Trane RTCA 108-216 Owner's manual

Installation

Operation

Maintenance

RTUB 207-224 - Liquid chillers with

helical rotary compressors

RTCA 108-216 - Remote air-cooled

condenser

RLC-SVX03A-E4

Foreword

These installation, operation and

maintenance instructions are given

as a guide to good practice in the

installation, putting into service,

operation, and maintenance by the

user ofTrane RTUB and RTCA units.

They do not contain full service

procedures necessary for the

continued successful operation of

this equipment;The services of a

qualified technician should be

employed through the medium of a

maintenance contract with a

reputable service company.

Warranty

Warranty is based on the general

terms and conditions of Société

Trane orTrane UK Ltd.The warranty

is void if the equipment is repaired

or modified without the written

approval ofTrane, if the operating

limits are exceeded or if the control

system or the electrical wiring is

modified.

Damage due to misuse, lack of

maintenance or failure to comply

with the manufacturer's instructions

or recommendations is not covered

by the warranty obligation.

If the user does not conform to the

rules of chapter "Maintenance", it

may entail cancellation of warranty

and liabilities byTrane.

Reception of the

unit

On arrival, inspect the unit before

signing the delivery note. Specify

any damage on the delivery note,

and send a registered letter of

protest to the last carrier of the

goods within 72 hours of delivery.

Notify the localTrane Sales Office at

the same time.The unit should be

totally inspected within 7 days of

delivery. If any concealed damage is

discover, send a registered letter of

protest to the carrier within 7 days of

delivery and notify the localTrane

Office.

Units are shipped with the

refrigerant operating or holding

charge and should be examined with

an electronic leak detector to

determine the hermetic integrity of

the unit.The refrigerant charge is not

included in the standardTrane

Warranty Cover.

Cautions and

warnings

Cautions and warnings appear at

appropriate places in this instruction

manual.Your personal safety and the

proper operation of this machine

require that you follow them

carefully.The constructor assumes

no liability for installations or

servicing performed by unqualified

personnel.

Refrigerant

The refrigerant provided by Société

Trane orTrane UK Ltd meets all the

requirements of our units. When

using recycled or reprocessed

refrigerant, it is advisable to ensure

its quality is equivalent to that of a

new refrigerant. For this, it is

necessary to have a precise analysis

made by a specialized laboratory. If

this condition is not respected, the

SociétéTrane UK Ltd warranty could

be cancelled.

©American Standard Inc. 2002

RLC-SVX03A-E4 3

Contents

Foreword 2

Warranty 2

Reception of unit 2

Cautions and warnings 2

Refrigerant 2

General information

Unit Inspection 5

Inspection Checklist 5

Loose Parts Inventory 6

Description of the Unit 6

General Data RTUB 7

General Data RTCA 8

Installation

Installation Responsibilities 9

Storage 9

Special Lifting and Moving Instructions 10

Isolation 10

Foundation 10

Clearances 11

Drainage 12

Releasing the Nitrogen Holding Charge 12

Water Connections (RTUB) 12

Flow Switch Installation 13

Water Pressure Gauges 13

Refrigeration Safety Valves 14

Water Pressure Relief Valves 14

Installing and ConnectingTemperature Sensors 14

Connecting RTUB with the Remote Air-cooled Condenser 15

Operation

Pre-start Checkout 21

Unit Voltage Power Supply 21

Unit Voltage Imbalance 21

Unit Voltage Phasing 21

Water System Flow Rates 22

Water System Pressure Drop 22

Daily Unit Start-up Procedure 22

Seasonal Unit Start-up Procedure 23

Temporary Shutdown and Restart 23

Extended Shutdown Procedure 23

System Restart after Extended Shutdown 23

Maintenance

Periodic Maintenance 25

Refrigerant and Oil Charge Management 27

R134a Field-charging Procedure 28

Charge Isolation on the High or Low Side of the System 28

Filter Replacement Procedure 29

Lubrication System 29

Oil Charging Procedure 29

Safety Recommendations 32

Maintenance Contract 32

Training 32

CG-PRC010-E4

Contents

RLC-SVX03A-E4 5

General information

This manual describes installation,

operation, and maintenance of RTUB

and RTCA units.

A separate manual is available for

the use and maintenance of the

RTUB controls (UCM-CLD).

Unit Inspection

When the unit is delivered, verify

that it is the correct unit and that it is

property equipped. Compare the

information that appears on the unit

nameplate with the ordering and

submittal information. A typical unit

nameplate is shown in Figure 1.

Inspect all exterior components for

visible damage. Report any apparent

damage or material shortage to the

carrier and make a "unit damage"

notation on the carrier's delivery

receipt. Specify the extent and type

of damage found and notify the

appropriateTrane Sales Office. Do

not proceed with installation of a

damaged unit without sales office

approval.

Inspection Checklist

To protect against loss due to

damage incurred in transit, complete

the following checklist upon receipt

of the unit.

• Inspect the individual pieces of the

shipment before accepting the unit.

Check for obvious damage to the

unit or packing material.

• Inspect the unit for concealed

damage as soon as possible after

delivery and before it is stored.

Concealed damage must be

reported within 15 days.

If concealed damage is discovered,

stop unpacking the shipment. Do not

remove damaged material from the

receiving location.Take photos of the

damage, if possible.The owner must

provide reasonable evidence that the

damage did not occur after delivery.

• Notify the carrier's terminal of the

damage immediately, by phone and

by mail. Request an immediate,

joint inspection of the damage with

the carrier and the consignee.

• Notify theTrane sales

representative and arrange for

repair. Do not repair the unit,

however, until damage is inspected

by the carrier's representative.

Loose Parts Inventory

Check all the accessories and loose

parts that are shipped with the unit

against the shipping list. Included in

these items will be water vessel

drain plugs, rigging and electrical

diagrams, and service literature,

which are placed inside the control

panel and/or starter panel for

shipment.

Description of the Unit

The RTUB units are liquid chillers

equipped with two helical rotary

compressors and an evaporator

designed to operate with remote

RTCA air-cooled condensers or other

manufacturers' remote condensers.

The RTUB is shipped once it has

been assembled and wired in the

factory.The discharge piping is

blocked at the oil separator outlet.

Water connections - chilled water

inlet and outlet - are blocked for

transportation. Both RTUB and RTCA

units are dried and vacuum-pumped

in the factory, and contain a nitrogen

holding charge when shipped.

General information

RLC-SVX03A-E4

RTCA

RTUB

Figure 1 -Typical Unit Nameplates

Table 1 - General data - RTUB

Unit size 207 208 210 211 212 214

Compressor

Type/quantity Helical rotary/2

Nominal size (tons) 35/35 40/40 50/50 60/50 60/60 70/70

Evaporator

Evaporator Model EG 120 EG 120 EG 140 EG 170 EG 170 EG 200

Water Storage (l) 105 105 365 220 220 200

Minimum Flow (l/s) 4.5 4.5 6.0 7.0 7.0 9.0

Maximum Flow (l/s) 13.4 13.4 18.0 21.0 21.0 25.0

Evaporator inlet diameter (inches) 556666

Evaporator outlet diameter (inches) 556666

Minimum Starting/

Operating Ambient (°C) 5

Refrigerant R134a

Number of Independent

Refrigerant Circuits 2

Percent Minimum Load (%) 17

Refrigerant Charge (kg) 26 26 40 40 40 40

Oil Charge (l) 12 12 14 14 14 16

Operating Weight (kg) 2130 2130 2845 2845 2845 3250

Shipping Weight (kg) 1860 1860 2570 2570 2570 2975

Unit size 216 217 218 220 222 224

Compressor

Type/Quantity Helical rotary/2

Nominal size (tons) 70/85 85/85 100/85 100/100 120/100 120/120

Evaporator

Evaporator Model EG 200 EG 200 EG 250 EG 250 EG 340 EG 340

Water Storage (l) 200 200 415 415 560 560

Minimum Flow (l/s) 9.0 9.0 11.0 11.0 14.0 14.0

Maximum Flow (l/s) 25.0 25.0 33.0 33.0 43.0 43.0

Evaporator inlet diameter (inches) 666666

Evaporator outlet diameter (inches) 666666

Minimum Starting/

Operating Ambient (°C) 5

Refrigerant R134a

Number of Independent

Refrigerant Circuits 2

Percent Minimum Load (%) 17

Refrigerant Charge (kg) 40 40 46 46 50 50

Oil Charge (l) 16 16 16 16 19 22

Operating Weight (kg) 3250 3250 3880 4050 4480 4550

Shipping Weight (kg) 2975 2975 3405 3575 3855 3925

General information

RLC-SVX03A-E4

General information

Table 2 - General data - RTCA

Unit size 108 109 111 113 115 116

Condenser

Condenser type Aluminium fins/copper tubes

Fin spacing (fins/ft) 168 168 144 168 168 144

Frontal surface area (m²) 5.7 6.9 6.9 11.3 11.7 13.7

Airflow

Standard unit (m3/h) 42500 50400 69300 77200 84700 98500

Low noise unit (m3/h) 34500 40900 56300 62700 68800 80000

Condenser fans

Number of fans 4468812

Fan speed

Standard unit (rpm) 690

Low noise unit (rpm) 560

Nominal fan power

Standard unit (kW) 0.85

Low noise unit (kW) 0.54

Current fan amps

Standard unit (A) 2.4

Low noise unit (A) 1.2

Minimum Starting/

Operating Ambient (1) (°C) 7 Standard units/-18 Low ambient units

Refrigerant R134a

Number of Independent

Refrigerant Circuits 111111

Refrigerant Charge (kg) 22 26 36 44 52 72

Operating Weight (2) (kg) 810 890 1090 1535 1770 2050

Shipping Weight (2) (kg) 1020 1100 1300 1870 2170 2450

Hot gas connection (inches) 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8

Liquid connection (inches) 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8

Unit size 208 209 211 213 215 216

Condenser

Condenser type Aluminium fins/copper tubes

Fin spacing (fins/ft) 168 168 144 168 168 144

Frontal surface area (m²) 5.7 6.9 6.9 11.3 11.7 13.7

Airflow

Standard unit (m3/h) 42500 50400 69300 77200 84700 98500

Low noise unit (m3/h) 34500 40900 56300 62700 68800 80000

Condenser fans

Number of fans 2 x 2 2 x 2 2 x 3 2 x 4 2 x 4 2 x 6

Fan speed

Standard unit (rpm) 690

Low noise unit (rpm) 560

Nominal fan power

Standard unit (kW) 0.85

Low noise unit (kW) 0.54

Current fan amps

Standard unit 2.4

Low noise unit 1.2

Minimum Starting/

Operating Ambient (1) (°C) 7 Standard units/-18 Low ambient units

Refrigerant R134a

Number of Independent

Refrigerant Circuits 222222

Refrigerant Charge (kg) 2 x 11 2 x 13 2 x 18 2 x 22 2 x 26 2 x 36

Operating Weight (2) (kg) 810 890 1090 1535 1770 2050

Shipping Weight (2) (kg) 1020 1100 1300 1870 2170 2450

Hot gas connection (inches) 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8

Liquid connection (inches) 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8

(1) Based on a 2.2 m/s wind across the condenser

(2) With aluminium fins

RLC-SVX03A-E4 9

Installation responsibilities

Generally, the contractor must do the

following when installing an

RTUB/RTCA unit.

• Install the units on a flat

foundation, level (within 1/4"

[6 mm] across the length of the

unit), and strong enough to support

unit loading.

• Install the units per the instructions

contained in the Installation section

of this manual.

• Install any optional sensors and

make electrical connections at the

UCM-CLD.

• Where specified for the RTUB,

provide and install valves in the

water piping upstream and

downstream of the evaporator

water connections, to isolate the

evaporator for maintenance and to

balance and trim the system.

• Furnish and install a flow switch

and/or auxiliary contacts to prove

chilled-water flow.

• Furnish and install pressure gauges

in the inlet and outlet piping of the

evaporator (for RTUB).

• Furnish and install a drain valve to

the bottom of the evaporator water

box (for RTUB).

• Supply and install a vent cock to the

top of the evaporator water box (for

RTUB).

• Furnish and install strainers ahead

of all pumps and automatic

modulating valves.

• Furnish and install check valves on

the discharge lines (between oil

separators and condenser) in order

to avoid any refrigerant migration

leading to catastrophic damages to

evaporator and/or compressor (due

to freeze-up or liquid slugging).

• Interconnect the RTUB and the

remote condenser.

• Provide and install field wiring.

• Install heat tape and insulate the

chilled-water lines and any other

portions of the system, as required,

to prevent sweating under normal

operating conditions or freezing

during low-ambient temperature

conditions.

• Start the unit under the supervision

of a qualified service technician.

Storage

If the chiller is stored for a long period

of time prior to installation, the

following precautionary measures must

be taken:

• Store the unit in a safe place

sheltered from bad weather

• At least every three months

(quarterly), check the pressure in

the refrigerant circuits to verify that

the nitrogen holding charge is

intact. If it is not, contact a qualified

service organization and the

appropriateTrane sales office.

• Close the discharge and liquid-line

isolation valves.

Installation

Special Lifting and Moving

Instructions

A specific lifting method is

recommended as follows:

1. Four lifting points are built into the

unit.

2. Slings and spreader bar to be

provided by rigger and attached to

the four lifting points.

3. Minimum rated lifting capacity

(vertical) of each sling and

spreader bar shall be no less than

the tabulated unit shipping weight.

CCAAUUTTIIOONN

This unit must be lifted with the

utmost care. Avoid shock load by

lifting slowly and evenly.

WWAARRNNIINNGG

To prevent any damage, position the

lifting bar so that the slings do not

touch the unit.

Isolation

The most effective form of isolation

is to locate the unit away from any

sound-sensitive area. Structurally

transmitted sound can be reduced by

elastomeric vibration eliminators.

Spring isolators are not

recommended for units equipped

with helical rotary compressors.

Consult an acoustical engineer in

critical sound applications. For

maximum isolation effect, isolate

water lines and electrical conduit.

Wall sleeves and rubber- isolated

piping hangers can be used to

reduce the sound transmitted

through water piping.To reduce the

sound transmitted through electrical

conduit, use flexible electrical

conduit. State and local codes on

sound emissions should always be

considered.

Foundation

Provide rigid, non-warping mounting

pads or a concrete foundation of

sufficient strength and mass to

support the unit's operating weight

(that is, including completed piping,

and full operating charges of

refrigerant, oil, and water). After it is

in place, the unit must be level

within 1/4" [6 mm] over its length

and width. Use shims if necessary.

The manufacturer is not responsible

for equipment problems resulting

from an improperly designed or

constructed foundation.

Note for RTCA:The unit must be

positioned so that the airflow

through the condensation coils is not

hindered by any obstacle.The

Installation

Figure 2- Rigging the unit - RTUB 207-208 Figure 3- Rigging the unit - RTUB 210-224 Figure 4- Rigging the unit - RTCA 108-216

Table 3 - Sling Lengths (mm) for lifting

ABCDE

RTUB unit size

207-208 2200 3000 2600 2100 -

210-211-212 2400 3000 2550 3150 3650

214-216-217 2500 3000 2550 3150 3650

218-220 2450 3050 2600 3150 3650

222-224 2450 3100 2650 3150 3650

RTCA unit size

108/109/111/208/209/211 2240 1700 1700 - -

113/115/115/213/215/216 2240 2800 2800 - -

RLC-SVX03A-E4

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