delay after a "loss-of-flow" diagnostic before shutting theunit down. Contact a qualifiedservice representative if nuisancemachine shutdowns persist.3. Adjust the switch to open when

water flow falls below nominal.Evaporator data is given in Tables 1,2 and 3. Flow switch contacts areclosed on proof of water flow.4. Install a pipe strainer in the

entering evaporator water line toprotect components fromwaterborne debris.

Water TreatmentCAUTION: If calcium chloride is used

for water treatment, an applicable

corrosion inhibitor must also be

used. Failure to do so may result in

damage to system components.

Dirt, scale, products of corrosion andother foreign material will adverselyaffect heat transfer between thewater and system components.Foreign matter in the chilled watersystem can also increase pressuredrop and, consequently, reducewater flow. Proper water treatmentmust be determined locally,

4 Level the unit carefully. Fullytighten the isolator mounting bolts.

Drainage

Provide a large capacity drain forwater vessel drain-down duringshutdown or repair. The evaporatoris provided with a drain connection.All local and national codes apply.The vent on the top of theevaporator shell is provided toprevent a vacuum by allowing airinto the evaporator for completedrainage.

Evaporator Water PipingThoroughly flush all water piping tothe unit before making the finalpiping connections to the unit.Caution: If using an acidic

commercial flushing solution,

construct a temporary bypass

around the unit to prevent damage

to internal components of the

evaporator.To avoid possible

equipment damage, do not use

untreated or improperly treated

system water.

Evaporator PipingComponents and layout will varyslightly, depending on the location ofconnections and the water source.Caution:The chilled water

connections to the evaporator are to

be flange type connections.

To prevent damage to chilled watercomponents, do not allowevaporator pressure (maximumworking pressure) to exceed 150 psig(10.5 bar).Provide shutoff valves in lines to thegauges to isolate them from thesystem when they are not in use.Use rubber vibration eliminators toprevent vibration transmissionthrough the water lines. If desired,install thermometers in the lines tomonitor entering and leaving watertemperatures. Install a balancingvalve in the leaving water line tocontrol water flow balance. Installshutoff valves on both the enteringand leaving water lines so that theevaporator can be isolated forservice.

12 RTAD-SVX01A-E4


depending on the type of system andlocal water characteristics. Neithersalt nor brackish water isrecommended for use in Trane air-cooled Series R™ chillers. Use ofeither will lead to a shortened life toan indeterminable degree. The TraneCompany encourages theemployment of a reputable watertreatment specialist, familiar withlocal water conditions, to assist inthis determination and in theestablishment of a proper watertreatment program.Using untreated or improperlytreated water in these units mayresult in inefficient operation andpossible tube damage. Consult aqualified water treatment specialistto determine whether treatment isneeded. The following disclamatorylabel is provided on each RTAD unit:Note: The use of improperly treatedor untreated water in this equipmentmay result in scaling, erosion,corrosion, algae or slime. Theservices of a qualified watertreatment specialist should beengaged to determine whattreatment, if any, is advisable. TheTrane Company warranty specificallyexcludes liability for corrosion,erosion or deterioration of Traneequipment.Caution: Do not use untreated or

improperly treated water. Equipment

damage may occur.

Water Pressure GaugesInstall field-supplied pressurecomponents as shown in Figure 5.Locate pressure gauges or taps in astraight run of pipe; avoid placementnear elbows, etc. Be sure to installthe gauges at the same elevation oneach shell if the shells have opposite-end water connections.To read manifolded pressure gauges,open one valve and close the other(depending upon the readingdesired). This eliminates errorsresulting from differently calibratedgauges installed at unmatchedelevations.

1

10

100

1000

1 10 100

WPD

kPa

12

34

Figure 4: Evaporator Water Pressure Drop RTAD

Evaporator Water Pressure Drops (SI units)

Water Flow l/s

Legend

Curve RTAD Std RTAD HE RTAD HELN RTAD HA

1 85 *** *** ***2 100 85 85 853 115 100 100 1004 125 115 - 125 115 - 125 115 - 125

7

8

9

10

6

5

43

21

134

Figure 5 - Suggested piping for typical RTAD evaporator

1. Gate valve2. Water strainer3. Thermometer (user option)4. Vibration eliminator5. Relief valve

6. Valved pressure gauge7. Vent8. Drain9. Flow switch10. Balancing valve

RTAD-SVX01A-E4 13


Water Pressure Relief

ValvesCaution:To prevent shell damage,

install pressure relief valves in the

evaporator water system.

Install a water pressure relief valve inthe evaporator inlet piping betweenthe evaporator and the inlet shutoffvalve, as shown in Figure 8. Watervessels with close-coupled shutoffvalves have a high potential forhydrostatic pressure buildup on awater temperature increase. Refer toapplicable codes for relief valveinstallation guidelines.

Freeze ProtectionIf the unit will remain operational atsubfreezing ambient temperatures,the chilled water system must beprotected from freezing, followingthe steps listed below1 Heaters are factory-installed on the

packaged unit evaporator and willprotect it from freezing in ambienttemperatures down to -18°C (0°F).

2 Install heat tape on all waterpiping, pumps, and othercomponents that may be damagedif exposed to freezingtemperatures. Heat tape must bedesigned for low ambienttemperature applications. Heattape selection should be based onthe lowest expected ambienttemperature.

3 Add a non-freezing, lowtemperature, corrosion inhibiting,heat transfer fluid to the chilledwater system. The solution must bestrong enough to provideprotection against ice formation atthe lowest anticipated ambienttemperature. Refer to Table 1through Table 3 in Section 1 forevaporator water storagecapacities.

Note: Use of glycol type antifreezereduces the cooling capacity of theunit and must be considered in thedesign of the system specifications.

14 RTAD-SVX01A-E4

Installation - Electrical

General RecommendationsWARNING:The warning label shown

in Figure 6 is displayed on the

equipment. Strict adherence to these

warnings must be observed. Failure

to do so may result in personal

injury or death.

All wiring must comply with localcodes. Typical field wiring diagrams areincluded in the unit control panel.Minimum circuit ampacities and otherunit electrical data are on the unitnameplate and in the general datatables. See the unit order specificationsfor actual electrical data. Specificelectrical schematics and connectiondiagrams are shipped with the unit.

!

Figure 6 - Warning Label

Caution:To avoid corrosion and

overheating at terminal connections,

use copper conductors only. Failure

to do so may result in damage to the

equipment.

Do not allow conduit to interfere

with other components, structural

members or equipment. Control

voltage (115V) wiring in conduit

must be separate from conduit

carrying low voltage (<30V) wiring.

Caution:To prevent control

malfunctions, do not run low voltage

wiring (<30V) in conduit with

conductors carrying more than

30 volts.

RTAD-SVX01A-E4 15


Table 4 RTAD 85-125 Electrical Data (400V/3Ph/50Hz)Unit Wiring

RTAD Standard 85 1 229 250 0.89 250 A 6 x 125 A 0.217100 1 279 305 0.86 400 A 6 x 160 A 0.217115 1 324 359 0.89 400 A 6 x 200 A 0.217125 1 390 426 0.90 500 A 6 x 250 A 0.217RTAD High Efficiency/High Ambient85 1 229 250 0.89 400 A 6 x 160 A 0.217100 1 288 314 0.86 400 A 6 x 200 A 0.217115 1 333 368 0.89 400 A 6 x 250 A 0.217125 1 408 444 0.90 500 A 6 x 250 A 0.217RTAD High Efficiency Low Noise85 1 218 239 0.89 250 A 6 x 125 A 0.217100 1 273 299 0.86 400 A 6 x 160 A 0.217115 1 318 353 0.89 400 A 6 x 200 A 0.217125 1 389 425 0.90 500 A 6 x 250 A 0.217

Electrical Data RTAD 085 - 125 (continued)Motor Data

Compressor (Each) Fans (Each) Control

Unit RLA Amps Max Amps (3) Starting Amps (4) Fans fuse (400V)

Size Qty Ckt 1 Ckt 2 Ckt 1 Ckt 2 Ckt 1 Ckt 2 Qty kW FLA size (A) VA A

RTAD Standard85 2 75 75 99 99 144 144 6 2.05 4.5 3 x 50 A 1600 4100 2 94 94 124 124 180 180 6 2.05 4.5 3 x 50 A 1600 4115 2 111 111 147 147 217 217 6 2.05 4.5 3 x 50 A 1600 4125 2 136 136 180 180 259 259 6 2.05 4.5 3 x 50 A 1600 4RTAD High Efficiency/High Ambient85 2 75 75 99 99 144 144 6 2.05 4.5 3 x 50 A 1600 4100 2 94 94 124 124 180 180 8 2.05 4.5 3 x 50 A 1600 4115 2 111 111 147 147 217 217 8 2.05 4.5 3 x 50 A 1600 4125 2 136 136 180 180 259 259 10 2.05 4.5 3 x 50 A 1600 4RTAD High Efficiency Low Noise85 2 75 75 99 99 144 144 6 1.05 2.6 3 x 50 A 1600 4100 2 94 94 124 124 180 180 8 1.05 2.6 3 x 50 A 1600 4115 2 111 111 147 147 217 217 8 1.05 2.6 3 x 50 A 1600 4125 2 136 136 180 180 259 259 10 1.05 2.6 3 x 50 A 1600 4(1) Maximum Compressors FLA + all fans FLA + control Amps(2) Starting Amps of the circuit with the largest compressor circuit including fans plus RLA of the second circuit including fans + control Amps(3) Maximum FLA per compressor.(4) Compressors starting Amps, Star delta start.(5) Compressor Power Factor

1. As standard, all units have singlepoint power connection.

2. LRA (Locked Rotor Amps) - basedon full winding (x-line) start units.LRA for wye-delta starters is 1/3 ofLRA of x-line units.

3. VOLTAGE UTILIZATION RANGE:

Rated Voltage Utilization Range 400/50/3 340-460

For the RTAD 100 only, the UtilizationRange is 360 - 460 Volts

Installer-Supplied

ComponentsCaution: 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 supplieddevices.

❏ Fused-disconnect switches orcircuit breakers.

❏ Power factor correction capacitors.

Power Supply WiringAll power supply wiring must besized and selected accordingly by theproject engineer in accordance withEN 60204.WARNING:To prevent injury or

death, disconnect all electrical power

sources before completing wiring

connections to the unit.

All wiring must comply with localelectrical codes. The installing (orelectrical) contractor must provideand install the systeminterconnecting wiring and thepower supply wiring. It must beproperly sized and equipped with theappropriate fused disconnectswitches. The type and installationlocation(s) of the fused disconnectsmust comply with all applicablecodes.Caution: Use only copper conductors

for terminal connections to avoid

corrosion or overheating.

Cut holes into the sides of thecontrol panel for the appropriatelysized power wiring conduits.

UnitSize

Nbr of PowerConnections

MaximumAmps (1)

StartingAmps (2)

Power Factor (5)

DisconnectSwitch Size

CompressorFuse Size (A)

Evaporatorheater (kW)

16 RTAD-SVX01A-E4


The wiring is passed through theseconduits and connected to theterminal blocks, optional unit-mounted disconnects, or circuitbreakers. To provide proper phasing of 3-phase input, make connections asshown in field wiring diagrams andas stated on the Warning label in thestarter panel. For additionalinformation on proper phasing, referto "Unit Voltage Phasing." Properequipment ground must be providedto each ground connection in thepanel (one for each customer-supplied conductor per phase).

Control Power Supply

The unit is equipped with a controlpower transformer; it is notnecessary to provide additionalcontrol power voltage to the unit. TheRTAD units are factory-connected for400V/3/50 with a factory-installedcontrol power transformer.

Heater Power Supply

The evaporator shell is insulatedfrom ambient air and protected fromfreezing temperatures by electricheaters. Whenever the watertemperature drops to approximately37°F (2.8°C), the thermostatenergizes the heaters. The heaterswill provide protection from ambienttemperatures down to -18°C (0°F).The heaters are factory-wired back tothe unit control panel.

CAUTION: Control panel main

processor does not check for loss of

power to the heat tape nor does it

verify thermostat operation. A

qualified technician must verify

power to the heat tape and confirm

operation of the heat tape

thermostat to avoid catastrophic

damage to the evaporator.

Water Pump Power Supply

Provide power supply wiring withfused disconnect for the chilledwater pump(s).

Interconnecting WiringChilled Water Flow (Pump) InterlockThe model RTAD chiller requires afield-supplied control voltage contactinput through a flow proving switch6S56 and an auxilary contact 6K51 ofthe chilled water pump contactor.IMPORTANT: Do not turn the chiller

on or off using the chilled-water

interlocks.

When making field connections,refer to the appropriate field layout,wiring schematics, and controldiagrams that ship with the unit.

Chilled-water pump control

CAUTION:The chilled-water pump

must operate for a minimum of one

minute after the UCM-CLD receives a

command, through the external

Auto/Stop input, to shut down the

chilled-water system.

On the RTAD units, the controller willinitiate the "Run:Unload" mode toterminate a cycle from any of thefollowing:• Stop key pressed• Loss of load• External Auto/Stop input openedThe "Run:Unload" operating modecommands the compressor tocompletely unload, which takesabout ½ minute. This will allow thecompressors to be totally unloadedfor the next start-up. If only theproof-of-chilled-water-flow interlockis used, the chiller will shut downwith an immediate (non-friendly)shutdown and initiate an automaticreset diagnostic.1. External Auto/Stop (terminals A1

TB3-3 and -4). This input issupplied by the field. A contactclosure will start the chiller waterpump and chiller, via the UCM-CLDpump control contacts. Openingthe contact will put the operatingcompressors into "Run:Unload"mode and initiate a timing period(1 to 30 minutes, adjustablethrough the Clear LanguageDisplay). This will delaytermination of the chilled-waterpump operation via the UCMpump control contacts. Examplesof the input terminals 1UTB3-3 and

-4 would be a time clock, ambientthermostat, building automationsystem, etc.2. UCM-CLD Pump Control Contacts

(Terminals A1 TB4-8 and -9) This output is a set of contacts thatwill close, starting the chilled-waterpump when the external Auto/Stopcontacts are closed. When thecontacts are opened, 1 to 30 minuteslater (adjustable through the ClearLanguage Display), the UCM-CLDpump control contacts open.3. Proof-of-Chilled-Water-Flow

Interlock (Terminals A1 TB3-1and -2)

This terminal must be field-installed.Contact closure between theterminals indicates proof of chilled-water flow. Examples of this are apump starter auxiliary contact, flowswitch, differential pressure switch,or a contact from a buildingautomation system. Opening of thiscontact will immediately shut downthe chiller and initiate an automaticreset diagnostic, indicating loss ofchilled-water flow.

Alarm and Status Relay

Output (Programmable

Relays)Alarm/Running/Maximum Capacity

Outputs

Terminals 1 to 7 on terminal strip TB4of the A1 board provide a variety ofcontact outputs on the RTAD. Theseare dependent on the setting ofProgrammable Relay Setup (ServiceSetting Menu) and its relationship todiagnostics, compressors operating,and the system operating at fullcapacity.As shown in Figure 7, there are threerelays.

RTAD-SVX01A-E4 17


Table 5 - Alarm / Running / Maximum capacity relay output configuration Relay output configuration

1 Relay 1 AlarmRelay 2 Compressor runningRelay 3 Maximum capacity

2 Relay 1 Circuit 1 alarmRelay 2 Circuit 2 alarmRelay 3 Maximum capacity

3 Relay 1 AlarmRelay 2 Circuit 1 runningRelay 3 Circuit 2 running

Table 6 - Alarm / Running / Maximum capacity menu setting

1 1 YES NO NO2 1 YES YES NO3 1 YES YES YES4 1 YES NO YES5 2 YES NO NO6 2 YES YES NO7 2 YES YES YES8 2 YES NO YES9 3 YES NO NO10 3 YES YES NO11 3 YES YES YES12 3 YES NO YES

Notes:MMR: Machine Manual ResetCMR: Circuit Manual ResetMAR: Machine Auto ResetCAR: Circuit Auto ResetIFW: Informational Warnings

Figure 7 - Alarm / Running / Maximum capacity relay output for the RTAD unit.

Diagnostic that the Alarmrelay(s) is active

Programmable Relay SetupSetting (service setting menu)

Relay OutputConfiguration(Table 5)

MMR / CMR diag.

MAR / CARdiag.

IFW diag.

18 RTAD-SVX01A-E4


Low-voltage wiringThe remote devices described belowrequire low-voltage wiring. All wiringto and from these remote analogdevices to the UCM-CLD, asdescribed in this paragraph, must bemade with shielded, twisted-pairconductors. Be sure to ground theshielding only at the Clear LanguageDisplay.CAUTION:To prevent control

malfunction, do not run low-voltage

wiring (<30V) in conduits with

conductors carrying more than 30 V.

External Emergency stop

(normal trip)The Clear Language Display providesauxiliary control for a customer-specified or -installed latchingtripout. When this remote contact6S2 (furnished by the customer) isprovided, the chiller will runnormally when the contact is closed.When the contact opens, the unit willtrip off on a manually resettablediagnostic. This condition requiresmanual reset at the chiller switch onthe front of the Clear LanguageDisplay. To connect, first remove thejumper located between terminal 3and 4 of A1 TB1. Refer to the fielddiagrams that are shipped with theunit.

External Auto/StopIf the unit requires the externalAuto/Stop function, the installermust provide leads from theremote contacts 6S1 to the properterminals of the module A1 terminalsTB3-3 and TB3-4 inthe control panel.The chiller will run normally whenthe contact is closed. When thecontact opens, thecompressor(s), ifoperating, will go to theRUN:UNLOAD operating mode andcycle off. Unitoperation will beinhibited. Re-closure of the contactswill permit the unit to automaticallyreturn to normal operation.Field-supplied contacts for all low voltageconnections must be compatiblewith dry circuit 24VDC for a 12 mAresistive load.

Refer to the field diagrams that areshipped with the unit.

External circuit lockout -

Circuit 1The UCM provides auxiliary controlof a customer-specified or -installedcontact closure, for individualoperation of circuit number 1. If thecontact is closed, the refrigerantcircuit will not operate. Therefrigerant circuit will run normallywhen the contact is opened. Externalcircuit lockout will only function ifExternal Circuit Lockout (servicesetting Menu) is enabled.Connections are shown in the fielddiagrams that are shipped with theunit.

External circuit lockout -

Circuit 2The UCM provides auxiliary controlof a customer-specified or -installedcontact closure, for individualoperation of circuit number 2. If thecontact is closed, the refrigerantcircuit will not operate. Therefrigerant circuit will run normallywhen the contact is opened. Externalcircuit lockout will only function ifExternal Circuit Lockout (servicesetting Menu) is enabled.Connections are shown in the fielddiagrams that are shipped with theunit.

Ice-making optionIce-machine control (OperatorSetting Menu) must be enabled. TheUCM provides auxiliary control for acustomer-specified or installedcontact closure for ice making. Whenthe remote contact connected to themodule A9, terminals TB1 1 and 2, isprovided, the chiller will runnormally when the contact is open.Upon contact closure, the UCM willinitiate an ice-building mode, inwhich the unit runs fully loaded at alltimes. In ice-building, the currentsetpoint will be set at 120%. Forexample, if the front panel orexternal current limit setpoint is setto 80%, in ice-building the activecurrent limit is 120%.

RTAD-SVX01A-E4 19


If, while in ice-building mode, theunit gets down to the freezestatsetting (water or refrigerant), the unitwill shut down on a manuallyresettable diagnostic, just as innormal operation.

External chilled-water

setpoint: voltage source

2-10 V (dc), or Current

source 4-20 mAThis option allows the externalsetting of the chilled-water setpoint(CWS), independent of the frontpanel chilled-water setpoint, by oneof two means:1 - An isolated voltage input 2-10 V

(dc)2 - An isolated current loop input

4-20 mA

Isolated 2-10 V (dc) voltage

source inputSet dipswitch SW1-1 of the optionmodule A9 to "OFF." Connect thevoltage source to terminals 4 (+) and5 (-) on option module A9 TB1. CWSis now based on the followingequation:CWS °C = (V (dc) * 4.88) - 27.56Sample values for CWS vs. V (dc)signals are shown in Table 7

Table 7: Input values vs. External chilled-water setpoint

Voltage Current(V (dc)) (mA)

3.6 7.2 -104.6 9.2 -55.6 11.3 06.7 13.3 57. 7 1 5.4 1 0

Isolated 4-20 mA current

source inputSet dipswitch SW1-1 of the optionmodule A9 to "ON." Connect the current source terminals4 (+) and 5 (-).CWS is now based on the followingequation:Setpoint (°C) = (mA * 2.44) - 27.56

External current limit

setpoint: voltage source

2-10 V (dc)or current source

4- 20 mA.This option allows the externalsetting of the current limit setpoint(CLS), independent of the front panelcurrent-limit setpoint, by one of thetwo means:1 - an isolated voltage input 2-10 V

(dc)2 - an isolated voltage input 4-20 mATo enable external current-limitsetpoint operation, external current-limit setpoint (operator settingmenu) should be set to "E" using theclear language display.1- 2-10 V (dc) voltage source input Set dipswitch SW1-2 of the optionmodule A9 to "OFF." Connect the voltage source toterminals 7 (+) and 8 (-) of the optionmodule A9. CLS is now based on thefollowing equation: CLS % = (V (dc)*10) + 20Sample values for CLS vs.V(dc)signals are shown in Table 8.Minimum setpoint: 40% (2.0 V(dc)input)Maximum setpoint: 120% (10.0 V(dc)input)4-20 mA Current source inputSet dipswitch SW1-2 of the optionmodule A9 to "ON." Connect thecurrent source to terminal 7 (+) and 8(-) of option module A9. CLS is nowbased on the following equation:CLS % = (mA * 5) + 20Sample values for CLS versus mAsignals are shown in Table 8.Minimum setpoint = 40% (4.0 mA)Maximum setpoint = 120% (20.0 mA)

Table 8: Input values vs. external current-limit setpoint

Voltage Current(V (dc)) (mA)

2.0 4.0 403.0 6.0 504.0 8.0 605.0 10.0 706.0 12.0 807. 0 1 4.0 9 08.0 16.0 1009.0 18.0 11010.0 20.0 120

Outdoor air-temperature

sensorThis sensor is used for low ambientlockout and chilled-water reset byoutdoor air temperature. This sensoris optional on the RTAD units.Remove the sensor from its shippinglocation in the control panel andinstall it in the fresh-air intake on thenorth wall of the building. Protect thesensor from direct sunlight andshelter it from the elements. Connectleads to terminals 1 and 2 frommodule A9 TB1. All wiring to andfrom the remote sensor must bemade with shielded, twisted-pairconductors.Be sure to ground the shielding onlyat the UCM-CLD. Apply tape to thesensor end of the shielding toprevent it from contacting thesurface.WARNING:To prevent injury or

death, disconnect the electrical

power source before completing

wiring connections to the unit.

RTAD-SVX01A-E4 20

Resultingchilled-watersetpoint (°C)

Resultingchilled-watersetpoint (°C)


CAUTION:To prevent overheating at

the terminal connections, use copper

conductors only.

Communication card CSRThis option allows the ClearLanguage Display in the controlpanel on RTAD units to exchangeinformation (operating setpoints andAuto/Standby commands) with ahigher-level control device, such asTracer. A shielded, twisted-pairconnection establishes thebidirectional communications linkbetween the unit control panel andthe Tracer.Note: The shielded, twisted-pairconductors must run in a separateconduit.Caution:To prevent control

malfunction, do not run low-voltage

wiring (<30V) in conduits with

conductors carrying more than 30

volts.

Field wiring for the communicationlink must meet the followingrequirements:1. All wiring must be in accordance

with local codes.2. Communication link wiring must

be shielded, twisted-pair wiring.3. The maximum total length for

each communication link is 1,500meters.

4. The communication link cannotpass between buildings.

5. All UCM-CLD on thecommunication link can beconnected in a "daisy chain"configuration.

Communication-link

connection procedure1. Refer to the Tracer installation

literature to determine propercommunication-link terminationconnections at the Tracer module.

2. Connect the shield of thecommunication-link wiring to thedesignated shield terminal at theTracer module.

3. Connect leads to terminals 1 to 4of TB2 of the module A9 of theUCM-CLD to the Tracer. There is nopolarity requirement for theconnection.

4. At the UCM-CLD, the shield shouldbe cut and taped to prevent anycontact between the shield andground.

Note: On multiple-unit installations,splice the shielding of the twistedpairs that come into each UCM-CLDin the "daisy chain" system. Tape thespliced connections to prevent anycontact between the shield andground. At the last Clear LanguageDisplay in the chain, the shieldshould be cut and taped off.5. To get the chiller to communicate

with a Tracer on a multiple-unitcontroller, the ICS address underthe "service settings" menu mustbe set and the optional A9 modulemust be installed. Contact yourlocal Trane representative for thismatter.

RTAD-SVX01A-E4 21

Operating Principles

1. To compressor2. CLD3. Control panel4. Power panel:

InvertersFuses (fans, comp)Disconnect switchTransformer

5. Fans6. Fan deck7. Inverter driven motor8. Fan motors9. Oil cooler10. Condenser temperature sensor11. Condenser coil with subcooler12. Condenser service valves13. Isolation valve14. Liquid line filter

15. Evaporator temperature sensor16. Water inlet temperature17. Water outlet temperature18. Water inlet19. Water outlet20. Evaporator21. Evaporator service valves22. Relief valves23. Suction temperature sensor24. Compressor25. Discharge isolation valve (option)26. Oil filter27. High pressure cutout

Load control solenoids28. Oil line shutoff29. Oil temperature sensor30. Oil line31. Oil separator

32. Oil drain valve33. Heater34. Relief valve

Figure 8: System/Oil system schematic

22 RTAD-SVX01A-E4

Installation ChecklistComplete this checklist as the unit isinstalled and verify that allrecommended procedures areaccomplished before the unit isstarted. This checklist does notreplace the detailed Instructionsgiven in the "Installation -Mechanical" and "Installation -Electrical" sections of this manual.Read both sections completely, tobecome familiar with the installationprocedures, prior to beginning thework.

Receiving❏ Verify that the unit nameplate data

corresponds to the orderinginformation.

❏ Inspect the unit for shippingdamage and any shortages ofmaterials. Report any damage orshortage to the carrier.

Unit Location and

Mounting❏ Inspect the location desired for

installation and verify adequateservice access clearances.

❏ Provide drainage for evaporatorwater.

❏ Remove and discard all shippingmaterials (cartons, etc.)

❏ Install optional rubber isolators, ifrequired.

❏ Level the unit and secure it to themounting surface.

Unit Piping❏ Flush all unit water piping before

making final connections to theunit.

CAUTION: If using an acidic

commercial flushing solution,

construct a temporary bypass

around the unit to prevent damage

to internal components of the

evaporator.To avoid possible

equipment damage, do not use

untreated or improperly treated

system water.

❏ Connect the chilled water piping tothe evaporator.

❏ Install pressure gauges and shutoffvalves on the chilled water inletand outlet to the evaporator.

❏ Install a water strainer in theentering chilled water line.

❏ Install a balancing valve and flowswitch (recommended) in theleaving chilled water line.

❏ Install a drain with shutoff valve ora drain plug on the evaporatorwaterbox.

❏ Vent the chilled water system athigh points in the system piping.

❏ Apply heat tape and insulation, asnecessary, to protect all exposedpiping from freeze-up.

Electrical Wiring WARNING:To prevent injury or

death, disconnect electrical power

source before completing wiring

connections to the unit.

CAUTION:To avoid corrosion and

overheating at terminal connections,

use copper conductors only.

❏ Connect the unit power supplywiring with fused-disconnect tothe terminal block or lugs (or unit-mounted disconnect) in the powersection of the control panel.

❏ Connect power supply wiring tothe evaporator heater.

❏ Connect power supply wiring tothe chilled water pump.

❏ Connect power supply wiring toany auxiliary heat tapes.

❏ Connect the auxiliary contact ofthe chilled water pump (6K51) inseries with the flow switch, ifinstalled, and then connect to theproper terminals.

❏ For the External Auto/Stopfunction, install wiring fromremote contact (6S1) to the properterminals on the circuit board.

CAUTION: Information in

Interconnecting Wiring: Chilled Water

Pump Interlock and External

Auto/Stop must be adhered to or

equipment damage may occur.

❏ If alarm and status relay outputsare used, install leads from thepanel to the proper terminals oncircuit board.

❏ If the emergency stop function isused, install low voltage leads toterminals on circuit board.

❏ Connect separate power for theExternal Emergency Stop option, ifapplicable.

❏ If the ice making-option is used,install leads on terminals TB1-1and 2 on module A9.

GeneralWhen installation is complete, butprior to putting the unit into service,the following pre-startprocedures must be reviewed andverified correct:Disconnect all electric power

including remote disconnects before

servicing. Failure to disconnect

power before servicing can cause

severe personal injury or death.

1 Inspect all wiring connections inthe compressor power circuits(disconnects, terminal block,contactors, compressor junctionbox terminals, etc.). to be sure theyare clean and tight.

CAUTION:Verify all connections are

made. Loose connections can cause

overheating and undervoltage

conditions at the compressor motor.

2 Open all refrigerant valves in thedischarge, liquid, oil and oil returnlines.

CAUTION: Do not operate the unit

with the compressor, oil discharge,

liquid line service valves and the

manual shutoff on the refrigerant

supply to the coolers "CLOSED".

Failure to have these "OPEN" may

cause serious compressor damage.

3 Check the power supply voltage tothe unit at the main power fused-disconnect switch. Voltage must bewithin the voltage utilization rangeand also stamped on the unitnameplate. Voltage imbalancemust not exceed 3%.

4 Check the unit power phasing L1-L2-L3 in the starter to be sure thatit has been installed in an "ABC"phase sequence.

CAUTION: Improper power phasing

can result in equipment damage due

to reverse rotation.

CAUTION: Do not use untreated or

improperly treated water.

Equipment damage may occur.

5 Fill the evaporator chilled watercircuit. Vent the system while it isbeing filled. Open the vents on thetop of the evaporator shell whilefilling and close when filling iscompleted.

Pre-Start Checkout

RTAD-SVX01A-E4 23

Pre-Start Checkout

Important:The use of improperly

treated or untreated water in this

equipment may result in scaling,

erosion, corrosion, algae or slime.

The services of a qualified water

treatment specialist should be

engaged to determine what

treatment, if any, is advisable.The

Trane Company warranty specifically

excludes liability of corrosion,

erosion or deterioration of Trane

equipment.Trane assumes no

responsibilities for the results of the

use of untreated or improperly

treated water or saline or brackish

water.

6 Close the fused-disconnectswitch(es) that supplies power tothe chilled water pump starter.

7 Start the chilled water pump tobegin circulation of the water.Inspect all piping for leakage andmake any necessary repairs.

8 With water circulating through thesystem, adjust water flow andcheck water pressure drop throughthe evaporator.

9 Adjust the chilled water flow switchfor proper operation.

Warning: Use extreme caution when

performing the following procedure

with power applied. Failure to do so

can result in personal injury or

death.

10 Reapply power to completeprocedures.

11 Prove all Interlock andInterconnecting Wiring Interlockand External as described in theElectrical Installation section.

12 Check and set, as required, allUCM-CLD menu items.

13 Stop the chilled water pump.14 Energize compressor and oil

separators 24 hours prior to unitstart-up.

Unit Voltage Power SupplyVoltage to the unit must meet thecriteria given in the Installation-Electrical Section. Measure each legof the supply voltage at the unit'smain power fused- disconnect. If themeasured voltage on any leg is notwithin specified range, notify thesupplier of the power and correct thesituation before operating the unit.

CAUTION: Provide adequate voltage

to the unit. Failure to do so can

cause control components to

malfunction and shorten the life of

relay contact, compressor motors

and contactors.

Unit Voltage ImbalanceExcessive voltage imbalancebetween the phases of three-phasesystem can cause motors tooverheat and eventually fail. Themaximum allowable imbalance is 3percent. Voltage imbalance isdetermined using the followingcalculations:

% Imbalance = [(Vx - V ave) x

100]/Vave

V ave = (V1 + V2 + V3)/3

Vx = phase with the greatest

difference from V ave (without

regard to the sign)

For example, if the three measured

voltages are 221, 230, and 227 volts,

the average would be:

(221+230+227)/3 = 226

The percentage of the imbalance is

then:

[100(221-226)]/226 = 2.2%

This exceeds the maximum

allowable (2%) by 0.2 percent.

Unit Voltage PhasingWarning: It is imperative that L1, L2,

L3 in the starter be connected in the

A-B-C phase sequence to prevent

equipment damage due to reverse

rotation.

It is important that proper rotation ofthe compressors be establishedbefore the unit is started.Proper motor rotation requiresconfirmation of the electrical phasesequence of the power supply. Themotor is internally connected forclockwise rotation with the incomingpower supply phased A, B, C.Basically, voltages generated in eachphase of a polyphase alternator orcircuit are called phase voltages. Ina three-phase circuit, three sine wavevoltages are generated, differing inphase by 120 electrical degrees. Theorder in which the three voltages of a

three-phase system succeed oneanother is called phase sequence orphase rotation. This is determined bythe direction of rotation of thealternator. When rotation isclockwise, phase sequence is usuallycalled "ABC," when counter-clockwise, "CBA."This direction may be reversedoutside the alternator byinterchanging any two of the linewires. It is this possible interchangeof wiring that makes a phasesequence indicator necessary if theoperator is to quickly determine thephase rotation of the motor.Proper compressor motor electricalphasing can be quickly determinedand corrected before starting theunit. Use a quality instrument, suchas the Associated Research Model 45Phase Sequence Indicator, andfollow this procedure.1 Press the STOP key on the UCM-

CLD.2 Open the electrical disconnect or

circuit protection switch thatprovides line power to the linepower terminal block(s) in thestarter panel (or to the unit-mounted disconnect).

3 Connect the phase sequenceindicator leads to the line Powerterminal block, as follows:

4 Turn power on by closing the unitsupply power fused-disconnectswitch.

5 Read the phase sequence on theindicator. The "ABC" LED on theface of the phase indicator willglow if phase is "ABC."

WARNING:To prevent injury or death

due to electrocution, take extreme

care when performing service

procedures with electrical power

energized.

6 If the "CBA" indicator glowsinstead, open the unit main powerdisconnect and switch two lineleads on the line power terminalblock(s) (or the unit mounteddisconnect). Reclose the mainpower disconnect and recheck thephasing.

24 RTAD-SVX01A-E4

Pre-Start Checkout

CAUTION: Do not interchange any

load leads that are from the unit

contactors or the motor terminals.

Doing so may damage the

equipment.

7 Reopen the unit disconnect anddisconnect the phase indicator.

Water System Flow Rates Establish a balanced chilled waterflow through the evaporator. Theflow rates should fall between theminimum and maximum valuesgiven on the pressure drop curves.Chilled water flow rates below theminimum values will result inlaminar flow, which reduces heattransfer and causes either loss ofEXV control or repeated nuisance,low temperature, cutouts. Flow ratesthat are too high can cause tubedamage in the evaporator.

Water System Pressure

DropMeasure water pressure dropthrough the evaporator at the field-installed pressure taps on the systemwater piping. Use the same gaugefor each measurement. Do notinclude valves, strainers fittings inthe pressure drop readings.Pressure drop readings should beapproximately those shown in thepressure drop charts in theInstallation -Mechanical section.

RTAD-SVX01A-E4 25

Daily Unit Start-UpThe time line for sequence ofoperation is shown at the end of thissection and depicts the nominaldelays and sequences that a chillerwould experience during a typicaloperational cycle. The time linebegins with a power up of the mainpower to the chiller. The sequenceassumes a RTAD chiller with nodiagnostics ormalfunctioning components.External events such as the operatorplacing the chiller in Autoor Stop, chilled water flow throughthe evaporator, and application ofload to the chilled waterloop causing loop water temperatureincreases are depicted and thechillers responses to thoseevents are shown, with appropriatedelays noted. The effects ofdiagnostics, and other externalinterlocks other than evaporatorwater flow proving, are notconsidered. The response of theCLD Display is also depicted on thetime line.

GeneralIf the pre-start checkout, as discussedabove, has been completed, the unitis ready to start.1 Press the STOP key on the CLD

module.2 As necessary, adjust the setpoint

values in the UCM-CLD « OperatorSettings » menu.

3 Close the fused-disconnect switchfor the chilled water pump.Energize the pump(s) to start watercirculation.

4 Check the service valves on thedischarge line, oil line and liquidline for each circuit. These valvesmust be open (backseated) beforestarting the compressors.

CAUTION:To prevent compressor

damage, do not operate the unit

until all refrigerant and oil line

service valves are opened.

5 Verify that the chilled water pumpruns for at least one minute afterthe chiller is commanded to stop(for normal chilled water systems).

6 Press the AUTO key. If the chillercontrol calls for cooling and all

safety interlocks are closed, theunit will start. The compressor(s)will load and unload in response tothe leaving chilled watertemperature.

Once the system has been operatingfor approximately 30 minutes andhas become stabilized, complete theremaining start-up procedures, asfollows:1 Check the evaporator refrigerant

pressure and the condenserrefrigerant pressure underRefrigerant Report on the CLDModule. The pressures arereferenced to sea level (1013 mbar -14.7 psia).

2 Measure the system dischargesuperheat.

3 Measure the system subcooling.4 A shortage of refrigerant is

indicated if operating pressures arelow and subcooling is also low. Ifthe operating pressures, sightglass, superheat and subcoolingreadings indicate a refrigerantshortage, gas-charge refrigerantinto each circuit, as required. Withthe unit running, add refrigerantvapor by connecting the chargingline to the suction charging servicevalve port until operatingconditions become normal.

CAUTION: If both suction and

discharge pressures are low but

subcooling is normal, a problem

other than refrigerant shortage

exists. Do not add refrigerant, as this

may result in overcharging the

circuit. Use only refrigerants

specified on the unit nameplate (HFC

134a) and Trane Oil 00048. Failure to

do so may cause compressor

damage and improper unit

operation.

Seasonal Unit Start-Up

Procedure1 Close all valves and re-install the

drain plugs in the evaporator.2 Service the auxiliary equipment

according to the start-up/maintenance instructionsprovided by the respectiveequipment manufacturers.

3 Close the vents in the evaporatorchilled water circuits.

4 Open all the valves in theevaporator chilled water circuits.

5 Open all refrigerant valves to verifythey are in the open condition.

6 If the evaporator was previouslydrained, vent and fill theevaporator and chilled watercircuit. When all air is removedfrom the system , re-install the ventplugs on top of the evaporatorshell.

CAUTION: Ensure that the

compressor and oil separator

heaters have been operating for a

minimum of 24 hours before

starting. Failure to do so may result

in equipment damage.

7 Check the adjustment andoperation of each safety andoperating control.

8 Close all disconnect switches.9 Refer to the sequence for daily unit

startup for the remainder of theseasonal startup.

Unit Start-up Procedures

26 RTAD-SVX01A-E4

System Restart After

Extended ShutdownFollow the procedures below torestart the unit after extendedshutdown:1 Verify that the liquid line service

valves, oil line, compressordischarge service valves (whensupplied) are open (backseated).

CAUTION:To prevent damage to the

compressor, be sure that all

refrigerant valves are open before

starting the unit.

2 Check the oil separator oil level(see Maintenance Proceduressection).

3 Fill the evaporator water circuit.Vent the system while it is beingfilled. Open the vent on the top ofthe evaporator while filling andclose when filling is completed.

CAUTION: Do not used untreated or

improperly treated water.

Equipment damage may occur.

4 Close the fused-disconnectswitches that provides power tothe chilled water pump.

5 Start the evaporator water pumpand, while water is circulating,inspect all piping for leakage. Makeany necessary repairs beforestarting the unit.

6 While the water is circulating,adjust the water flows and checkthe water pressure drops throughthe evaporator. Refer to "WaterSystem Flow Rates" and "WaterSystem Pressure Drop".

7 Adjust the flow switch on theevaporator piping for properoperation.

8 Stop the water pump. The unit isnow ready for start-up as describedin "Start-Up Procedures".

Unit Start-up Procedures

RTAD-SVX01A-E4 27

Unit Shutdown Procedures

Temporary Shutdown And

RestartTo shut the unit down for a shorttime, use the following procedure:1 Press the STOP key on the UCM-

CLD. The compressors willcontinue to operate and, afterunloading for 20 seconds, will stopwhen the compressor contactorsde-energize.

2 Stop the water circulation byturning off the chilled water pump.To restart the unit after a temporaryshutdown, enable the chilled waterpump and press the AUTO key. Theunit will start normally, providedthe following conditions exist:

❏ The UCM-CLD receives a call forcooling and the differential-to-startis above the setpoint.

❏ All system operating interlocksand safety circuits are satisfied.

Extended Shutdown

ProcedureThe following procedure is to befollowed if the system is to be takenout of service for anextended period of time, e.g.seasonal shutdown:1 Test the unit for refrigerant leaks

and repair as necessary.2 Open the electrical disconnect

switches for the chilled waterpump. Lock the switches in the"OPEN" position.

CAUTION: Lock the chilled water

pump disconnect Switch in the

"OPEN" position, to prevent pump

damage.

3 Close all chilled water supplyvalves. Drain the water from theevaporator.

4 Open the unit main electricaldisconnect and unit-mounteddisconnect (if installed) and lock onthe "OPEN" position.

CAUTION: Lock the disconnects in

the "OPEN" position to prevent

accidental start-up and damage to

the system when it has been setup

for extended shutdown.

5 At least every three months(quarterly), check the refrigerantpressure in the unit to verify thatthe refrigerant charge is intact.

28 RTAD-SVX01A-E4

Maintenance

GeneralPerform all maintenance proceduresand inspections at the recommendedintervals. This will prolong the life ofthe chiller and minimize thepossibility of costly failures. Recordan operating history for the unit,which will serve as a valuablediagnostic tool for service personnel.By observing trends in operatingconditions, an operator cananticipate and prevent problemsituations before they occur. If theunit does not operate properlyduring maintenance inspections,refer to "Diagnostics andTroubleshooting". After the unit hasbeen operating for approximately30 minutes and the system hasstabilized, check the operatingconditions and complete theprocedures below:

Weekly MaintenanceWhile unit is running in stableconditions.1 Check UCM-CLD pressure for

Evaporator, Condenser and Oil.2 The subcooling should never be

less than 3°C (5.4 F) under anycircumstances.

CAUTION: A clear sightglass alone

does not mean that the system is

properly charged. Also check rest of

system operating conditions.

3 Inspect the entire system forunusual conditions and inspect thecondenser coils for dirt and debris.If the coils are dirty, refer to coilcleaning.

Monthly Maintenance1 Perform all weekly maintenance

procedures.2 Record the system subcooling.3 Record the system superheat.4 Make any repairs necessary.

Annual Maintenance1 Perform all weekly and monthly

procedures.2 Check oil sump oil level while unit

is off.Note: Routine changing of the oil isnot required. Use an oil analysis todetermine the condition of the oil.

3 Have a qualified laboratoryperform a compressor oil analysisto determine system moisturecontent and acid level. Thisanalysis is a valuable diagnostictool.

4 Contact a qualified serviceorganization to leak test the chiller,to check operating and safetycontrols, and to inspect electricalcomponents for deficiencies.

5 Inspect all piping components forleakage and damage. Clean outany inline strainers.

6 Clean and repaint any areas thatshow signs of corrosion.

7 Clean the condenser coils.Warning: Position all electrical

disconnects in the "Open" position

and lock them to prevent injury or

death due to electrical shock.

8 Check and tighten all electricalconnections as necessary.

RTAD-SVX01A-E4 29

All the air-cooled RTAD chillers aregiven a complete functional test atthe factory covering sensors, wiring,electrical components,microprocessor function,communication capability, expansionvalve performance and fans. Whereapplicable, each unit is factory presetto the customer's design conditions,including leaving water temperaturesetpoint, current limit, and resettemperature setpoint.

Refrigerant Emission

ControlConservation and emissionreduction can be accomplished byfollowing recommended Traneoperation, maintenance and serviceprocedures, with specific attention tothe following:1 Refrigerant used in any type of air

conditioning or refrigeratingequipment should be recovered forreuse, recovered and/or recycledfor reuse, or reprocessed(reclaimed). Never releaserefrigerant into the atmosphere.

2 Always determine possible recycleor reclaim requirements of therecovered refrigerant beforebeginning recovery by any method.

3 Use approved containment vesselsand safety standards. Comply withall applicable transportationstandards when shippingrefrigerant containers.

4 To minimize emissions whilerecovering refrigerant, userecycling equipment. Alwaysattempt to use methods which willpull the lowest possible vacuumwhile recovering and condensingrefrigerant into containment.

5 Refrigeration-system cleanupmethods that use filters and dryersare preferred. Do not use solventsthat have ozone depletion factors.Properly dispose of used materials.

6 Take extra care to properlymaintain all service equipment thatdirectly supports refrigerationservice work, such as gauges,hoses, vacuum pumps andrecycling equipment.

7 Stay aware of unit enhancements,conversion refrigerants,

compatible parts andmanufacturer's recommendationswhich will reduce refrigerantemissions and increase equipmentoperating efficiencies. Followmanufacturer's specific guidelinesfor conversion of existing systems.

8 In order to assist in reducingpower-generation emissions,always attempt to improveequipment performance withimproved maintenance andoperations that will help conserveenergy resources.

Refrigerant and Oil Charge

ManagementProper oil and refrigerant charge isessential for proper unit operation,unit performance, andenvironmental protection. Onlytrained and licensed service personalshould service the chiller.Some symptoms of a refrigerant

under charged unit:

- Low Subcooling- Larger than normal evaporator

approach temperatures (LeavingWater Temperature -Saturated Evaporator Temperature)

- Low Evaporator RefrigerantTemperature Limit

- Low Refrigerant TemperatureCutout diagnostic

- Fully open expansion valve- Possible whistling sound coming

from liquid line (due to high vaporvelocity)

- Possible low discharge superheat athigh loads

- High Condenser + SubcoolerPressure drop

Some symptoms of a refrigerant

over charged unit:

- High Subcooling- Larger than normal condenser

approach temperatures (EnteringCondenser Saturated Temperature -Entering Air Temperature)

- Condenser Pressure Limit- High Pressure Cutout diagnostic- More than normal number of fans

running- Erratic Fan Control- Higher than normal compressor

power

Maintenance Procedures

30 RTAD-SVX01A-E4


- Very low discharge superheat atstartup

- Compressor rattle or grindingsound at startup

Some symptoms of an oil over

charged unit:

- Larger than normal evaporatorapproach temperatures (LeavingWater Temperature -Saturated Evaporator Temperature)

- Low Evaporator RefrigerantTemperature Limit

- Low Refrigerant TemperatureCutout diagnostic

- Very erratic liquid level control- Low unit capacity- Low discharge superheat

(especially at high loads)- Compressor rattle or grinding

sound- High oil sump level after normal

shut downSome symptoms of an oil under

charged unit:

- Compressor rattle or grindingsound

- Lower than normal pressure dropthrough oil system

- Seized or Welded Compressors- Low oil sump level after normal

shut down- Lower than normal oil

concentrations in evaporator

R134a Field Charging

ProcedureBe certain that the electrical power tothe unit is disconnected beforeperforming this procedure.Warning: Position all electrical

disconnects in the "OPEN" position

and lock them to prevent injury or

death due to electrocution.

Refrigerant ChargingIf the refrigerant charge chargeneeds to be adjusted, be certain tomonitor the subcooling andsuperheat measurements. Thesubcooling needs to be between 6°C(10F) and 12°C (20F) when the unit isrunning fully loaded. The ambienttemperature is between 24°C (75F)and 38°C (100F) and the leavingwater temperature is between 5°C(41F) and 13°C (55F).

Isolating the refrigerant

charge in the high pressure

side for Low Side Repairs.

To perform this operation

the unit must be equipped

with the optional discharge

service valveIf the refrigerant charge needs to beisolated in the high side of the unit,perform the following procedures :1 Press the STOP key and send the

unit to a stopping mode.2 Place a manifold gauge set on the

backseat port of the liquid lineservive valve before actuallyclosing the valve.

3 Close the liquid line service valve.4 While the unit is in the STOP mode,

enable Service Pumpdown for thespecific compressor. ServicePumpdown is found under theService Tests menu of the UCM-CLD.

Note : Service Pumpdown can onlybe enabled for one compressor at atime. Only one pumpdown percompressor can be performed, untilthe unit has been reset. With Service Pumpdown enabled,the Restart inhibit will be ignored,the EXV will be prepositioned andthe selected compressor will startand run for one minute.5 Once the compressor stops, close

the discharge service valve on thecompressor (this valve is optionalon RTAD).

6 The remaining refrigerant needs tobe recovered from the suction lineservice valve. Attach the inlet of arecovery system to the port of thecharging valve. Attach the outlet ofthe recovery system to themanifold gauge set that is alreadyattached to the access port on theliquid line service valve. Thecondenser will be used as astorage vessel.

7 Complete all necessary repairs.8 Evacuate out of the suction line

service charging valve.9 Break the vaccum by adding

refrigerant in the suction linethrough the service valve.

RTAD-SVX01A-E4 31


10 Open all valves, start the unit andverify the refrigerant charge bymeasuring the subcooling.

Isolating the refrigerant

charge in the low pressure

side for High Side RepairsIf the refrigerant charge needs to beisolated in the low side of the unit,perform the following procedures :1 Press the STOP key and send the

unit to a stopping mode.2 Close the discharge service valve

(optional on RTAD).3 Before closing the liquid line

service valve, attach a manifoldgauge set to the liquid linebackseat port.

4 Close the liquid line service valve.5 Attach the inlet of a liquid transfer

pump to the manifold gauge setand the outlet of the service valvemounted on the suction line.

This will transfer the liquidrefrigerant. As the low pressure sidecannot contain all the charge, theremaining refrigerant will betransferred to a separate vessel.6 Remove all of the vapor from the

high side of the system.7 Complete all necessary repairs.8 Evacuate the high side through the

access port on the liquid lineservice valve.

9 Open all the valves and run theunit. Verify the refrigerant chargeby measuring the subcooling.

Adding RefrigerantIf the entire charge has beenremoved, perform the followingprocedures to recharge the unit.1 Open all service valves2 Establish water flow through the

evaporator. Connect a hose fromthe refrigerant bottle to thebackseat port on the liquid lineshutoff valve. Midseat the valve.

Caution :The evaporator water flow

needs to be established and

maintained while adjusting the

charge to avoid freezing and

rupturing the tubes.

3 It may not be possible to put theentire amount of refrigerant chargerequired using step 2. If so, startthe unit and add liquid refrigerant

through the liquid line servicevalve.

4 Once the unit has been chargedwith refrigerant, start the unit.Measure the subcooling and verifythat the refrigerant charge iscorrect.

Table 9 Refrigerant Charge per Circuitin kg.

RTAD Circuit A Circuit B

085 std 26 25085 HE 24 26100 std 24 26100 HE 33 36115 std 33 36115 HE 42 45125 std 34 37125 HE 42 45

Refrigerant Filter Changing

ProcedureA dirty filter is indicated by atemperature gradient across thefilter, corresponding to a pressuredrop. If the temperature downstreamof the filter is 4.4°C (8°F) lower thanthe upstream temperature, the filtershould be replaced. A temperaturedrop can also indicate that the unit isundercharged. Ensure propersubcooling before takingtemperature readings.1 With the unit off, verify that the

EXV is closed. Close liquid lineisolation valve. On units withremote evaporators or oil coolingcircuits, close ball valve on oilcooler liquid line.

2 Attach vacuum hose to service porton liquid line filter flange.

3 Evacuate refrigerant from liquidline and store.

4 Remove vacuum hose.5 Depress schrader valve to equalize

pressure in liquid line withatmospheric pressure.

6 Remove bolts that retain filterflange.

7 Remove old filter element.8 Inspect replacement filter element

and lubricate o-ring with TraneOIL00048.

Note: do not use mineral oil. It willcontaminate the system.9 Install new filter element in filter

housing.10 Inspect flange gasket and replace

if damaged.

32 RTAD-SVX01A-E4


11 Install flange and torque bolts to19-22 mN (14-16 lb-ft).

12 Attach vacuum hose and evacuateliquid line.

13 Remove vacuum hose from liquidline and attach charging hose.

14 Replace stored charge in liquidline.

15 Remove charging hose.16 Open liquid line isolation valve.

On units with remote evaporatorsor oil cooler circuits, open oilcooler liquid line ball valve.

Lubrication SystemThe lubrication system has beendesigned to keep most of the oillines filled with oil as long as there isa proper oil level in the oil sump.The total oil charge can be removedby draining the oil system, oil returnline from the evaporator, theevaporator, and the compressor. Verysmall quantities of oil may be foundin other components.

Oil Charging ProcedureProper charging of the oil system iscritical to the reliability of thecompressor and chiller.Too little oil can cause thecompressor to run hot andinefficiently. When taken to anextreme, low oil level may result ininfant failure of the compressor. Toomuch oil will result in high oil-circulation rates, which will foul thecondenser and evaporatorperformance. This will result ininefficient operation of the chiller.Taken to an extreme, high oil levelsmay result in erratic expansion valvecontrol or shut down of the chillerdue to low evaporator-refrigeranttemperature. Too much oil maycontribute to long-term bearingwear. Additionally, excessivecompressor wear is probable whenthe compressor is started with the oillines dry.Note: The oil system schematic isrepresented in dotted line on therefrigerant circuit schematic, Figure 8The oil system consists of thefollowing components:• Compressor• Oil separator

• Discharge line with optional servicevalve

• Oil line from separator tocompressor

• Oil line drain (lowest point insystem)

• Oil cooler• Oil temperature sensor• Oil line shut off valve with flare

service connection• Oil filter (internal to compressor)

with flare fitting service connectionand schrader valve

• Oil flow control valve (internal tothe compressor after the filter)

The standard oil charge for eachcircuit size is in Table 10.

Table 10 - Standard oil chargeUnit size Oil charge (l)

RTAD 085 5 RTAD 100 6 RTAD 115 8 RTAD 115HE 9RTAD 125 9

Recommendation: check the oil levelin the sump using a sight glassattached to charging hoses.

1 To measure the oil level, use the oildrain valve on the oil line and aservice valve on the discharge line.This measurement can only bemade when the circuit is notrunning. Note: the bottom plate of the oilseparator is approximately 25mm(1'') thick.

2 After the unit has run for a while,the oil level in the sump can varygreatly. However, if the unit hasrun "normal" conditions for a longtime the level should be between25 to -100mm (+1" to - 4" )

The field charging proceduredepends on the circumstances thatresulted in the need for oilcharge.1 Some service procedures may

result in loss of small quantities ofoil that must be replaced (oilanalysis, compressor filterreplacement, re-tubing theevaporator, and so forth.).

2 Additionally, some maintenanceprocedures may result in virtuallyall of the oil being removed(compressor motor burn or total

RTAD-SVX01A-E4 33


removal of the charge to troubleshoot a unit).

3 Finally, leaks may result in a loss ofoil that must be replaced.

Factory (initial) Oil-

Charging ProcedureThe initial charging procedureshould be followed any time the unitis new or has had all of the oilremoved.1 Add 1 liter oil to the motor cavity

or suction line prior to installingthe compressor into the chiller.

2 The oil-line shutoff valve must beopen to allow the oil to pass intothe oil lines and the oil separator.

3 The oil charging port is a ¼" (6mm)flare fitting with a schrader valvethat is on the side of the oil-filterhousing. This is the port that mustbe used to add oil into thecompressor so that the filter andlines are full at the first start of thecompressor.

4 Oil may be put into the unit usingeither of two methods:

CAUTION: Use only Trane Oil 00048

in the RTAC units to avoid any

catastrophic damage to the

compressor or unit.

• Have the unit in vacuum. Hook upthe oil charging hose to oil chargingfitting and submerse the other endinto the oil container. Let thevacuum draw the required amountof oil into the unit.

• Have the unit at the same pressureas the oil. Hook up the oil charginghose to the oil charging fitting andthe other end to an oil pump. Usethe pump to draw oil out of the oilcontainer and push the requiredamount of oil into the unit.

Note: the compressor filter has aninternal shut off valve that willprevent oil from entering thecompressor while the compressor isnot running. Therefore, there is noconcern about flooding thecompressor with oil.

Field Oil-Charging

ProcedureUse the initial charging procedurewhen virtually all of the oil has beenremoved.

Note: this procedure can be followedeven with the refrigerant chargeisolated in the evaporating section ofthe unit.

If small quantities of oil were

removed to service refrigeration

components, such as theevaporator, simply replace the oilthat was removed into the servicedcomponent prior to vacuum andrecharge of the refrigerant.

If oil was removed to service a

compressor or change the filter

follow this procedure:1 If the compressor is a new

compressor or has been removedfrom the system and reworked,add 1 liter oil to the motor cavityprior to installing the compressorinto the chiller.

2 Install the compressor in thesystem. Make sure that the filtershut off valve is closed.

Other compressor isolation valvesmay also be closed depending uponthe service that was completed. Forexample, changing the oil filterwould require the compressor to beisolated and pulled into vacuum.Note: Ensure that the compressor isnot pressurized.3 Open the flare fitting on the oil-line

shut off valve.4 Open the flare fitting on the filter

housing. This is the port that mustbe used to put oil into thecompressor.

5 Install charging hose on oilcharging port (with the Schradervalve) and the other on the oilcanister.

6 Lift the oil canister, or use a pump,to pour oil into the filter housing.

7 When oil comes out of the flarefitting on the oil line shut off valvethe filter is full. Stop adding oil.

8 Put the cap on the flare on the oilline shut off valve, remove thecharging hose and put the cap backon the flare on the filter housing.

9 Vacuum the compressor (low side)and prepare it for inclusion in thesystem. There is a service valve onthe suction line. Use these valvesto vacuum the compressor.

34 RTAD-SVX01A-E4


10 Open the oil line shut off valve.Severe damage to the compressorcan result if the oil line shut offvalve is closed when thecompressor is started.

WARNING: Catastrophic damage to

the compressor will occur if the oil

line shut off valve or the isolation

valves are left closed on unit start-

up.

11 Open the other compressorisolation valves.

Note: this procedure assumes thatthe oil that is put into the filterhousing does not have contaminantssuch as non-condensable gases. Theoil forces these gases out of the filterand oil line shut off valve without theneed to pull a vacuum on this smallvolume. If the oil has been in anopen container or is otherwisecontaminated, then this smallvolume must be subject to vacuumas well. However, the filter cavity isfull of oil. Therefore, be sure to use aflash tank in line with the vacuumpump to make sure that oil, that ispulled out of the filter cavity, doesnot slug the vacuum pump.

Evaporator Heat Tape

Checkout ProcedureCAUTION: If the heat tapes wrapped

around the evaporator barrel fail, the

evaporator will freeze causing

catastrophic damage to the entire

unit.

To check the heat tapes wrappedaround the barrel follow theprocedures below.1 Locate the connection under the

evaporator insulation near thebottom of the barrel.

CAUTION: Do not cut past the

evaporator insulation. Electrical

damage to the heat tape wires will

occur if cutting of the insulation is

done improperly.

The resistance can be checked withan ohmmeter to determine if there isan open or a short. If a heater hasfailed, replace as follows:1 Remove the insulation around the

heater.2 Remove the old heater.3 The factory installed heaters have

the wire run under the insulation of

the evaporator. This can be copiedby cutting a small strip ofinsulation out and replacing it withtape.

4 Replace any insulation that wasremoved.

5 Wire the heaters into the system asper the wiring diagram.

6 Recheck the resistance to verifythat they are wired correctly.

Safety recommendationsTo avoid accidents and damage, thefollowing recommendations shouldbe observed during maintenanceand service visits:1. The maximum allowable pressures

for system leak testing on low andhigh pressure side are given in thechapter "Installation". Alwaysprovide a pressure regulator.

2. Disconnect the main supply beforeany servicing on the unit.

3. Service work on the refrigerationsystem and the electrical systemshould be carried out only byqualified and experiencedpersonnel.

Maintenance contractIt is strongly recommended that yousign a maintenance contract withyour local Service Agency. Thiscontract provides regularmaintenance of your installation by aspecialist in our equipment. Regularmaintenance ensures that anymalfunction is promptly detectedand corrected and minimizes thepossibility that serious damage willoccur. Finally, regular maintenanceensures the maximum operating lifeof your equipment. We remind youthat failure to respect theseinstallation and maintenanceinstructions may result in immediatecancellation of the warranty.

TrainingThe equipment described in thismanual is the result of many years ofresearch and continuousdevelopment. To assist you inobtaining the best use of it, andmaintaining it in perfect operatingcondition over a long period of time,the constructor has a refrigeration

and air conditioning service school atyour disposal. The principal aim ofthis is to give operators andmaintenance technicians a betterknowledge of the equipment theyare using, or that is under theircharge. Emphasis is particularlygiven to the importance of periodicchecks on the unit operatingparameters as well as on preventivemaintenance, which reduces the costof owning the unit by avoidingserious and costly breakdowns.

RTAD-SVX01A-E4 35

The manufacturer has a policy of continuousproduct improvement, and reserves the rightto alter any details of the products at any timewithout notice.

This publication is a general guide to install,use and properly maintain our products. Theinformation given may be different from thespecification for a particular country or for aspecific order. In this event, please refer toyour nearest office.

Société Trane – Société Anonyme au capital de 61 005 000 Euros – Siege Social: 1 rue des Amériques –88190 Golbey – France – Siret 306 050 188-00011 – RSC Epinal B 306 050 188Numéro d’identification taxe intracommunautaire: FR 83 3060501888

The Trane Company

An American Standard Company

www.trane.com

For more information contactyour local sales office ore-mail us at [email protected]

Since The Trane Company has a policy of continuous product improvement, it reserves the right to changedesign and specifications without notice.

For additional information, contact:Distributor/Installer stamp

Literature Order Number RTAD-SVX01A-E4

Date 10/01

New

Stocking Location Europe

Date post:	06-May-2018
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