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Installation

Operation
Maintenance
RTUB 207-224 - Liquid chillers with
helical rotary compressors
RTCA 108-216 - Remote air-cooled
condenser

RLC-SVX03A-E4
Foreword Units are shipped with the
refrigerant operating or holding
These installation, operation and charge and should be examined with
maintenance instructions are given an electronic leak detector to
as a guide to good practice in the determine the hermetic integrity of
installation, putting into service, the unit. The refrigerant charge is not
operation, and maintenance by the included in the standard Trane
user of Trane RTUB and RTCA units. Warranty Cover.
They do not contain full service
procedures necessary for the
continued successful operation of Cautions and
this equipment; The services of a
qualified technician should be warnings
employed through the medium of a Cautions and warnings appear at
maintenance contract with a appropriate places in this instruction
reputable service company. manual. Your personal safety and the
proper operation of this machine
require that you follow them
Warranty carefully. The constructor assumes
Warranty is based on the general no liability for installations or
terms and conditions of Socit servicing performed by unqualified
Trane or Trane UK Ltd. The warranty personnel.
is void if the equipment is repaired
or modified without the written
approval of Trane, if the operating Refrigerant
limits are exceeded or if the control The refrigerant provided by Socit
system or the electrical wiring is Trane or Trane UK Ltd meets all the
modified. requirements of our units. When
Damage due to misuse, lack of using recycled or reprocessed
refrigerant, it is advisable to ensure
maintenance or failure to comply
its quality is equivalent to that of a
with the manufacturer's instructions new refrigerant. For this, it is
or recommendations is not covered necessary to have a precise analysis
by the warranty obligation. made by a specialized laboratory. If
If the user does not conform to the this condition is not respected, the
rules of chapter "Maintenance", it Socit Trane UK Ltd warranty could
may entail cancellation of warranty be cancelled.
and liabilities by Trane.

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 local Trane 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 local Trane
Office.

American Standard Inc. 2002 RLC-SVX03A-E4


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 Connecting Temperature Sensors 14
Connecting RTUB with the Remote Air-cooled Condenser 15

RLC-SVX03A-E4 3
Contents

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

4 CG-PRC010-E4
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
appropriate Trane 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.

RLC-SVX03A-E4 5
General information

Notify the Trane sales been assembled and wired in the


representative and arrange for factory. The discharge piping is
repair. Do not repair the unit, blocked at the oil separator outlet.
however, until damage is inspected Water connections - chilled water
by the carrier's representative. inlet and outlet - are blocked for
transportation. Both RTUB and RTCA
Loose Parts Inventory units are dried and vacuum-pumped
Check all the accessories and loose in the factory, and contain a nitrogen
parts that are shipped with the unit holding charge when shipped.
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

Figure 1 - Typical Unit Nameplates

RTUB RTCA

6 RLC-SVX03A-E4
General information

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) 5 5 6 6 6 6
Evaporator outlet diameter (inches) 5 5 6 6 6 6
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) 6 6 6 6 6 6
Evaporator outlet diameter (inches) 6 6 6 6 6 6
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

RLC-SVX03A-E4 7
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 (m) 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 4 4 6 8 8 12
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 1 1 1 1 1 1
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 (m) 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 2x2 2x2 2x3 2x4 2x4 2x6
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 2 2 2 2 2 2
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

8 RLC-SVX03A-E4
Installation

Installation responsibilities Install heat tape and insulate the


Generally, the contractor must do the chilled-water lines and any other
following when installing an portions of the system, as required,
RTUB/RTCA unit. to prevent sweating under normal
operating conditions or freezing
Install the units on a flat during low-ambient temperature
foundation, level (within 1/4" conditions.
[6 mm] across the length of the
unit), and strong enough to support Start the unit under the supervision
unit loading. of a qualified service technician.

Install the units per the instructions Storage


contained in the Installation section
If the chiller is stored for a long period
of this manual.
of time prior to installation, the
Install any optional sensors and following precautionary measures must
make electrical connections at the be taken:
UCM-CLD.
Store the unit in a safe place
Where specified for the RTUB, sheltered from bad weather
provide and install valves in the
At least every three months
water piping upstream and
(quarterly), check the pressure in
downstream of the evaporator
the refrigerant circuits to verify that
water connections, to isolate the
the nitrogen holding charge is
evaporator for maintenance and to
intact. If it is not, contact a qualified
balance and trim the system.
service organization and the
Furnish and install a flow switch appropriate Trane sales office.
and/or auxiliary contacts to prove
Close the discharge and liquid-line
chilled-water flow.
isolation valves.
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.

RLC-SVX03A-E4 9
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


A B C D E
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 - -

Special Lifting and Moving conduit, use flexible electrical


WARNING conduit. State and local codes on
Instructions
To prevent any damage, position the sound emissions should always be
A specific lifting method is
lifting bar so that the slings do not considered.
recommended as follows:
touch the unit.
1. Four lifting points are built into the Foundation
unit. Isolation Provide rigid, non-warping mounting
2. Slings and spreader bar to be The most effective form of isolation pads or a concrete foundation of
provided by rigger and attached to is to locate the unit away from any sufficient strength and mass to
the four lifting points. sound-sensitive area. Structurally support the unit's operating weight
transmitted sound can be reduced by (that is, including completed piping,
3. Minimum rated lifting capacity
elastomeric vibration eliminators. and full operating charges of
(vertical) of each sling and
Spring isolators are not refrigerant, oil, and water). After it is
spreader bar shall be no less than
recommended for units equipped in place, the unit must be level
the tabulated unit shipping weight.
with helical rotary compressors. within 1/4" [6 mm] over its length
and width. Use shims if necessary.
C AUTION Consult an acoustical engineer in
The manufacturer is not responsible
critical sound applications. For
This unit must be lifted with the maximum isolation effect, isolate for equipment problems resulting
utmost care. Avoid shock load by water lines and electrical conduit. from an improperly designed or
lifting slowly and evenly. Wall sleeves and rubber- isolated constructed foundation.
piping hangers can be used to Note for RTCA: The unit must be
reduce the sound transmitted positioned so that the airflow
through water piping. To reduce the through the condensation coils is not
sound transmitted through electrical hindered by any obstacle. The

10 RLC-SVX03A-E4
Installation

condensation coils must be dimensions and recommended


protected from side winds when clearances. Unobstructed flow of
their speed exceeds 16 km/h. condenser air is essential to maintain
Position the unit above the average chiller capacity and operating
height of snow observed in the efficiency.
region where it is installed. Never Note for RTCA: When determining
install temporary or permanent unit placement, give careful
objects (tarp or roof) over the unit, consideration to ensuring a sufficient
because recycling of hot air would flow of air across the condenser
reduce the capacity of the heat-transfer surface.
condensation coils. Discharged air
from the fans must not be
obstructed. It is prohibited to install
ducts for the fan discharge air (even
short ones). This is because the fans
supplied on standard units do not
generate any additional static
pressure.

Clearances
Provide enough space around the
unit to allow the installation and
maintenance personnel unrestricted
access to all service points. Refer to
Figure 5 and Table 4 for unit

Figure 5: Unit Dimensions and Figure 6: Unit Dimensions and


Recommended Minimum Recommended Minimum
Clearances - RTCA Clearances - RTUB

C
D

A A

D
C

Table 4 - Unit Dimensions and Recommended Minimum Clearances (mm)


Length Width Height A B C D
RTCA 108/109/111/208/209/211 2870 2285 1630 1000 1000 1000 1000
RTCA 113/213 4610 2285 1630 1000 1000 1000 1000
RTCA 115/116/215/216 5450 2285 1630 1000 1000 1000 1000
RTUB 207/208 2880 890 1789 950 800 1800 500
RTUB 210/211/212/214/216/217 4150 890 1832 950 800 2750 500
RTUB 218/220 4150 890 1932 950 800 2750 500
RTUB 222/224 4150 890 2041 950 800 2750 500

RLC-SVX03A-E4 11
Installation

Drainage boxes that can lead to premature


Provide a large-capacity drain for failure of the water box. C AUTION
water vessel drain-down during A vent line is located on the top part Install a strainer in the evaporator-
shutdown or repair. The evaporator of the evaporator at the water return water inlet piping. Failure to do so
is provided with a drain connection. piping end. Install additional vent can result in evaporator tube
All local and national codes apply. lines at the highest points in the damage.
The vent on the top of the piping to vent the air present in the
Leaving Chilled-Water Piping
evaporator water box is provided to chilled water circuit. Install
manometers to monitor the pressure Air vents (to bleed air from system).
prevent a vacuum, by allowing air
into the evaporator for complete of chilled water entering and leaving Water pressure gauges with shutoff
drainage. the evaporator. valves.

Releasing the Nitrogen C AUTION Vibration eliminators.

To prevent damage to chilled-water Shutoff (isolation) valves.


Holding Charge
The nitrogen holding charge can be components, do not allow Thermometers (if desired).
released into the atmosphere. evaporator pressure (maximum Clean out tees.
working pressure) to exceed 10.5
Balancing valve.
C AUTION bars.
Provide shutoff valves in lines to the Flow Switch
When releasing nitrogen holding gauges, in order to isolate them from
charge, ventilate the room. Avoid Evaporator Drain
the system when they are not in use.
breathing in the nitrogen. A 3/4" drain connection is located
Use rubber vibration eliminators to
under the outlet end of the
prevent vibration transmission
Water Connections (RTUB) evaporator water box. This may be
through the water lines. If desired,
Thoroughly flush all water piping to connected to a suitable drain to
install thermometers in the lines to
the unit before making the final permit evaporator drainage during
monitor entering- and leaving-water
piping connections to the unit. unit servicing. A shutoff valve must
temperatures. Install a balancing
be installed on the drain line.
valve in the leaving-water line to
C AUTION control water flow balance. Install Evaporator Flow Switch (accessory)
If using an acidic commercial shutoff valves on both the entering- The chilled water flow is protected
flushing solution, construct a and leaving-water lines so that the by the UCM-CLD without the
temporary bypass around the unit to evaporator can be isolated for assistance of a chilled water flow
prevent damage to internal service. A pipe strainer must be switch. The flow switch is optional,
components of the evaporator. To installed in the entering water line. but if it is not installed, a signal must
avoid possible equipment damage, Failure to do so can allow be sent to the chiller to indicate the
do not use untreated or improperly waterborne debris to enter the water flow is established, for
treated system water. evaporator. example the auxiliary contacts of the
When making the water connections, "Piping components" include all chilled water pump starter.
use flange connectors. Insulate all devices and controls used to provide If additional protection of the chilled
piping to reduce temperature proper water system operation and water flow proves necessary,
increases and to prevent unit operating safety. These connect a flow switch installed on
condensation. Figure 7 shows all the components and their general site, or a differential pressure switch
piping systems for the evaporator locations are given in Figure 7. to control the system's water flow.
and its components. The Connect the flow switch in series
Entering Chilled-Water Piping
arrangement of the pipes and the with the auxiliary contacts of the
Air vents (to bleed air from system). chilled water pump motor starter. A
other components varies slightly
according to the positioning of the Water pressure gauges with shutoff special connector is supplied with
connections and the water source. valves. the unit, with the wiring diagrams.
Some piping and control schemes,
Vibration eliminators.
C AUTION particularly those using a single
Shutoff (isolation) valves. water pump for both chilled- water
The chilled water connections to the and hot water, must be analyzed to
evaporator are Victaulic connections. Thermometers (if desired).
determine how and/or if a flow-
Do not attempt to weld these Clean out tees. sensing device will provide the
connections, because the heat Pipe strainer. desired operation.
generated from welding can cause
microscopic and macroscopic
fractures on the cast- iron water

12 RLC-SVX03A-E4
Installation

Follow the manufacturer's 4. Install a pipe strainer in the use in Trane units. Use of either will
instructions for the installation entering evaporator-water line to lead to a shortened life to an
procedures. protect components from indeterminable degree. The Trane
Flow Switch Installation waterborne debris. Company encourages the
employment of a reputable water
1. Mount the switch upright, with a treatment specialist, familiar with
minimum of 5 pipe diameters of Water Treatment
local water conditions, to assist in
straight horizontal run on each
side. Do not install close to C AUTION this determination and in the
establishment of a proper water-
elbows, orifices, or valves. Note: If calcium chloride is used for waste treatment program.
The arrow on the switch must treatment, an applicable corrosion
point in the direction of flow. inhibitor must also be used. Failure Water Pressure Gauges
2. To prevent switch fluttering, to do so may result in damage to
Install field-supplied pressure
remove all air from the water system components. Dirt, scale,
components as shown in Figure 7.
system. Note: The UCM-CLD waits products of corrosion, and other
Locate pressure gauges or taps in a
for six seconds after a flow loss foreign material will adversely affect
straight run of pipe; avoid placement
diagnosis before stopping the unit. heat transfer between the water and
near elbows, and so forth. Be sure to
Contact a qualified service system components. Foreign matter
install the gauges at the same
representative if nuisance machine in the chilled-water system can also
elevation on each shell if the shells
shutdowns persist. increase pressure drop and,
have opposite-end water
consequently, reduce water flow.
3. Adjust the switch to open when connections. Note: After the unit is
Proper water treatment must be
water flow falls below nominal. installed at a site, one vertical (or one
determined locally, depending on the
Evaporator data is given in Table 1. diagonal) unit support can be
type of system and local water
Flow-switch contacts are closed on permanently removed if it creates an
characteristics. Neither salt nor
proof of water flow. obstruction for water piping. To read
brackish water is recommended for

Figure 7 - Typical piping of the evaporator (RTUB)

1 Air vent
2 Balance valve
3 Flow switch 7
4 Thermometers
5 Expansion joints
6 Stop valves
7 Manometer
8 Evaporator 3 8
9 Filter
10 Drainage 2
6

1 5
4

6
9

10

RLC-SVX03A-E4 13
Installation

Figure 8- RTUB Evaporator water pressure drops

Evaporator Water Pressure Drop


kPa

Water Flow Rate l/s

the values given by the pressure Water Pressure-Relief Install the sensor at 4 o'clock on the
gauges, open one valve and close Valves water piping to prevent any
the other. condensation. When installing
standard or optional temperature
Refrigerant Safety Valves C AUTION sensors described in the following
Discharge valves are an option for To prevent shell damage, install paragraphs, comply with the
the RTUB. If installation requires this pressure-relief valves in the instructions:
valve to be mounted, it is mandatory evaporator water system. Install a Put thermocontact paste in each
to install two safety valves: one water pressure-relief valve in the sensor bulbwell before inserting the
between the compressor and the evaporator inlet piping, between the sensor. All the temperature sensors
service valve and the other after the evaporator and the inlet shutoff installed on site have an
service valve to protect the valve. Water vessels with close- identification number and a serial
condenser. coupled shutoff valves have a high number marked on the part body.
potential for hydrostatic pressure Also note that both sensors in each
C AUTION buildup on a water temperature pair have the same serial number.
increase. Refer to applicable codes
The safety valve calibration must not
exceed 25 bars. The liquid line must
for relief-valve installation WARNING
guidelines. To prevent degraded operation due
be connected at the inlet to the drier
filter which is supplied with a bend to electrical interference, run the
blocked by a brazed plug. The Installing and connecting sensor cables in a duct. However, do
connection piping must be correctly temperature sensors not lay sensor cables with other
dimensioned and installed, because cables whose voltage is greater than
General Recommendations
these factors have a substantial 30 VAC.
Regardless of the type of monitoring
impact on the system's performance sensor required by a particular Extension of sensor power cable
and reliability. application, the sensor must always A temperature sensor's power cable
be positioned far enough from the may not be long enough to reach the
evaporator or condenser to enable UCM. If this is the case for your
the sensor to read a correct installation, connect the cable to a
temperature for the mixed water. junction box installed in a more

14 RLC-SVX03A-E4
Installation

convenient position. Plug the sensor correctly, refer to the general withstanding high temperatures
cable and the cable connected to the recommendations. Connect the without degradation.
control panel into the junction box. outside air sensor 5R3 to terminals 1
The shielded cable can be cut to the and 2 on terminal board 1. Connect C AUTION
required length. the condenser sensor 5R56-1 to A defect in fixing or insulating the
Note: To lengthen the sensor's power terminals 4 and 5 on terminal board condensation sensors may cause
cable, use 0.75 to 1.25 mm J4 on module A20-1. Connect the incorrect adjustment and/or damage
conductors, 600V. The cable used condenser sensor 5R56-2 to to the compressor.
between the junction box and the terminals 4 and 5 on terminal J4 on
control panel must either be shielded module A20-2. If the sensor cannot be mounted in
or in a duct. If a shielded cable is the place where the saturated gas
If the condenser is not an RTCA, enters the sub-cooler, it must be
used, make sure it is not used with ambient temperature and condenser
other cables carrying 30 V or more. positioned on the sub-cooler side
temperature sensors must be and not on the condenser side. If the
Evaporator leaving water connected to the RTUB to monitor it. condenser temperature cannot be
temperature sensor 5R51 (standard) The ambient temperature sensor measured, it is preferable to
Install this temperature sensor in the must be installed in a position which measure the liquid temperature
evaporator's leaving water piping represents most accurately the instead of the discharge
system. To install it correctly, refer to condenser's surrounding temperature.
the general recommendations. environment. It must not be exposed
Connect this sensor to terminals to sunlight or precipitation. Ensure C AUTION
X7-1 and X7-2. that the sensor is not located in the
flow of recycled air from the To prevent interference, separate the
Evaporator entering water sensor cables from the power cables.
temperature sensor 5R52 (standard) condenser discharge. The
Install this sensor in the evaporator condensation temperature sensors
must be installed on the refrigerant Electrical connections
water piping. To install it correctly,
refer to the general piping at the place where it leaves performed by the installer
recommendations. Connect this the condenser to enter the sub- All wiring must comply with local
sensor across terminals X6-1 and cooler. It is necessary to install a codes. Specific electrical schematics
X6-2. condenser temperature sensor on and connection diagrams are
each refrigerant circuit. This sensor shipped with the unit.
Condenser sensors 5R56-1, 5R56-2, must be fixed in compliance with the
5R3 (option) method used to attach the bulb for a C AUTION
If an RTCA condenser is used with an thermostat expansion valve. This
To avoid corrosion and overheating
RTUB, the sensors required are sensor can be fixed outside the
at terminal connections, use copper
installed on the RTCA. To install them piping if it is sufficiently insulated
conductors only. Failure to do so
with insulation capable of
may result in damage to the
equipment. Do not allow conduit to
Figure 9: UCM water temperature sensor installation
interfere with other components,
structural members or equipment.
Control voltage (110 V) wiring in
7 conduit must be separate from
conduit carrying low voltage (<30 V)
6 wiring. To prevent control
malfunctions, do not run low voltage
5 wiring (<30 V) in conduit with
conductors carrying more than 30 V.
4
Connecting the RTUB with a remote
2 air-cooled condenser
1
The RTUB unit is shipped with a
holding nitrogen charge and a
3 separate oil charge. The RTCA
condenser is designed to operate
with the RTUB unit. To ensure
1 In 5 Compression fitting (Trane-supplied) optimum operation and
2 Out 6 Fitting body performance, the RTUB must be
3 UCM sensor 7 Clamping nut installed with the RTCA condenser. If
4 " NPT coupling (customer-supplied)

RLC-SVX03A-E4 15
Installation

Figure 10 - Detail of positions of refrigerant sensors 5R56-1 and 5R6-2 another manufacturer's condenser in
used, operation and performance
may be degraded. Depending on the
fan settings, malfunctioning may
3 2 1 damage the RTUB due to instability
of the high pressure.
Sound and vibration attenuating
device installation on the discharge
lines is strongly recommended in
order to avoid any acoustical
annoyance and distubing vibrations
leading to discharge line failures.
57
1 Sensor
WARNING
2 Connector If the condenser connected to a dual-
3 Brazed connector on the condenser
circuit RTUB is not an RTCA, it must
comprise two refrigerant circuits,
each with its own ventilation. The
ventilation cannot be common to the
two circuits.
For this type of installation, (non-
RTCA condenser), an On/Off signal is
available on the unit control module
(UCM) of the RTUB for each
refrigerant circuit, indicating whether
the fans on each condenser circuit
are on or off. The now autonomous
control of the fan on each condenser
circuit must comprise the following
staging:
For an ambient temperature between
0 and 40C, there must be four
airflow control stages for each circuit
(i.e. 25% of the nominal airflow in
each stage).

16 RLC-SVX03A-E4
Installation

Figure 11: Units on the same level

Limitations:The distance between the two units must not exceed 60 m in reality or the equivalent of 90 m taking into
account pressure drops. The height of the liquid line in relation to the unit base must be less than 5 m. It is
recommended to place a trap on the discharge line at the oil separator outlet, if this discharge line is horizontal for a
distance greater than 5 m, at a height greater than the connection to the oil separators.

Figure 12: RTCA (or other manufacturer's condenser) above the RTUB

Limitations:The distance between the two units must not exceed 60 m in reality or the equivalent of 90 m taking into
account pressure drops. Each 30 m3level difference causes a 2% efficiency loss.

RLC-SVX03A-E4 17
Installation

Figure 13: RTCA (or other manufacturer's condenser) below the RTUB

Limitations:The distance between the two units must not exceed 60 m in reality or the equivalent of 90 m taking into
account pressure drops. The height of the liquid line in relation to the condenser base must be less than 5 m.

Legend for Figures 11-12-13:


1 Discharge line connections
2 Liquid line connections
3 Trap
4 Counter-trap

18 RLC-SVX03A-E4
Installation

Equivalent pressure drops The minimum slope of the suction


To correctly determine the size of the line to the condenser must be 5%.
liquid and discharge lines for Isolate refrigerant fluid lines from the
connection on site, it is first building to prevent the vibrations
necessary to establish the equivalent normally generated by the ducts
pressure drops for each line, from being transmitted to the
comprising the additional flow building's structure. Also avoid
resistances, from bends, valves, etc. bypassing the unit's isolation system
As a first approximation, we can by fixing the refrigerant fluid lines or
estimate the equivalent pressure the electrical ducts very rigidly. Any
drops at 1.5 times the piping length. vibrations may be propagated into
Size of the liquid line the building via rigid piping or lines.
The standpipe must not be more
than 5 m above the air-cooled Pressure tests and leak
condenser base. It is not necessary detection
to slope the liquid line. It is
recommended to have a line WARNING
diameter as small as possible, while
During these operations, take the
maintaining an acceptable pressure
following precautions:
drop so as to minimize the
1. Do not use oxygen or acetylene
refrigerant charge (length and
instead of the refrigerant fluid and
maximum pressure drops defined
nitrogen to detect leaks. This may
above).
cause a violent explosion.
Determine the size using the
following criteria: 2. Always use the expansion valve,
1. Operating conditions with full load safety valves and manometers to
control the test pressure in the
2. Maximum pressure drops of
system. Excessive pressure may
100-kPa
cause piping to rupture, damage
3. Liquid speed not exceeding 3 m/s
the unit or cause explosion
(to prevent liquid shocks)
resulting in personal injury.
In normal operating conditions
Carry out the liquid line and hot gas
(suction temperature 4.5C,
line pressure tests using the
condenser air inlet temperature 35C
standards in force. The test pressure
or condensation temperature of
applied to the liquid line and the
52C), the liquid leaving the
discharge line must comply with
condenser is sub-cooled by
local regulations. Insert enough
approximately 10C. Take this value
refrigerant fluid into the circuit to
as a basis to determine the
obtain a pressure of 1 bar.
maximum permitted pressure drops,
and use it to calculate the liquid line By injecting dry nitrogen using a
pressure drops. pump, increase this pressure to
7 bars. Look for leaks in the entire
Discharge line
system using a detector.
Install them so as to obtain a gas
If leaks are detected, evacuate the
speed in the horizontal and vertical
fluid from the system and repair the
lines making it possible to carry
defective component. Repeat the test
along the compressor oil. Determine
process to check the repair is
the dimensions of the suction line
watertight.
using the following criteria:
1. 2.5 m/s (minimum) in the
horizontal parts
2. 5.0 m/s (minimum) in the vertical
parts
3. Maximum speed 20 m/s

RLC-SVX03A-E4 19
Installation

Vacuum pumping Do not use rubber or synthetic pipes


For this operation, use a vane pump which retain humidity, increase the
making it possible to obtain a partial duration of the vacuum pumping
vacuum or 100 microns or less. and cause pressure rises during the
When pumping out to create a vacuum tests. An electronic vacuum
vacuum, it is important to connect measurement manometer must be
the pump to the high and low installed upstream of the vacuum
pressure sides of the system. Follow pump stop valve.
the pump manufacturer's 1. Close valve B and open valve A.
recommendations. The pipes used to After a few minutes, the
connect the pump to the system manometer reading indicated the
must be made of copper, with the lowest vacuum level that can be
largest diameter possible. A large obtained by the pump.
pipe diameter reduces flow 2. Open valve B and operate the
resistance and shortens the duration vacuum pump until 1500 Hg
of the vacuum pumping. microns (0.67 mbar) or less is
obtained. Close valve A when you
read the manometer.
3. Once the value of 500 microns or
less has been reached and valve A
has been closed, the pressure will
rise.
The maximum permissible increase
is 200 microns after 15 minutes. If
this limit is exceeded and the value
remains constant, there is too much
humidity in the system. A continuous
increase in pressure indicates there
Figure 14 - Vacuum pump connection
is a leak in the system.

2 1

6
5

1 Header
3
2 Valve B
3 Vacuum pump
4 Vacuum manometer
5 Valve A
6 Low pressure side
7 High pressure side 7

20 RLC-SVX03A-E4
Operation

Pre-start checkout Do not use untreated or improperly- Energize the compressor and oil
treated water. Equipment damage separators 24 hours prior to unit
Installation Checklist may occur. startup.
When installation is complete, but Fill the evaporator chilled-water Unit Voltage Power Supply
prior to putting the unit into service, circuit. Vent the system while it is Voltage to the unit must meet the
the following pre-start procedures being filled. Open the vents on the criteria given in the Installation
must be reviewed and verified: top of the evaporator water box section. Measure each leg of the
Inspect all wiring connections to be while filling and close when filling supply voltage at the main power
sure they are clean and tight. is completed. fused-disconnect switch for the unit.
The use of improperly-treated or If the measured voltage on any leg is
WARNING untreated water in this equipment not within the specified range, notify
may result in scaling, erosion, the supplier of the power and correct
Disconnect all electric power,
corrosion, algae, or slime. The the situation before operating the
including remote disconnects, before
services of a qualified water- unit.
servicing. Failure to disconnect
power before servicing can cause treatment specialist should be
severe personal injury or death. engaged to determine what C AUTION
treatment, if any, is advisable. Trane's Provide adequate voltage to the unit.
C AUTION warranty specifically excludes Failure to do so can cause control
liability of corrosion, erosion, or components to malfunction and
Check the tightness of all
deterioration of Trane equipment. shorten the life of relay contact,
connections in the compressor
Trane assumes no responsibilities for compressor motors and contactors.
power circuit (disconnects, terminal
the results of the use of untreated or Unit Voltage Imbalance
block, contactors, compressor
improperly-treated water, or saline or Excessive voltage imbalance
junction box terminals,). Loose
brackish water. between the phases of a three-phase
connections can cause overheating
at the connections and Close the fused-disconnect system can cause motors to
undervoltage conditions at the switch(es) that supplies power to overheat and eventually fail. The
compressor motor. the chilled-water pump starter. maximum allowable imbalance is
Start the chilled-water pump to 2%. Voltage imbalance is determined
Open all refrigerant valves in the
begin circulation of the water. using the following calculations:
discharge, liquid, oil, and oil return
lines. Inspect all piping for leakage and % Imbalance = [(Vx - V ave) x 100]/V
make any necessary repairs. ave
C AUTION With water circulating through the V ave = (V1 + V2 + V3)/3
Do not operate the unit with the system, adjust the water flow and Vx = phase with the greatest
compressor, oil discharge, liquid-line check the water pressure drop difference from V ave (without
service valves, or the manual shutoff through the evaporator. regard to the sign)
on the refrigerant supply to the Adjust the chilled-water flow switch
auxiliary coolers "CLOSED." Failure For example, if the three measured
for proper operation. voltages are 391, 407, and 402 volts,
to have these "OPEN" may cause
the average would be:
serious compressor damage. WARNING
Check the power-supply voltage to (391+407+402)/3 = 400
Use extreme caution when
the unit at the main-power fused- performing the following procedure The percentage of the imbalance is
disconnect switch. Voltage must be with power applied. Failure to do so then:
within the voltage utilization range can result in personal injury or [100(400-391)]/400 = 2.25%
and also stamped on the unit death.
nameplate. Voltage imbalance must This exceeds the maximum
not exceed 2%. Reapply power to complete the allowable (2%) by 0.25%
procedures.
Check the unit power phasing L1- Unit Voltage Phasing
L2-L3 in the starter to ensure that it Prove all Interlock and It is imperative that L1, L2, and L3 in
has been installed in an "A B-C" Interconnecting Wiring Interlock the starter be connected in the A-B-C
phase sequence. and External as described in the phase sequence to prevent
Installation section. equipment damage due to reverse
C AUTION Check and set, as required, all rotation.
Improper power phasing can result UCM-CLD menu items. It is important that proper rotation of
in equipment damage due to reverse Stop the chilled-water pump. the compressors be established
rotation. before the unit is started. Proper

RLC-SVX03A-E4 21
Operation

motor rotation requires confirmation Do not interchange any load leads control calls for cooling and all the
of the electrical phase sequence of that are from the unit contactors or safety interlocks are closed, the unit
the power supply. The motor is the motor terminals. Doing so may will start. The compressor(s) will
internally connected for clockwise damage the equipment. load and unload in response to the
rotation with the incoming power 7. Reopen the unit disconnect and temperature of the leaving chilled-
supply phased A-B-C. disconnect the phase-sequence water temperature.
When rotation is clockwise, the indicator. After the system has been operating
phase sequence is usually called Water-System Flow Rates for approximately 30 minutes and
"ABC;" when counterclockwise, Establish a balanced chilled-water has become stabilized, complete the
"CBA." This direction may be flow through the evaporator. The flow start-up procedure as follows:
reversed outside the alternator by rates should be between the Check the evaporator refrigerant
interchanging any two of the line minimum and maximum values pressure and the condenser
wires. It is this possible interchange given on the pressure-drop curves. refrigerant pressure in the
of wiring that makes a phase Refrigerant report of the UCM-CLD.
sequence indicator necessary if the Water-System Pressure Drop
operator is to quickly determine the Measure the water-pressure drop Measure the system overheat.
phase rotation of the motor. through the evaporator at the field- Measure the system subcooling.
installed pressure taps on the system
1. Press the Stop key on the UCM- water piping. Use the same gauge for A shortage of refrigerant is indicated
CLD. each measurement. Do not include if the operating pressures and the
2. Open the electrical disconnect or valves, strainers, or fittings in the subcooling are low. If the operating
circuit protection switch that pressure-drop readings. pressures, superheat, and
provides line power to the line- subcooling readings indicate a
power terminal block(s) in the Start-up Procedures refrigerant shortage, gas-charge
starter panel (or to the unit- refrigerant into each circuit as
Daily Unit Start-up Procedure required. With the unit running, add
mounted disconnect).
When the verification operations refrigerant vapor by connecting the
3. Connect the phase-sequence prior to start-up have been performed charging line to the suction service
indicator leads to the line power (see previous sections), the unit is valve and charging through the
terminal block as follows: ready to start. backseat port until operating
Phase Sequence Lead Terminal Press the Stop key on the UCM-CLD. conditions become normal.
Black (Phase A) L1 If necessary, adjust the setpoint
values in the UCM-CLD reports
WARNING
Red (Phase B) L2
(refer to the UCM-CLD user guide). If both suction and discharge
Yellow (Phase C) L3 pressures are low and subcooling is
Close the fused disconnect switch
4. Turn power on by closing the unit normal, a problem other than
for the chilled water pumps and the
supply-power fused-disconnect refrigerant shortage exists. Do not
cooling water pumps.
switch. add refrigerant, as this may result in
Energize the pumps to start the overcharging the circuit.
5. Read the phase sequence on the water circulation.
indicator. The "ABC" LED on the Only use the refrigerant specified on
face of the phase indicator will Check the service valves on the the unit nameplate.
glow if the phase is "ABC." discharge line, suction line, oil line
If operating conditions indicate a
and liquid line for each circuit.
refrigerant overcharge, remove
WARNING These valves must be open before
refrigerant at the liquid line service
starting the compressors.
valve. Allow refrigerant to escape
To prevent injury or death due to
slowly to minimize oil loss. Do not
electrocution, take extreme care WARNING discharge refrigerant into the
when performing service procedures To prevent compressor damage, do atmosphere.
with electrical power energized. not operate the unit until all
6. If the "CBA" indicator glows refrigerant and oil-line valves are WARNING
instead, open the unit main-power opened.
Do not allow refrigerant to directly
disconnect and interchange two Verify that the chilled water pump contact skin, or injury from frostbite
line leads on the line-power runs for one minute after the chiller may result.
terminal block(s) (or the unit- is commanded to stop for normal
mounted disconnect). Close the Overheating
chilled water systems).
main-power disconnect and Normal overheating for each circuit
recheck the phasing. Press the Auto key. If the chiller is approximately 3-4C at full

22 RLC-SVX03A-E4
Operation

operating load. Overheating may Shutdown procedures and damage to the system when it
vary slightly on the circuit if the has been set up for extended
system load is lower, when the slide Temporary Shutdown and Restart shutdown.
valve is moving. To shut the unit down for a short
time, use the following procedure: 5. At least every three months
Overheating must stabilize at (quarterly), check the refrigerant
approximately 4C when the above 1. Press the Stop key on the UCM- pressure in the unit to verify that
components have stabilized. CLD. The compressors will the refrigerant charge is intact.
continue to operate and, after
Subcooling
Normal subcooling for each circuit
unloading for 20 seconds, will stop C AUTION
when the compressor contactor
ranges from 8-10C, depending on de-energizes. During an extended shutdown
the units. If subcooling for either period, especially over the winter
circuit does not fall within these 2) Stop the water circulation by season, the evaporator must be
values, check the overheating for the disconnecting the power supply to drained of water, if the chilled water
circuit and adjust if necessary. If the chilled water and cooling loop does not contain glycol, to
overheating is normal but water pumps. prevent any risk of evaporator freeze-
subcooling is not, contact a qualified up.
service technician. C AUTION
System Restart After Extended
Seasonal Unit Start-up Under freezing conditions, the chilled Shutdown
1. Close all valves and reinstall the water pump must remain in 1. Verify that the liquid-line service
drain plugs in the evaporator. operation during the full shutdown valves, oil line, compressor
period of the chiller if the chilled discharge service valves, and
2. Service the auxiliary equipment water loop does not contain glycol,
according to the startup and suction service valves are open
to prevent any risk of evaporator (backseated).
maintenance instructions provided freeze-up.
by the respective equipment
manufacturers. Extended period shutdown C AUTION
The procedure below must be To prevent damage to the
3. Close the vents in the evaporator performed if the system has to be
chilled-water circuits. compressor, ensure that all
stopped for a prolonged period, for refrigerant valves are open before
4. Open all the valves in the example seasonal shutdown. starting the unit.
evaporator chilled-water circuits. 1. Test the unit for refrigerant leakage 2. Check the oil separator oil level
5. Open all refrigerant valves to and repair as necessary. (see Maintenance section).
verify they are in the open 2. Open the electrical disconnect
condition. 3. Fill the evaporator water circuit.
switches for the chilled-water Vent the system while it is being
6. If the evaporator was previously pump. Lock the switches in the filled. Open the vent on the top of
drained, vent and fill the "Open" position. the evaporator and condenser
evaporator and chilled-water while filling, and close it when
circuit. When all air is removed C AUTION filling is completed.
from the system (including each Lock the chilled-water pump
pass), install the vent plugs in the disconnects open to prevent pump C AUTION
evaporator water boxes. damage. Do not use untreated or improperly
C AUTION 3. Close all chilled-water supply treated water. Equipment damage
valves. Drain the water from the may occur.
Ensure that the compressor and oil- evaporator. 4. Close the fused-disconnect
separator heaters have been switches that provide power to the
operating for a minimum of 24 hours 4. Open the unit main electrical
chilled-water pump.
before starting. Failure to do so may disconnect and unit-mounted
result in equipment damage. disconnect (if installed) and lock in 5. Start the evaporator water pump
the "Open" position. If the optional and, while water is circulating,
7. Check the adjustment and control-power transformer is not inspect all piping for leakage.
operation of each safety and installed, open and lock the 115 V Make any necessary repairs before
operating control. disconnect. starting the unit.
8. Close all disconnect switches. 6. While the water is circulating,
9. Refer to the sequence for daily C AUTION adjust the water flows and check
unit startup for the remainder of Lock the disconnects in the "Open" the water pressure drops through
the seasonal startup. position to prevent accidental startup the evaporator. Refer to "Water-

RLC-SVX03A-E4 23
Operation

System Flow Rates" and "Water-


System Pressure Drop."
7. Adjust the flow switch on the
evaporator piping for proper
operation.
8. Stop the water pump. The unit is
now ready for startup as described
in "Startup Procedures."

24 RLC-SVX03A-E4
Maintenance

Perform all maintenance procedures components for deficiencies. Chemical Cleaning of the Evaporator
and inspections at the recommended 5. Inspect all piping components for (RTUB)
intervals. This will prolong the life of leakage and damage. Clean out The chilled water circuit is a closed
the chiller and minimize the any inline strainers. circuit, and therefore should not
possibility of costly failures. After the accumulate scale or sludge. If the
unit has been operating for 6. Clean and repaint any areas that chiller becomes obstructed, you can
approximately 30 minutes and the show signs of corrosion. attempt to unblock it by reversing
system has stabilized, check the 7. Clean the condenser coils. the water flow direction. If
operating conditions and complete unsuccessful after several attempts,
the following procedures: WARNING clean the evaporator chemically.
Weekly Maintenance Position all electrical disconnects in
While the unit is running in stable the "Open" position and lock them
WARNING
conditions: to prevent injury or death due to Do not use an acid cleaning product
1. Check the UCM pressure for electrical shock. which might damage steel,
Evaporator, Condenser, and galvanized steel, polypropylene and
8. Check and tighten all electrical
Intermediate Oil. copper parts.
connections as necessary.
Contact a local water treatment
2.Measure the subcooling entering Coil Maintenance company advice on a suitable
the EXV. The subcooling should Because seacoast applications are chemical product for this unit. The
never be less than 2.2C under any considered to be a "dirty" supplier of the cleaning product
circumstances. environment for condenser coils, it is must supply or approve:
logical that the coils will need to be
C AUTION cleaned more often than a coil
All devices used in the circuit

Also check the rest of the system located inland. Cleaning four times a The quantity of chemical product to
operating conditions. year may be required or even more if use
conditions are very poor or if The duration for which the chemical
3. Inspect the entire system for corrosion damage begins to occur.
unusual conditions and inspect the product must circulate in the
To clean the coils, use a soft brush evaporator
condenser coils for dirt and debris. and a sprayer (garden pump-up
If the coils are dirty, refer to coil type). A high-quality detergent, such Safety precautions and
cleaning. as "Trane Coil Cleaner, CHM0021" is recommendations for using and
Monthly Maintenance recommended for both standard and handling the chemical product
1. Perform all weekly maintenance coils with aluminium coating. Replacing the Oil Filter
procedures. Follow the directions included with Note: Routine changing of the oil or
2. Record the system subcooling. the detergent. The most effective oil filter is not recommended. The oil
method of coil cleaning is to remove filter is oversized for this application
3. Record the system superheat. the condenser end panels and clean and should not require replacement.
4. Make any repairs necessary. the coils from the inside out using The oil and filter should be replaced
the sprayer. only if analysis reveals that the oil is
Annual Maintenance
1. Perform all weekly and monthly contaminated. Oil type and system
procedures.
C AUTION capacities are shown in Table 1.
If the detergent used is strongly Pressure drop across the oil filter is
2. Check the oil sump oil level while
alkaline (pH greater than 8.5), an shown in Figure 15. Oil filter
the unit is off.
inhibitor must be added. pressure drop is the difference
Note: Routine changing of the oil is Rinse the coil thoroughly after between the two pressure-control
not required. Use an oil analysis to cleaning. Failure to completely flush ports.
determine the condition of the oil. the detergent from the coil can result To change the oil filter in the unit,
3. Have a qualified laboratory in accelerated coil corrosion. Blow refer to Figure 15 and follow the
perform a compressor oil analysis excess water from the coil using low- steps listed.
to determine system moisture pressure air. The water used to clean
content and acid level. This the coils should always be clean,
analysis is a valuable diagnostic fresh water (it should not be
tool. brackish, or contain excessive
dissolved minerals, chlorine, or
4. Contact a qualified service water softener salts.)
organization to leak-test the chiller,
to check operating and safety
controls, and to inspect electrical

RLC-SVX03A-E4 25
Maintenance

Figure 15 - Oil filter change 12. Charge the unit with refrigerant
R134a refer to charging
procedure).
1. Oil charging valve For units with the discharge valve
2. Oil pressure control port option:
3. Oil pressure control port
1. Close the angle valve placed on
the refrigerant liquid line to store
the refrigerant in the condenser.
2. After the compressor stops, close
the compressor discharge valve
and disconnect the unit.
Note: Do not make successive
vacuums by using the compressor.
Irreversible compressor damage
could occur.
Figure 16 - Oil filter pressure drop 3. Vacuum the remaining refrigerant
in the evaporator.
4. Remove the seven bolts on the oil
Normal pressure drop filter cover. A pan may be
Maximum pressure drop
necessary to catch any oil that is
Oil filter pressure drop (bar)

released after the cover is


loosened.
5. Remove the cover and the oil filter
element.
6. Install the new filter element.
7. Coat the new cover gasket with
refrigerant oil.
8. Install the cover plate and cover
plate gasket.
9. Install a new copper gasket under
Condensing Pressure - Suction Pressure (bar) the bolt head that had one at time
of removal. Replace all other bolts
and tighten to 89.5 Nm.
For units without discharge valve 8. Install a new copper gasket under
option the bolt head that had one at time 10. Vacuum the refrigerant circuit at
1. Shut off the compressor and of removal. Replace all other bolts 500 micron and isolate the
disconnect all electrical service to and tighten to 89.5 Nm. vacuum pump.
the compressor. 11. Confirm that no moisture or leaks
9. Vacuum the refrigerant circuit at
2. Vacuum the refrigerant out of the 500 micron and isolate the are present by letting the vacuum
circuit. vacuum pump. stand for 2 hours. The pressure
should not raise more than
3. Remove the seven bolts on the oil 10. Confirm that no moisture or leaks 250 microns.
filter cover. A pan may be are present by letting the vacuum
necessary to catch any oil that is stand for 2 hours. The pressure 12. Charge the unit with oil, in a
released after the cover is should not raise more than quantity equal to what has been
loosened. 250 microns. removed, by using the charging
valve placed on the oil filter.
4. Remove the cover and the oil filter 11. Charge the unit with oil, in a
element. quantity equal to what has been Note: the oil is very sensitive to
removed, by using the charging moisture. Use the oil immediately
5. Install the new filter element. after the oil can has been opened.
valve placed on the oil filter.
6. Coat the new cover gasket with 13. Open all the valves before
refrigerant oil. Note: the oil is very sensitive to
moisture. Use the oil immediately restarting the chiller.
7. Install the cover plate and cover after the oil can has been opened.
plate gasket.

26 RLC-SVX03A-E4
Maintenance

Checking the separator oil Some symptoms of a refrigerant


level under-charged unit:
Low subcooling
Figure 17 - System Oil Specifications
Larger-than-normal evaporator
approach temperatures (Leaving-
Water Temperature - Saturated
Evaporator Temperature)
Low Evaporator-Refrigerant
Temperature Limit
Low Refrigerant-Temperature
1 Oil separator
2 Valve Cutout diagnostic
3 " refrigeration hose
Fully-open expansion valve
4 Sight glass
5 Minimum oil level Possible whistling sound coming
6 Maximum oil level
from liquid line (due to high vapor
velocity)
High Condenser + Subcooler
Pressure drop
Some symptoms of a refrigerant
over-charged unit:
High subcooling
Larger-than-normal condenser
approach temperatures (Entering-
Condenser Saturated Temperature -
Entering-Air Temperature)
Condenser Pressure Limit
High-Pressure Cutout diagnostic
More-than-normal number of fans
Follow the steps listed below and running
4. After the level has been
refer to the notes listed in Figure 17. determined, remove the sight Erratic fan control
1. Turn off the unit. glass and hoses. Higher-than-normal compressor
2. Attach the hoses and sight glass to power
the oil-separator Schrader valves, Refrigerant and Oil-Charge
as shown in Figure 17. Remove Very low discharge superheat at
Management startup
non-condensables. Proper oil and refrigerant charge is
3. After the unit has been off for essential for proper unit operation, Compressor rattle or grinding
10 minutes, move the sight glass unit performance, and sound at startup
up and down until the level can be environmental protection. Only Some symptoms of an oil over-
seen. trained and licensed service personal charged unit:
should service the unit. Larger-than-normal evaporator
approach temperatures (Leaving-
Water Temperature - Saturated
Evaporator Temperature)
Low Evaporator-Refrigerant
Temperature Limit
Low Refrigerant-Temperature
Cutout diagnostic
Table 5 - Oil level limit Low unit capacity
Oil separator diameter (mm) Compressor rattle or grinding
152 203 254 sound
Minimum oil level (mm) 90 120 145
Maximum oil level (mm) 155 205 235 High oil-sump level after normal
shutdown

RLC-SVX03A-E4 27
Maintenance

Some symptoms of an oil under- [9 mm] flare). Open the service 8. Remove the remainder of the
charged unit: valve. charge with the vacuum pump.
Compressor rattle or grinding 2. Add 4.5 kg of refrigerant (R134a) Recommendation: Do not pump
sound charge. the remaining charge into the high
Lower-than-normal pressure drop side. This may introduce non-
3. Close the valve, remove the condensable gasses and other
through oil system charging hose and start the unit. contaminants into the unit.
Seized or Welded Compressors Monitor subcooling.
9. The low side and the compressor
Low oil-sump level after normal 4. If subcooling is still insufficient, may be serviced at this time.
shutdown return to step number 2.
Returning the unit to running
Lower-than-normal oil Note: Proper subcooling can be condition:
concentrations in the evaporator determined from run-log history, 1. Open all the valves.
service experience, or by contacting
R134a Field-Charging Trane technical service. The service 2. Manually open EXV for 15 minutes
tool may include a calculation to allow the refrigerant to drain to
Procedure the evaporator by gravity.
Be certain that the electrical power to module that determines the proper
the unit is disconnected before subcooling for any operating 3. Let the unit sit with heaters on to
performing this procedure. condition (Trane Service only). drive refrigerant out of the oil and
warm up the compressor
WARNING Charge Isolation in the high bearings. Depending upon
or low side of the system ambient conditions, this may take
Position all electrical disconnects in up to 24 hours.
the "Open" position and lock them to All the refrigerant may be trapped
prevent injury or death due to into the high side (condenser) of the 4. After the oil level has returned to
electrocution. Follow this procedure unit for maintenance on the normal, the unit can be put back
when the unit is empty of all compressor (or low side). With the into operation.
refrigerant and under a vacuum. suction-line service valve option, Low-side charge-isolation procedure:
charge may also be isolated in the After normal shutdown, most of the
C AUTION evaporator for maintenance on the charge resides in the evaporator.
compressor (or high side). It is much Running cold water through the
Water must be flowing through the more preferable to isolate the charge
evaporator during the entire evaporator may also drive much of
in the evaporator, if this option is the refrigerant to the evaporator.
charging process to avoid freezing available.
and rupturing of the evaporator 1. Make sure the circuit is off.
tubes. High side charge isolation procedure: 2. Close the suction-line isolation
1. Find the weight of the amount of 1. Make sure the circuit is off. valve.
charge given in Table 1. 2. Shut the liquid-line service valve. 3. Close the oil return-line service
2. Attach the charging hose to the 3. Shut the oil return-line service valve.
evaporator service valve (3/8" valve. 4. Close the liquid line service valve.
[9 mm] flare). Open the service 4. Start the circuit with the service
valve. 5. Manually open the EXV.
tool in charge-isolation mode:
3. Add charge to the evaporator to 6. Use a liquid pump or vacuum
All fans will turn on pump to move refrigerant from
bring the total circuit charge up to
the level given in Table 1. EXV will open 100% the condenser to the evaporator.
4. Close the service valve and The oil return-line solenoid will The liquid pump will only be
disconnect the charging hose. open effective if there is a lot of charge in
The unit will start at minimum load the condenser. It may be connected
Adding charge to the condenser drain port on the
This procedure should be followed The unit will run until it cuts out on liquid-line isolation valve.
when adding charge to an low pressure (~6 psia) [0.41 bar].
undercharged unit. When low charge Note: if a pump is to be used,
5. When the unit trips, the discharge connect it before closing this valve.
is indicated by low subcooling in the
check valve and the oil-line shutoff This port is only isolated when the
liquid line, charge should be added
valve close. valve is backseated. If a vacuum
until sufficient subcooling is
achieved. 6. Close the discharge isolation pump is used, then connect it to the
valve. discharge-line service valve near the
1. Attach the charging hose to the oil separator. A vacuum pump will be
evaporator service valve (3/8" 7. Close the oil-line shutoff valve.
required for part of the procedure.

28 RLC-SVX03A-E4
Maintenance

The evaporator is large enough to 12. Attach the vacuum hose and Oil line drain (lowest point in
hold all the charge, for any unit, evacuate the liquid line. system)
below the centerline of the shell. 13. Remove the vacuum hose from Oil cooler
Therefore, no special precautions are the liquid line and attach the
required to restart the unit after Oil temperature sensor
charging hose.
isolating the charge in the Oil line shutoff valve with flare
evaporator. 14. Replace the stored charge in the service connection
liquid line.
Oil filter (internal to compressor)
Filter Replacement 15. Remove the charging hose. with flare-fitting service connection
Procedure 16. Open the liquid-line isolation and Schrader valve
A dirty filter is indicated by a valve. On units with remote Oil flow-control valve (internal to
temperature gradient across the evaporators or oil cooler circuits, the compressor after the filter)
filter, corresponding to a pressure open the oil cooler liquid-line ball
drop. If the temperature downstream valve. Oil return line from evaporator with
of the filter is 8F [4.4C] lower than shutoff valve, strainer, and solenoid
Lubrication System control valve. The standard oil
the upstream temperature, the filter
The lubrication system has been charge for each circuit size is shown
should be replaced. A temperature
designed to keep most of the oil in Table 1.
drop can also indicate that the unit is
lines filled with oil as long as there is
undercharged. Ensure proper Measuring the oil level
a proper oil level in the oil sump. The
subcooling before taking 1. To measure the oil level, use the
total oil charge can be removed by
temperature readings. oil drain valve on the oil line and a
draining the oil system, the oil return
1. With the unit off, verify that the service valve on the discharge line.
line from the evaporator, the
EXV is closed. Close the liquid-line This measurement can only be
evaporator, and the compressor. Very
isolation valve. On units with made when the circuit is not
small quantities of oil may be found
remote evaporators or oil cooling running. Note: the bottom plate of
in other components.
circuits, close the ball valve on the the oil separator is approximately
oil cooler liquid line. 1" [25 mm] thick.
Oil Charging Procedure
2. Attach the vacuum hose to the Proper charging of the oil system is 2. The initial oil charge should be
service port on the liquid-line filter critical to the reliability of the approximately at the level as
flange. compressor and chiller. Too little oil shown in Table 6. This is the
3. Evacuate the refrigerant from the can cause the compressor to run hot approximate oil level if all the oil is
liquid-line and store. and inefficiently. When taken to an in the oil lines, filter, and oil sump,
extreme, low oil level may result in and the unit is in vacuum so that
4. Remove the vacuum hose.
infant failure of the compressor. Too there is no refrigerant dissolved in
5. Depress the Schrader valve to much oil will result in high oil- the oil.
equalize pressure in the liquid line circulation rates, which will foul the 3. After the unit has run for a while,
with atmospheric pressure. condenser and evaporator the oil level in the sump can vary
6. Remove the bolts that retain the performance. This will result in greatly.
filter flange. inefficient operation of the chiller.
Taken to an extreme, high oil levels The field-charging procedure
7. Remove the old filter element. depends on the circumstances that
may result in erratic expansion-valve
8. Inspect the replacement filter control or shut down of the chiller resulted in the need for oil charge.
element and lubricate the o-ring due to low evaporator-refrigerant 1. Some service procedures may
with Trane OIL00048. temperature. Too much oil may result in loss of small quantities of
contribute to long-term bearing oil that must be replaced (oil
C AUTION wear. Additionally, excessive analysis, compressor filter
compressor wear is probable when replacement, re-tubing the
Do not use mineral oil. It will evaporator, and so forth).
contaminate the system. the compressor is started with the oil
lines dry. Oil system consists of the 2. Additionally, some maintenance
9. Install the new filter element in the following components: procedures may result in virtually
filter housing. all of the oil being removed
Compressor
10. Inspect the flange gasket and (compressor motor burn or total
replace it with a new one if Oil separator removal of the charge to trouble-
damaged. Discharge line with service valve shoot a unit).
11. Install the flange and torque the Oil line from separator to 3. Finally, leaks may result in a loss
bolts to 14-16 lb-ft [19-22 n-m]. compressor of oil that must be replaced.

RLC-SVX03A-E4 29
Maintenance

Factory (initial) Oil-Charging oil-charging hose to the oil- shutoff valve is closed. Other
Procedure charging fitting and the other end compressor isolation valves may
The initial charging procedure to an oil pump. Use the pump to also be closed depending upon
should be followed any time the unit draw oil out of the oil container and the service that was completed.
is new or has had all of the oil push the required amount of oil For example, changing the oil filter
removed. into the unit. Note: the compressor would require the compressor to be
1. Add 0.95 liter (0.90 kg) of oil to the filter has an internal shutoff valve isolated and pulled into vacuum.
motor cavity or suction line prior that will prevent oil from entering Note: Ensure that the compressor is
to installing the compressor into the compressor while the not pressurized.
the chiller. compressor is not running.
Therefore, there is no concern 3. Open the flare fitting on the oil-line
2. If the unit is not equipped with shutoff valve.
suction-line isolation valves, it about flooding the compressor with
should contain no charge. If it has oil. 4. Open the flare fitting on the filter
isolation valves, then the charge housing. This is the port that must
may be trapped in the evaporator. Field Oil-Charging be used to put oil into the
In either case, the high side of the Procedure compressor.
system should not be pressurized. Use the initial charging procedure 5. Install one end of the charging
3. The oil-line shutoff valve must be under the following circumstances: hose on the oil charging port (with
open to allow the oil to pass into When virtually all of the oil has the Schrader valve) and the other
the oil lines and the oil separator. been removed. on the oil canister.
4. The oil charging port is a " If the oil charge is removed from 6. Lift the oil canister, or use a pump,
[6 mm] flare fitting with a Schrader the compressor and oil system to pour oil into the filter housing.
valve that is on the side of the oil- only, but the unit has been run for 7. When oil comes out of the flare
filter housing. This is the port that less than 15 minutes. fitting on the oil-line shutoff valve,
must be used to add oil into the If the oil charge is removed from the filter is full. Stop adding oil.
compressor so that the filter and the compressor and oil system 8. Put the cap on the flare on the oil-
lines are full at the first start of the only, and the unit has been run for line shutoff valve, remove the
compressor. more than 15 minutes. charging hose, and put the cap
5. On single-compressor circuits, all However, reduce the amount of oil back on the flare on the filter
the oil should be put into the added to the unit by the normal housing.
circuit through the oil-charging quantity of oil in the refrigeration 9. Vacuum the compressor (low side)
port on the compressor filter system. and prepare it for inclusion in the
housing. On two-compressor
Note: this procedure can be followed system. There is a service valve on
circuits, put approximately of
even with the refrigerant charge the suction line and on the
the oil into the unit through each
isolated in the evaporating section of evaporator. Use these valves to
of the two oil-charging ports on
the unit. vacuum the compressor.
the two compressors.
If small quantities of oil were 10. Open the oil-line shutoff valve.
6. Oil may be put into the unit using
removed to service refrigeration Severe damage to the
either of two methods:
components, such as the evaporator, compressor can result if the oil-
line shutoff valve is closed when
C AUTION replace the oil that was removed
the compressor is started.
back into the serviced component
Use only Trane OIL 00048 in the units prior to vacuum and recharge of the
to avoid any catastrophic damage to refrigerant. C AUTION
the compressor or unit.
If oil was removed to service a Catastrophic damage to the
Have the unit in vacuum. Note that compressor or change the filter compressor will occur if the oil-line
the vacuum connection should be follow this procedure: shutoff valve or the isolation valves
made on the unit at the service are left closed on unit startup.
valve that is on the discharge line. 1. If the compressor is a new
compressor or has been removed 11. Open the other compressor
Hook up one end of the oil-charging
from the system and reworked, isolation valves.
hose to the oil-charging fitting and
immerse the other end into the oil add 0.95 liter (0.90 kg) of oil to the Note: this procedure assumes that
container. Let the vacuum draw the motor cavity prior to installing the the oil that is put into the filter
required amount of oil into the unit. compressor into the chiller. housing does not have contaminants
2. Install the compressor in the such as non- condensable gases. The
Have the unit at the same pressure
system. Make sure that the filter oil forces these gases out of the filter
as the oil. Hook up one end of the

30 RLC-SVX03A-E4
Maintenance

and oil- line shutoff valve, without


the need to pull a vacuum on this
small volume. If the oil has been in
an open container or is otherwise
contaminated, then this small
volume must be subject to vacuum
as well. However, the filter cavity is
full of oil. Therefore, be sure to use a
flash tank in line with the vacuum
pump to ensure that the oil that is
pulled out of the filter cavity does
not slug the vacuum pump.

RLC-SVX03A-E4 31
Safety recommendations Maintenance contract Training
To avoid accidents and damage, the It is strongly recommended that you The equipment described in this
following recommendations should sign a maintenance contract with manual is the result of many years of
be observed during maintenance your local Service Agency. This research and continuous
and service visits. contract provides regular development. To assist you in
1. The maximum allowable pressures maintenance of your installation by a obtaining the best use of it, and
for system leak testing on low and specialist in our equipment. Regular maintaining it in perfect operating
high pressure side are given in the maintenance ensures that any condition over a long period of time,
chapter "Installation". Always malfunction is detected and the constructor has at your disposal
provide a pressure regulator. corrected in good time and a refrigeration and air conditioning
minimizes the possibility that serious service school. The principal aim of
2. Disconnect the main supply before damage will occur. Finally, regular this is to give operators and
any servicing on the unit. maintenance ensures the maximum maintenance technicians a better
3. Service work on the refrigeration operating life of your equipment. We knowledge of the equipment they
system and the electrical system would remind you that failure to are using, or that is under their
should be carried out only by respect these installation and charge. Emphasis is particularly
qualified and experienced maintenance instructions may result given to the importance of periodic
personnel. in immediate cancellation of the checks on the unit operating
warranty. parameters as well as on preventive
maintenance, which reduces the cost
of owning the unit by avoiding
serious and costly breakdown.

Literature Order Number RLC-SVX03A-E4


Date 0202
Supersedes B20IM004-E 0400
Stocking Location Europe
The Trane Company Trane has a policy of continuous product and product data improvement and reserves the right to
An American Standard Company change design and specifications without notice. Only qualified technicians should perform the
www.trane.com installation and servicing of equipment referred to in this publication.

For more information contact Socit Trane Socit Anonyme au capital de 61 005 000 Euros Sige Social: 1 rue des Amriques
your local sales office or 88190 Golbey France Siret 306 050 188-00011 RSC Epinal B 306 050 188
e-mail us at comfort@trane.com Numro didentification taxe intracommunautaire: FR 83 3060501888