Trane RTAA User manual

Models: RTAA, KIT16221

January 2021 PART-SVN251A-EN

SAFETY WARNING

Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of

heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training.

Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury.

When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are

attached to the equipment.

130–400 Ton RTAA Chiller Controls

Upgrade Procedure

MOD01421 and BRD03015 No Longer

Available

Installation Instructions

Introduction

Warnings, Cautions, and Notices

Safety advisories appear throughout this manual as required. Your personal safety and the proper

operation of this machine depend upon the strict observance of these precautions.

The three types of advisories are defined as follows:

WARNING Indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury.

CAUTIONsIndicates a potentially hazardous situation which, if not avoided, could result in

minor or moderate injury. It could also be used to alert against unsafe practices.

NOTICE Indicates a situation that could result in equipment or property-damage only

accidents.

Important Environmental Concerns

Scientific research has shown that certain man-made chemicals can affect the earth’s naturally

occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the

identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine

and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all

refrigerants containing these compounds have the same potential impact to the environment.

Trane advocates the responsible handling of all refrigerants-including industry replacements for

CFCs and HCFCs such as saturated or unsaturated HFCs and HCFCs.

Important Responsible Refrigerant Practices

Trane believes that responsible refrigerant practices are important to the environment, our

customers, and the air conditioning industry. All technicians who handle refrigerants must be

certified according to local rules. For the USA, the Federal Clean Air Act (Section 608) sets forth the

requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the

equipment that is used in these service procedures. In addition, some states or municipalities may

have additional requirements that must also be adhered to for responsible management of

refrigerants. Know the applicable laws and follow them.

WARNING

Proper Field Wiring and Grounding Required!

Failure to follow code could result in death or serious injury. All field wiring MUST be

performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE

and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field

wiring installation and grounding as described in NEC and your local/state electrical codes.

Failure to follow code could result in death or serious injury.

WARNING

Personal Protective Equipment (PPE) Required!

Failure to wear proper PPE for the job being undertaken could result in death or serious injury.

Technicians, in order to protect themselves from potential electrical, mechanical, and chemical

hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well

as the instructions below:

• Before installing/servicing this unit, technicians MUST put on all PPE required for the work

being undertaken (Examples; cut resistant gloves/sleeves, butyl gloves, safety glasses, hard

hat/bump cap, fall protection, electrical PPE and arc flash clothing). ALWAYS refer to

appropriate Safety Data Sheets (SDS) and OSHA guidelines for proper PPE.

• When working with or around hazardous chemicals, ALWAYS refer to the appropriate SDS

and OSHA/GHS (Global Harmonized System of Classification and Labeling of Chemicals)

guidelines for information on allowable personal exposure levels, proper respiratory

protection and handling instructions.

• If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE

in accordance with OSHA, NFPA 70E, or other country-specific requirements for arc flash

protection, PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING,

DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC

FLASH CLOTHING. ENSURE ELECTRICAL METERS AND EQUIPMENT ARE PROPERLY RATED

FOR INTENDED VOLTAGE.

WARNING

Follow EHS Policies!

Failure to follow instructions below could result in death or serious injury.

• All Trane personnel must follow the company’s Environmental, Health and Safety (EHS)

policies when performing work such as hot work, electrical, fall protection, lockout/tagout,

refrigerant handling, etc. Where local regulations are more stringent than these policies,

those regulations supersede these policies.

• Non-Trane personnel should always follow local regulations.

Introduction

PART-SVN251A-EN 3

This document and the information in it are the property of Trane, and may not be used or

reproduced in whole or in part without written permission. Trane reserves the right to revise this

publication at any time, and to make changes to its content without obligation to notify any person

of such revision or change.

Trademarks

All trademarks referenced in this document are the trademarks of their respective owners.

Plexiglas is a registered trademark of Arkema France Corporation.

Discussion

4 PART-SVN251A-EN

Discussion

Electronic component availability has required Trane to obsolete the MOD01421 (1U1 control

module) which includes BRD03015. The following procedure describes the process by which you

can upgrade your 130–400 ton RTAA chiller to the newer clear language display (CLD) control

system, eliminating the need for the obsolete module.

Table 1. KIT16221 contents

Description Quantity Part Number(a)

(a)Part Numbers may change over time.

Clear Language Display 1 MOD00942

CPM 1U1 1 MOD01424

Bezel with adhesive tape 1 COV02180

Transformer, 120 to 24 Vac 1 TRR00463

Connector, CPM to CLD 2 CON01543

Mounting brackets and hardware 1 KIT16214

Replacement Procedure

WARNING

Live Electrical Components!

During installation, testing, servicing and troubleshooting of this product, it may be necessary

to work with live electrical components. Have a qualified licensed electrician or other

individual who has been properly trained in handling live electrical components perform these

tasks. Failure to follow all electrical safety precautions when exposed to live electrical

components could result in death or serious injury.

1. Stop the chiller if it is running.

a. Open the left control panel door (as you’re facing the control panel).

b. Toggle the Chiller Switch to the Stop/Reset position.

c. Wait for all running compressors to shut down (approximately 20 sec).

2. Record unit configuration settings from menus P1,P2,P3,P4,and P5.

a. Use to Table 2 through Table 6 to record the configuration settings if your chiller display and

keypad are still functional. If you are unable to retrieve the configuration settings from your

chiller and they were not recorded elsewhere, use your unit model number and refer to

Figure 8, p. 22 in RTAA-IOM-3 (Installation, Operation, and Maintenance: Air-Cooled Series®

Rotary Liquid Chillers). For default configuration settings not identified in the unit model

number, refer to p. 94–97 of RTAA-IOM-3.

b. Use the following key sequence to access hidden menus P4 and P5.

i. Press the Set Point Down button to the left and the up/down display arrows until the

display reads P0.

ii. Press the Set Point Up button twice.

iii. Press the Set Point Down button once.

iv. Press the Set Point Up button twice.

Replacement Procedure

PART-SVN251A-EN 5

v. Press the Set Point Down button once.

vi. Press the Set Point Up button twice.

vii.You should now be at menu P4. Press the Set Point Up button once to get to menu P5.

Unit Configuration Settings

Table 2. Menu P1

10 Front Panel Chilled Water Setpoint

11 Design Delta Temperature Setpoint

12 Differential to Start Setpoint

13 Front Panel Current Limit Setpoint

14 Outdoor Air Temperature (optional) Not a Setting

15 Low Ambient Lockout d/E

16 Low Ambient Lockout Setpoint

17 Condenser Entering Water Temperature (Not applicable for RTAA)

18 Condenser Leaving Water Temperature (Not applicable for RTAA)

19(1) Service Pumpdown Circuit 1 d/E

19(2) Service Pumpdown Circuit 2 d/E

1A(1) Circuit Lockout – Circuit 1 d/E

1A(2) Circuit Lockout – Circuit 2 d/E

1b(1) Diagnostics Reset – Circuit 1 d/E

1b(2) Diagnostics Reset – Circuit 2 d/E

Table 3. Menu P2

20–28 These menu items are not settings Not settings

29(A) Compressor A Starts

29(B) Compressor B Starts

29(C) Compressor C Starts

29(D) Compressor D Starts

2A(A) Compressor A Hours

2A(B) Compressor B Hours

2A(C) Compressor C Hours

2A(D) Compressor D Hours

Table 4. Menu P3

30 External Chilled Water Setpoint d/E

31 External Current Limit Setpoint d/E

32 Ice Machine Control d/E

33 Active Ice Termination Setpoint Not a setting

34 Front Panel Ice Termination Setpoint

35 Return Reset d/E

36 Zone Reset d/E

37 Outdoor Reset d/E

38 Reset Ratio Setpoint

39 Start Reset Setpoint

3A Maximum Reset Setpoint

3b External Circuit Lockout d/E

Table 5. Menu P4

40 Leaving Water Temperature Cutout Setpoint

41 Low Refrigerant Temperature Cutout Setpoint

42 Condenser Limit Setpoint

43 Balanced Compressor Starts and Hours (Lead/Lag) d/E

44 SI Display Units d/E

45 Unit Line Voltage

46 Under/Over Voltage Protection d/E

47 Phase Imbalance Protection d/E

48 Phase Reversal Protection d/E

49 Superheat Setpoint

4A(1) EXV Control Response Setpoint – Circuit 1

4A(2) EXV Control Response Setpoint – Circuit 2

4b Leaving Water Temperature Control Response Setpoint

4C ICS Address

4d(1) Fan Control Deadband Bias – Circuit 1

4d(2) Fan Control Deadband Bias – Circuit 2

4E Programmable Relay Setup

4F Restart Inhibit Timer

Replacement Procedure

6 PART-SVN251A-EN

Table 6. Menu P5

50 Number of Compressors

51(A) Compressor A Tons

51(B) Compressor B Tons

51(C) Compressor C Tons

51(D) Compressor D Tons

52 Low Water Temperature EXV Gain Compensation d/E

53 Fan Control d/E

54(1) Number of Fans on Circuit 1

54(2) Number of Fans on Circuit 2

55 Reduced Inrush Starting d/E

56(A) Compressor A Current Overload Setting

56(B) Compressor B Current Overload Setting

56(C) Compressor C Current Overload Setting

56(D) Compressor D Current Overload Setting

57 GP Compressor Unit Disabled

58 Low Ambient – Half Air Flow Fan d/E

59 Low Ambient Two Speed Motors d/E

5A Night Noise Setback d/E

5b(1) Number of EXV’s on Circuit 1

5b(2) Number of EXV’s on Circuit 2

5C(1) Future Option

5C(2) Future Option

WARNING

Hazardous Voltage w/Capacitors!

Disconnect all electric power, including remote disconnects and discharge all motor start/run

capacitors before servicing. Follow proper lockout/tagout procedures to ensure the power

cannot be inadvertently energized. For variable frequency drives or other energy storing

components provided by Trane or others, refer to the appropriate manufacturer’s literature for

allowable waiting periods for discharge of capacitors. Verify with an appropriate voltmeter that

all capacitors have discharged. Failure to disconnect power and discharge capacitors before

servicing could result in death or serious injury.

For additional information regarding the safe discharge of capacitors, see PROD-SVB06*-EN

Replacement Procedure

PART-SVN251A-EN 7

3. Disconnect and lockout the power to the chiller.

a. Open the unit disconnect switch that feeds power to the chiller.

b. Install lockout/tagout lock(s).

4. Cut the hole for the new CLD in the control panel door.

a. Remove the existing clear Plexiglas®window from the control panel door.

b. If necessary, remove the control panel door from the chiller.

c. Measure and mark 4.75 in. from the middle hole on top of the existing cutout to just outside

the right and left edges.

d. Measure and mark 1 in. from top edge of existing hole.

e. Measure and mark 11 in. down from the mark made in the previous step.

Replacement Procedure

8 PART-SVN251A-EN

f. Trace square on door as shown in Figure 1, p. 7.

g. Cut along the traced lines.

h. Deburr the edges of the new hole.

Figure 1. Existing cutout and modifications required

5. Install the CLD2 into the control panel door.

a. Using the new CLD as your template. Hold up the new CLD to the hole and make marks

where holes should be drilled.

b. Drill holes.

c. Starting at the top, attach brackets from the outside of the door in such a way that the door

panel is sandwiched between the CLD on the inside and mounting brackets on the outside

of the door panel as shown in Figure 2. The screw head should be flush with the bracket.

d. Tighten the nuts so that the gasket on the CLD is properly compressed.

e. Remove the tape backing from the plastic bezel and apply it to the outside of the door

opening so it covers the mounting brackets.

Figure 2. New CLD assembly

Replacement Procedure

PART-SVN251A-EN 9

6. Replace the 1U1 module.

a. If required, mark the wires connected to TB1, TB2, TB3, TB4, and TB5.

b. Remove all wires and connectors from the 1U1 module.

c. Loosen but do not remove the two lower 1U1 mounting screws.

d. Remove the two upper 1U1 mounting screws. If star washers exist on any of the screws, be

careful not to lose them.

e. Remove the 1U1 from the control panel.

f. Install the new 1U1 into the control panel reusing the same screws.

g. Replace the two upper 1U1 mounting screws.

h. Tighten the two lower 1U1 mounting screws.

i. Re-connect wiring to the 1U1. There are differences between TB4 on the old and new 1U1.

Refer to Table 7 when reconnecting wiring to that terminal block.

Table 7. Old-to-new wiring terminal positions on CPM

Terminal 130-400T RTAA 1U1 New RTAA 1U1

TB4-1 ALARM (COMMON) ALARM (COMMON)

TB4-2 ALARM (NORMALLY OPEN) ALARM (NORMALLY OPEN)

TB4-3 ALARM (NORMALLY CLOSED) ALARM (NORMALLY CLOSED)

TB4-4 COMPRESSOR RUNNING (COMMON) COMPRESSOR RUNNING (COMMON)

TB4-5 COMPRESSOR RUNNING (NORMALLY OPEN) COMPRESSOR RUNNING (NORMALLY OPEN)

TB4-6 COMPRESSOR RUNNING (NORMALLY CLOSED) MAXIMUM CAPACITY (COMMON)

TB4-7 MAXIMUM CAPACITY (NORMALLY COMMON) MAXIMUM CAPACITY (NORMALLY OPEN)

TB4-8 MAXIMUM CAPACITY (NORMALLY OPEN) EVAPORATOR PUMP (COMMON)

TB4-9 EVAPORATOR PUMP (NORMALLY OPEN)

Replacement Procedure

10 PART-SVN251A-EN

7. Install the 24 Vac transformer.

•Install the 120/24 Vac transformer in the bottom part of the control panel to the left of 1TB3.

Install the transformer so the primary connections face 1TB3.

8. Install additional wiring.

a. Connect the 24 Vac transformer primary (120 Vac side) wires to 1TB3-1 and 1TB3-2.

b. Connect the 24 Vac transformer secondary to CLD terminals J2-1 and J2-2.

c. Connect the IPC communications wires.

Note: IPC communications is a daisy-chain communications system that is connected to

the J1 connectors on all of the modules in the RTAA control system except for the

CLD.

i. Inspect all of the J1 connectors on the upper left-hand side of each silver control module

and find two open terminals on the IPC communications bus.

ii. When you find two open terminals, remove the white cover from the back of the orange

plug and use a small screwdriver to push 18 AWG wires into the knives on the connector

until they cut through the wire insulation and hold the conductors securely.

iii. Re-install the white plug cover.

Note: If there are no open J1 terminals, you can splice into the IPC communications link

using butt splices or wire nuts. Connect the other end of the IPC communications

wires to J1-1 and J1-2 on the new CLD module.

9. Remove lockout lock and restore power to the chiller.

10. Configure the chiller.

a. Use the settings recorded in Step 2,p.4to configure the new CLD. Refer to p. 72 of

RTAA-SVX01A-EN (Installation, Operation, and Maintenance: Series R®Air-Cooled Rotary

Liquid Chillers) to help you enter settings into the new CLD.

b. Variable Speed Fans should be set to DISABLE for both circuits.

Re-start the chiller by pressing the green Auto button on the keypad.

Starts and Hours

Note: The compressor starts and hours recorded in Step 2,p. 4 cannot be transferred into the new

control system. Therefore, it is recommended that you record these numbers for all

compressors. All counters will start from zero in the new CLD control system.

Chilled Water Pump Control

The new control system you’re installing has an added feature. It has a normally open contact

output that can be used to control the evaporator water pump. Refer to Table 7, p. 9 for the

connection points on the new 1U1 module. Chilled Water Pump can be set to ON or AUTO in the

Operator Settings menu. If this setting is ON, the pump output will remain energized any time

the control system is powered. If set to AUTO, the pump output will be energized whenever the

chiller is put into the Auto mode and will de-energize from 1 to 30 minutes (the default is

10 minutes) after the chiller leaves the Auto mode. The 1- to 30-minute timer can be configured in

the Chilled Water Pump Off Delay setting.

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