Installation RTHA-IOM-1A Operation Maintenance pray Service Literature Product Section Refrigeration Product Rotary Liguld Chillers - Water-Cooled Model RTHA J iteeatre Type Installation.Operation, Maintenance. Sequence 1 Date __ Maren 1982 File No. ee ‘SV-RF-RLC-RTHAAOM ‘Supercedes: RTHA-IN-1, RTHA-SD-1, RTHA-M-1, RTHAIOM-1 Series R Water-Cooled Hermetic CenTraVac Rotary Liquid Chillers Doerr seavecee (Includes extended shell option and oll recovery system) . Models RTHA 130 RTHA215—- RTHA 380 RTHA 150 = RTHA255 —- RTHA 450 RTHA 180 ATHA300 eau “io nace The renee ssovcnp eta azpect ares fisbeoke rade doe cs, see rane ‘Sno Th Yana Comey hs ley of eros ec root tenes ne nt age pein ad arsTable of Contents 5 5A 53 General Information Literature Change History Unt laenareaton Inspection Creckist Loose Pars Inventory Unit Description ‘Commenly Used Acronyms ‘Wamings ana Cautions Installation Responsbtties Nameplates “Unt Nameplates Mode! Number Coding Oyster Installation Mechanical Storage Location Requrements “Foundation ‘Srearances =Vertlation rsinage Installation Access Restrictions igang Litng Procedure ‘Alternate Moving Methods Shipoing Std Removal Isolation Pacs Und Leveting Water Ping Piping Connections “Reversing Water Boxes “Gonaenser Water Temperature “Making Flange Connections Vens and Drains Evaporator Piping Components ~Gondense: Piping Components =“Cuuliny Tomer Syste Wal (iy) tee Syetom later Regulating Valve Fale installs Water Temperature Sensors ‘Standard Sensor ~Load-based, Setpoint Reset Option Wlatar Temperature Sensing Kit Option Sensor Instaation Procedure Water Trestment Customer Note Water Pressure Gauges and Thermometers vate Pressure Holt Vaves Flow Sensing Devices “Thecmal insulation Fotigoran Pressure Relief Vave Venting Installation — Electrical General Recommendations Installer Supplied Components ower Supply wing ~Wiator Pump Power Supply Control Power Supoly -Starer Panel Power Supply (ner Supply Power Components cy ° rR n Power Factor Corton Capacitors ~Disuonnett Suites Intereenneeting Wing Remote Starter Panel “Compressor Motor Power Wiring Terminal Lugs ‘Active Oil Ptun Gyeter Optical Sensor ductor Acve Oi Retum Contal Unit Joe Makng Too Making Pane! Oporation for Design Sequences AO thru H Ice Making Panel Operation for Design Sequences JO and Later Operai InguOutput Charactritice External Inhibit Leaving Evaporator Wator Temperature Sensor BTB2-1 and 6TB2-2 “Machine Uniogs -Ice Bank Leaving Temperature Sensor (6TB2-7 and 6782-8 Make ice Contact Closure “excernal Pump “Power Panel -Chlled Water Flow Swe (S52) ~Condenser Water Flow Swcn -Optional Heed Rie! Request and Alam “Low Votage Canto! Wing Chilled Water Temperature Sensors ~Condensing Wator Sensors Optional Chea Water Reset Sensors “Generic BASICWR Interface Option ~-Optonal Bdrectional Communueatons Link (BCL) Uns Startup “Chiller hacksheet and Request for Serviceman” map come "See oie Sean a a oon Sooke ace i a89 Operating Principles ~ Electrical 9 ills Contct Oyster 91 Unit Cont Panal 85. Relay Output Module (101) 85 Power Supply Output Moduie (102) 31 Wier wocule (UCM oF 103), a1 TES a1 —1TBa 81 1786 92. ~Electromectanical Controls 93 Operating Principles - UCM 98 UCM Power Monitor Feature 84 Operator Interface 94 Chiller Swen 85 ~Ctilled Water Setpoint Potentemetar 98 ~Curent Limit Setpoint Potantometer 96 Sige valve Conor Swi 87 Unit Statue Lights 98 "Unit Condon” Display 89 Service interface 89 Clear Resta Inhibit Push Button 100 ~Conto! Response Seipint Potantometor 100 ~Stat Diferental Setpoint Potantiometer 100 =-Conderser Lim Setpoint Potentometer 101 Evaporator Retigerant Trip Soipoint Potentometer 103 Electrical Sequence of ‘Operation 108 Genera 103 Series R Compressor Motor Soquencing 103 Genera 104 ~Curvecting Improper Clectrcl Phage Sequence 104 System Power Supply 105 ~Micre Module TUS and Relay ‘Ourpur Mogure 12 105 —Wator Pump Intorok Cire 105 “Oil Tank Heater (4H and 4+R2) 114 “Micro Mocule and "Wye-Dotta" Startor Control Ccuts 114 “Solenoid Conta! 114 Pressure Gauges 114 Ralay Package 115 Cont! Options 115 Water Temperature Sensor Kt 115 Gofal Communicate intorace (sc, 197 Chilled Water Reset (CWR) 117 “Load-Based CWR 119 “Ambient Based CWR 439 Remote Generic BASICWR Interface (CWA) 121 Unit Start-Up Procedures 121 Daly Unit startup 121 Geasonal Unit Cart Us 123 Unit Shut-Down Procedures 128 Dally Unt Snut Down 123 Seasonal Unkt Shut Down 125 Periodic Maintenance 125 Overview 125 Daly Maintenance and Checks 125 Weekly Maintenance 125 Every Months 125 Every 6 Months 125 Annual Maintenance 125 Scneautng Uiner Mantenance 127 CenTraVac Operating Log 129 Maintenance Procedures 129 Retrigerant Charge 129: Checking The Oil Level 130 Cleaning the Condenser 190 Mechanical Cleaning Procedure 130 Chemical Cieaning Proceaure 481 Cleaning the Evaporetor 131 Comorasen Ol 131 “Removing Compressor Oi 481 Oil Charging the Compressor 132 “Charging Proceaure 132 “Replacing the Ol Fiter 132 “Filer Replacement - Design Sequence A thru D 132 =Filler Replacement - Design Sequence E end Above 132 Conta! Settings and Adustments 132 Trouble Analysis 4182 Control System 193 Troubleshooting Charts THA 1OM 1A,FTHAION 48 List of Illustrations 0 ” 4 6 16 at 2 24 8 Ea “0 2 30 8 Figure 1 (Component Layout for Typeal HTHA Unt (rent View) Figura > CCompanent Layout for Typical ATHA Unit (ight Enc View) Figure 3 ‘Component Layout for Typioal ATHA Unit (Back View) Figure 4 Installation Responsbilly Char for RHTA 190 Thre 00 Uns Figue s Unit Nameplate Locations Figure 6 Magel Number Goaing System Figue 7 Wits and Rigging for 8-Poit Liting Figure 8 Weighs and Rigging for 4-Point Liting Figure ® ocommended Operating and Serves CGearances for RTHA Units Figure 10 Isolato Pad Placoment fr Typcal RTHA Unt Figura 14 Evaporator Entering and Leaving Water Connections Figure 12 Condenser Entering and Leaving Water Connections Figure 13, Bot Tightening Sequence for 4-Bolt and 2-Bok Pipe Flanges Figure 1 ‘Sensor Installation Schematic fr Typical THA Uni Figure 19 Water Tempera Figure 16 “Typical Thermometer, Vaving, and Manfoided Pressure Gauge Setup Figure 17 “TWpleal RTHA Insuiation Requirements Figure 18 Ferigerant Charging and Rote Valve Locations for Typical THA Unis Figure 10 “Typical Fela Wiring Diagram for RTHA Unt with Unit Mounted Starter Panel, Design Sequence A tu Ht Figure 20 Fle Wing and Remote Sensor Layout for Typical RTHA Uni, Design Sequence Atwul Figute 21 “Typical Field Wiring Diagram for THA Unit with UnieMounted Starter Pane! Design Sequence JO Figure 20 Filet Wring and Remote Sensor Layout for Typical RTHA Unt, Design Sequence 0 1° Genser nation 55 56 57 6 6 04 6 ry o 7” rR rR n 7 % % 7 2 83 4 CE ornare So Saco Ss ne re oe (SoS cetarte ase $B rwanda reo ae ee eclnamcowniine 2 emotonby Seo roses a or or ees ES cas rae Ew ress Fs Come CAMOH Me oo Pees fa Bovis Tea HA eros eae coneEE Br Fgue 48 “Typical BTHA Compressor Oil Sunply ‘System Design Sequence A~D a7 Figure 43 “Typical ATHA Compressor Oi Supply ‘System Design Sequence E- PO 88 Figure 50 THA Ol Cooler 89 FigureSt Exiemal Comaonents of Typical UCP Used On RTHA Units 90 Figura 52 Typical UCP Layout for RTHA Units (Boor Removed) 94 Figure 9s UCM Operator Pana 99 Figure 54 UCM Service interface Controls (Quattiaa Technicians Only) 03 Figure 55 -Asvociated Research Model 45 Phase Sequence inccator 108 Figue sé Electrical Scbemate for RTH 130°Thra 300 Unts writ - Mounted Starter, Design Sanuanee A they H 109 Figure 57 ‘Sequence of Operation Schematic Yor HTFIA 130 Tru 300 Unt, Dosign Saquonce A shns 110 Figure 58 Electrical Schematic for ATHA 190 thry 300 Units w/Un-Mountes Sianer, Design Bequence JO 118 Figure 59 ‘Sequence of Operation Schematic foe ATHA 130 thru 800 Units, Design Sequence JO He Figure 60 “Typeal BCL Network for SCP and Three Series F Callers 118 Figure 61 Micro Module 103 Equipped with Chilled ister Raset Options 120 Figure 62 Remote Generic BASICWR Interface Opton 429 Figure 63 Confguration For Checking Oi Level 130 Figue 6& “ypical Condenser/Evanorator Chemica! leaning Setup RTHAIOM-1A,RTHAIOM-1A List of Tables 4 “ 43 57 e 3 99 100 19 131 Table t FITIIA 190 Thi 450 Evaperaton ated Condenser ats Table 2 THA Insulation Requirements ‘apie 3 Preseure Rll! Valve Discharge Setpoint for THA 120 Thru 450 Unite Tabs Wire Selection Char for BTHA ‘Compressor Motor ang Meroe starter Leads Teale 5 THA Feld Wiring Requirements Table 6 ‘Troubleshooting Que fr Aut Ol Firm System Contra Unie Tabie7 ‘Sensor Conversion Data lee Termination Tene 8 Unit Time Dolaye end Gatety Controt Cutout Setinas| “Teble9 Unt Diagnostic Codes Tee 10 Diepiay Menus Table 11 Codes for Unt Operating Modes Tee 12 THA Compressor “Stop Points “able 13 THA Discharge Superheat Parameters Table 14 ‘Refrigerant and O# Charging Data for THA UniteImportant Notices Wits environmental scientists nave concluded, bazod on tho boct curently Availabe evidence. that the ozone in ur Upper atmosphere is being reduced, due to the roloase oF GFL tully-nalogenarod ‘compound ‘The Trane Company urges all HVAC servicers, working on Trane and other rmanutactuers'produets, to make every efor to cima i pose, or vaorouly reduced emissions of CFC. a re neckegwotire a each from instalation, paration ruin maintenance, oF major service on this equipment. Alvays actin a responsible marries a vse religerants for ontined use, even when acrepta ‘altematives are avaiable. ‘Conservation and omission reduction can be accomplished ay folowing recommended “Trane operation, maintenance and service proceaures, wht spectic attertion tothe following 1. Refrigerant used in any type of ait chinloning or refrigerating equipment Should he marwared fo russe, covered ‘andlor recycled fr reuse, reprocessed (ceclaimed), or property destroyed, wimenever iis removed rom equipment Never release fetrigerant into the atmosphere, 2 Aiways determine possible racycle or reclaim requiremenis othe recovered religerant before beginning racovory by fry method. Questions about rvoveres Teligarants and aoceptabereigerant qualty standards are adcressed in AR Standard 700, 3. Use approved containment vessels and Safety standards. Comply wih all applicable ‘raneporaton stanoares when shippers religarant containers 4. In order to assist in reducing power {generation emissions, always atamet to imarove equipment performance with improved maintenance and oporations that wil elp conserve energy resources. RTHAIOM-1A,General Information Literature Change History FTIIAION- —_(Ceplember 1900) Original manual. Covers instalation, ‘operaton, and maintenance of A thru Ht ‘design sequance RTHA-130 thru RTHA-300 unis ATHAION-HA (March 1002) Manual reissued to update electrical tlagrams and make accitonal changes sted below Incorporate new mocels Incorporate extended shel option, Incorporate ol reoovery eystom. Incorporate changes to ice making system. Unit Identification \Whea the unt arrives. compare all nameplate data with ordering and shipping ‘ntormaton, Unit Inspection \When the unit ie deivared very that itis the corect unt and that tis property ‘quipped. Compare the infamation which ‘appears onthe unit namepiate with he frdering and submital information. Refer to ‘Nameplates Inspect al exterior component for visible damage. Hepor any apparent damage or fraterial shortage tothe oarror and make a “Unit damage’ notation on the carer's delivery receipt. Spocty the extent and type (oF camage found and noty the appropriate Trane Salve Offes, Do not proceed with installation of a dermaged unit thout sales office approval THA 1OM 44,CBionent out ot Typical THA q w/Unit-Mount ront View) Unit Conta! Pane! cmon Nameplate petigerent Service ‘Unie woourtng Flange Pa Nameplate "Nameplate RTHAIONA,Conse ent Layout of Typical RTHA faghtena View) Starter Panel Pull Box Evaporator Evaporator ‘Water Outlet _ Unit Mounting Flange see —_Figure 3 ‘Component Layout of Iypical RTHA Back View) youn or ATHAIOMIA, Compressor Helet valves) Motor Cooling Line ‘Compressor Rotor Housing Compressor NotorlEconomizer Housing Economizer ‘Sump LineInspection Checklist Ta protect against loss chia to damage incured in transit, complete the following Checklist upon receipt ofthe unt. LJ Inspect the individual pioces of the shipment before acoapting the unt. ‘Check for obvious damage to te unit or packing material [Inspect the unt for concealed damage as ‘9000 as possibe ater delivery and nator it stored. Concealed damage must be reported within 10 days. [ Jf concealed damage is diccovered, stop uunpackina the shipment. Do not remove ‘damaged material from the rocehving Jocaton. Take photos ofthe damage, possible. The owner must provide reasonable evidence thatthe damage did ot oocur afer delivery. 2 Notiy the cartior’s terminal ofthe ‘damage immediately, by phono and by ‘mall, Request an Immediate, ont Inspection ofthe damage wth the carton and the consignee. [J Nouty vie Tne sales representative and ‘arrange for repair Na pat rapa tha FRowever, unt damago is inspected by the carers representative. Loose Parts Inventory ‘Check al items against shipping list. Water vessel drain plugs, Isolation pads, rigging tnd electrical diagram, aenioe ikerature ‘and optional water temperature sensors are placed inside the contol panel andor starter panel for shipment. Ine starter panel wire pulbox, required on come unit mounted Starters, fs also shipped on the unit. It may be removed, and subsequently reinstalled, if ‘ovemead ciarance is requred curing installation Unit Description “The 190 thru 480-07 Model RTHA unis ate ingle compressor, holicabrtary type. water Cooled quid fillers designed for instalation indoors, Each unt a completely assembled erotic chia als latory ped, wire laakctestad, dehydrated, charged. and tested for proper cereal operation before shipment Figure 4 thu chow atypical RTHA unit and its components. Water init and outlet ‘openings are covered before shipment. The Compressor of tank Is factory charged with the proper amount of rargaration ail The unit's factory charged with reigerant, On nits with condenser isolation valves, the (Gharge is lated inthe condense, Commonly Used Acronyms ‘The unit-mounted contol panel used on the Model RTHA liquid chilis refered to inthis manual as ne "UCP. Ine microprocessor {oF “mier" i looatod in tho upper portion of the UCP and is designated the "UCM. ‘Acronyms used in this manual are defined blow. |AMB= Cutdoor Ambient Temperature BAG — Building Automation System BCL= _Bidirectonal Communicatons Link CLS= Current Limit Setpoint GWR= Chilea Water Heset GWE = Chiles Wator Setpoint Design Delta-T (ie. the aference bemeen entering ahd teaving chilled water temperatures) Entering Chilod Wator “Tomperature Hot Gas Bypass ‘Heating, Venttatng and Air Condticning Input and Outout Wiring Leaving Chiled Water “Tomperature National Elsce Code Front Panel Chiled Water Setpoint Power Factor Correction Capacitors PSID= Paunds-per-Square-inch Differential (pressure ferential), PSIG= Pounds:perSquere-nch (gauge pressure) Reset Action Setpoint Rated Load Amps ROWS - Rese! Chilod Water Setpoint (wR) Reset Reference Sotpoint (CWA) Type of rane Bulging Auromanon yetem RRS. “Tracer ‘SCI= Serial Communications Interace UGLS= Unt Current Limt Setpoint ‘UeM = Unit Gontro! Module (Mioroprocascos) UCP = _Uni-Mounted Control Panel UGWS = Unt Chiled Water Setpoint Warnings and Cautions ‘Warnings and Cautions appear in boldface type at aporoprate points in this ‘manuel Warnings are provided i ale parsnnnel to potential hazards that can resultin personal injury or death they do not replace the manufacturer's recommendations Cautions ler personnel to conditions that ‘ould resur in equipment damage. Your personal eafaly and reliable aparation ofthis frachine depend upon stict observance of these precautions. The Trane Company SSUES 1 Hay forsale ot service receduros performed by ungualiied personnel, Installation Responsibilities The “Installation Responsibly Chart" on the ‘ext cage pinpoints responsi for furnishing ang instaling a fele-provised ystem components. Generally, the contractor must do the folowing when instaling an RTHA unit [install unit ona fat, level (within 1/16" [1.6 mm) foundation, strong enough to Support unit lading. Piace manutacturer- ‘supplied isolation pade under unt [Install unit per applicable Trane Instataion manual. [ 1 Complete all water and electrical ‘connections. [1 Tighten al electrical connections inthe conto! panel and starter pane! {Install any optional sensors in system water piping and make electrical ‘connections atthe UCM. Note: The standard leaving chiled water ‘sensor is factory installed in the evaporator feaving water outlet, [ 1Wher spectod, provide and install valves n water ping upstream ana \downetream of evaporator and condenser \wator boxes to isolate shells for ‘maintenance, and to balancattim system U1 Supply and instal ow switches (or ‘equivalent devioes) in both chilled wator €and condenser water ping: ntotock ‘each ewiton wih proper pump lator to ensure unit can only operate f water low is established. [1 Fumish and instal thermamataes ant pressure gauges ininlet and outlet piping Df both evaparator and condenser. 1 Fumish and instal can valves to each ator box L}Supely and install vent cooks on each water box [1 Where specified, tumish and install svainers ahead of al pumps and automatic modulating valves. LJ Furnish and instal vent piping trom all relict valves o atmosphere, 1 Provide and instal field wiring, [LJStart unt under supervision of a quaitieg Servi technician, [ 1Whare specifies, insulate evaporator ana any other portions of machine as required to prevent sweating under Formal operating constons. RTHAION-1A,