Installation Operation Maintenance RTWB Helical-Rotary ...

RTWB Helical-RotaryChillers200 to 700 kWSizes 207-224

RTWB-SVN01B-E4

InstallationOperationMaintenance

Personal protection

Safety glasses with sideshields before enteringconstruction sites ormanufacturing areas.

Goggles and gloves whenhandling chemicals; whenwelding, cutting, brazing orgrinding.

Hard hat wherever there ispotential danger fromfalling or flying objects.

Gloves before touching anypart of the machine that isoperating or one that hasrecently been shutdown.Assume that metal is hot.

Hearing protection.

Safety shoes.

CCAAUUTTIIOONN

Risk of damage to equipment.

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Risk for safety or health.

Pressure vessel

Do not attempt to removefittings and covers or breaklines while the machine is

under pressure or while it isrunning.

Do not weld or flamecut any vesselor line until all refrigerant has beenremoved.

Do not use oxygen to purge lines,leak test, or pressurize a machine.

Do not pressure test any vessel at itsdesign pressure (found on theequipment nameplate). Testing at thepressures must be done in a specialenclosure or be using hydraulic,refer to national regulation.

RTWB-SVN01B-E4

ImportantNotice

©American Standard Inc. 2001

Refrigerant emissioncontrol

In respect of the environment allservice operation must use recoverysystems to minimize losses ofrefrigerant to the atmosphere whenservicing units with HFCrefrigerants.

Leak check and inspect all reliefdevices in accordance with nationalregulation.

Handling refrigerant

Heavy concentration of refrigerantwithin a confined area can displaceenough oxygen to cause suffocation.

Do not weld or flamecut in anatmosphere containing refrigerantvapor until the area has been wellventilated.

Avoid breathing refrigerant fumes.

Hazardous voltage

Disconnect and lockout or tagout allelectrical power, includingremote disconnects beforeservicing.

Trane assume no liability forinstallation or service proceduresperformed by unqualified personnel.

Regulations on safety, construction,and environment vary from onecountry to another. Make sure thatthe equipment complies with localregulations.

In addition to this publication, readcarefully Société Trane’s and/or theSeller’s General Terms andConditions of Sale and any specificinstruction which you may havereceived.

RTWB-SVN01B-E4

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Contents

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General InformationLiterature change historyUnit inspectionInspection checklistLoose parts inventoryUnit descriptionInstallation overview

Installation – MechanicalStorageLocation requirementsAccess restrictionsMoving and riggingLifting procedureIsolation padsShipping itemsUnit levelingWater pipingWater pressure-drop dataWater treatmentWater pressure gauges and thermometersWater pressure-relief valvesFlow sensing devicesRefrigerant pressure-relief valve ventingThermal insulation

Installation – ElectricalGeneral recommendationsPower supply wiringCompressor-motor phase sequencingModule and control panel connectorsInterconnecting wiring (field wiring required)

Operating Principles – MechanicalGeneral

Unit Start-Up ProcedureDaily unit start-up procedureSeasonal unit start-up procedure

Unit Shutdown ProcedureDaily unit shutdown procedureSeasonal unit shutdown procedure

Periodic MaintenanceOverviewWeekly maintenance and checksMaintenance Contract and Training

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RTWB-SVN01B-E44

GeneralInformation

Literature change history

This manual describes theinstallation, operation, andmaintenance of RTWB units.

When the unit arrives, compare allnameplate data with ordering,submittal, and shipping information.A typical nameplate is shown inFigure 1.

Figure 1 – Typical unit name plate

An Owner Guide on the operationof the UCM-CLD chiller controls isavailable as a separate document.

RTWB-SVN01B-E4 5

GeneralInformation

Unit inspection

When the unit is delivered, verifythat it is the correct unit and that it isproperly equipped.

Inspect all interior components forvisible damage. Report any apparentdamage or material shortage to thecarrier and make a “unit damage“notation on the carrier's deliveryreceipt. Specify the extent and typeof damage found and notify theappropriate Trane sales office.Do not proceed with the installationof a damaged unit without salesoffice approval.

Inspection checklist

To protect against loss due todamage incurred in transit, completethe checklist upon receipt of the unit.

• Inspect the individual pieces of theshipment before accepting theunit. Check for obvious damage tothe unit or packing material.

• Inspect the unit for concealeddamage as soon as possible afterdelivery and before it is stored.

• Concealed damage must bereported within 72 hours afterreceipt and confirmed byregistered delivery to the carrierand the Trane sales office.

• If concealed damage is discovered,stop unpacking the shipment. Donot remove the damaged materialfrom the receiving location. Takephotos of the damage, if possible.The owner must providereasonable evidence that thedamage did not occur afterdelivery.

• Notify the Trane salesrepresentative and arrange forrepair. Do not repair the unit,however, until damage isinspected by the transportationrepresentative.

Loose parts inventory

Check all items against the shippinglist. Water flow switch (option),water-vessel drain plugs, isolationpads, rigging and electricaldiagrams, and service literature areshipped in the starter panel.

RTWB-SVN01B-E46

Unit description

The RTWB units are helical-rotarytype, water-cooled, liquid chillersdesigned for indoor installation . Theunits have two independentrefrigerant circuits, with onecompressor per circuit.

Each RTWB unit is completelyassembled, wired, leak-tested,dehydrated, charged, and tested forproper control operation prior toshipment. The chilled-water inlet andoutlet openings are covered forshipment.

The RTWB series features Trane'sexclusive Adaptive Control™ logicwith Clear Language Display. Itmonitors the control variables thatgovern the operation of the unit.Adaptive Control logic can correctthese variables, when necessary, tooptimize operational efficiencies,avoid chiller shutdown, and keepproducing chilled water.

Compressor unloaders are oilpressure operated. Each refrigerantcircuit is provided with filter,electronic expansion valve, andcharging valves.

Figure 2 -– Component location for typical RTWB unit

Figure 3 – Component location for typical RTWB unit (back view)

1 Starter panel2 Control panel3 Evaporator4 Oil separator5 Helical-Rotary Compressor7 Condenser-water outlet8 Condenser-water inlet

3 Evaporator5 Helical-Rotary Compressor6 Condenser9 Evaporator-water outlet

10 Evaporator-water inlet11 Electronic expansion valve12 Filter dryer

GeneralInformation

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RTWB-SVN01B-E4 7

GeneralInformation

Installation overview

For convenience, Table 1summarizes responsibilities that aretypically associated with the RTWBchiller installation process.

• Locate and maintain the looseparts, for example, isolators, bulbwells, temperature sensors, flowsensors, or other factory-ordered,field-installed options, forinstallation, as required.

• Install the unit on a foundationwith flat support surfaces, levelwithin 6 mm and of sufficientstrength to support concentratedweight. Place the manufacturer-supplied isolation pad assembliesunder the unit.

• Install the unit per the instructionsoutlined in the mechanicalinstallation section. Complete allwater piping and electricalconnections.

Note: Field piping must be arrangedand supported to avoid stress onthe equipment. It is stronglyrecommended that the pipingcontractor provide at least 1 m ofclearance between the pre-installation piping and the plannedlocation of the unit. This will allowfor proper fit-up upon arrival of theunit at the installation site. Allnecessary piping adjustments canbe made at that time.

Where specified, supply and installvalves in the water piping upstreamand downstream of the evaporatorand condenser water boxes toisolate the shells for maintenanceand to balance and trim the system.

• Supply and install flow switches orequivalent devices in both thechilled-water and condenser-waterpiping. Interlock each switch withthe proper pump starter and UCP2to ensure that the unit can onlyoperate when water flow isestablished.

• Supply and install taps forthermometers and pressuregauges in the water piping,adjacent to the inlet and outletconnections of both theevaporator and the condenser.

• Supply and install drain valves oneach water box.

• Supply and install vents cocks oneach water box.

• Where specified, supply and installstrainers ahead of all pumps andautomatic modulating valves.

• Supply and install refrigerantpressure-relief piping from thepressure relief to the atmosphere.

• Start the unit under supervision ofa qualified service technician.

• Where specified, supply andinsulate the evaporator and anyother portion of the unit, asrequired, to prevent sweatingunder normal operatingconditions.

• For unit-mounted starters, cutoutsare provided at the top of thepanel for line-side wiring.

• Supply and install the wireterminal lugs to the starter.

• Supply and install field wiring tothe line-side lugs of the starter.

RTWB-SVN01B-E48

Table 1 – Installation overviewRefer to the installation mechanical and electrical sections of this manual for detailed installation instructions.Requirement Trane supplied Trane supplied Field supplied

Trane installed Field installed Field installedRigging Safety chains

Clevis connectorsLifting beam

Isolation Isolation pads Isolation padsElectrical Disconnect switch (optional) Disconnect switch

Flow switches (may be field supplied) BAS wiring (optional)Water pump contactor

Water piping Flow switches (may be field supplied) ThermometersWater flow pressure gaugesIsolation and balancing valves water pipingVents and drain valvesPressure relief valves

Pressure relief Relief valves Vent lineInsulation Insulation (optional) Insulation

Table 2 - General data207 208 210 211 212 214 216 217 218 220 222 224

Evaporator type EG 120 EG 120 EG 140 EG 170 EG 170 EG 200 EG 200 EG 200 EG 250 EG 250 EG 340 EG 340Condenser type CG 120 CG 120 CG140 CG 170 CG 170 CG 200 CG 200 CG 200 CG 230 CG 230 CG 230 CG 230Compressor type K1/K1 K2/K2 L1/L1 L2/L1 L2/L2 M1/M1 M2/M1 M2/M2 N1/M2 N1/N1 N2/N1 N2/N2Oil charge (l) 6/6 6/6 7/7 7/7 7/7 8/8 8/8 8/8 8/8 8/8 11/8 11/11Oil type OIL 023 E or OIL 048 ERefrigerant charge (kg) 39/39 39/39 60/60 60/60 60/60 60/60 60/60 60/60 69/69 69/69 74/74 74/74

Operating weight (kg) 2620 2620 3370 3450 3450 3725 3725 3725 4325 4500 4925 5000

Shipping weight (kg) 2450 2450 3050 3150 3150 3500 3500 3500 3900 4050 4250 4400Length (mm) 2880 2880 4150 4150 4150 4150 4150 4150 4150 4150 4150 4150Width (mm) (1) 890 890 890 890 890 890 890 890 890 890 890 890Height (mm) (1) 1789 1789 1832 1832 1832 1832 1832 1832 1932 1932 2041 2041(1) With compressor sound enclosure and disconnect switch handle not mounted.

GeneralInformation

RTWB-SVN01B-E4 9

Installation Mechanical

Figure 4: Minimum service clearance

1 Minimum clearance for maintenance.2 Minimum clearance for tube removal of the evaporator or condenser (at

either end of the unit).Dimensions in mm

Storage

If the chiller is to be stored for atleast one month prior to theinstallation, observe the followingprecautions:

– Do not remove the protectivecoverings from the unit.

– Store the chiller in a dry, vibration-free secure area.

– At least every three months, checkthe pressure in the refrigerantcircuit. If the condensing pressureis below 4 bar at 20°C, call aqualified service organization andthe appropriate Trane sales office.

Location requirements

Noise considerations– Refer to the engineering bulletin

for noise-considerationapplications.

– Locate the unit away from sound-sensitive areas.

– Install the isolation pads under theunit.

– Install the rubber vibrationisolators in all water piping.

– Use flexible electrical conduit.

Note: Consult an acoustical engineerfor critical applications.

FoundationProvide rigid, non-warpingmounting pads or a concretefoundation of sufficient strength andmass to support the chiller operatingweight (including completed pipingand full operating charges ofrefrigerant, oil, and water). Refer toTable 2 for unit operating weights.

When in place, level the chillerwithin 6 mm over its length andwidth. The Trane Company is notresponsible for equipment problemsresulting from an improperly-designed or -constructedfoundation.

Vibration eliminators– Provide rubber boot-type isolators

for all water piping at the unit.

– Provide flexible conduit forelectrical connections to the unit.

– Isolate all pipe hangers and besure they are not supported bymain structure beams that couldintroduce vibration into occupiedspaces

– Make sure that the piping doesnot put additional stress on theunit.

Note: Do not use metal-braided-type eliminators on the waterpiping. Metal braided eliminatorsare not effective at the frequenciesat which the unit will operate.

ClearancesProvide enough space around theunit to allow the installation andmaintenance personnel unrestrictedaccess to all service points. Refer tosubmittal drawings for the unitdimensions.

Allow adequate clearance forcondenser and compressorservicing. A minimum of 1 meter isrecommended for compressorservice and to provide sufficientclearance for the opening of thecontrol panel doors. Refer to Figure4 for minimum clearances requiredfor condenser-tube service. In allcases, local codes will takeprecedence over theserecommendations.

Note: Required vertical clearanceabove the unit is 1 meter. Thereshould be no piping or conduitlocated over the compressor motor.If the room configuration requires avariance to the clearancedimensions, contact your Trane salesoffice representative.

Note: Maximum clearances aregiven depending on the unitconfiguration; some units mayrequire less clearance than others inthe same category.

Local regulations may provide forspecific requirements.

Size “A”

207 and 208 1615

210 to 224 2250

RTWB-SVN01B-E410

VentilationThe unit produces heat even thoughthe compressor is cooled by therefrigerant . Make provisions toremove heat generated by unitoperation from the equipment room.Ventilation must be adequate tomaintain an ambient temperaturelower than 40°C.

Vent the evaporator, condenser, andcompressor pressure-relief valvesventing.

Make provisions in the equipmentroom to keep the chiller from beingexposed to freezing temperatures(0°C).

Water drainageLocate the unit near a large capacitydrain for water vessel drain-downduring shutdown or repair.Condensers and evaporators areprovided with drain connections.Refer to “water piping“.

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To prevent unit damage, positionthe lifting beam so that cables donot come in contact with the unit.

Do not use the threaded holes in thecompressor to lift, or assist in lifting,the unit.They are not intended forthat purpose and could create adangerous situation.

Do not remove the wood shippingmounts until the unit is in its finallocation. Removal of wood shippingmounts prior to unit final locatingcould result in injury or death andequipment damage.

Connect an anti-rotation strapbetween the lifting beam and thecompressor before lifting the unit.Failure to do so may result inpersonal injury or death, if a liftingcable fails.


Figure 5 – Lifting and rigging

Table 3 – Shipping weights and sling lengths for lifting1 2 3 4 5 6 Shipping Weight

Unit Size (mm) (mm) (mm) (mm) (mm) (mm) (kg)

207 - - 2500 3000 2650 2200 2600208 - - 2500 3000 2650 2200 2600210 2500 3030 2400 3000 3650 3050211 2500 3030 2400 3000 3650 3150212 2500 3030 2400 3000 3650 3150214 2500 3030 2400 3000 3650 3500216 2500 3030 2400 3000 3650 3500217 2500 3030 2400 3000 3650 3500218 2470 3060 2450 3000 3650 3900220 2470 3060 2450 3000 3650 4050222 2450 3100 2500 3000 3650 4250224 2450 3100 2500 3000 3650 4400

Access restrictions

Door clearances for the RTWB unitsare given in Figure 8. Refer to theunit submittals for specific “perunit“ dimensional information.

Lifting procedure

The unit can be moved by using afork lift or chains, cables, and alifting beam. The total lifting weightand required lifting-beamdimensions are shown in Figure 5and on the lifting diagram shippedwith each unit. Lifting-beamcrossbars must be positioned sothat lifting cables do not come incontact with the sides of the unit.

Dimension of theholes for the forklift

Sizes 207 and 208 Sizes 210-224

RTWB-SVN01B-E4 11


Isolation padsThe elastomeric pads shipped areadequate for most installations. Foradditional details on isolationpractices, consult an acousticalengineer for sensitive installations.

Water pipingPiping connections

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To prevent equipment damage,bypass the unit if using an acidicflushing agent.

Make water piping connections tothe evaporator and condenser.Isolate and support piping toprevent stress on the unit. Constructpiping according to local andnational codes. Isolate and flushpiping before connecting it to theunit.

Figure 6 – Isolator pad location

Evaporator water pipingFigure 7 illustrates typicalevaporator piping components.Components and layout will varyslightly, depending on the locationof connections and the watersource.

The chilled-water connections areon the back of the unit, when facingthe control panel.

A vent is provided on the top of theevaporator at the return end. Besure to provide additional vents athigh points in the piping to bleed airfrom the chilled-water system.Install necessary pressure gauges tomonitor the entering and leavingchilled-water pressures.

To prevent damage to chilled-watercomponents, do not allowevaporator pressure (maximumworking pressure) to exceed 10 bar.

Provide shutoff valves in lines to thegauges, in order to isolate themfrom the system when they are notin use. Use rubber vibrationeliminators to prevent vibrationtransmission through the waterlines.

If desired, install thermometers inthe lines to monitor entering andleaving-water temperatures. Install abalancing valve in the leaving-waterline to control the balance of thewater flow. Install shutoff valves onboth the entering and leaving-waterlines so that the evaporator can beisolated for service.

A pipe strainer should be installed inthe entering water line to preventwater-borne debris from entering theevaporator.

Dimensions in mm

Size “A”

207 and 208 2880

210 to 224 4150

RTWB-SVN01B-E412


Flow switch

Balance valve

Air vent

Stop valves

ThermometersExpansion joints

Stop valves

Evaporator

Filter

Drainage

Manometer

Figure 7 – Suggested piping for typical RTWB evaporator

Evaporator pipingcomponents

“Piping components“ include alldevices and controls used to provideproper water-system operation andunit operating safety.

These components and their generallocation are given above:

Entering chilled-water piping

• Air vents (to bleed air from system)• Water pressure gauges with shutoff

valves• Vibration eliminators• Shutoff (isolation) valves•Thermometers (if desired)• Cleanout tees• Pipe strainer

To prevent tube damage, install astrainer in the water inlet piping ofthe evaporator.

Leaving chilled-water piping

• Air vents ( to bleed air fromsystem).

• Water pressure gauges with shutoffvalves.

• Vibration eliminators.• Shutoff (isolation) valves.•Thermometers.• Cleanout tees.• Balancing valve.• Flow switch• Pressure-relief valve.

RTWB-SVN01B-E4 13


Condenser pipingcomponents

“Piping components“ include alldevices and controls used toprovide proper water-systemoperation and unit operating safety.These components and theirgeneral locations are given below.

Entering condenser-water piping.

• Air vents (to bleed air fromsystem)

• Water pressure gauges withshutoff valves

• Vibration eliminators • Shutoff (isolation) valves. •Thermometers• Cleanout tees• Pipe strainer

Leaving condenser-water piping

• Air vents (to bleed air fromsystem)

• Water pressure gauges withshutoff valves

• Pipe unions• Vibration eliminators• Shutoff (isolation) valve•Thermometers• Cleanout tees• Balancing valve• Pressure relief valve

To prevent condenser damage donot exceed 10 bar water pressure.

To prevent tube damage, install astrainer in the water inlet piping ofthe condenser.

Condenser WaterLimitation (RTWB only)The RTWB starts and operatesatisfactorily over a wide range ofload conditions with controlledentering condenser watertemperature. Reducing thecondenser water temperature is aneffective method of lowering thepower input to the compressors. Theoptimum condenser watertemperature is related to the leavingchilled water temperature and thepercentage of load on the chiller.Nevertheless it is required tomaintain a minimum temperaturedifferential of 18°C between theleaving chilled water temperatureand the leaving condensertemperature. This minimumtemperature differential must bereached within 2 minutes from start-up and maintained thereafter.

Furthermore, the enteringcondenser water temperatureshould never drop below 20°C,whatever the other operatingconditions of the chiller.

When one of these 2 parameters isexpected to drop below the limitstated here above, even at start up,it is required that some form ofcondenser water temperaturecontrol be implemented to satisfycompressor safety and to ensureoptimum chiller performance.

There are numerous methods tocontrol condenser watertemperature. Methods other thanthose shown can be employed toachieve the same results. Contactyour local Trane office for details.

Throttling valve This method maintains condensingpressure and temperature bythrottling water flow leaving thecondenser in response to condenserpressure or system differentialpressures.

Figure 8

1 = 2-way valve2 = Customer controller3 = Condenser water pump4 = To/from cooling device5 = Temperature sensor

Advantages:• Good control with proper valve

sizing at relatively low cost.• Pumping cost can be reduced.

Disadvantages:• Increased rate of fouling due to

lower condenser water velocity.• Requires pumps that can

accommodate variable flow.


RTWB-SVN01B-E414

Water treatment

Do not use untreated or improperlytreated water. Use of untreated orimproperly treated water may resultin equipment damage.

The use of improperly treated oruntreated water in this equipmentmay result in scaling, erosion,corrosion, algae or slime. Theservices of a qualified water-treatment specialist should beengaged to determine whattreatment, if any, is advisable. TheTrane Company warrantyspecifically excludes liability forcorrosion, erosion or deteriorationof Trane equipment. Trane assumesno responsibility for the results ofthe use of untreated or improperlytreated water, or saline or brackishwater.

Figure 9

Cooling device bypass Cooling device bypass is also a validcontrol method if the chillertemperature requirements can bemaintained.

1 = 3-way valve or 2 2-way valves2 = Customer controller3 = Condenser water pump4 = To/from cooling device5 = Temperature sensor

Advantage:• Excellent control by maintaining

constant water flow through thecondenser.

Disadvantage:• Higher cost because of the

dedicated pump required for eachchiller if condenser pressure is thecontrol signal.

Figure 10

Condenser water pump withvariable frequency drive

1 = Customer controller2 = Condenser water pump with VFD3 = To/from cooling device4 = Temperature sensor

Advantages:• Pumping cost can be reduced.

Good cooling device temperaturecontrol.

• Relatively low first cost.

Disadvantages:• Increased rate of fouling due to

lower water velocity in thecondenser.

RTWB-SVN01B-E4 15


Water pressure gauges andthermometers

Install field-supplied thermometersand pressure gauges (withmanifolds, whenever practical) asshown in Figure 7. Locate pressuregauges or taps in a straight run ofpipes -avoid placement near elbows-. Be sure to install the gauges at thesame elevation on each shell if theshell has opposite-end waterconnections.

To read manifolded water-pressuregauges, open one valve and closethe other (depending upon thereading desired). This eliminateserrors resulting from differentlycalibrated gauges installed atunmatched elevations.

Water-pressure-relief valves

Install pressure-relief valves in bothevaporator and condenser systems.Failure to do so could result in shelldamage.

Install water-pressure-relief valves inone of the condenser and one of theevaporator water box drainconnections or on the shell side ofany shutoff valve. Water vessels withclose-coupled shutoff valves have ahigh potential for hydrostaticpressure buildup with a watertemperature increase. Refer to theapplicable regulation for relief-valveinstallation guidelines.

Flow sensing devices

Use field-provided flow switches ordifferential pressure switches withpump interlocks to sense systemwater flow. Flow switch locations areschematically shown in Figure 7.

To provide chiller protection, installand wire flow switches in series withthe water pump interlocks, for bothchilled-water and condenser-watercircuits (refer to the installationelectrical section). Specificconnections and schematic wiringdiagrams are shipped with the unit.

Flow switches must stop or preventcompressor operation if eithersystem water flow drops offdrastically. Follow themanufacturer's recommendationsfor selection and installationprocedures. General guidelines forflow switch installation are outlinedbelow.

• Mount the flow switch upright,with a minimum of 5 pipediameters of straight, horizontalrun on each side.

• Do not install close to elbows,orifices, or valves.

Note:The arrow on the switch mustpoint in the direction of the waterflow.

To prevent switch fluttering, removeall air from the water system.

Note:The Unit Control Moduleprovides a 6-second time delay onthe flow-switch input before shuttingdown the unit on a loss-of-flowdiagnostic. Contact a qualifiedservice organization if machineshutdowns persist.

Adjust the switch to open whenwater flow falls below nominal.Refer to the evaporator andcondenser data table for minimumflow recommendations. Flow-switchcontacts are closed on proof ofwater flow.

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Refrigerant pressure relief-valve venting

To prevent injury due to inhalationof R134a gas, do not dischargerefrigerant anywhere. If multiplechillers are installed, each unit musthave separate venting for its reliefvalves. Consult local regulations forany special relief-line requirements.

All relief-valve venting is theresponsibility of the installingcontractor.

All RTWB units use evaporator,compressor, and condenserpressure-relief-valves that must bevented to the outside of thebuilding. Relief-valve connectionsizes and location are shown in theunit submittals. Refer to nationalregulation for relief valve vent linesizing information.

To prevent capacity reduction andrelief-valve damage, do not exceedvent piping code specifications.

Note: After being opened once, reliefvalves tend to leak.

RTWB-SVN01B-E416

Figure 11 – Dimensions for RTWB units

Unit size 1 (mm) 2 (mm) 3 (mm) 4 (mm) 5 (mm) 6 (mm) 7 (mm) 8 (mm) 9 (mm) 10 (mm)

207 1800 1789 1792 544 384 911 318 215 806 1016208 1800 1789 1792 544 384 911 318 215 806 1016210 1898 1832 2844 653 408 959 258 279 854 1064211 1898 1832 2844 653 408 959 258 279 854 1064212 1898 1832 2844 653 408 959 258 279 854 1064214 1898 1832 2844 653 408 959 258 279 854 1064216 1898 1832 2844 653 408 959 258 279 854 1064217 1898 1832 2844 653 408 959 258 279 854 1064218 2008 1932 2952 599 498 1063 181 215 958 1168220 2008 1932 2952 599 498 1063 181 215 958 1168222 2097 2041 2952 599 522 1150 95 215 1045 1255224 2097 2041 2952 599 522 1150 95 215 1045 1255

1: Evaporator drain21: 1 pass condenser22: condenser 2 passes right23: condenser 2 passes left


Sizes 210-224

Sizes 207-208

RTWB-SVN01B-E4 17


Table 4 –Evaporator and condenser dataEvaporator water content Condenser water content

Model RTWB Evaporator code Condenser code Liter Liter

207 EG 120 CG 120 105 60208 EG 120 CG 120 105 60210 EG 140 CG 140 265 55211 EG 170 CG 170 220 66212 EG 170 CG 170 220 66212 EG 170 CG 170 220 66214 EG 200 CG 200 200 75216 EG 200 CG 200 200 75217 EG 200 CG 200 200 75218 EG 250 CG 230 415 78220 EG 250 CG 230 415 78222 EG 340 CG 230 560 78224 EG 340 CG 230 560 78

Minimum and maximum evaporator water flow (L/s)

Evaporator Code Pass Number Minimum Water Flow Maximum Water Flow Connection Diameter (in.)

EG 120 1 4.5 13.4 5EG 140 1 6.0 18.0 6EG 170 1 7.0 21.0 6EG 200 1 9.0 25.0 6EG 250 1 11.0 33.0 6EG 340 1 14.0 43.0 6

Minimum and maximum condenser water flow (L/s)

Condenser Code Pass Number Minimum Water Flow Maximum Water Flow Connection Diameter (in.)

CG 120 1 8.4 31.0 5CG 140 1 9.5 34.9 5CG 170 1 11.9 43.7 5CG 200 1 17.0 61.0 5CG 230 1 17.0 61.0 5

Table 5 – RTWB Evaporator water pressure drop (kPa)Water flow (L/s)

Model RTWB 5 10 15 20 25 30 35 40 45

207 1 6 24 - -208 1 6 24 - -210 1 - 57 122 -211 1 - 29 61 104212 1 - 29 61 104214 1 11 24 41 62216 1 11 24 41 62217 1 11 24 41 62218 1 17 29 45 64220 1 17 29 45 64222 1 23 35 49 66 85 106224 1 23 35 49 66 85 106

Table 6 – RTWB Condenser water pressure drop (kPa)Water flow (L/s)

Model RTWB 10 15 20 25 30 35 40 45 50 55 50

207 1 10 20 34 51 71 - -208 1 10 20 34 51 71 - -210 1 6 12 20 30 42 -211 1 - 8 14 21 29 38 48212 1 - 8 14 21 29 38 48214 1 12 18 24 32 40 48 58 68 79216 1 12 18 24 32 40 48 58 68 79217 1 12 18 24 32 40 48 58 68 79218 1 12 18 24 32 40 48 58 68 79220 1 12 18 24 32 40 48 58 68 79222 1 12 18 24 32 40 48 58 68 79224 1 12 18 24 32 40 48 58 68 79

PassNumber

PassNumber

RTWB-SVN01B-E418

General recommendations

For proper electrical componentoperation, do not locate the unit inareas exposed to dust, dirt,corrosive fumes, or excessivehumidity. If any of these conditionsexist, corrective action must betaken.

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Disconnect all electrical power,including remote disconnects,before servicing. Failure todisconnect power before servicingcan cause severe personal injury ordeath.

Table 7 – Electrical data RTWB 207 208 210 211 212 214 216 217 218 220 222 224Nominal voltage (V) 400 400 400 400 400 400 400 400 400 400 400 400Frequency (Hz) 50 50 50 50 50 50 50 50 50 50 50 50

(V) Mini 360 360 360 360 360 360 360 360 360 360 360 360Maxi 440 440 440 440 440 440 440 440 440 440 440 440

Max. unit kW (kW) 90 106 132 142 152 182 202 222 243 264 292 320(A) 147 170 215 235 255 297 329 360 396 432 477 521

Starting Amps (1) (A) 170 196 228 264 279 332 374 398 430 457 520 554Power factor 0.91 0.92 0.90 0.89 0.88 0.89 0.90 0.90 0.89 0.89 0.89 0.89Fuse size (2) 80A 100A 125A 60/125 160A 2*160 160+200 2*200 250+200 2*250 2*315 2*315

(A) 315 315 315 400 400 400 630 630 630 630 800 800

mm² 240 240 240 240 240 240 2*300 2*300 2*300 2*300 2*300 2*300(1) Star delta start. Maximum starting Amps: one compressor at full load, the other one starting.(2) With disconnect switch option(3) mm²/phaseNote: To prevent control malfunctions, do not run low-voltage wiring (<30V) in conduits with conductors carrying more than 30 V.

All wiring must comply withnational electrical regulations.Electrical characteristics and otherunit electrical data are on the unitnameplate. Specific electricalschematics and connectiondiagrams are shipped with the unit.

Use copper conductors only. Unitterminals are not designed to acceptother types of conductors. Failure todo so may cause damage to theequipment.

Do not allow conduits to interferewith other components, structuralmembers, or equipment. Allconduits must be long enough toallow compressor and starterremoval.

Installation Electrical

Maximum connectingwire (2)(3)

Maximum RatedLoad Amps

Voltage utilizationrange

Disconnectswitch size

RTWB-SVN01B-E4 19


Power supply wiring

Model RTWB chillers are designedaccording to European standardEN60204. All power-supply wiringmust be sized and selectedaccordingly by the project engineer.

Water pump power supplyProvide power-supply wiring withfused disconnect switch for both thechilled-water and condenser-waterpumps.

Electrical panel power supplyPower supply wiring instructions forthe starter/control panel are: run linevoltage wiring in conduit to accessopening(s) on the starter/controlpanel.

Compressor-motor phasesequencing

Always verify that proper rotation ofthe RTWB compressors isestablished before the machine isstarted. Proper motor rotationrequires confirmation of theelectrical phase sequence of thepower supply. The motor isinternally connected for clockwiserotation with the incoming powersupply phased A,B,C (L1,L2,L3).

This direction may be reversedoutside the alternator byinterchanging any two of the linewires. It is this possible interchangeof wiring that makes a phasesequence indicator necessary if theoperator is to quickly determine thephase rotation of the motor.

RTWB-SVN01B-E420


Control power transformer

The RTWB units are equipped with a control power transformer as standard. It is not necessary to provide controlpower voltage to these units.

Figure 12 - Electrical panel layout

1 Line voltage entrance 2 Power section3 Control section4 Free space for customer pump control5 Wye-delta, closed-transition starter circuit A6 Wye-delta, closed-transition starter circuit B7 Unit disconnect, non-fused8 CKT # 1 Lockout (module A20-1 6X7-8)9 CKT # 2 Lockout (module A20-2 6X9-10)

10 Emergency stop (Normal/Stop contact - module A1 TB1 3-4)11 Zone temperature sensor (6R3) or ice-machine control (6S55) option (6R3 and 6S55 cannot be used together) (module A9 TB1 1-2)12 External chilled-water setpoint 4-20 mA or 2-10 V (dc)with communication interface option (module A9 TB1 4-5 7-8)13 Communication serial link (A9 TB2 1…4)14 Leaving condenser-water temperature sensor (5R53-2) option (with option PCM A70)15 Chilled-water flow switch (6S56 - MODULE A1 TB3-4)16 External Auto/Stop (6S1 - module A1 TB3 3-4)17 Customer output:

Remote alarm indicator (from normally-closed signal)Maximum capacity indicatorCompressor running indicatorRemote alarm indicator (from normally-open signal)

18 Chilled-water pump starter (TRANE UCM pump control - module A1 TB4 8-9)19 Chilled-water pump starter (Auxiliary Interlock - MODULE A1 TB3 1-220 Tracer (Option - module A9 TB2 1…4)

RTWB-SVN01B-E4 21


Interconnecting wiring

IIMMPPOORRTTAANNTT

Do not turn the chiller on or offusing the chilled-water interlocks.

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

Chilled-water pump control

CCAAUUTTIIOONN

The chilled-water pump mustoperate for a minimum of oneminute after the UCM receives acommand, through the externalAuto/Stop input, to shut down thechilled-water system.

On the RTWB units, the controllerwill initiate the “Run:Unload“ modeto terminate a cycle from any of thefollowing:- Stop key pressed- Loss of load- External Auto/Stop input opened

The “Run:Unload“ operating modecommands the compressor tocompletely unload, which takesabout ½ minute. This will allow thecompressors to be totally unloadedfor the next start-up. If only theproof-of-chilled-water-flow interlockis used, the chiller will shut downwith an immediate (non-friendly)shutdown and initiate an automaticreset diagnostic.

1. External Auto/Stop (terminals A1TB3-3 and -4)This input is supplied by the field.A contact closure will start thechiller water pump and chiller, viathe UCM pump control contacts.Opening the contact will put theoperating compressors into“Run:Unload“ mode and initiate atiming period (1 to 30 minutes,adjustable through the ClearLanguage Display). This will delaytermination of the chilled-waterpump operation via the UCMpump control contacts. Examplesof the input terminals 1UTB3-3and -4 would be a time clock,ambient thermostat, buildingautomation system.

2. UCM Pump Control Contacts(Terminals A1 TB4-8 and -9)This output is a set of contactsthat will close, starting the chilled-water pump when the externalAuto/Stop contacts are closed.When the contacts are opened, 1to 30 minutes later (adjustablethrough the Clear LanguageDisplay), the UCM pump controlcontacts open.

3. Proof-of-Chilled-Water-FlowInterlock (Terminals A1 TB3-1 and-2) This terminal must be field-installed. Contact closurebetween the terminals indicatesproof of chilled-water flow.Examples of this are a pumpstarter auxiliary contact, flowswitch, differential pressureswitch, or a contact from abuilding automation system.Opening of this contact willimmediately shut down the chillerand initiate an automatic resetdiagnostic, indicating loss ofchilled-water flow

4. Condenser-Water PumpFor the condenser-water pumpinterlock on the RTWB units,connect leads from terminals 6X3to 6X6 and the water pumpcontrol. The circuit is 110 V (ac)andthe load is not to exceed 1150 VAinrush, 115 VA sealed.This will interlock the condenser-water pump operation with theunit operation. This insures thatthe condenser-water pump isoperating before thecompressor(s) is started.

5. Alarm/Running/MaximumCapacity OutputsTerminals 1 to 7 on terminal stripTB4 of the A1 board provide avariety of contact outputs on theRTWB. These are dependent onthe setting of ProgrammableRelay Setup (Service SettingMenu) and its relationship todiagnostics, compressorsoperating, and the systemoperating at full capacity.

As shown in Figure 13, there arethree relays.

Figure 13 – Alarm / Running / Maximum capacity relay output for the RTWB unit.

RTWB-SVN01B-E422


Table 9 – Alarm / Running / Maximum capacity menu settingProgrammable Relay Setup Setting Relay Output Configuration Diagnostic that the Alarm relay(s) is active

(service setting menu) (Table 6) MMR / CMR diag. MAR / CAR diag. IFW diag.

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

10 3 YES YES NO11 3 YES YES YES12 3 YES NO YES

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

Table 8 – Alarm / Running / Maximum capacity relay output configurationRelay output configuration

1 Relay 1 AlarmRelay 2 Compressor runningRelay 3 Maximum capacity

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

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

RTWB-SVN01B-E4 23

Low-voltage wiringThe remote devices describedbelow require low-voltage wiring.All wiring to and from these remoteinput devices to the UCM, asdescribed in the hereafterparagraph, must be made withshielded, twisted-pair conductors.Be sure to ground the shielding onlyat the Clear Language Display.

CCAAUUTTIIOONN

To prevent control malfunction, donot run low-voltage wiring (<30V) inconduits with conductors carryingmore than 30 V.

Emergency stop (normal trip)The Clear Language Displayprovides auxiliary control for acustomer-specified or -installedlatching tripout. When this remotecontact 6S2 (furnished by thecustomer) is provided, the chillerwill run normally when the contactis closed. When the contact opens,the unit will trip off on a manually-resettable diagnostic. This conditionrequires manual reset at the chillerswitch on the front of the ClearLanguage Display.


To connect, first remove the jumperlocated between terminal 3 and 4 ofA1 TB1. Refer to the field diagramsthat are shipped with the unit.

External circuit lockout - Circuitnumber 1The UCM provides auxiliary controlof a customer-specified or -installedcontact closure, for individualoperation of circuit number 1. If thecontact is closed, the refrigerantcircuit will not operate. Therefrigerant circuit will run normallywhen the contact is opened.

External circuit lockout will onlyfunction if External Circuit Lockout(service setting Menu) is enabled.

Connections are shown in the fielddiagrams that are shipped with theunit.

RTWB-SVN01B-E424

External circuit lockout - Circuitnumber 2The UCM provides auxiliary controlof a customer-specified or -installedcontact closure, for individualoperation of circuit number 2. If thecontact is closed, the refrigerantcircuit will not operate. Therefrigerant circuit will run normallywhen the contact is opened.

External circuit lockout will onlyfunction if External Circuit Lockout(service setting Menu) is enabled.

Connections are shown in the fielddiagrams that are shipped with theunit.

Ice-making optionIce-machine control (OperatorSetting Menu) must be enabled. TheUCM provides auxiliary control for acustomer-specified or -installedcontact closure for ice making.When contact 6S55, module A9,terminals TB1 1 and 2, is provided,the chiller will run normally whenthe contact is open. Upon contactclosure, the UCM will initiate an ice-building mode, in which the unitruns fully loaded at all times. Ice-building shall be determined eitherby opening the contact or based onthe entering evaporator-watertemperature setting under Active IceTermination Setting (Chiller ReportMenu). The UCM will not permit ice-building mode to be reentered untilthe unit has been switched out ofice-building mode (open 6S55contacts) and then switched backinto ice-building mode.

In ice-building, the current setpointwill be set at 120%. For example, ifthe front panel or external currentlimit setpoint is set to 80%, in ice-building the active current limit is120%.

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

External chilled-water setpoint:voltage source 2-10 V (dc), or Currentsource 4-20 mAThis option allows the externalsetting of the chilled-water setpoint,independent of the front panelchilled-water setpoint, by one of thetwo means:

1 - An isolated voltage input 2-10 V(dc)

2 - An isolated current loop input 4-20 mA

Isolated 2-10 V (dc)voltage sourceinputSet dip switch SW1-1 of the optionmodule A9 to “OFF.“ Connect thevoltage source to terminals 4 (+) and5 (-) on option module A9 TB1. CWSis now based on the followingequation:

CW Setpoint °C = (V (dc) * 4.88) -27.56

Sample values for CWS vs. V (dc)signals are shown in Table 10.

Table 10: Input values vs. External chilled-water setpointVoltage (V (dc)) Current (mA) Resulting chilled-water setpoint (°C)

3.6 7.2 -104.6 9.2 -55.6 11.3 06.7 13.3 57.7 15.4 10


RTWB-SVN01B-E4 25


Isolated 4-20 mA current sourceinputSet dip switch SW1-1 of the optionmodule A9 to “ON.“ Connect thecurrent source terminals 4 (+) and5 (-). CWS is now based on thefollowing equation:

Setpoint (°C) = (mA * 2.44) - 27.56

External current limit setpoint:voltage source 2-10 V (dc)or currentsource 4-20 mA.

This option allows the externalsetting of the current limit setpoint,independent of the front panelcurrent-limit setpoint, by one of thetwo means:

1 - an isolated voltage input 2-10 V(dc)

2 - an isolated voltage input 4-20 mA

To enable external current-limitsetpoint operation, external current-limit setpoint (operator settingmenu) should be set to “E“ usingthe clear language display.

1- 2-10 V (dc) voltage source inputSet dip switch SW1-2 of the optionmodule A9 to “OFF.“ Connect thevoltage source to terminals 7 (+) and8 (-) of the option module A9. CLS isnow based on the followingequation:

CL Setpoint % = (V (dc)*10) + 20

Sample values for CLS vs. V(dc)signals are shown in Table 9.

Minimum setpoint : 40% (2.0 V(dc)input)

Maximum setpoint : 120% (10.0 V(dc)input)

4-20 mA Current source inputSet dip switch SW1-2 of the optionmodule A9 to “ON.“ Connect thecurrent source to terminal 7 (+) and8 (-) of option module A9. CLS isnow based on the followingequation:

CL Setpoint % = (mA * 5) + 20

Sample values for CLS vs mAsignals are shown in Table 9.

Minimum setpoint = 40% (4.0 mA)

Maximum setpoint = 120%(20.0 mA)

Table 11: Input values vs. external current-limit setpointVoltage (V (dc)) Current (mA) Resulting current-limit setpoint (% RLA)

2.0 4.0 403.0 6.0 504.0 8.0 605.0 10.0 706.0 12.0 807.0 14.0 908.0 16.0 1009.0 18.0 110

10.0 20.0 120

Outdoor air-temperature sensorThis sensor is used for low ambientlockout and chilled-water reset byoutdoor air temperature. This sensoris optional on the RTWB units.

Remove the sensor from itsshipping location in the controlpanel and install it in the fresh-airintake on the north wall of thebuilding. Protect the sensor fromdirect sunlight and shelter it fromthe elements.

Connect leads to terminals 1 and 2from module A9 TB1. All wiring toand from the remote sensor must bemade with shielded, twisted-pairconductors. Be sure to ground theshielding only at the UCM. Applytape to the sensor end of theshielding to prevent it fromcontacting the surface.

WWAARRNNIINNGG

To prevent injury or death,disconnect the electrical powersource before completing wiringconnections to the unit.

CCAAUUTTIIOONN

To prevent overheating at theterminal connections, use copperconductors only.

Communication cardThis option allows the ClearLanguage Display in the controlpanel on RTWB units to exchangeinformation (operating setpoints andAuto/Standby commands) with ahigher-level control device, such asTracer. A shielded, twisted-pairconnection establishes thebidirectional communications linkbetween the unit control panel andthe Tracer.

CCAAUUTTIIOONN

Note:The shielded, twisted-pairconductors must run in a separateconduit.

CCAAUUTTIIOONN

To prevent control malfunction, donot run low-voltage wiring (<30V) inconduits with conductors carryingmore than 30 volts.

RTWB-SVN01B-E426

GeneralField wiring for the communicationlink must meet the followingrequirements:

1. All wiring must be in accordancewith local codes.

2. Communication link wiring mustbe shielded, twisted-pair wiring.

3. The maximum total length foreach communication link is 1,500meters.

4. The communication link cannotpass between buildings.

5. All UCM on the communicationlink can be connected in a “daisychain“ configuration.


Communication-link connectionprocedure

1. Refer to the Tracer installationliterature to determine propercommunication-link terminationconnections at the Tracer module.

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

3. Connect leads to terminals 1 and2 of TB2 of the module A9 of theUCM to the Tracer. There is nopolarity requirement for theconnection.

4. At the UCM, the shield should becut and taped to prevent anycontact between the shield andground.

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

5. To get the chiller to communicatewith a Tracer on a multiple-unitcontroller, the ICS address underthe “service settings“ menu mustbe set and the optional A9module must be installed. TheTracer will look for chilleraddresses 55,56,57,58,59, or 60.Each chiller must have a uniqueaddress.

RTWB-SVN01B-E4 27


Installation check list

Complete this checklist as the unit is installed, to verify that allrecommended procedures are accomplished before the unit is started. Thischecklist does not replace the detailed instructions given in sections 2 and 3of this manual. Read both sections completely, to become familiar with theinstallation procedures, prior to beginning the work.

Receiving

[ ] Verify that the unit nameplate data corresponds to the orderinginformation.

[ ] Inspect the unit for shipping damage and any material shortage. Reportany damage or material shortage to the carrier.

Unit location and mounting

[ ] Inspect the location desired for installation and verify adequate service-access clearances.

[ ] Provide drainage for evaporator and condenser water, if applicable.

[ ] Remove and discard all shipping materials.

[ ] Install optional neoprene if required.

[ ] Level the unit and secure it to the mounting surface.

Unit water piping

[ ] Flush all unit water piping before making final connections to the unit.

CCAAUUTTIIOONN

If using an acidic, commercial flushing solution, construct a temporarybypass around the unit to prevent damage to internal components of theevaporator.

CCAAUUTTIIOONN

To avoid possible equipment damage, do not use untreated or improperlytreated system water.

[ ] Connect the water piping to the evaporator and condenser.

[ ] Install pressure gauges and shutoff valves on the water inlet and outlet, ifapplicable.

[ ] Install a water strainer in the entering chilled-water line, if applicable.

[ ] Install a balancing valve and flow switch in the leaving chilled-water line,if applicable.

[ ] Install a drain with shutoff valve or a drain plug on the evaporator, ifapplicable.

[ ] Vent the chilled-water and condenser-water systems at high points in thesystem piping, if applicable.

RTWB-SVN01B-E428

Operating Principles –Mechanical

General

This section describes themechanical operating principles ofthe RTWB chillers equipped withmicroprocessor-based controlsystems.

The model RTWB chillers are dual-compressor, helical-rotary-type,water-cooled liquid chillers. Thebasic components of a RTWB unitare:

- Clear Language Display andcontrol modules

- Helical-rotary compressor

- Direct-expansion evaporator

- Water-cooled condenser

- Oil supply system

- Interconnecting piping

Components of a typical RTWB unitare identified in Figure 2 and 3.

Figure 14 – RTWB refrigeration system and control components

1 Compressor2 Condenser3 Evaporator4 Oil separator5 Electronic expansion valve6 Oil cooler (option)7 Low-pressure switch8 High-pressure switch9 Solenoid valve

10 Refrigerant charging valve11 Oil-separator draining valve12 Oil-cooler expansion valve13 Compressor discharge valve (option)14 Liquid-line service valve15 Oil-circuit service and charging valve16 Filter17 Chilled-water outlet connection18 Chilled-water inlet connection19 High-pressure safety valve (supply if required by code vessel approval)20 Low-pressure safety valve21 Low-pressure gauges (option)22 High-pressure gauges (option)23 Saturated refrigerant temperature sensor (condenser)24 Saturated Refrigerant temperature sensor (evaporator)25 Refrigerant temperature sensor (suction)26 Oil temperature sensor27 Leaving chilled-water temperature sensor28 Entering chilled-water temperature sensor (option)

RTWB-SVN01B-E4 29

Pre-start checkout

GeneralWhen installation is complete, butprior to putting the unit into service,the following pre-start proceduresmust be reviewed and verified:

[ ] Inspect all wiring connections tobe sure they are clean and tight.

WWAARRNNIINNGG

Disconnect all electric power,including remote disconnects,before servicing. Failure todisconnect power before servicingcan cause severe personal injury ordeath.

CCAAUUTTIIOONN

Check the tightness of allconnections in the compressorpower circuit (disconnects, terminalblock, contactors, compressorjunction box terminals, …). Looseconnections can cause overheatingat the connections andundervoltage conditions at thecompressor motor.

[ ] Verify that all refrigerant valvesare open.

CCAAUUTTIIOONN

Do not operate the unit with thecompressor, oil discharge, or liquidline valves closed. Failure to havethese open may cause seriouscompressor damage.

[ ] Check the power supply voltageto the unit at the main-power,fused disconnect switch. Voltagemust be within the voltageutilization range, given in Table 7and also stamped on the unitnameplate. Voltage imbalancemust not exceed 2%

WWAARRNNIINNGG

Disconnect all electric power,including remote disconnects,before servicing. Failure todisconnect power before servicingcan cause severe personal injury ordeath.

[ ] Check the unit power phasing tobe sure that it has been installedin an “ABC“ sequence.

WWAARRNNIINNGG

It is imperative that l1-l2-l3 in thestarter be connected in the A-B-Cphase sequence to preventequipment damage due to reverserotation.

[ ] Fill the evaporator and condenserchilled-water circuits. Refer toTable 2 for liquid capacities. Ventthe system while it is being filled.Open the vents on the top of theevaporator and condenser duringfilling, and close them whenfilling is completed

The use of improperly treated oruntreated water in this equipmentmay result in scaling, erosion,corrosion, algae, or slime. Theservices of a qualified watertreatment specialist should beengaged to determine whattreatment, if any, is advisable. TheTrane Company warranty specificallyexcludes liability of corrosion,erosion, or deterioration of Traneequipment. Trane assumes noresponsibilities for the results of theuse of untreated or improperlytreated water or saline or brackishwater.

CCAAUUTTIIOONN

Do not use untreated or improperlytreated water. Equipment damagemay occur

[ ] Close the fused disconnectswitch that supplies power to thechilled-water pump starter andthe condenser pump starter.

[ ] Start the chilled-water pump andcondenser-water pump to begincirculation of the water. Inspectall piping for leakage and makeany necessary repairs.

[ ] With water circulating throughthe system, adjust the water flowand check the water-pressuredrop through the evaporator andcondenser. Refer to Tables 5 and6.

[ ] Adjust the chilled-water flowswitch and the condenser-waterflow switch (if installed) forproper operation.

[ ] Prove all interlock andinterconnecting wiring interlockas described in section 3.

[ ] Check and set, as required, allClear Language Display menuitems.

[ ] Stop the chilled-water pump andthe condenser-water pump.

Unit Start-UpProcedures

RTWB-SVN01B-E430

Unit voltage power supplyVoltage to the unit must meet thecriteria given in Table 7. Measureeach phase of the supply voltage atthe unit main-power, fuseddisconnect. If the measured voltageon any phase is not within thespecified range, notify the supplierof the power and correct thesituation before operating the unit.

CCAAUUTTIIOONN

Inadequate voltage to the unit cancause control components tomalfunction and shorten the life ofrelay contacts, compressor motors,and contactors.

Unit voltage imbalanceExcessive voltage imbalancebetween the phases of a three-phasesystem can cause motors tooverheat and eventually fail. Themaximum allowable imbalance is2%. Voltage imbalance is determinedusing the following calculations:

% imbalance =(Ux - U average)U average

U average = (U1 + U2 + U3) / 3

Ux = phase with greatest differencefrom U average (without regardto sign).

For example, if the three measuredvoltages are 401, 410, and 407 volts,the average would be:

401 + 412 + 417 = 4103

The percentage of imbalance isthen:

100 * ( 410 - 401) = 2.2%410

This exceeds the maximumallowable (2%) by 0.2%.

Unit voltage phasing

WWAARRNNIINNGG

It is imperative that L1-L2-L3 in thestarter be connected in the A-B-Cphase sequence, to preventequipment damage due to reverserotation.

It is important that proper rotation ofthe compressors be establishedbefore the unit is started. Propermotor rotation requires confirmationof the electrical phase sequence ofthe power supply. The motor isinternally connected for clockwiserotation, with the incoming powersupply phased A,B,C.

When rotation is clockwise, phasesequence is usually called “ABC;“when counterclockwise, “CBA.“

This direction may be reversedoutside the alternator byinterchanging any two of the linewires. It is this possible interchangeof wiring that makes a phasesequence indicator necessary if theoperator is to quickly determine thephase rotation of the motor.

Water system flow ratesEstablish a balanced chilled-waterflow through the evaporator. Theflow rates should be between theminimum and maximum valuesgiven in Table 4.

The flow rates through thecondenser must also be balancedaccording to the flow rates table(Table 4).

Water system pressure dropMeasure the water pressure dropthrough the evaporator andcondenser at the field-installedpressure taps, on the system waterpiping. Use the same gauge for eachmeasurement. Do not includevalves, strainers, or fittings in thepressure drop reading.


RTWB-SVN01B-E4 31

Start up procedure

GeneralIf the pre-start checkout, asdiscussed above, has beencompleted, the unit is ready to start.The Clear Language Display isshown in Figure 12. Complete eachstep in sequence, as follows:

[ ] Press the Stop key on the ClearLanguage Display.

[ ] As necessary, adjust the setpointvalues in the Clear LanguageDisplay menus.

[ ] Close the fused disconnectswitch for the chilled-water pumpand the condenser-water pump.Energize the pumps to start thewater circulation.

[ ] Check the service valves on thedischarge line, suction line, oilline, and liquid line for eachcircuit. These valves must beopen before starting thecompressors.

CCAAUUTTIIOONN

To prevent compressor damage, donot operate the unit until allrefrigerant and oil-line service valvesare opened.

[ ] Verify that the chilled-water pumpruns for one minute after thechiller is commanded to stop (fornormal chilled-water systems).

[ ] Press the Auto key. If the chillercontrol calls for cooling and allsafety interlocks are closed, theunit will start. The compressor(s)will load and unload in responseto the temperature of the leavingchilled-water temperature.

After the system has been operatingfor approximately 30 minutes andhas become stabilized, complete thestart-up procedures as follows.

[ ] Check the evaporator refrigerantpressure and the condenserrefrigerant pressure under theRefrigerant Report on the ClearLanguage display.

[ ] Measure the system superheat.

[ ] Measure the system subcooling.

[ ] A shortage of refrigerant isindicated if the operatingpressures are low and thesubcooling is also low. If theoperating pressures, superheat,and subcooling readings indicatea refrigerant shortage, gas-chargerefrigerant into each circuit asrequired. With the unit running,add refrigerant vapor byconnecting the charging line tothe suction service valve andcharging through the backseatport until operating conditionsbecome normal.

CCAAUUTTIIOONN

If both suction and dischargepressures are low and subcooling isnormal, a problem other thanrefrigerant shortage exists. Do notadd refrigerant, as this may result inovercharging the circuit.

Use only the refrigerant specified onthe unit nameplate, to preventcompressor damage and insure fullsystem capacity.

[ ] If operating conditions indicate arefrigerant overcharge, removerefrigerant at the liquid lineservice valve. Allow refrigerant toescape slowly to minimize oilloss. Do not discharge refrigerantinto the atmosphere.

WWAARRNNIINNGG

Do not allow refrigerant to directlycontact skin, or injury from frostbitemay result.

System superheatNormal suction superheat for eachcircuit is approximately 3°C at fulloperating load. Superheattemperature can be expected to bemoving around a 3°C setpoint whenthe chiller is pulling down or whenthe compressor slide valve is beingmodulated.

System subcoolingNormal subcooling for each circuitranges from 5.5°C to 11°C,depending on the unit. If subcoolingfor either circuit does notapproximate these figures, check thesuperheat for the circuit and adjustit, if required. If superheat is normalbut subcooling is not, contact aqualified service technician.


RTWB-SVN01B-E432

Unit shutdown procedures

Temporary shutdown and restartTo shut the unit down for a shorttime, use the following procedure:

• Press the Stop key on the ClearLanguage Display. Thecompressors will continue tooperate and, after unloading for 20seconds, will stop when thecompressor contactor de-energizes.

• Stop the water circulation byturning off both the chilled-waterpump and the condenser-waterpump.

To restart the unit after a temporaryshutdown, restart the chilled-waterpump and the condenser-waterpump, and press the Auto key. Theunit will start normally if thefollowing conditions exist:

• The UCM must receive a call forcooling and the differential-to-startmust be above the setpoint.

• All system operating interlocks andsafety circuits must be satisfied.

Extended shutdown procedureThe following procedure is to befollowed if the system is to be takenout of service for an extendedperiod of time as a seasonalshutdown:

Test the unit for refrigerant leakageand repair as necessary.

Open the electrical disconnectswitches for the chilled-water pumpand the condenser-water pump. Lockthe switches in the “open“ position.

CCAAUUTTIIOONN

Lock the chilled-water andcondenser-water pump disconnectsopen, to prevent pump damage.

• Close all chilled-water supplyvalves and the condenser-watersupply valves. Drain the waterfrom the evaporator and thecondenser.

• Open the unit main electricaldisconnect and the unit-mounteddisconnect (if installed), and lock inthe “Open“ position.

CCAAUUTTIIOONN

Lock the disconnects on the “Open“position to prevent accidental start-up and damage to the system whenit has been set up for extendedshutdown.

At least every three months, checkthe pressure in the unit to verify thatthe refrigerant charge is intact.

System restart after extendedshutdown

• Follow the procedures below torestart the unit after an extendedshutdown:

• Verify that the liquid-line servicevalves, oil line, and compressordischarge service valves are open.

CCAAUUTTIIOONN

To prevent damage to thecompressor, be sure that allrefrigerant valves are open beforestarting the unit.

• Check the oil-separator oil level.See the Maintenance paragraph.

• Fill the evaporator- and condenser-water circuits. Refer to Table 4 forevaporator- and condenser-watercontent. Vent the system while it isbeing filled. Open the vents on thetops of the evaporator andcondenser during filling and closethem when filling is completed.

CCAAUUTTIIOONN

Do not use untreated or improperlytreated water. Equipment damagemay occur.

• Close the fused disconnectswitches that provide power to thechilled-water pump and thecondenser-water pump.

• Start both the evaporator- andcondenser-water pumps and, whilewater is circulating, inspect allpiping for leakage. Make anynecessary repairs before startingthe unit.

• While the water is circulating,adjust the water flows and checkthe water pressure drops throughthe evaporator and the condenser.Refer to “Water System FlowRates“ and “Water SystemPressure Drop.“

• Adjust the flow switch (s) on theevaporator piping and thecondenser piping (if installed) forproper operation.

• Stop both water pumps. The unit isnow ready for the start-upprocedure.

Unit ShutdownProcedures

RTWB-SVN01B-E4 33

PeriodicMaintenance

Periodic maintenance

General

Perform all maintenance proceduresand inspections at therecommended intervals. This willprolong the life of the equipmentand minimize the possibility ofcostly failures.

Weekly maintenance

After the unit has been operating forapproximately 30 minutes and thesystem has stabilized, check theoperating conditions and completethe procedures below:

[ ] Check the evaporator refrigerantpressure and the condenserrefrigerant pressure in theRefrigerant Report Menu on theClear Language Display.

[ ] If operating pressure conditionsseem to indicate a refrigerantshortage, measure the systemsuperheat and systemsubcooling. Refer to the Start-upprocedure paragraph.

[ ] If operating conditions indicate arefrigerant overcharge, removerefrigerant at the liquid-lineservice valve. Allow refrigerant toescape slowly to minimize oilloss. Do not discharge refrigerantinto the atmosphere.

WWAARRNNIINNGG

Do not allow refrigerant to directlycontact skin, or injury from frostbitemay result.

[ ] Inspect the entire system forunusual conditions.

Monthly maintenance

[ ] Perform all weekly maintenanceprocedures

[ ] Measure and record the systemsuperheat. Refer to the Start-upprocedure paragraph.

[ ] Measure and record the systemsubcooling. Refer to the Start-upprocedure paragraph.

WWAARRNNIINNGG

Position all electrical disconnects inthe “Open“ position and lock them,to prevent injury or death due toelectrical shock.

Annual maintenance

[ ] Perform all weekly and monthlymaintenance procedures.

[ ] Check the refrigerant charge andoil level. Refer to the Refrigerantcharging paragraph. Routinechanging of oil is not required.

[ ] Have a qualified laboratoryperform a compressor-oil analysisto determine the system moisturecontent and acid level. Thisanalysis is a valuable diagnostictool.

[ ] Check the pressure drop acrossthe oil filter. See the Maintenanceparagraph.

[ ] Contact a qualified serviceorganization to leak-test thechiller, to check operating andsafety controls, and to inspectelectrical components fordeficiencies.

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

[ ] Clean and repaint any areas thatshow signs of corrosion.

WWAARRNNIINNGG


RTWB-SVN01B-E434

Maintenance

General

This section describes specificmaintenance procedures that mustbe performed as a part of the normalmaintenance program for this unit.Be certain that electrical power tothe unit is disconnected beforeperforming these procedures.

WWAARRNNIINNGG


Cleaning the evaporator

The evaporator water system is apart of a closed loop and should notaccumulate an appreciable amountof scale or sludge. If it is determinedthat the chiller is fouled, attempt todislodge any foreign material bybackflushing the system severaltimes. If this does not worksatisfactorily, chemically clean thechiller using the procedures outlinedin the following section.

Cleaning the condenser

GeneralWater that is available forcondensing frequently containsminerals or other contaminants thatcollect on the inside of thecondenser tubes. Scaleaccumulation will accelerate withhigh condensing temperatures andthe use of water with high mineralcontent. Cooling devices collect dustand foreign material that are alsodeposited on the condenser tubes,forming sludge.

To maintain maximum efficiency, thecondenser must remain as free ofthese deposits as possible. Even avery thin layer on the inside tubesurfaces reduces the heat-transferability of the condenser. Indicationsof scale deposits are: decreasedwater flow through the condenser,reduced temperature differentialbetween the entering and leavingcondenser-water, and abnormallyhigh condensing temperatures.

There are two accepted methods ofcleaning the condenser tubes, asdiscussed in the followingparagraphs.

Mechanical cleaningThe mechanical cleaning method isused primarily to remove sludge andother loose material from thecondenser tubes.

Follow the steps below:

Turn off the chiller and condenserwater supplies.

Break piping connections and theunions.

Remove the condenser heads.

Run a round nylon brush from theend through the tubes, to loosendeposits.

Flush the tubes with water. Theninspect the tubes for scaleaccumulation. If there is no scale inthe tubes, reassemble the condenserand piping.

If there is scale in the tubes, followthe procedures in the followingparagraph.

Chemical cleaningChemical cleaning is the mostsatisfactory method of cleaningscale from the condenser. With thistreatment, scale is dissolved andflushed away by circulating achemical solution through the tubesand headers.

Internal condenser components arecomposed of copper, steel, and castiron. With this information, watertreatment firms will be able torecommend a suitable chemical forthis purpose. If water treatment isnot available, consult a chemicalsupply house.

Water treatment

The use of untreated or improperlytreated water in the unit may resultin the formation of scale, algae, orslime. It may also cause erosion orcorrosion. It is recommended that aqualified water treatment specialistprovide recommendations forproper water treatment. The TraneCompany assumes no responsibilityfor equipment failure caused by theuse of untreated or improperlytreated water.

PeriodicMaintenance

RTWB-SVN01B-E4 35

Oil separator check level

Follow the steps listed below andrefer to the notes listed in Figure 12.

1. Turn off the unit.

2. Attach the hoses and sight glassto the oil-separator Schradervalves, as shown in Figure 12.Remove non-condensibles.

3. After the unit has been off for 10minutes, move the sight glass upand down until the level can beseen.

4. After the level has beendetermined, remove the sightglass and hoses.

Figure 15 – System Oil Specifications

1: Oil separator2: Valve3: ¼" refrigeration hose4: Sight glass5: Minimum oil level6: Maximum oil level

Table 12 – Oil level limitOil separator diameter

152 mm 203 mm 254 mmMinimum oil level (mm) 90 120 145Maximum oil level (mm) 155 205 235

PeriodicMaintenance

RTWB-SVN01B-E436

Oil filter change

Note: Routine changing of the oil orthe oil filter is not recommended.The oil filter is oversized for thisapplication.

The oil and filter should be replacedonly if analysis reveals that the oil iscontaminated. Oil type and systemcapacities are shown in Table 2.

Pressure drop across the oil filter isshown in Figure 13. Oil filterpressure drop is the differencebetween the two pressure-controlports.

Refrigerant filter change

If the temperature drop through thefilter is higher than 4K, the filtershould be changed.

Figure 16 – Oil filter pressure drop

PeriodicMaintenance

Oil Filter Pressure Drop

Normal Pressure Drop

Maximum Pressure DropO

il Fi

lter

Pre

ssu

re D

rop

(B

ar)

Condensing Pressure – Suction Pressure (Bar)

RTWB-SVN01B-E4 37

To change the oil filter in the unit,refer to Figure 14 and follow thesteps listed below.

For units without the dischargevalve option:

1. Shut off the compressor anddisconnect all electrical serviceto the compressor.

2. Vacuum the refrigerant out ofthe circuit.

3. Remove the seven bolts on theoil filter cover. A pan may benecessary to catch any oil that isreleased after the cover isloosened.

4. Remove the cover and the oilfilter element.

5. Install the new filter element.

6. Coat the new cover gasket withrefrigerant oil.

7. Install the cover plate and coverplate gasket.

PeriodicMaintenance

8. Install a new copper gasketunder the bolt head that had oneat time of removal. Replace allother bolts and tighten to 89.5Nm.

9. Vacuum the refrigerant circuit at500 micron and isolate thevacuum pump.

10. Confirm that no moisture orleaks are present by letting thevacuum stand for 2 hours. Thepressure should not raise morethan 250 microns.

11. Charge the unit with oil, in aquantity equal to what has beenremoved, by using the chargingvalve placed on the oil filter.

Note: the oil is very sensitive tomoisture. Use the oilimmediately after the oil can hasbeen opened.

12. Charge the unit with refrigerantR134a (refer to the chargingprocedure)

RTWB-SVN01B-E438

Figure 17 – Oil filter change

1: Oil charging valve2: Oil pressure control port3: Oil pressure control port

3

21

PeriodicMaintenance

For units with the discharge valveoption:

1. Closed the angle valve placed onthe refrigerant liquid line to storethe refrigerant in the condenser.

2. After the compressor stops,closed the compressor dischargevalve and disconnect the unit.

Note: Do not make successivevacuums by using thecompressor. Irreversiblecompressor damage could occur.

3. Vacuum the refrigerantremaining in the evaporator.

4. Remove the seven bolts on theoil filter cover. A pan may benecessary to catch any oil that isreleased after the cover isloosened.

5. Remove the cover and the oilfilter element.

6. Install the new filter element.

7. Coat the new cover gasket withrefrigerant oil.

8. Install the cover plate and coverplate gasket.

9. Install a new copper gasketunder the bolt head that had oneat time of removal. Replace allother bolts and tighten to 89.5Nm.

10. Vacuum the refrigerant circuit at500 micron and isolate thevacuum pump.

11. Confirm that no moisture or leaksare present by letting thevacuum stand for 2 hours. Thepressure should not raise morethan 250 microns.

12. Charge the unit with oil, in aquantity equal to what has beenremoved, by using the chargingvalve placed on the oil filter.

Note: the oil is very sensitive tomoisture. Use the oilimmediately after the oil can hasbeen opened.

13. Charge the unit with refrigerantR134a (refer to the refrigerantcharging paragraph).

14. Open all the valves beforerestarting the chiller.

RTWB-SVN01B-E4 39

Refrigerant charging

If the refrigerant needs to beadjusted, be certain to monitor thesubcooling and superheatmeasurements. The subcoolingneeds to be between 6 and 12°Cwhen the unit is running fullyloaded. The superheat needs to beclose to, or at, the superheatsetpoint entered in the UCM.

CCAAUUTTIIOONN

The evaporator water flow must beestablished and maintained whileadjusting the charge. Refrigerantpressures below 2,3 bar gauge cancause freezing and rupturing of theevaporator tubes.

Adding refrigerantThe RTWB units are shipped with anentire charge of refrigerant and oil. Ifthe unit has no pressure, the systemmust be leak tested prior to addingrefrigerant. Evacuate the systemdown to at least 500 microns prior toadding the refrigerant.

CCAAUUTTIIOONN

Water must be flowing through thetube bundles during this entireprocess. Refrigerant pressuresbelow 2,3 bar gauge can causefreezing and rupturing of the heatexchangers.

1. Connect 110 V power to thefemale stepload solenoid and themale load/unload solenoids. Thismust be done to evacuate all ofthe cavities in the compressor.

2. Open all service valves.

3. Connect hoses from the vacuumpump to the LP and HP ports onthe unit.

4. Evacuate the system to 500microns and isolate the vacuumpump.

PeriodicMaintenance

5. Confirm that no moisture orleaks are present by letting thevacuum stand for 2 hours. Thepressure should not raise morethan 250 microns.

6. Close the liquid line valve placedat the outlet of the condenser.

7. Open the EXV and addrefrigerant by using the chargingvalve placed on the liquid line.

8. After the pressure between therefrigerant bottle and therefrigerant circuit is balanced,make a vacuum by using thecompressor in order to store therefrigerant in the condenser.

9. Continue to charge the machineby using the refrigerant chargingvalve placed on the liquid line.

10. After the pressure is balancedbetween the bottle and themachine, open the liquid linevalve and start the compressor.

11. Complete the charge by usingthe charging valve placed on thesuction line. For the correctrefrigerant charge refer to theTable 2.

Trane

A business of American Standard Companies

www.trane.com

For more information contact your local district office or e-mail us at [email protected]

Literature Order Number

Date

Supersedes

Stocking Location

Trane has a policy of continuous product and product data improvement and reserves the right tochange design and specifications without notice. Only qualified technicians should perform theinstallation and servicing of equipment referred to in this publication.

RTWB-SVN01B-E4

1003

RTWB-SVN01A-E4_0801

Europe

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

Maintenance Contract

It is strongly recommended that yousign a maintenance contract withyour local Service Agency. Thiscontract provides regularmaintenance of your installation bya specialist in our equipment.Regular maintenance ensures thatany malfunction is detected andcorrected in good time andminimizes the possibility thatserious damage will occur. Finally,regular maintenance ensures themaximum operating life of yourequipment. We would remind youthat failure to respect theseinstallation and maintenanceinstructions may result in immediatecancellation of the warranty.

Training

The equipment described in thismanual is the result of many yearsof research and continuousdevelopment. To assist you inobtaining the best use of it, andmaintaining it in perfect operatingcondition over a long period of time,the constructor have at yourdisposal a refrigeration and airconditioning service school. Theprincipal aim of this is to giveoperators and maintenancetechnicians a better knowledge ofthe equipement they are using, orthat is under their charge. Emphasisis particularly given to theimportance of periodic checks on theunit operating parameters as well ason preventive maintenance, whichreduces the cost of owning the unitby avoiding serious and costlybreakdowns.

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