O&m HQ CHW System

KING ABDULAZIZ CITY FOR SCIENCE AND TECHNOLOGY
GENERAL DIRECTORATE OF PROJECT
CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND CAR

PARKS FOR KACST BIOTECHNOLOGY RESEARCH FACILITY AND
HEADQUARTERS BUILDING AT KACST MAIN CAMPUS
OPERATION AND MAINTENANCE MANUAL

HQ – CHILLED WATER SYSTEM
AL-TA’AFUF COMPANY
FOR ELECTRICAL WORKS
A Subsidiary of KSB Holding Company
P.O Box 295407 Riyadh 11351 – Saudi Arabia
Tel: +966 11 2109853 (Ext-202) l Fax: +966 11 2109853 (Ext-204)
01


MECHANICAL – HQ CHILLED WATER SYSTEM
TABLE OF CONTENT
SECTION 01 HQ CHILLED WATER SYSTEM NARRATIVE.
SECTION 02 HQ CHILLED WATER SYSTEM MAIN COMPONENTS
SECTION 03 CHILLERS
SECTION 04 CHILLED WATER PUMPS
SECTION 05 EXPANSION TANK AND AIR SEPARATOR
SECTION 06 CHEMICAL DOSING SYSTEM
SECTION 07 TESTING AND COMMISSIONG
SECTION 08 AS BUILT DRAWING LIST
SECTION 09 AS BUILT DRAWING HARD COPY
SECTION 10 AS BUILT DRAWING CD
SECTION 11 OPERATION AND MAINTENANCE MANUAL TRANE CHILLER CD
02

SECTION-01
MECHANICAL – HQ CHILLED WATER SYSTEM NARRATIVE
03

SECTION-01
MECHANICAL – HQ CHILLED WATER SYSTEM NARRATIVE
SECTION 01.01 Description of the HQ-Chilled water system

SECTION 01.02 Drawing Series
SECTION 01.03 Reference Drawings Register
04

SECTION-01.01
Description of the HQ-Chilled water system
05
SECTION 01.01 Description of the HQ-Chilled water system
Chilled water systems provide cooling to HQ building by using chilled water

to absorb heat from the building’s spaces. At the heart of the water chilled
system, a number of 5 chillers remove heat from water by means of
a refrigeration cycle.
A chilled water system’s refrigeration cycle works by removing heat from chilled
water in the evaporator of the 5 chillers. The compressor is what drives the entire
process. It also uses the most energy in a chilled water system.
In the condensers of the 5 chillers, the heat is transferred to the condenser water,
or directly to the outside air.
The chilled water loop consists of 5 TRANE Sintesis air cooled chillers Model RTAF,
with 502 Tons nominal capacity each, three Secondary chilled water Pumps that
move chilled water through HQ building. And a Five Primary chilled water pumps
(CHWP) push chilled water through the chiller and through the chilled water
return line from HQ building.
The location of the five chillers and the five Primary CHWPs are in the chiller yard
with all connected piping and valves, while the location of the three secondary
CHWPS are inside pump room number 106 along with air separator tank and all
connected piping and valves.
The primary circuit pumps are running at a constant speed, while the secondary
circuit pumps are running at variable speed to provide better energy efficiency
and control as they can vary with the demand of HQ building.
06

SECTION-01.02
Drawing Series
07
SECTION 01.02 Drawing Series:
Main Plan:
MAC: 100
Standard Details:
MAC: 300
Equipment Schedule:
MAC: 000
08

SECTION-01.03
Reference Drawings Register
09
SECTION 01.03 Reference Drawings Register
Drawing Number Description

CPC/CP-06/M/001/X GENERAL NOTES, LEGENDS AND ABBREVIATIONS (MECHANICAL)
CPC/CP-06/M/002/X EQUIPMENT SCHEDULE
CPC/CP-06/MAC/101/X CHW PIPING GROUND FLOOR LAYOUT OF CHILLER YARD AND PUMP ROOM (MASTER)
CPC/CP-06/MAC/102/X CHW PIPING GROUND FLOOR LAYOUT OF CHILLER YARD AND PUMP ROOM (PART-1)
CPC/CP-06/MAC/104/X HVAC GROUND FLOOR LAYOUT - MASTER
CPC/CP-06/MAC/105/X HVAC GROUND FLOOR LAYOUT PART-1
CPC/CP-06/MAC/107/X HVAC ROOF FLOOR LAYOUT - MASTER
CPC/CP-06/MAC/108/X HVAC ROOF FLOOR LAYOUT PART-1
CPC/CP-06/MAC/301/AB HVAC STANDARD DETAILS-1
10

SECTION-02
MAIN COMPONENTS
11
SECTION-02 HQ- CHILLED WATER SYSTEM MAIN COMPONENTS
SR ITEM MANUFACTURER MODEL LOCATION

1 CHILLER-01 TRANE TRAF 500C UAGH CHILLER YARD
6 PCHWP-01 ARMSTRONG SERIES 4300, 6x6x8 CHILLER YARD
11 SCHWP-01 ARMSTRONG SERIES 4300, 8x8x10 PUMP ROOM
14 EXP. TANK-01 AMTROL VERTICAL AX-1000L PUMP ROOM
16 AIR SEPARATOR AMTROL 16-AS PUMP ROOM
17 CHEMICAL DOSING SYSTEM PROMINENT FLUID CONTROL 0704 PPE PUMP ROOM
12

SECTION-03
CHILLERS
13

SECTION-03
CHILLERS
SECTION 03.01 Description and model.

SECTION 03.02 Name plate data.
SECTION 03.03 General Catalogue.
SECTION 03.04 Operation And Maintenance Manual.
SECTION 03.05 Equipment Schedule.
SECTION 03.06 Control And Wiring Diagrams.
SECTION 03.07 Manufacturer/Vendors.
SECTION 03.08 Spare Parts
SECTION 03.09 Warranty Certificate
14

SECTION-03.01
HQ - CHILLERS
Description and Model
15
SECTION 03.01 HQ – CHILLERS - DESCRPITION AND MODEL

The Sintesis RTAF units are helical-rotary type, air-cooled chillers designed
for outdoor installation. The refrigerant circuits are factory-piped, leak tested and
dehydrated.
Every unit is electrically tested for proper control operation before shipment.
Chilled water inlet and outlet openings are covered for shipment. The Sintesis RTAF
features Trane’s exclusive Adaptive Control™ logic, which monitors the control
variables that govern the operation of the chiller unit.
Adaptive control logic can adjust capacity variables to avoid chiller shutdown when
necessary and keep producing chilled water. The units feature two independent
refrigerant circuits. Each circuit utilizes at least one compressor driven by an
Adaptive Frequency Drive. Each refrigerant circuit is provided with filter, sight glass,
electronic expansion valve, and charging valves.
The shell-and-tube CHIL™ (Compact-High performance Integrated Design-Low
charge) evaporator is manufactured in accordance with the ASME standards or
other international codes. Each evaporator is fully insulated and equipped with
water drain and vent connection.
Units are shipped with full oil charge and can be ordered with either a factory
refrigerant charge or optional nitrogen charge.
16

SECTION-03.02
HQ - CHILLERS
NAME PLATE DATA
17
18
19
20

SECTION-03.03
HQ - CHILLERS
GENERAL CATALOGUE
21
Product Catalog
Sintesis™ Air-Cooled Chillers

Model RTAF
115 to 500 NominalTons
August 2015 RLC-PRC049B-EN

22
Introduction
The newTrane Sintesis™ model RTAF chiller is the result of a search for higher reliability, higher
energy efficiency, and lower sound levels for today’s environment.
Sintesis is the newest member of Ingersoll Rand’s EcoWise™ portfolio of
products, designed to lower environmental impact with next-generation,
low global warming potential (GWP) refrigerant and high efficiency
operation. Sintesis chillers are designed to operate with either R-134a or
DuPont™ Opteon® (R-513A), a next generation refrigerant with 55 percent lower GWP than R-134a.
The Sintesis chiller uses the proven design of theTrane helical-rotary compressor, which embraces
all of the design features that have made theTrane helical-rotary compressor liquid chillers such
a success since 1987.
Sintesis chillers offers high reliability coupled with greatly improved energy efficiency, and
improved acoustical performance, due to its advanced design, low-speed, direct- drive
compressor, and proven Sintesis performance.
The major advantages of the Sintesis chiller are:
• High reliability
• Lower sound levels
• Higher energy efficiency at full load & part load.
The Sintesis model RTAF chiller is an industrial-grade design, built for both the industrial and
commercial markets. It is ideal for schools, hotels, hospitals, retailers, office buildings, and
industrial applications.
Copyright
This document and the information in it are the property ofTrane, and may not be used or
reproduced in whole or in part without written permission.Trane reserves the right to revise this
publication at any time, and to make changes to its content without obligation to notify any person
of such revision or change.
Trademarks
All trademarks referenced in this document are the trademarks of their respective owners.
Revision History
RLC-PRC049B-EN (04 Aug 2015)
Extended product family size to 500T.
© 2015Trane All rights reserved RLC-PRC049B-EN
23
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Application Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Model Number Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
RLC-PRC049B-EN 3
24
Features and Benefits
Sintesis Helical-Rotary Compressor
• Unequaled-reliability.The Sintesis™Trane helical-rotary compressor is designed, built, and
tested to the same demanding and rugged standards as theTrane scroll compressors, the
centrifugal compressors, and the previous generation helical-rotary compressors used in both
air- and water-cooled chillers for more than 27 years.
• Years of research and testing.TheTrane helical-rotary compressor has amassed thousands of
hours of testing, much of it at severe operating conditions beyond normal commercial air-
conditioning applications.
• Proven track record.TheTrane Company is the world’s largest manufacturer of large helical-
rotary compressors used for refrigeration. Over 300,000 compressors worldwide have proven
Trane helical- rotary compressor reliability.
• Resistance to liquid slugging.The robust design of the compressor can ingest amounts of liquid
refrigerant that normally would severely damage compressor.
• Fewer moving parts.The helical- rotary compressor has only two rotating parts: the male rotor
and the female rotor.
• Direct-drive, low-speed, semi- hermetic compressor for high efficiency and high reliability.
• Suction-gas-cooled motor.The motor operates at lower temperatures for longer motor life.
• Five minute start-to-start and two minute stop-to-start anti-recycle timer allows for closer water-
loop temperature control.
Capacity Control and Load Matching

The combination unloading system onTrane helical- rotary compressors uses the adaptive
frequency drive for the majority of the unloading function.This allows the compressor to modulate
infinitely, to exactly match building load and to maintain chilled-water supply temperatures within
±0.5°F [± 0.3°C] of the set point. Helical- rotary chillers that rely on stepped capacity control must
run at a capacity equal to or greater than the load, and typically can only maintain water
temperature to around ± 2°F [±1°C]. Much of this excess capacity is lost because overcooling goes
toward removing building latent heat, causing the building to be dried beyond normal comfort
requirements.
The combination of the variable unloading valve plus the adaptive frequency drive allow to exact
load matching and excellent efficiencies at full load and part load.
Figure 1. Cutaway of a compressor
4 RLC-PRC049B-EN
25
Close Spacing Installation

The Sintesis™ chiller is minimally affected in many restricted air flow situations due to its advanced
Adaptive Control™ microprocessor, which has the ability to understand the operating environment
of the chiller and adapt to it by first optimizing its performance and then staying on line through
abnormal conditions.
Consult your sales engineer for more details.
Factory Testing Means Trouble-Free Start-up

All Sintesis chillers are given a complete functional test at the factory.This computer-based test
program completely checks the sensors, wiring, electrical components, microprocessor function,
communication capability, expansion valve performance, and fans. In addition, each compressor
is run-tested to verify capacity and efficiency.The result of this test program is that the chiller
arrives at the job site fully tested and ready for operation.
Microchannel Condenser Coils

Microchannel condensing coils are all-aluminum coils with fully-brazed construction.This design
reduces risk of leaks and provides increased coil rigidity — making them more rugged on the
jobsite.
Microchannel all-aluminum construction provides several additional benefits:
• Light weight (simplifies coil handling)
• Easy to recycle
• Minimize galvanic corrosion
Their flat streamlined tubes with small ports and metallurgical tube-to-fin bond allow for
exceptional heat transfer.
Bottom line, less refrigerant is being used, which creates a healthier and greener environment.
Figure 2. Microchannel condensing coils

Slit Fins and Braze Contact
Air Condenser Inlet for Improved Heat Transfer
and Strength
Microchannels Air Condenser Outlet

for Refrigerant
RLC-PRC049B-EN 5
26
CHIL evaporator
Compact - High performance - Integrated design - Low refrigerant charge (CHIL) evaporator
optimizes the flow of refrigerant for excellent heat transfer and minimizes the volume of refrigerant
used.
Figure 3. CHIL evaporator, 115 to 250 ton units, 2-pass,
Circuit 1
Refrigerant
Out
Circuit 2
Refrigerant
Out
Return
Waterbox
Supply
Waterbox
Circuit 1
Circuit 2
Refrigerant In
Refrigerant In
Figure 4. CHIL evaporator, 280 to 500 tons, 1-pass

Circuit 2
Circuit 1 Refrigerant
Refrigerant Out
Out
Return
Supply Waterbox
Waterbox
Circuit 1
Refrigerant In Circuit 2
Refrigerant In
Fans
Sintesis chillers use Electronically Commutated (EC) fans in order to reduce power consumption
at full load and at part load. EC fans allow a significant reduction of sound level and a better
operation of the chiller at low ambient conditions.
Precision Control
• New 7 inch color touch screen display with graphics
• Powered by UC800 industry-leading control algorithms
• Enhanced flow management provides unmatched system performance in variable flow
water systems
• Adaptive Control™ keeps the chiller running in extreme conditions
• Tight set point control
• Graphical trending
• Maximized chiller update
• BACnet®, Modbus™, LonTalk®, communications protocol interface available without the need
for gateways
• Optional condenser fan speed control to help meet preset nighttime sound requirements
6 RLC-PRC049B-EN
27
Application Consideration
Certain application constraints should be considered when sizing, selecting, and installingTrane
Sintesis™ chillers. Unit and system reliability is often dependent on properly and completely
complying with these considerations. When the application varies from the guidelines presented,
it should be reviewed with your local sales engineer.
Unit Sizing
Unit capacities are listed in the performance data section. Intentionally oversizing a unit to ensure
adequate capacity is not recommended. Erratic system operation and excessive compressor
cycling are often a direct result of an oversized chiller. In addition, an oversized unit is usually more
expensive to purchase, install, and operate. If oversizing is desired, consider using two units.
Water Treatment
Dirt, scale, products of corrosion, and other foreign material will adversely affect heat transfer
between the water and system components. Foreign matter in the chilled-water system can also
increase pressure drop and, consequently, reduce water flow. Proper water treatment must be
determined locally, depending on the type of system and local water characteristics. Neither salt
nor brackish water is recommended for use inTrane Sintesis chillers. Use of either will lead to a
shortened chiller life.Trane encourages the employment of a reputable water-treatment specialist,
familiar with local water conditions, to assist in this determination and in the establishment of a
proper water- treatment program.
Effect of Altitude on Capacity

At elevations substantially above sea level, the decreased air density will reduce condenser
capacity and, therefore, unit capacity and efficiency.
Ambient Limitations
Trane Sintesis chillers are designed for year-round operation over a range of ambient
temperatures. For operation outside of these ranges, contact the local sales office.
• Standard Ambient Range = 14 to 115°F (-10 to 46°C)
• Low Ambient Range = -4 to 115°F (-20 to 46°C)
• High Ambient Range = 14 to 130°F (-10 to 54.4°C)
• Wide Ambient Range = -4 to 130°F (-20 to 54.4°C)
The minimum ambient temperatures are based on still conditions (winds not exceeding five mph).
Greater wind speeds will result in a drop in head pressure, therefore increasing the minimum
starting and operating ambient temperature.The Adaptive Frequency™ microprocessor will
attempt to keep the chiller on-line when high or low ambient conditions exist, making every effort
to avoid nuisance trip-outs and provide the maximum allowable tonnage.
Water Flow Limits

The minimum water flow rates are given in Table 1, p. 16. Evaporator flow rates below the
tabulated values will result in laminar flow and cause freeze-up problems, scaling, stratification,
and poor control.
The maximum evaporator water flow rate is also given in the general data section. Flow rates
exceeding those listed may result in excessive tube erosion.
Note: Flow rates in General data tables are for water only.They do not include glycol.
RLC-PRC049B-EN 7
28
Flow Rates Out of Range

Many process cooling jobs require flow rates that cannot be met with the minimum and maximum
published values for the evaporator. A simple piping change can alleviate this problem. For
example: a plastic injection molding process requires 80 gpm(5.0 l/s) of 50°F (10°C) water and
returns that water at 60°F (15.6°C).The selected chiller can operate at these temperatures, but has
a minimum flow rate of 120 gpm (7.6 l/s).The following system can satisfy the process.
Figure 5. Flow rate out of range
50°F
79.3 gpm
50°F CV Pump
120.5 gpm 79.3 gpm
50°F Load
39.7 gpm
56.7°F
120.5 gpm
60°F
CV Pump
Flow Proving
Trane provides a factory-installed water flow switch monitored by UC800 which protects the chiller
from operating in loss of flow conditions.
Flow Control
Trane requires the chilled water flow control in conjunction with the Sintesis™ Chiller to be done
by the chiller.This will allow the chiller to protect itself in potentially harmful conditions.
Leaving-Water Temperature Limits
Sintesis RTAF chillers have three distinct leaving water categories:
• Standard, with a leaving solution range of 40 to 68°F (4.4 to 20°C)
• Low temperature process cooling, with leaving solution less than 40°F (4.4°C)
• Ice-making, with a leaving solution range of 10.4 to 68°F (-12 to 20°C)
Since leaving solution temperatures below 40°F (4.4°C) result in suction temperature at or below
the freezing point of water, a glycol solution is required for all low temperature and ice-making
machines. Ice making control includes dual setpoints and safeties for ice making and standard
cooling capabilities. Consult your localTrane account manager for applications or selections
involving low temperature or ice making machines.
The maximum water temperature that can be circulated through the evaporator when the unit is
not operating is 125°F (51.7°C). Evaporator damage may result above this temperature.
Leaving-Water Temperature Out of Range

Many process cooling jobs require temperature ranges that cannot be met with the minimum and
maximum published values for the RTAF evaporator. A simple piping change can alleviate this
problem. For example: a laboratory load requires 120 gpm (7.6 l/s) of water entering the process
at 85°F (*29.4°C) and returning at 95°F (35°C).The accuracy required is higher than the cooling
8 RLC-PRC049B-EN
29
tower can give.The selected chiller has adequate capacity, but has a maximum leaving-chilled-
water temperature of 64°F (18°C). In the example shown, both the chiller and process flow rates are
equal.This is not necessary. For example, if the chiller had a higher flow rate, there would be more
water bypassing and mixing with warm water.
Figure 6. Leaving water temperature flow rate out of range
60°F 85°F
35 gpm 120.5 gpm
60°F CV Pump
120.5 gpm
95°F
85.5 gpm
60°F
Load
85.5gpm
70°F
120.5 gpm
60°F 95°F
CV Pump
Series Chiller Arrangements

Another energy saving strategy is to design the system around chillers arranged in series.The
actual savings possible with such strategies depends on the application dynamics and should be
researched by consulting yourTrane Systems Solutions Representative and applying an analysis
tool from theTrace software family. It is possible to operate a pair of chillers more efficiently in a
series chiller arrangement than in a parallel arrangement. It is also possible to achieve higher
entering to leaving chiller differentials, which may, in turn, provide the opportunity for lower chilled
water design temperature, lower design flow, and resulting installation and operational cost
savings.TheTrane screw compressor also has excellent capabilities for “lift,” which affords an
opportunity for “lift,” which affords an opportunity for savings on the evaporator water loop.
Series chiller arrangements can be controlled in several ways. Figure 7shows a strategy where
each chiller is trying to achieve the system design set point. If the cooling load is less than 50 percent
of the systems capabilities, either chiller can fulfill the demand. As system loads increase, the
Chiller 2 becomes preferentially loaded as it attempts to meet the leaving chilled water setpoint.
Chiller 1 will finish cooling the leaving water from Chiller 2 down to the system design setpoint.
Staggering the chiller set points is another control technique that works well for preferentially
loading Chiller 1. If the cooling load is less than 50 percent of the system capacity, Chiller 1 would
be able to satisfy the entire call for cooling. As system loads increase, Chiller 2 is started to meet
any portion of the load that Chiller 1 can not meet.
RLC-PRC049B-EN 9
30
Figure 7. Typical series chiller arrangement
Chiller 2 Chiller 1
Setpoint = 42°F (5.6°C) Setpoint = 42°F (5.6°C)
Blending
Valve
Variable
58°F depending
on load 42°F (5.6°C)
(14.4°C)
Typical Water Piping

All building water piping must be flushed prior to making final connections to the chiller.To reduce
heat loss and prevent condensation, insulation should be applied. Expansion tanks are also usually
required so that chilled water volume changes can be accommodated.
Avoidance of Short Water Loops

Adequate chilled water system water volume is an important system design parameter because it
provides for stable chilled water temperature control and helps limit unacceptable short cycling of
chiller compressors.
The chiller’s temperature control sensor is located in the waterbox.This location allows the
building to act as a buffer to slow the rate of change of the system water temperature. If there is
not a sufficient volume of water in the system to provide an adequate buffer, temperature control
can suffer, resulting in erratic system operation and excessive compressor cycling.
Typically, a two-minute water loop circulation time is sufficient to prevent short water loop issues.
Therefore, as a guideline, ensure the volume of water in the chilled water loop equals or exceeds
two times the evaporator flow rate. For systems with a rapidly changing load profile the amount
of volume should be increased.
If the installed system volume does not meet the above recommendations, the following items
should be given careful consideration to increase the volume of water in the system and, therefore,
reduce the rate of change of the return water temperature.
• A volume buffer tank located in the return water piping.
• Larger system supply and return header piping (which also reduces system pressure drop and
pump energy use).
Minimum water volume for a process application
If a chiller is attached to an on/off load such as a process load, it may be difficult for the controller
to respond quickly enough to the very rapid change in return solution temperature if the system
has only the minimum water volume recommended. Such systems may cause chiller low
temperature safety trips or in the extreme case evaporator freezing. In this case, it may be
necessary to add or increase the size of the mixing tank in the return line.
10 RLC-PRC049B-EN
31
Multiple Unit Operation

Whenever two or more units are used on one chilled water loop,Trane recommends that their
operation be coordinated with a higher level system controller for optimum system efficiency and
reliability.TheTraneTracer system has advanced chilled plant control capabilities designed to
provide such operation.
Ice Storage Operation

An ice storage system uses the chiller to make ice at night when utilities generate electricity more
efficiently with lower demand and energy charges.The stored ice reduces or even replaces
mechanical cooling during the day when utility rates are at their highest.This reduced need for
cooling results in significant utility cost savings and source energy savings.
Another advantage of an ice storage system is its ability to eliminate chiller over sizing. A “right
sized” chiller plant with ice storage operates more efficiently with smaller support equipment while
lowering the connected load and reducing operating costs. Best of all this system still provides a
capacity safety factor and redundancy by building it into the ice storage capacity for practically no
cost compared to over sized systems.
TheTrane air-cooled chiller is uniquely suited to low temperature applications like ice storage
because of the ambient relief experienced at night. Chiller ice making efficiencies are typically
similar to or even better than standard cooling daytime efficiencies as a result of night-time dry-
bulb ambient relief.
Standard smart control strategies for ice storage systems are another advantage of the Sintesis
chiller.The dual mode control functionality is integrated right into the chiller.TraneTracer building
management systems can measure demand and receive pricing signals from the utility and decide
when to use the stored cooling and when to use the chiller.
Unit Placement
Setting The Unit
A base or foundation is not required if the selected unit location is level and strong enough to
support the unit’s operating weight. (See “Weights,” p. 46.)
For a detailed discussion of base and foundation construction, see the sound engineering bulletin
or the unit IOM. Manuals are available through online product portal pages or from your local
office.
HVAC equipment must be located to minimize sound and vibration transmission to the occupied
spaces of the building structure it serves. If the equipment must be located in close proximity to
a building, it should be placed next to an unoccupied space such as a storage room, mechanical
room, etc. It is not recommended to locate the equipment near occupied, sound sensitive areas of
the building or near windows. Locating the equipment away from structures will also prevent
sound reflection, which can increase sound levels at property lines or other sensitive points.
Isolation and Sound Emission

Structurally transmitted sound can be reduced by elastomeric vibration eliminators. Elastomeric
isolators are generally effective in reducing vibratory noise generated by compressors, and
therefore, are recommended for sound sensitive installations. An acoustical engineer should
always be consulted on critical applications.
RLC-PRC049B-EN 11
32
Figure 8. Installation example
Piping isolation
Chilled water piping

should be supported
Isolators
Isolators
Flexible
electrical
Concrete Base conduit
For maximum isolation effect, water lines and electrical conduit should also be isolated. Wall
sleeves and rubber isolated piping hangers can be used to reduce sound transmitted through water
piping.To reduce the sound transmitted through electrical conduit, use flexible electrical conduit.
Local codes on sound emissions should always be considered. Since the environment in which a
sound source is located affects sound pressure, unit placement must be carefully evaluated. Sound
power levels for chillers are available on request.
Servicing
Adequate clearance for evaporator, condenser and compressor servicing should be provided.
Recommended minimum space envelopes for servicing are located in the dimensional data
section and can serve as a guideline for providing adequate clearance.The minimum space
envelopes also allow for control panel door swing and routine maintenance requirements. Local
code requirements may take precedence.
Unit Location
General
Unobstructed flow of condenser air is essential to maintain chiller capacity and operating
efficiency. When determining unit placement, careful consideration must be given to assure a
sufficient flow of air across the condenser heat transfer surface.Two detrimental conditions are
possible and must be avoided: warm air recirculation and coil starvation. Air recirculation occurs
when discharge air from the condenser fans is recycled back to the condenser coil inlet. Coil
starvation occurs when free airflow to the condenser is restricted.
Condenser coils and fan discharge must be kept free of snow or other obstructions to permit
adequate airflow for satisfactory unit operation. Debris, trash, supplies, etc., should not be allowed
to accumulate in the vicinity of the air-cooled chiller. Supply air movement may draw debris into
the condenser coil, blocking spaces between coil fins and causing coil starvation.
Both warm air recirculation and coil starvation cause reductions in unit efficiency and capacity due
to higher head pressures.The Sintesis™ chiller offers an advantage over competitive equipment
in these situations. Operation is minimally affected in many restricted air flow situations due to its
advanced Adaptive Control™ microprocessor which has the ability to understand the operating
environment of the chiller and adapt to it by first optimizing its performance and then staying on
line through abnormal conditions. For example, high ambient temperatures combined with a
restricted air flow situation will generally not cause the chiller to shut down. Other chillers would
typically shut down on a high pressure nuisance cut-out in these conditions.
Cross winds, those perpendicular to the condenser, tend to aid efficient operation in warmer
ambient conditions. However, they tend to be detrimental to operation in lower ambients due to
the accompanying loss of adequate head pressure. Special consideration should be given to low
12 RLC-PRC049B-EN
33
ambient units. As a result, it is advisable to protect air-cooled chillers from continuous direct winds
exceeding 10 mph (4.5 m/s) in low ambient conditions.
The recommended lateral clearances are depicted in the Close-Spacing and Restricted Airflow
Engineering Bulletin RLC-PRB037*-EN available on product portal pages or from your local office.
Provide Sufficient Unit-to-Unit Clearance

Units should be separated from each other by sufficient distance to prevent warm air recirculation
or coil starvation. Doubling the recommended single unit air-cooled chiller clearances will
generally prove to be adequate. See Close-Spacing and Restricted Airflow Engineering Bulletin
RLC-PRB037*-EN for more information.
Walled Enclosure Installations

When the unit is placed in an enclosure or small depression, the top of the surrounding walls
should be no higher than the top of the fans.The chiller should be completely open above the fan
deck.There should be no roof or structure covering the top of the chiller. Ducting individual fans
is not recommended. See Close-Spacing and Restricted Airflow Engineering Bulletin RLC-
PRB037*-EN for more information.
RLC-PRC049B-EN 13
34
Model Number Descriptions
Digits 1, 2 — Unit Model Digit 17 — Evaporator Digit 27 — Compressor Starter
RT = Rotary Chiller Application V = Adaptive Frequency Drive
Digit 3 — Unit Type N = Standard Cooling Digit 28 — Incoming Power Line
(above 40°F/5.5°C)
A = Air-cooled P = LowTemp Process Cooling
Connection
Digit 4 — Development (below 40°F/5.5°C) 1 = Single Point Power Connection
C = Ice Making 2 = Dual Point Power Connection
Sequence
F = Development Sequence Digit 18 — Evaporator Digit 29 — Power Line
Configuration Connection Type
Digits 5-7 — Nominal Capacity
2 = 2-pass Evaporator X = Terminal Block
115 = 115 NominalTons
T = 2-pass Evaporator C = Circuit Breaker
withTurbulators H = Circuit Breaker with High Fault
1 = 1-pass Evaporator Rated Control Panel
180 = 180 NominalTons R = 1-pass Evaporator Digit 30— Short Circuit Current
200 = 200 NominalTons withTurbulators
Rating
215 = 215 NominalTons Digit 19 — Evaporator Fluid Type A = Default Amp Short Circuit Rating
1 = Water B = High Amp Short Circuit Rating
2 = Calcium Chloride
3 = Ethylene Glycol
Digit 31 — Electrical Accessories
310 = 310 NominalTons X = No Convenience Outlet
4 = Propylene Glycol
350 = 350 NominalTons P = 15A 115V Convenience Outlet
5 = Methanol
450 = 450 NominalTons Digit 20 — Water Connection Digit 32 — Remote
500 = 500 NominalTons X = Grooved Pipe Connection Communication Options
Digit 8— Unit Voltage W = Grooved Pipe + Flange X = None
B = BACnet® Interface
C = 380/60/3 Digit 21 — Flow Switch M = Modbus™ Interface
D = 400/50/3 1 = Factory Installed - Other Fluid L = LonTalk® Interface
E = 460/60/3 15 cm/s
2 = Factory Installed - Water Digit 33 — Hard Wire
Digit 9 — Manufacturing
35 cm/s Communication
Location 3 = Factory Installed - Water X = None
U = Trane Commercial Systems, 45 cm/s A = Hard Wired Bundle - All
Pueblo, CO USA
Digit 22 — Insulation B = Remote Leaving WaterTemp
Digits 10, 11— Design Sequence N = Factory Insulation
Setpoint
XX = Factory assigned C = Remote LeavingTemp and
All Cold Parts 0.75” Demand Limit Setpoints
Digit 12 — Unit Efficiency Digit 23 — Unit Application D = Programmable Relay
H = High Efficiency X = Standard Ambient E = Programmable Relay and
(14 to 115°F/-10 to 46°C) Leaving Water and Demand
Digit 13— Unit Sound Package Limit Setpoint
L = Low Ambient
X = Standard Noise F = Percent Capacity
(-4 to 115°F/-20 to 46°C
Digit 14 — Agency Listing H = High Ambient G = Percent Capacity and Leaving
(14 to 130°F/-10 to 54.4°C) Water and Demand Limit
U = UL/CUL Listing Setpoint
W = Wide Ambient
Digit 15 — Pressure Vessel Code (-4 to 130°F/-20 to 54.4°C) H = Percent Capacity and
Programmable Relay
A = ASME Pressure Vessel Code Digit 24 — Condenser Fin
C = CRN or Canadian Equivalent Digit 34 — Energy Meter
Pressure Vessel Code Options
X = None
D = Australia Pressure Vessel Code N = Aluminum Microchannel
C = CompleteCoat™ Microchannel Digit 35 — Smart Flow Control
Digit 16 — Factory Charge
Digit 25 — Fan Type X = None
1 = Refrigerant Charge R-513A
2 = Refrigerant Charge R-134a C = Variable Speed Fans Digit 36 — Structural Options
3 = Nitrogen Charge Digit 26 — Oil Cooler A = Standard Unit Structure
(R-513A Field Supplied)
4 = Nitrogen Charge C = Oil Cooler Digit 37 — Appearance Options
(R-134a Field Supplied) X = No Appearance Options
14 RLC-PRC049B-EN
35
Model Number Descriptions
Digit 38 — Unit Isolation

X = None
1 = Elastomeric Isolators
Digit 39 — Shipping Package
X = No Shipping Package
A = Containerization Package
T = Shipped withTarp Covering
Full Unit
Digits 40-42
XXX= Reserved for future use
Digit 43 — Special Requirement
0 = None
S = Special Requirement
RLC-PRC049B-EN 15
36
General Data
Table 1. General data table

Unit Size (tons) 115 130 150 170 180 200 215
Compressor Model (ckt1/ckt 2)(a) 55/55 65/65 70/70 85/70 85/85 100/85 100/100
Quantity # 2 2 2 2 2 2 2
Evaporator
Water Connection Size in 4 4 5 5 5 6 6
Passes # 2 2 2 2 2 2 2
Water Storage gal 14.0 15.8 19.3 20.6 21.6 21.9 23.9
L 53.1 59.9 73.2 78.0 81.9 82.8 90.5
Minimum Flow gpm 128 150 171 187 199 202 228
l/s 8.1 9.5 10.8 11.8 12.6 12.8 14.4
Maximum Flow gpm 470 551 626 684 731 742 835
l/s 29.7 34.8 39.5 43.2 46.1 46.8 52.7
Condenser
Qty of Coils (ckt 1/ckt 2) 5/5 5/5 6/6 6/6 6/6 7/7 7/7
Coil Length in 77.4 77.4 77.4 77.4 77.4 77.4 77.4
mm 1967 1967 1967 1967 1967 1967 1967
Coil Height in 47.8 47.8 47.8 47.8 47.8 47.8 47.8
mm 1214 1214 1214 1214 1214 1214 1214
Condenser Fans
Quantity (ckt 1/ckt 2) # 5/5 5/5 6/6 6/6 6/6 7/7 7/7
Diameter in 31.5 31.5 31.5 31.5 31.5 31.5 31.5
mm 800 800 800 800 800 800 800
Nominal speed rpm 810 810 810 810 810 909 909
Airflow cfm 9959 9959 9959 9959 9959 11230 11230
m3/s 4.7 4.7 4.7 4.7 4.7 5.3 5.3
Tip Speed ft/min 6673 6673 6673 6673 6673 7500 7500
m/s 33.9 33.9 33.9 33.9 33.9 38.1 38.1
Ambient Temperature Range
Standard Ambient °F (°C) 14 to 115 (-10 to 46)
Low Ambient °F (°C) -4 to 115 (-20 to 46)
High Ambient °F (°C) 14 to 130 (-10 to 54.4)
Wide Ambient °F (°C) -4 to 130 (-20 to 54.4)
General Unit
Refrigerant R-134a or R-513A
Refrigerant Ckts # 2 2 2 2 2 2 2
Minimum Load % 15 15 15 15 15 15 15
86.4/ 86.6/ 101.4/ 111.1/ 109.0/
Refrigerant Charge (ckt 1/ckt 2) lb 134.3/129.4 134.7/129.8
84.9 84.9 99.0 99.0 96.3
kg 39.2/38.5 39.3/38.5 46.0/44.9 50.4/44.9 49.5/43.7 60.9/58.7 61.1/59.0
Oil Trane Oil 00311 (bulk)/OIL00315 (1 gal)/OIL00317 (5 gal)
Oil Charge/ckt gal 1.53 1.56 1.56 1.56 1.64 1.96 2.01
L 5.8 5.9 5.9 5.9 6.2 7.4 7.6
(a) Nominal tonnage at 60 Hz.
16 RLC-PRC049B-EN
37
General Data
Table 2. General data table

Unit Size (tons) 230 250 280 310 350 410 450 500
Compressor Model 100-100/ 100-100/ 100-120/ 100-100/ 100-120/ 120-120/
120/100 120/120
(ckt 1/ckt 2)(a) 70 100 120 100-100 100-120 120-120
Quantity # 2 2 3 3 3 4 4 4
Evaporator
Water Connection Size in 6 6 8 8 8 8 8 8
Passes # 2 2 1 1 1 1 1 1
Water Storage (gal) 28.5 30.6 31.2 32.6 35.8 41.8 44.8 46.1
(L) 107.7 115.9 118.1 123.3 135.4 158.1 169.5 174.7
Minimum Flow (gpm) 261 288 304 323 367 446 487 506
(l/s) 16.5 18.2 19.2 20.4 23.1 28.1 30.7 31.9
Maximum Flow (gpm) 957 1055 1113 1183 1345 1635 1786 1855
(l/s) 60.4 66.6 70.2 74.6 84.9 103.2 112.7 117.1
Condenser
Qty of Coils (ckt 1/ckt 2) 7/7 7/7 12/6 14/6 14/6 12/12 14/14 14/14
Coil Length (in) 77.4 77.4 77.4 77.4 77.4 77.4 77.4 77.4
(mm) 1967 1967 1967 1967 1967 1967 1967 1967
Coil Height (in) 47.8 47.8 47.8 47.8 47.8 47.8 47.8 47.8
(mm) 1214 1214 1214 1214 1214 1214 1214 1214
Condenser Fans
Quantity (ckt 1/ckt 2) # 7/7 7/7 12/6 14/6 14/6 12/12 14/14 14/14
Diameter (in) 31.5 31.5 31.5 31.5 31.5 31.5 31.5 31.5
(mm) 800 800 800 800 800 800 800 800
Total Airflow (cfm) 909 909 909 909 909 909 909 909
(m3/hr) 11230 11230 11230 11230 11230 11230 11230 11230
Tip Speed (ft/min) 5.3 5.3 5.3 5.3 5.3 5.3 5.3 5.3
(M/S) 7500 7500 7500 7500 7500 7500 7500 7500
Ambient Temperature Range
Standard Ambient °F (°C) 14 to 115 (-10 to 46)
Low Ambient °F (°C) -4 to 115 (-20 to 46)
High Ambient °F (°C) 14 to 130 (-10 to 54.4)
Wide Ambient °F (°C) -4 to 130 (-20 to 54.4)
General Unit
Refrigerant R-134a or R-513A
Refrigerant Ckts # 2 2 2 2 2 2 2 2
Minimum Load % 15 15 15 15 15 15 15 15
Refrigerant Charge 155.4/ 155.4/ 230.8/ 239.0/ 242.1/ 232.2/ 244.8/ 252.4/
(lbs)
(ckt 1/ckt 2) 154.8 154.8 115.0 116.5 117.7 238.2 255.8 264.0
(kg) 70.7/70.4 70.7/70.4 104.9/52.3 108.6/52.9 110.0/53.5 105.5/108.3 111.3/116.3 114.7/120.0
Oil Trane Oil 00311 (bulk)/OIL00315 (1 gal)/OIL00317 (5 gal)
Oil Charge (ckt 1/ckt 2) (gal) 2.35/2.35 2.35/2.35 4.24/1.72 4.26/2.17 4.27/2.17 4.26/4.29 4.30/4.33 4.33/4.37
(L) 8.9/8.9 8.9/8.9 16.1/6.5 16.1/8.2 16.2/8.2 16.1/16.2 16.3/16.4 16.4/16.5
(a) Nominal tonnage at 60 Hz. Where there are 2 compressors on a circuit, they are indicated 1A-1B/2A-2B.
RLC-PRC049B-EN 17
38
Dimensions
Service Clearance
Figure 18. RTAF service clearances
NO OBSTRUCTIONS ABOVE UNIT
Unit sizes 115 to 250 tons:
36”
(914mm) 24”
(610 mm)
36”
(914mm)
See note 4
78”
(1941mm)
See note 3
Unit sizes 280 to 500 tons:
36”
(914mm)
36”
(914mm) 36”
See note 4 (914mm)
See note 4
78”
(1941mm)
See note 3
Notes:
1. Area above unit required for operation, maintenance, panel access and airflow.
NO OBSTRUCTIONS ABOVE UNIT
2. For installations with obstructions or multiple units, see Close Spacing and Restricted Airflow
Bulletin RLC-PRB037*-EN.
3. Clearance of 78” (1981 mm) on the side of the unit is required for coil replacement. Preferred
side for coil replacement is shown (right side of unit, as facing circuit 1 control panel). However,
either side is acceptable.
4. A full 36” (914 mm) clearance is required in front of the control panels. Must be measured from
front of panel, not end of unit base.
5. Clearances shown are sufficient for tube pull.
36 RLC-PRC049B-EN
39
Dimensions
Unit Dimensions
Figure 19. RTAF unit dimensions - 115, 130 ton
49
RLC-PRC049B-EN 37
40
Dimensions
Figure 20. RTAF unit dimensions - 150, 170, 180 ton
49
38 RLC-PRC049B-EN
41
Dimensions
RLC-PRC049B-EN 39
42
Dimensions
40 RLC-PRC049B-EN
43
Dimensions
Figure 23. RTAF unit dimensions - 280 ton
RLC-PRC049B-EN 41
44
Dimensions
42 RLC-PRC049B-EN
45
Dimensions
Figure 25. RTAF unit dimensions - 410 ton
RLC-PRC049B-EN 43
46
Dimensions
Figure 26. RTAF unit dimensions - 450, 500 ton(a)
dimensions of opposite side

See separate drawing
mounting location
(a) Mounting locations shown are for circuit 1 only (front view of unit). See Figure 27, p. 45 for circuit 2 mounting locations (back view).
44 RLC-PRC049B-EN
47
Dimensions
Figure 27. RTAF unit dimensions - 450, 500 ton, circuit 2 mounting point locations
RLC-PRC049B-EN 45
48
Weights
Table 6. Unit weights
Shipping Weight Operating Weight

Unit Size (tons) lb kg lb kg
115 7974 3617 8091 3670
130 8071 3661 8203 3721
150 9467 4294 9628 4367
170 9497 4308 9669 4386
180 9821 4455 10002 4537
200 10829 4912 11012 4995
215 11155 5060 11355 5151
230 12549 5692 12829 5819
250 12962 5880 13242 6007
280 16705 7578 16838 7638
310 17228 7815 17367 7878
350 18177 8245 18375 8335
410 21199 9616 21411 9712
450 23569 10691 23794 10793
500 23669 10736 23907 10844
46 RLC-PRC049B-EN
49
Mechanical Specifications
General
Units are leak and pressure tested at 385 psig high side, 220 psig low side, then evacuated and
charged. All chillers are factory tested to confirm operation prior to shipment. Packaged units ship
with a full operating charge of oil and refrigerant as standard. Units can also be shipped with a
nitrogen charge if required.
Unit panels, structural elements and control boxes are constructed of galvanized steel and
mounted on a bolted galvanized steel base. Unit panels, control boxes and the structural base are
finished with a baked on powder paint. All paint meets the requirement for outdoor equipment of
the US Navy and other federal government agencies.
Chiller is built and certified to UL2014 and Canadian safety standards.
Refrigerant Circuit
Each unit has two refrigerant circuits, with one or two rotary screw compressors per circuit. Each
refrigerant circuit includes compressor suction and discharge service valves, liquid line shut off
valve, removable core filter, liquid line sight glass with moisture indicator, charging port, high
pressure and low pressure safety valve and electronic expansion valve. Fully modulating
compressor and electronic expansion valve provide variable capacity modulation over the entire
operating range.
Evaporator
The evaporator is a tube-in-shell heat exchanger design with internally and externally finned
copper tubes roller expanded into the tube sheets.The evaporator is designed, tested and stamped
in accordance with the ASME Boiler and Pressure Vessel Code Section VIII for a refrigerant side
working pressure of 200 psig.The evaporator is designed for a water side working pressure of 150
psig. Waterboxes are provided in a 2 pass configuration on units up to a nominal size of 250 tons.
Evaporators for 280 to 500 ton units utilized a 1-pass configuration. Each waterbox includes a vent,
a drain and fittings for temperature control sensors.
Standard water connections are grooved for victaulic style pipe couplings, with groove to flange
style adapters available. Evaporators are insulated with 0.75 inch closed cell insulation.
Evaporator water heaters with thermostat are provided to help protect the evaporator from
freezing at ambient temperatures down to -4°F (-20°C).
Note: A separate field supplied low voltage power source is required to power the evaporator
freeze protection.
A factory installed flow switch is installed on the supply water box in the evaporator inlet
connection.
Condenser and Fans

The air-cooled microchannel condenser coils use all aluminum brazed fin construction.The
condenser coil has an integral subcooling circuit.The maximum allowable working pressure of the
condenser is 350 psig. Condensers are factory proof and leak tested at 525 psig. Coils can be
cleaned with high pressure water.
Direct-drive vertical-discharge airfoil condenser fans are dynamically balanced.The condenser fan
motors are permanent magnet motors with integrated drive to provide variable speed fan control
for all fans.
Sintesis™ chillers are equipped with EC condenser fan motors with permanently lubricated ball
bearings and external overload and overcurrent protection.
RLC-PRC049B-EN 47
50
Compressor and Lube Oil System

The rotary screw compressor is semi-hermetic, direct drive, with capacity control via an adaptive
frequency drive, rolling element bearings, differential refrigerant pressure oil pump and oil heater.
The motor is a suction gas cooled, hermetically sealed, two-pole squirrel cage induction motor.
Oil separator is provided separate from the compressor. Oil filtration is provided internal to the
compressor. Check valves in the compressor discharge and lube oil system are also provided.
Unit Controls
All unit controls are housed in an outdoor rated weather tight enclosure per UL2014 with removable
plates to allow for customer connection of power wiring and remote interlocks. All controls,
including sensors, are factory mounted and tested prior to shipment.
Microcomputer controls provide all control functions including startup and shut down, leaving
chilled water temperature control, evaporator flow proving, compressor staging and speed control,
electronic expansion valve modulation, condenser fan sequencing and speed control, anti-recycle
logic, automatic lead/lag compressor starting, load limiting and chilled water pump control.
Tracer UC800
TheTracer ™UC800 unit control module, utilizing Adaptive Control™ microprocessor,
automatically takes action to avoid unit shut-down due to abnormal operating conditions
associated with low refrigerant pressure, high condensing pressure and motor current overload.
Should the abnormal operating condition continue until a protective limit is violated, the unit will
be shut down.
Unit protective functions of the UC800 include: low evaporator refrigerant pressure, high
condenser refrigerant pressure, low oil flow, critical sensor or detection circuit faults, current
overload, high compressor discharge temperature, communications lost between modules,
electrical distribution faults, phase loss, phase imbalance, phase reversal, external and emergency
stop, momentary power loss, under/over voltage and loss of evaporator water flow.
UC800 provides an optional flexible alarm or chiller status indication to a remote location through
a hard wired interface to a dry contact closure. Four relays are available for this function.
Tracer Adaptiview TD7 Display

A full colorTracer AdaptiView™TD7 touch screen display indicates all important unit and circuit
parameters, in logical groupings on various screens.The parameters including chilled water set
point, leaving chilled water temperature, demand limit set point, evaporator and condenser
refrigerant temperatures and pressures, compressor and fan speeds, and all pertinent electrical
information.The display also provides “on screen” trending graphs of predefined parameters as
well as customizable trend graphs based on user defined parameters from a list of all available
parameters.The display also provides indication of the chiller and circuits’ top level operating
modes with detailed sub-mode reports available with a single key press, as well as diagnostics
annunciation and date and time stamped diagnostic history.The color display is fully outdoor
rated, and, can be viewed in full daylight without opening any control panel doors.
• Outdoor capable:
• UV ResistantTouchscreen
• -40C to 70C OperatingTemperature
• IP56 rated (Power Jets of Water from all directions)
• RoHS Compliant
• UL 916 Listed
• CE Certification
48 RLC-PRC049B-EN
51
• Emissions: EN55011 (Class B)

• Immunity: EN61000 (Industrial)
• Display:
• 7” diagonal
• 800x480 pixels
• TFT LCD @ 600 nits brightness
• 16 bit color graphic display
• Display Features:
• Alarms
• Reports
• Chiller Settings
• Display Settings
• Service Settings
• Graphing
• Global Application with Support for 26 Languages
Adaptive Frequency Drive (AFD) Compressor Starter

Sintesis chillers utilizeTrane’sTR200 series of Adaptive Frequency™ Drive (AFD) technology for
controlling the compressors.TR200 AFD is a family of adaptive frequency drives specifically
designed forTrane applications. AFD data such as drive status, temperatures, modes and
diagnostic information are accessible via a remote mounted keypad and through theTrane Drive
Utility service tool.
The AFD contains technology that enables the drive to last the lifetime of the chiller and to operate
with less downtime.The technology enables operation on various power systems including
alternative energy sources. AFD will protect itself and the compressor motor from overcurrent, low
or high line voltage, phase loss, incoming phase imbalance, and over-temperature due to loss of
panel ventilation.
The AFD incorporates improved serviceability and troubleshooting tools.
The drive is air-cooled with ventilation fan in the panel.
Chilled Water Reset

Control logic and factory installed sensors are provided to reset leaving chilled water temperature.
The set point can be reset based on ambient temperature or return evaporator water temperature.
Factory Mounted Flow Proving and Flow Control

The factory installed evaporator water flow switch is provided with the control logic and relays to
turn the chilled water flow on and off as the chiller requires for operation and protection.This
function is a requirement on the Sintesis™ chiller.
RLC-PRC049B-EN 49
52
Options
Application options
Ice Making
The ice making option provides special control logic to handle low temperature brine applications
(less than 40°F [4.4°C] leaving evaporator temperature) for thermal storage applications.
Low Temperature Brine

Low temperature option provides special control logic and oil cooler is installed to handle low
temperature brine applications including part load conditions below 40°F (4.4°C) leaving
evaporator temperature.
Low Ambient
The low ambient option adds unit controls to allow start and operation when the unit works with
ambient temperatures between 14°F(-10°C) and -4°F (-20°C). High side of ambient range remains
at 115°F (46°C).
High Ambient
The high ambient option adds unit controls, oil coolers and oversized electrical components to
allow start and operation up to ambient temperatures of 130°F(54.4°C) operation. Low side of
ambient range remains at 14°F (-10°C).
Wide Ambient
The wide ambient option combines the features of low and high ambient options for an ambient
range of -4° to 130°F (-20 to 54.4°C).
Evaporator Turbulators
Turbulators will be installed internal to the tubes to promote turbulent flow for the following:
• Glycol solutions
• Low flow/high evaporator temperature deltas
• Low temperature applications.
Ice Making Contact

UC800 provides an output contact closure that can be used as a signal to the system that ice
building is in operation.This relay will be closed when ice building is in progress and open when
ice building has been terminated by either UC800 or the remote interlock. It is used to signal the
system changes required to convert to and from ice making.
Electrical options
Circuit Breaker
A HACR rated molded case capacity circuit breaker (UL approved) is available. Circuit breaker can
also be used to disconnect chiller from main power with a through-the-door handle. External
operator handle is lockable.
High Short Circuit Current Rating

A higher short circuit current rating offers a greater measure of safety for what the starter panel
enclosure is able to withstand in the event of an explosion caused by a short circuit.
50 RLC-PRC049B-EN
53
Options
Control options
BACnet Communications Interface
Allows the user to easily interface with BACnet® via a single twisted pair wiring to a factory
installed and tested communication board.
LonTalk (LCI-C) Communications Interface

Provides the LONMARK® chiller profile inputs/outputs for use with a generic building automation
system via a single twisted pair wiring to a factory installed and tested communication board.
ModBus Communications Interface

Allows the user to easily interface with ModBus™ via a single twisted pair wiring to a factory
installed and tested communication board.
Remote Input Options

UC800 accepts either a 2-10 VDC or a 4-20mA input signal to remotely adjust leaving water
temperature and/or demand limit setpoint.
Remote Output Options

Permits programmable relay alarms and/or percent capacity outputs.
Other Options
Elastomeric Isolators
Elastomeric Isolators provide isolation between chiller and structure to help eliminate vibration
transmission.
Convenience Outlet
Provides a 15 amp, 115V (60 Hz) convenience outlet on the unit.
Note: An additional field-supplied power connection must be provided to power the convenience
outlet.
Flanged Water Connection Kit

Consists of raised faced flanges to convert grooved pipe water connections to flanged water
connections.The victaulic-to-flange adapter will be shipped with the chiller.
Containerization Shipping Package

Pull rings are bolted to each side of the formed sheet metal unit base rail in order to pull the unit
out of the shipping container once it reaches its destination.
Shipping Tarp
The unit will be covered at the factory with a PVC coated polyester tarp that is tied to the chiller base
to help protect the chiller from debris during shipment especially in the winter months and on
shipping vessels.This option may also be helpful if the chiller will be stored at the jobsite before
use.
RLC-PRC049B-EN 51
54
Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, the leader in
creating and sustaining safe, comfortable and energy efficient environments, Trane offers a broad portfolio of advanced
controls and HVAC systems, comprehensive building services, and parts. For more information, visit www.Trane.com.
Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice.
© 2015Trane All rights reserved

RLC-PRC049B-EN 04 Aug 2015 We are committed to using environmentally
Supersedes RLC-PRC049A-EN (28 Apr 2015) conscious print practices that reduce waste.
55

SECTION-03.04
HQ - CHILLERS
56
Installation, Operation,
and Maintenance
Sintesis™ Air-Cooled Chillers

Model RTAF
Sintesis™ chillers are part of the Ingersoll Rand EcoWise™ portfo

of products that are designed to lower the environmental impact
with next-generation, low global warming potential (GWP)
refrigerants and high efficiency operation.
SAFETY WARNING
Only qualified personnel should install and service the equipment. The installation, starting up, and servicing
of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and
training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or
serious injury. When working on the equipment, observe all precautions in the literature and on the tags,
stickers, and labels that are attached to the equipment.
October 2019 RTAF-SVX001G-EN
57

SECTION-03.05
HQ - CHILLERS
EQUIPMENT SCHEDULE
58
HQ- CHILLERS – EQUIPMENT SCHEDULE
UNIT COOLER DATA POWER DATA
TAG NO. CAPACITY FLOW EWT LWT MAX. P.D TOTAL

MAKE MODEL MCA MOCP RBS
(KW)TR (L/S) GPM C C KPA KW
RTAF-5000C UAGH (48.14)

CHILLER 1-5 TRANE 502 12 6 38.7 710 1000 800 638.1
XUA2 763
59

SECTION-03.06
HQ - CHILLERS
CONTROL AND WIRING DIAGRAM
60
Controls
Tracer UC800 Controller
Sintesis™ chillers offer predictive controls that anticipate and compensate for load changes. Other
control strategies made possible with theTracer™ UC800 controls are:
Feedforward Adaptive Control

Feedforward is an open-loop, predictive control strategy designed to anticipate and compensate
for load changes. It uses evaporator entering-water temperature as an indication of load change.
This allows the controller to respond faster and maintain stable leaving-water temperatures.
Soft Loading
The chiller controller uses soft loading except during manual operation. Large adjustments due to
load or setpoint changes are made gradually, preventing the compressor from cycling
unnecessarily. It does this by internally filtering the setpoints to avoid reaching the differential-to-
stop or the demand limit. Soft loading applies to the leaving chilled-water temperature and demand
limit setpoints.
Adaptive Controls
Adaptive Controls directly sense the control variables that govern the operation of the chiller:
evaporator pressure and condenser pressure. When any one of these variables approaches a limit
condition when damage may occur to the unit or shutdown on a safety, Adaptive Controls takes
corrective action to avoid shutdown and keep the chiller operating.This happens through
combined actions of compressor and/or fan staging. Whenever possible, the chiller is allowed to
continue making chilled water.This keeps cooling capacity available until the problem can be
solved. Overall, the safety controls help keep the building or process running and out of trouble.
Rapid Restart
A Rapid Restart™ is performed after a momentary power loss if it occurs during operation.
Similarly, if the chiller shuts down on a non-latching diagnostic and the diagnostic later clears itself,
a Rapid Restart will be initiated
AdaptiSpeed Control
Compressor speed is used to control capacity of the chiller, optimizing mathematically with the
condenser fan speed to provide the highest level of performance.The increased performance of
the UC800 Controller allows the chiller to operate longer at higher efficiency, and with greater
stability.
18 RLC-PRC049B-EN
61
Controls
Tracer AdaptiView TD7 Operator Interface

The standardTracer AdaptiView™TD7 display provided with theTrane UC800 controller features
a 7” LCD touch-screen, allowing access to all operational inputs and outputs.This is an advanced
interface that allows the user to access any important information concerning setpoints, active
temperatures, modes, electrical data, pressure, and diagnostics. It uses full text display available
in 26 languages.
Display Features Include:

• LCD touch-screen with LED backlighting, for scrolling access to input and output operating
information
• Single-screen, folder/tab-style display of all available information on individual components
(evaporator, condenser, compressor, etc.)
• Manual override indication
• Password entry/lockout system to enable or disable display
• Automatic and immediate stop capabilities for standard or immediate manual shutdown
• Fast, easy access to available chiller data in tabbed format, including:
• Easy to view Operating Modes
• Logical Sub-Component Reports:
• Evaporator
• Condenser
• Compressor
• Motor
• 3 User Programmable Custom Reports
• ASHRAE report
• Logsheet Report
• Alarms Report
• 8 pre-defined Standard Graphs
• 4 User Programmable Custom Graphs
• Chiller Settings
• Feature Settings
• Chilled Water Reset
• Manual Control Settings
• Globalization Settings
• Support of 26 languages
• Brightness Setting
• Cleaning Mode
RLC-PRC049B-EN 19
62
Controls
Tracer TU Interface
Tracer™TU (non-Trane personnel, contact your localTrane office for software) adds a level of
sophistication that improves service technician effectiveness and minimizes chiller downtime.The
portable PC-based service-tool software,TracerTU, supports service and maintenance tasks.
TracerTU serves as a common interface to allTrane® chillers, and will customize itself based on
the properties of the chiller with which it is communicating.Thus, the service technician learns only
one service interface.The panel bus is easy to troubleshoot using LED sensor verification. Only the
defective device is replaced.TracerTU can communicate with individual devices or groups of
devices. All chiller status, machine configuration settings, customizable limits, and up to 100 active
or historic diagnostics are displayed through the service-tool software interface. LEDs and their
respectiveTracerTU indicators visually confirm the availability of each connected sensor, relay,
and actuator.
TracerTU is designed to run on a customer’s laptop, connected to theTracerTD7 control panel with
a USB cable.Your laptop must meet the following hardware and software requirements:
• 1 GB RAM (minimum)
• 1024 x 768 screen resolution
• CD-ROM drive
• Ethernet 10/100 LAN card
• An available USB 2.0 port
• Microsoft® Windows® XP Professional operation system with Service Pack 3 (SP3) orWindows
7 Enterprise or Professional operating system (32-bit or 64-bit)
• Microsoft.NET Framework 4.0 or later
Note: TracerTU is designed and validated for this minimum laptop configuration. Any variation
from this configuration may have different results.Therefore, support forTracerTU is
limited to only those laptops with the configuration previously specified.
Figure 9. Tracer TU interface screen
20 RLC-PRC049B-EN
63
Controls
System Integration
Stand-Alone Controls
Single chillers installed in applications without a building management system are simple to install
and control: only a remote auto/stop for scheduling is required for unit operation. Signals from the
chilled-water pump contactor auxiliary, or a flow switch, are wired to the chilled-water flow
interlock. Signals from a time clock or some other remote device are wired to the external auto/stop
input.
• Auto/Stop: A job-site provided contact closure turns the unit on and off.
• Emergency Stop: A job-site provided contact opening wired to this input turns the unit off and
requires a manual reset of the unit microcomputer.This closure is typically triggered by a job-
site provided system such as a fire alarm.
Hardwire Points
Microcomputer controls allow simple interface with other control systems, such as time clocks,
building automation systems, and ice storage systems via hardwire points.This means you have
the flexibility to meet job requirements while not having to learn a complicated control system.
Remote devices are wired from the control panel to provide auxiliary control to a building
automation system. Inputs and outputs can be communicated via a typical 4–20 mA electrical
signal, an equivalent 2–10 V dc signal, or by utilizing contact closures.This setup has the same
features as a stand-alone water chiller, with the possibility of having additional optional features:
• Ice making control.
• External chilled water setpoint, external demand limit setpoint
• Chilled water temperature reset.
• Programmable relays - available outputs are: alarm-latching, alarm-auto reset, general alarm-
warning, chiller limit mode, compressor running, andTracer control, Service Request.
BACnet Interface
Tracer AdaptiView™control can be configured for BACnet® communications at the factory or in the
field.This enables the chiller controller to communicate on a BACnet MS/TP network. Chiller
setpoints, operating modes, alarms, and status can be monitored and controlled through BACnet.
TracerTD7 controls conforms to the BACnet B-ASC profile as defined by ASHRAE 135-2004.
LonTalk Communications Interface (LCI-C)

The optional LonTalk® Communications Interface for Chillers (LCI-C) is available factory or field
installed. It is an integrated communication board that enables the chiller controller to
communicate over a LonTalk network.The LCI-C is capable of controlling and monitoring chiller
setpoints, operating modes, alarms, and status.TheTrane LCI-C provides additional points beyond
the standard LONMARK® defined chiller profile to extend interoperability and support a broader
range of system applications.These added points are referred to as open extensions.The LCI-C is
certified to the LONMARK Chiller Controller Functional Profile 8040 version 1.0, and follows LonTalk
FTT-10A free topology communications.
Modbus Interface
Tracer AdaptiView™ control can be configured for Modbus™ communications at the factory or in
the field.This enables the chiller controller to communicate as a slave device on a Modbus network.
Chiller setpoints, operating modes, alarms, and status can be monitored and controlled by a
Modbus master device.
RLC-PRC049B-EN 21
64
Controls
Tracer SC
TheTracer SC system controller acts as the central coordinator for all individual equipment devices
on aTracer building automation system.TheTracer SC scans all unit controllers to update
information and coordinate building control, including building subsystems such as VAV and
chiller water systems. With this system option, the full breadth ofTrane’s HVAC and controls
experience are applied to offer solutions to many facility issues.The LAN allows building operators
to manage these varied components as one system from any personal computer with web access.
The benefits of this system are:
• Improved usability with automatic data collection, enhanced data logging, easier to create
graphics, simpler navigation, pre-programmed scheduling, reporting, and alarm logs.
• Flexible technology allows for system sizes from 30-120 unit controllers with any combination
of LonTalk or BACnet® unit controllers.
• LEED certification through site commissioning report, energy data collection measurement,
optimizing energy performance, and maintaining indoor air quality.
Energy savings programs include: fan pressure optimization, ventilation reset, and chiller plant
control (adds and subtracts chillers to meet cooling loads).
Building Automation and Chiller Plant Control

The UC800 controller can communicate withTraneTracer Summit,Tracer SC andTracer ES
building automation systems, which include pre-engineered and flexible control for chiller plants.
These building automation systems can control the operation of the complete installation: chillers,
pumps, isolating valves, air handlers, and terminal units.Trane can undertake full responsibility for
optimized automation and energy management for the entire chiller plant.The main functions are:
• Chiller sequencing: equalizes the number of running hours of the chillers. Different control
strategies are available depending on the configuration of the installation.
• Control of the auxiliaries: includes input/output modules to control the operation of the
various auxiliary equipment (water pumps, valves, etc.).
• Time-of-day scheduling: allows the end user to define the occupancy period, for example:
time of the day, holiday periods and exception schedules.
• Optimization of the installation start/stop time: based on the programmed schedule of
occupancy and the historical temperature records.Tracer Summit andTracer SC calculate the
optimal start/stop time of the installation to get the best compromise between energy savings
and comfort of the occupants.
• Soft loading: the soft loading function minimizes the number of chillers that are operated to
satisfy a large chilled-water-loop pull down, thus preventing an overshoot of the actual capacity
required. Unnecessary starts are avoided and the peak current demand is lowered.
• Communication capabilities: local, through a PC workstation keyboard.Tracer Summit and
Tracer SC can be programmed to send messages to other local or remote workstations and or
a pager in the following cases:
• Analog parameter exceeding a programmed value
• Maintenance warning
• Component failure alarm
• Critical alarm messages. In this latter case, the message is displayed until the operator
acknowledges the receipt of the information. From the remote station it is also possible to
access and modify the chiller plants control parameters.
• Remote communication through a modem: as an option, a modem can be connected to
communicate the plant operation parameters through voice grade phone lines. A remote
terminal is a PC workstation equipped with a modem and software to display the remote plant
parameters.
22 RLC-PRC049B-EN
65
Controls
Integrated Comfort System (ICS)

The onboardTracer chiller controller is designed to be able to communicate with a wide range of
building automation systems. In order to take full advantage of chiller’s capabilities, incorporate
your chiller into aTracer Summit orTracer SC building automation system. But the benefits do not
stop at the chiller plant. AtTrane, we realize that all the energy used in your cooling system is
important.That is why we worked closely with other equipment manufacturers to predict the
energy required by the entire system.We used this information to create patented control logic for
optimizing HVAC system efficiency.The building owners challenge is to tie components and
applications expertise into a single reliable system that provides maximum comfort, control, and
efficiency.Trane Integrated Comfort systems (ICS) are a concept that combines system
components, controls, and engineering applications expertise into a single, logical, and efficient
system.These advanced controls are fully commissioned and available on every piece ofTrane®
equipment, from the largest chiller to the smallest VAV box. As a manufacturer, onlyTrane offers
this universe of equipment, controls, and factory installation and verification.
RLC-PRC049B-EN 23
66
Electrical
Electrical Data
Table 3. Electrical data, 115 to 250 ton — single point power

Default Short High Fault Short
Condenser Fans Drive Input Amps Circuit Rating (kA) Circuit Rating (kA)
Unit Rated
Size Voltage Qty CPT Ckt Ckt Term Circuit Circuit High Fault
(tons) (a) (b) HP FLA Amps 1 2 MCA(c) MOP(d) Block Breaker(e) Breaker(f) Ckt Breaker
380/60/3 5/5 3 3.4 2.7 113 113 291 400 10 10 35 65
115 460/60/3 5/5 3 2.8 2.2 94 94 242 300 10 10 35 65
400/50/3 5/5 3 3.5 2.5 108 108 281 350 10 10 35 65
380/60/3 5/5 3 3.4 2.7 134 134 339 450 10 10 35 65
130 460/60/3 5/5 3 2.8 2.2 111 111 280 350 10 10 35 65
400/50/3 5/5 3 3.5 2.5 127 127 324 450 10 10 35 65
380/60/3 6/6 3 3.4 2.7 157 157 397 500 10 10 35 65
150 460/60/3 6/6 3 2.8 2.2 130 130 329 450 10 10 35 65
400/50/3 6/6 3 3.5 2.5 149 149 380 500 10 10 35 65
380/60/3 6/6 3 3.4 2.7 184 157 431 600 10 10 35 65
170 460/60/3 6/6 3 2.8 2.2 152 130 356 500 10 10 35 65
400/50/3 6/6 3 3.5 2.5 174 149 411 500 10 10 35 65
380/60/3 6/6 3 3.4 2.7 184 184 458 600 10 10 35 65
180 460/60/3 6/6 3 2.8 2.2 152 152 378 500 10 10 35 65
400/50/3 6/6 3 3.5 2.5 174 174 436 600 10 10 35 65
380/60/3 7/7 3 3.4 2.7 221 184 511 700 10 10 35 65
200 460/60/3 7/7 3 2.8 2.2 183 152 423 600 10 10 35 65
400/50/3 7/7 3 3.5 2.5 210 174 488 600 10 10 35 65
380/60/3 7/7 3 3.4 2.7 221 221 548 700 10 10 35 65
215 460/60/3 7/7 3 2.8 2.2 183 183 454 600 10 10 35 65
400/50/3 7/7 3 3.5 2.5 210 210 524 700 10 10 35 65
380/60/3 7/7 3 3.4 2.7 267 221 606 800 10 10 35 65
230 460/60/3 7/7 3 2.8 2.2 220 183 500 700 10 10 35 65
400/50/3 7/7 3 3.5 2.5 253 210 578 800 10 10 35 65
380/60/3 7/7 3 3.4 2.7 267 267 652 900 10 10 35 65
250 460/60/3 7/7 3 2.8 2.2 220 220 537 700 10 10 35 65
400/50/3 7/7 3 3.5 2.5 253 253 621 800 10 10 35 65
(a) Voltage Utilization Range: +/- 10% of Rated voltage (use range): 380/60/3 (342-418), 400/50/3 (360-440), 460/60/3 (414-506)
(b) Number of fans is indicated by ckt 1/ckt 2.
(c) MCA - Minimum Circuit Ampacity - 125 percent of largest compressor VFD input plus 100 percent of all other loads.
(d) Max fuse or MOPD = 225 percent of largest compressor VFD input plus 100 percent of second compressor VFD input, plus sum of condenser fan FLAs
and CPT amps.
(e) This circuit breaker is selected if unit model number digits 29 and 30 are CA.
(f) This circuit breaker is selected if unit model number digits 29 and 30 are CB.
24 RLC-PRC049B-EN
67
Electrical
Table 4. Electrical data, 280 to 500 ton units
Input Amps
Condenser Default Short High Fault Short
Fans Ckt 1 Ckt 2 MCA(c) MOP(d) Circuit Rating (kA) Circuit Rating (kA)
Unit Rated CPT
Size Voltage Qty Amps 1A 1B 2A 2B Ckt Ckt Ckt Ckt Term Circuit Circuit High Fault
(tons) (a) (e) HP FLA (b) Drive Y-D Drive Y-D 1 2 1 2 Block Breaker(f) Brkr(g) Ckt Bkr
Single Point Power
380/60/3 12/6 3 3.4 2.7 221 243 157 - 749 900 10 10 10 10
280
460/60/3 12/6 3 2.8 2.2 183 201 130 - 620 800 10 10 10 10
380/60/3 14/6 3 3.4 2.7 221 243 221 - 820 1000 10 10 10 10
310
460/60/3 14/6 3 2.8 2.2 183 201 183 - 678 800 10 10 10 10
380/60/3 14/6 3 3.4 2.7 221 293 267 - 928 1200 10 10 10 10
350
460/60/3 14/6 3 2.8 2.2 183 242 220 - 766 1000 10 10 10 10
410 460/60/3 12/12 3 2.8 2.2 183 201 183 201 890 1000 10 10 10 10
Dual Point Power
380/60/3 12/6 3 3.4 2.7 221 243 157 - 569 220 800 350 10 10 35 65
280
460/60/3 12/6 3 2.8 2.2 183 201 130 - 471 182 600 300 10 10 35 65
380/60/3 14/6 3 3.4 2.7 221 243 221 - 576 300 800 500 10 10 35 65
310
460/60/3 14/6 3 2.8 2.2 183 201 183 - 476 248 600 400 10 10 35 65
380/60/3 14/6 3 3.4 2.7 221 293 267 - 638 357 900 600 10 10 35 65
350
460/60/3 14/6 3 2.8 2.2 183 242 220 - 527 294 700 500 10 10 35 65
380/60/3 12/12 3 3.4 2.7 221 243 221 243 569 569 800 800 10 10 35 65
410
460/60/3 12/12 3 2.8 2.2 183 201 183 201 471 471 600 600 10 10 35 65
380/60/3 14/14 3 3.4 2.7 221 293 221 293 638 638 900 900 10 10 35 65
450
460/60/3 14/14 3 2.8 2.2 183 242 183 242 527 527 700 700 10 10 35 65
380/60/3 14/14 3 3.4 2.7 267 293 267 293 684 684 900 900 10 10 35 65
500
460/60/3 14/14 3 2.8 2.2 220 242 220 242 564 564 800 800 10 10 35 65
(a) Voltage Utilization Range: +/- 10% of Rated voltage (use range): 380/60/3 (342-418), 460/60/3 (414-506)
(b) CPT amps is the same for circuit 1 and circuit 2.
(c) MCA - Minimum Circuit Ampacity - 125 percent of largest compressor load (larger of VFD input or fixed speed amps) plus 100 percent of all other loads.
(d) Max fuse or MOPD = 225 percent of largest compressor load (larger of VFD input or fixed speed amps) plus 100 percent of second compressor VFD input,
plus sum of condenser fan FLAs and CPT amps.
(e) Number of fans is indicated by ckt 1/ckt 2.
(f) This circuit breaker is selected if unit model number digits 29 and 30 are CA.
(g) This circuit breaker is selected if unit model number digits 29 and 30 are CB.
RLC-PRC049B-EN 25
68
Electrical
Customer Wiring
Table 5. Customer wiring selection
Single Point Power Dual Point Power

Unit
Terminal Block Circuit Breaker
Size Rated Terminal Circuit
(tons) Voltage Block Breaker Ckt 1 Ckt 2 Ckt 1 Ckt 2
380 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
115 460 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
400 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
380 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
130 460 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
400 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
380 2 x 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
150 460 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
400 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
380 2 x 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
170 460 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
400 2 x 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
380 2 x 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
180 460 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
400 2 x 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
380 2 x 500 kcmil - #4 3 x 500 kcmil - 3/0 - - - -
200 460 2 x 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
400 2 x 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
380 2 x 500 kcmil - #4 3 x 500 kcmil - 3/0 - - - -
215 460 2 x 500 kcmil - #4 2 x 500 kcmil - 2/0 - - - -
400 2 x 500 kcmil - #4 3 x 500 kcmil - 3/0 - - - -
380 4 x 600 kcmil - #2 - - - - -
230 460 4 x 600 kcmil - #2 - - - - -
400 4 x 600 kcmil - #2 - - - - -
380 4 x 600 kcmil - #2 - - - - -
250 460 4 x 600 kcmil - #2 - - - - -
400 4 x 600 kcmil - #2 - - - - -
380 4 x 600 kcmil - #2 - 2 x 500 kcmil - #4 500 kcmil - #4 3 x 500 kcmil - 3/0 2 x 500 kcmil - 2/0
280
310
350
380 - - 2 x 500 kcmil - #4 2 x 500 kcmil - #4 3 x 500 kcmil - 3/0 3 x 500 kcmil - 3/0
410
460 4 x 600 kcmil - #2 - 2 x 500 kcmil - #4 2 x 500 kcmil - #4 2 x 500 kcmil - 2/0 2 x 500 kcmil - 2/0
450
500
26 RLC-PRC049B-EN
69
Electrical
Page left intentionally blank
RLC-PRC049B-EN 27
70
Electrical Connections
Figure 10. Field wiring, 115 to 250 ton — sheet 1
A1
CONTROLS SECTION
B2
1
18 5K3 (OPTIONAL) ICE MAKING CONTROL
2
3
J2
1K22 DUAL LOW VOLTAGE BINARY INPUT
POWER CON
4
TERMINAL
1
15 2-10 VDC CAPACITY 2 (OPTIONAL) PERCENT CAPACITY
3
1K24
& CHILLED WATER SETPOINT CIRCUIT B
4 DUAL ANALOG I/0
5
J2
C3 6
1
13 EXTERNAL CHILLED 2
(OPTIONAL) PERCENT CAPACITY
WATER SETPOINT 3
1K24 & CHILLED WATER SETPOINT
4
DUAL ANALOG I/O
14 EXTERNAL DEMAND 5
LIMIT SETPOINT J2
6
CLASS 2 WIRING 5K2

1
18 (OPTIONAL) CHILLED WATER
2
D4 3
1K25 SETPOINT SETPOINT ENABLE
J2 DUAL LOW VOLTAGE BINARY INPUT
4
SHIELDED TWISTED
PAIR LEADS
TO TRACER OR OTHER 4
TRANE REMOTE DEVICE 3
1K2 (OPTIONAL) COMM 4 MODULE
2
8 10 TO NEXT UNIT J2
1
19
1
5K1 W1 LOCKOUT EXTERNAL STOP &
2
18 1K26 EMERGENCY STOP
E5 5S1 W2
3
4
SHIELDED TWISTED
PAIR LEADS
TO MOD BUS OR 5
BACNET INTERFFACE 6
1K1 UC800
7
8
115/60/1 OR 230/50/1 9
F6
5Q10 17
AUTO
1 21
OFF ON 2
3 WATER PUMP RELAYS
1K16
1Q1
4 DUAL RELAY OUTPUT
5
G7 6
J2
CLASS 1 WIRING
CIRCUIT BRE
5K22
1
OR
5K23
2
3
TERMINAL B
5K24
4
5K25
5
UNIT STATUS
6
1K23 PROGRAMMABLE RELAY
5K26
7
QUAD RELAY OUTPUT
5K27
8
9
5K28
10
5K29
H8 11
J2
12
1 2 3 4 5
28 RLC-PRC049B-EN
71
Figure 11. Field wiring, 115 to 250 ton — sheet 1 (continued)
DRAWN BY: R. SPENCER REV

C TRANE DATE:
MASTER FILE:
18-FEB-2015
R
23113537 SHEET
1 B
REVISION DATE:
FIELD WIRING DIAGRAM
REPLACES:
THIS DRAWING IS PROPRIETARY
AND SHALL NOT BE COPIED
RTAF 1
SIMILAR TO:
OR ITS CONTENTS DISCLOSED
TO OUTSIDE PARTIES WITHOUT
THE WRITTEN CONSENT OF TRANE
USED BY:
CAD: CREO SCHEMATICS
HAZARDOUS VOLTAGE!
DISCONNECT ALL ELECTRIC POWER INCLUDING
REMOTE DISCONNECTS AND FOLLOW LOCK OUT
POWER SECTION AND TAG PROCEDURES BEFORE SERVICING.

INSURE THAT ALL MOTOR CAPACITORS HAVE
DISCHARGED STORED VOLTAGE. UNITS WITH 2
VARIABLE SPEED DRIVE, REFER TO DRIVE
INSTRUCTIONS FOR CAPACITOR DISCHARGE.
FAILURE TO DO THE ABOVE COULD RESULT
POWER CONNECTION SELECTOIN CRITERIA CUSTOMER LUG SIZE IN DEATH OR SERIOUS INJURY.
MCA = 0 - 380 (1) 500 MCM - #4

TERMINAL BLOCK
MCA = 381 - 760 (2) 500 MCM - #4 TENSION DANGEREUSE!
COUPER TOUTES LES TENSIONS ET OUVRIR
LES SECTIONNEURS À DISTANCE, PUIS SUIVRE
MCA = 300 - 600 (2) 500 MCM - 2/0 LES PROCÉDURES DE VERROUILLAGE ET DES
CIRCUIT BREAKER ÉTIQUETTES AVANT TOUTE INTERVENTION.
MCA = 700 - 800 (3) 500 MCM - 3/0 VÉRIFIER QUE TOUS LES CONDENSATEURS
DES MOTEURS SONT DÉCHARGÉS. DANS LE CAS
D'UNITÉS COMPORTANT DES ENTRAÎNEMENTS
À VITESSE VARIABLE, SE REPORTER AUX 3
INSTRUCTIONS DE L'ENTRAÎNEMENT POUR
DÉCHARGER LES CONDENSATEURS.
UN MANQUEMENT À LA PROCÉDURE
CI-DESSUS PEUT ENTRAÎNER DES
BLESSURES GRAVES, VOIRE LA MORT.
iVOLTAJE PELIGROSO!
DESCONECTE TODA LA ENERGÍA ELÉCTRICA,
INCLUSO LAS DESCONEXIONES REMOTAS Y SIGA
LOS PROCEDIMIENTOS DE CIERRE Y ETIQUETADO
ANTES DE PROCEDER AL SERVICIO. ASEGÚRESE
DE QUE TODOS LOS CAPACITORES DEL MOTOR
HAYAN DESCARGADO EL VOLTAJE ALMACENADO.
PARA LAS UNIDADES CON TRANSMISIÓN 4
DE VELOCIDAD VARIABLE, CONSULTE LAS
INSTRUCCIONES PARA LA DESCARGA
DEL CONDENSADOR.
NO REALIZAR LO ANTEDICHO PUEDE PROVOCAR
LA MUERTE O LESIONES GRAVES.
DEVICE PREFIX LOCATION CODE

AREA LOCATION
1 CONTROL PANEL
2 NOT USED
3 CIRCUIT 1 5
4 CIRCUIT 2
5 CUSTOMER INSTALLED
6 UNIT WIRING
CONVENIENCE
EVAP OUTLET
HEATERS (OPTIONAL)
1X6 1 2 3 4 5
POWER HOOD
L1
1Q1 7
CIRCUIT BREAKER L2
N
OR 115V/60/1
TERMINAL BLOCK L3 H
6
N 115V/60/1
4 OR
11 H 230V/50/1
22
4 8
11
5 6 7 8
RLC-PRC049B-EN 29
72
A1
B2
C3
D4
PLACE CONDUIT
BELOW THIS POINT
E5
F6
KNOCKOUTS FOR EVAP HEATER AND CONVENIENCE

OUTLET CUSTOMER SUPPLIED POWER
PANEL SIDE VIEW PANEL ISO VIEW

G7
H8
1 2 3 4
30 RLC-PRC049B-EN
73

DRAWN BY: R. SPENCER REV
C TRANE DATE:
MASTER FILE:
18-FEB-2015
R
23113537 SHEET
2 B
REVISION DATE:
REPLACES:
RTAF 1
SIMILAR TO:
USED BY:
GENERAL NOTES
1. CAUTION-DO NOT ENERGIZE THE UNIT UNTIL CHECK OUT AND STARTUP PROCEDURES HAVE BEEN COMPLETED.
2. ALL MOTORS ARE PROTECTED FROM PRIMARY SINGLE PHASE FAILURES. 2

3. CAUTION-TRANE PUMP CONTROL MUST BE USED TO PROVIDE PUMP CONTROL. EVAPORATOR CHILLED WATER PUMP MUST
BE CONTROLLED BY THE CHILLER OUTPUT. FAILURE TO COMPLY WITH THIS REQUIREMENT MAY RESULT IN DAMAGE OT THE UNIT.
4 SINGLE SOURCE POWER IS PROVIDED AS STANDARD ON THESE PRODUCTS, FIELD CONNECTIONS ARE MADE TO 1Q1.
WIRING REQUIREMENTS
5. RECOMMENDED FIELD WIRING CONNECTIONS ARE SHOWN BY DOTTED LINES
POWER FOR THE EVAPORATOR HEATER AND/OR OPTIONAL CONVENIENCE OUTLET IS SUPPLIED BY A CUSTOMER PROVIDED POWER SUPPLY,
6 MAX FUSE SIZE IS 20 AMPS FOR EVAPORATOR HEATERS AND 20 AMPS FOR OPTIONAL CONVENIENCE OUTLET. WHEN POWERED, THE HEATERS WILL USE
2040VA.
7. DO NOT RUN LOW VOLTAGE CONTROL WIRING (30 VOLTS OR LESS) IN CONDUIT WITH 110 VOLT OR HIGHER WIRING. DO NOT EXCEED THE FOLLOWING
MAXIMUN RUN LENGTHS FOR A GIVEN SIZE: 14 AWG, 5000 FT; 16 AWG, 2000 FT; 18 AWG, 1000FT.
SHIELDED TWISTED PAIR LEADS ARE REQUIRED FOR CONNECTIONS TO THE COMMUNICATIONS INTERFACE MODULE (1K1 AND 1K2). THE SHIELD SHOULD BE 3
8 GROUNDED AT THE RTAF CONTROL PANEL END.
CUSTOMER SUPPLIED POWER 115/60/1PH OR 230/50/1PH TO POWER RELAYS. MAX. FUSE SIZE IS 20 AMPS. GROUND ALL CUSTOMER SUPPLIED POWER
9 SUPPLIES AS REQUIRED BY APPLICABLE CODES. GREEN GROUND SCREWS ARE PROVIDED IN UNIT CONTROL PANEL.
WIRED TO NEXT UNIT. 22 AWG SHIELDED COMMUNICATION WIRE EQUIVALENT TO HELIX LF22P0014216 RECOMMENDED. THE SUM TOTAL OF ALL
10 INTERCONNECTED CABLE SEGMENTS NOT TO EXCEED 4500 FEET. CONNECTION TOPOLOGY SHOULD BE DAISY CHAIN. REFER TO BUILDING AUTOMATION
SYSTEM (BAS) COMMUNICATION INSTALLATION LITERATURE FOR END OF LINE TERMINATION RESISTOR REQUIREMENTS.
ALL UNIT POWER WIRING MUST BE 600 VOLT COPPER CONDUCTORS ONLY AND HAVE A MINIMUM TEMPERATURE INSULATION RATING OF 90 DEGREE C.
11 REFER TO UNIT NAMEPLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION DEVICE. PROVIDE AN EQUIPMENT GROUND IN
ACCORDANCE WITH APPLICABLE ELECTRIC CODES. REFER TO WIRERANGE TABLE FOR LUG SIZES.
12. ALL FIELD WIRING MUST BE IN ACCORDANCE WITH NATIONAL ELECTRIC CODE AND LOCAL REQUIREMENTS.
CONTACT RATINGS AND REQUIREMENTS 4
13 WIRED TO CUSTOMER CHILLED WATER SET POINT 2-10 VDC FROM FACTORY. SEE OPERATING INSTRUCTIONS TO CONFIGURE FOR 4-20mA.
14 WIRED TO CUSTOMER CURRENT LIMIT SET POINT 2-10 VDC FROM FACTORY. SEE OPERATING INSTRUCTIONS TO CONFIGURE FOR 4-20mA.
15 WIRED TO CUSTOMER COMPRESSOR % RLA OUTPUT 2-10 VDC.

16. ALL CUSTOMER CONTROL CIRCUIT WIRING MUST BE COPPER CONDUCTORS ONLY AND HAVE A MINIMUM INSULATION RATING OF 300 VOLTS. EXCEPT
AS NOTED, ALL CUSTOMER WIRING CONNECTIONS ARE MADE TO CIRCUIT BOARD MOUNTED BOX LUGS WITH A WIRE RANGE OF 14 TO 18 AWG OR DIN RAIL
MOUNTED SPRING FORCE TERMINALS.
17 UNIT PROVIDED DRY CONTACTS FOR THE CONDENSER/CHILLED WATER PUMP CONTROL. RELAYS ARE RATED FOR 7.2 AMPS RESISTIVE, 2.88 AMPS PILOT
DUTY, OR 1/3 HP, 7.2 FLA AT 120 VOLTS 60 HZ, CONTACTS ARE RATED FOR 5 AMPS GENERAL PURPOSE DUTY 240 VOLTS.
18 CUSTOMER SUPPLIED CONTACTS FOR ALL LOW VOLTAGE CONNECTIONS MUST BE COMPATABLE WITH DRY CIRCUIT 24 VOLTS DC FOR A 12 mA RESISTIVE
LOAD. SILVER OR GOLD PLATED CONTACTS RECOMMENDED.
19 THE CONTACTS FOR AUTO STOP AND EMERGENCY STOP SWITCHES ARE JUMPERED AT THE FACTORY BY JUMPERS 1W1 & 1W2 TO ENABLE UNIT OPERATION. IF 5
REMOTE CONTROL IS DESIRED, REMOVED THE JUMPERS AND CONNECT TO THE DESIRED CONTROL CIRCUIT.
20. SOLID OVALS REPRESENT MAX NUMBER OF CONDUITS AND/OR CABLE GLANDS USED.
21 FIELD WIRING REQUIRED ONLY WITH FIELD INSTALLED PUMP OPTION.
22 400V, 50Hz UNITS WILL BE FACTORY WIRED TO UTILIZE 230V ACROSS THE EVAP HEATERS.
ANEL ISO VIEW

7
5 6 7 8
RLC-PRC049B-EN 31
74
APPROVED 04/Aug/2015 21:22:57
A1
CONTROLS SECTION
B2
1
18 5K3 (OPTIONAL) ICE MAKING CONTROL
2
3
J2
1K22 DUAL LOW VOLTAGE BINARY INPUT
POWER CO
4
TERMINA
1
15 2-10 VDC CAPACITY 2 (OPTIONAL) PERCENT CAPACITY
3 & CHILLED WATER SETPOINT
4
1K24
DUAL ANALOG I/0 CIRCUIT
5
J2
C3 6
1
13 EXTERNAL CHILLED 2
(OPTIONAL) PERCENT CAPACITY
WATER SETPOINT 3
4
1K24 & CHILLED WATER SETPOINT POWER CO
DUAL ANALOG I/O
14 EXTERNAL DEMAND
LIMIT SETPOINT
5
6
J2 TERMINA
CLASS 2 WIRING 5K2

1
18 (OPTIONAL) CHILLED WATER
2
D4 3
1K25 SETPOINT SETPOINT ENABLE
4
SHIELDED TWISTED
PAIR LEADS
TO TRACER OR OTHER 4
TRANE REMOTE DEVICE 3
1K2 (OPTIONAL) COMM 4 MODULE
2
1
19
5K1
1
W1 LOCKOUT EXTERNAL STOP &
2
18 5S1 1K26 EMERGENCY STOP
E5 3
W2 J2 DUAL LOW VOLTAGE BINARY INPUT
4
SHIELDED TWISTED
PAIR LEADS
TO MOD BUS OR 5
BACNET INTERFFACE 6
1K1 UC800
7
8
115V/60/1
9 OR
230V/50/1
F6 16 OR
(220V/60/1)
H(H) N(H)
5Q10 17
AUTO
1 21
OFF ON 2
3 WATER PUMP RELAYS
1K16
1Q1 / 2
4 DUAL RELAY OUTPUT
5
G7 6
J2
CLASS 1 WIRING
CIRCUIT BR
5K22
1
OR
5K23
2
3
1X2 / 2
5K24
4
TERMINAL B
5K25
5
UNIT STATUS
6
1K23 PROGRAMMABLE RELAY
5K26
7
QUAD RELAY OUTPUT
5K27
8
9
5K28
10
5K29
H8 11
J2
12
1 2 3 4
32 RLC-PRC049B-EN
75
ROVED 04/Aug/2015 21:22:57 GMT

DRAWN BY: N. SCHAMS REV
C TRANE DATE:
MASTER FILE:
14-JULY-2015
R
57227906 SHEET
1 A
REVISION DATE:
REPLACES:
RTAF 1
SIMILAR TO:
USED BY:
! WARNING
HAZARDOUS VOLTAGE!
DISCONNECT ALL ELECTRIC POWER INCLUDING
CTION
REMOTE DISCONNECTS AND FOLLOW LOCK OUT
POWER SECTION AND TAG PROCEDURES BEFORE SERVICING.

INSURE THAT ALL MOTOR CAPACITORS HAVE
DISCHARGED STORED VOLTAGE. UNITS WITH 2
VARIABLE SPEED DRIVE, REFER TO DRIVE
280T-500T DUAL POINT POWER 4 INSTRUCTIONS FOR CAPACITOR DISCHARGE.
NTROL FAILURE TO DO THE ABOVE COULD RESULT
Y INPUT
POWER CONNECTION SELECTION CRITERIA CUSTOMER LUG SIZE IN DEATH OR SERIOUS INJURY.
MCA = 0 - 380 (1) 500 MCM - #4 ! AVERTISSEMENT

TERMINAL BLOCK
MCA = 381 - 760 (2) 500 MCM - #4 TENSION DANGEREUSE!
COUPER TOUTES LES TENSIONS ET OUVRIR
LES SECTIONNEURS À DISTANCE, PUIS SUIVRE
CITY MOP = 300 - 600 (2) 500 MCM - 2/0 LES PROCÉDURES DE VERROUILLAGE ET DES
T ÉTIQUETTES AVANT TOUTE INTERVENTION.
CIRCUIT BREAKER MOP = 700 - 800 (3) 500 MCM - 3/0 VÉRIFIER QUE TOUS LES CONDENSATEURS
DES MOTEURS SONT DÉCHARGÉS. DANS LE CAS
D'UNITÉS COMPORTANT DES ENTRAÎNEMENTS
MOP = 900 - 1200 (4) 500 MCM - 3/0 À VITESSE VARIABLE, SE REPORTER AUX 3
INSTRUCTIONS DE L'ENTRAÎNEMENT POUR
DÉCHARGER LES CONDENSATEURS.
UN MANQUEMENT À LA PROCÉDURE
CI-DESSUS PEUT ENTRAÎNER DES
BLESSURES GRAVES, VOIRE LA MORT.
280T-500T SINGLE POINT POWER 4
CITY
T POWER CONNECTION SELECTION CRITERIA CUSTOMER LUG SIZE ! ADVERTENCIA
iVOLTAJE PELIGROSO!
TERMINAL BLOCK ALL (4) 600 MCM - #2 DESCONECTE TODA LA ENERGÍA ELÉCTRICA,
INCLUSO LAS DESCONEXIONES REMOTAS Y SIGA
LOS PROCEDIMIENTOS DE CIERRE Y ETIQUETADO
ANTES DE PROCEDER AL SERVICIO. ASEGÚRESE
DE QUE TODOS LOS CAPACITORES DEL MOTOR
HAYAN DESCARGADO EL VOLTAJE ALMACENADO.
E PARA LAS UNIDADES CON TRANSMISIÓN 4
DE VELOCIDAD VARIABLE, CONSULTE LAS
INPUT
INSTRUCCIONES PARA LA DESCARGA
DEL CONDENSADOR.
NO REALIZAR LO ANTEDICHO PUEDE PROVOCAR
LA MUERTE O LESIONES GRAVES.
E DEVICE PREFIX LOCATION CODE

AREA LOCATION
1 CONTROL PANEL #1
& 2 CONTROL PANEL #2
Y INPUT 3 CIRCUIT 1 5
4 CIRCUIT 2
5 CUSTOMER INSTALLED
6 UNIT WIRING
CONVENIENCE
EVAP OUTLET
HEATERS (OPTIONAL)
1X6 1 2 3 4 5
POWER HOOD
L1
1Q1 / 2Q1 7
CIRCUIT BREAKER L2
N
OR 115V/60/1
1X2 / 2X2 L3 H
6
TERMINAL BLOCK
N (H) 115/60/1
4 (220/60/1)
230/50/1
11 H (H)
22
4 8
11
EQUIPMENT GROUND 23
4 5 6 7 8
RLC-PRC049B-EN 33
76
APPROVED 04/Aug/2015 21:22:57
A1
B2
PLACE CONDUIT
BELOW THIS POINT
C3
D4
KNOCKOUTS FOR EVAP HEATER AND CONVENIENCE

OUTLET CUSTOMER SUPPLIED POWER
PANEL SIDE VIEW PANEL ISO VIEW

E5
F6
6X11
4
G7
H8
SINGLE POINT POWER OPTION

1 2 3 4
34 RLC-PRC049B-EN
77

OVED 04/Aug/2015 21:22:57 GMT
DRAWN BY: N. SCHAMS REV
C TRANE DATE:
MASTER FILE:
14-JULY-2015
R
57227906 SHEET
2 A
REVISION DATE:
REPLACES:
RTAF 1
SIMILAR TO:
USED BY:
GENERAL NOTES
1. CAUTION-DO NOT ENERGIZE THE UNIT UNTIL CHECK OUT AND STARTUP PROCEDURES HAVE BEEN COMPLETED.
2. ALL MOTORS ARE PROTECTED FROM PRIMARY SINGLE PHASE FAILURES. 2

3. CAUTION-TRANE PUMP CONTROL MUST BE USED TO PROVIDE PUMP CONTROL. EVAPORATOR CHILLED WATER PUMP MUST
BE CONTROLLED BY THE CHILLER OUTPUT. FAILURE TO COMPLY WITH THIS REQUIREMENT MAY RESULT IN DAMAGE OT THE UNIT.
4 FOR DUAL POINT POWER OPTION ON 280T-500T UNITS FIELD CONNECTIONS ARE MADE TO 1Q1/1X2 ON PANEL 1 AND 2Q1/2X2 IN PANEL 2. FOR SINGLE POINT
POWER OPTION ON 280T-500T UNITS FIELD CONNECTIONS ARE MADE TO 6X11 IN SINGLE POINT POWER BOX.
WIRING REQUIREMENTS
5. RECOMMENDED FIELD WIRING CONNECTIONS ARE SHOWN BY DOTTED LINES
6 POWER FOR THE EVAPORATOR HEATER AND/OR OPTIONAL CONVENIENCE OUTLET IS SUPPLIED BY A CUSTOMER PROVIDED POWER SUPPLY,
MAX FUSE SIZE IS 20 AMPS FOR EVAPORATOR HEATERS AND 15 AMPS FOR OPTIONAL CONVENIENCE OUTLET. SEE NAMEPLATE FOR HEATER
VA VALUES.
7. DO NOT RUN LOW VOLTAGE CONTROL WIRING (30 VOLTS OR LESS) IN CONDUIT WITH 110 VOLT OR HIGHER WIRING. DO NOT EXCEED THE FOLLOWING
MAXIMUN RUN LENGTHS FOR A GIVEN SIZE: 14 AWG, 5000 FT; 16 AWG, 2000 FT; 18 AWG, 1000FT.
3
SHIELDED TWISTED PAIR LEADS ARE REQUIRED FOR CONNECTIONS TO THE COMMUNICATIONS INTERFACE MODULE (1K1 AND 1K2). THE SHIELD SHOULD BE
8
GROUNDED AT THE RTAF CONTROL PANEL END.
9 CUSTOMER SUPPLIED POWER 115/60/1PH, 220/60/1PH, OR 230/50/1PH TO POWER RELAYS. MAX. FUSE SIZE IS 20 AMPS. GROUND ALL CUSTOMER SUPPLIED
POWER SUPPLIES AS REQUIRED BY APPLICABLE CODES. GREEN GROUND SCREWS ARE PROVIDED IN UNIT CONTROL PANEL.
WIRED TO NEXT UNIT. 22 AWG SHIELDED COMMUNICATION WIRE EQUIVALENT TO HELIX LF22P0014216 RECOMMENDED. THE SUM TOTAL OF ALL
10 INTERCONNECTED CABLE SEGMENTS NOT TO EXCEED 4500 FEET. CONNECTION TOPOLOGY SHOULD BE DAISY CHAIN. REFER TO BUILDING AUTOMATION
SYSTEM (BAS) COMMUNICATION INSTALLATION LITERATURE FOR END OF LINE TERMINATION RESISTOR REQUIREMENTS.
11 ALL UNIT POWER WIRING MUST BE 600 VOLT COPPER CONDUCTORS ONLY AND HAVE A MINIMUM TEMPERATURE INSULATION RATING OF 90 DEGREE C.
REFER TO UNIT NAMEPLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION DEVICE. PROVIDE AN EQUIPMENT GROUND IN
ACCORDANCE WITH APPLICABLE ELECTRIC CODES. REFER TO WIRERANGE TABLE FOR LUG SIZES.
12. ALL FIELD WIRING MUST BE IN ACCORDANCE WITH NATIONAL ELECTRIC CODE AND LOCAL REQUIREMENTS.
4
CONTACT RATINGS AND REQUIREMENTS
13 WIRED TO CUSTOMER CHILLED WATER SET POINT 2-10 VDC FROM FACTORY. SEE OPERATING INSTRUCTIONS TO CONFIGURE FOR 4-20mA.
14 WIRED TO CUSTOMER CURRENT LIMIT SET POINT 2-10 VDC FROM FACTORY. SEE OPERATING INSTRUCTIONS TO CONFIGURE FOR 4-20mA.
15 WIRED TO CUSTOMER COMPRESSOR % RLA OUTPUT 2-10 VDC.
16 ALL CUSTOMER CONTROL CIRCUIT WIRING MUST BE COPPER CONDUCTORS ONLY AND HAVE A MINIMUM INSULATION RATING OF 300 VOLTS. EXCEPT
AS NOTED, ALL CUSTOMER WIRING CONNECTIONS ARE MADE TO CIRCUIT BOARD MOUNTED BOX LUGS WITH A WIRE RANGE OF 14 TO 18 AWG OR DIN RAIL
MOUNTED SPRING FORCE TERMINALS.
PANEL ISO VIEW

17 UNIT PROVIDED DRY CONTACTS FOR THE CONDENSER/CHILLED WATER PUMP CONTROL. RELAYS ARE RATED FOR 7.2 AMPS RESISTIVE, 2.88 AMPS PILOT
DUTY, OR 1/3 HP, 7.2 FLA AT 120 VOLTS 60 HZ, CONTACTS ARE RATED FOR 5 AMPS GENERAL PURPOSE DUTY 240 VOLTS.
18 CUSTOMER SUPPLIED CONTACTS FOR ALL LOW VOLTAGE CONNECTIONS MUST BE COMPATABLE WITH DRY CIRCUIT 24 VOLTS DC FOR A 12 mA RESISTIVE
LOAD. SILVER OR GOLD PLATED CONTACTS RECOMMENDED.
5
19 THE CONTACTS FOR AUTO STOP AND EMERGENCY STOP SWITCHES ARE JUMPERED AT THE FACTORY BY JUMPERS 1W1 & 1W2 TO ENABLE UNIT OPERATION. IF
REMOTE CONTROL IS DESIRED, REMOVED THE JUMPERS AND CONNECT TO THE DESIRED CONTROL CIRCUIT.
20. SOLID OVALS REPRESENT MAX NUMBER OF CONDUITS AND/OR CABLE GLANDS USED.
21 FIELD WIRING REQUIRED ONLY WITH FIELD INSTALLED PUMP OPTION.
22 400V, 50Hz UNITS WILL BE FACTORY WIRED TO UTILIZE 230V ACROSS THE EVAP HEATERS.
23 FIELD WIRING TO 1Q1/2Q1/1X1/2X1 ONLY NEEDED ON DUAL POINT POWER UNITS.
6X11
TERMINAL BLOCK
7
L1 L2 L3
4
11
EQUIPMENT GROUND
8
TION
5 6 7 8
RLC-PRC049B-EN 35
78

SECTION-03.07
HQ - CHILLERS
MANUFACTURER/VENDORS
79
SECTION 03.07 HQ – CHILLERS – MANUFACTURER/VENDORS
MANUFACTURER
(518) 785-1315
301 Old Niskayuna Road

Suite 1
Latham, New York 12110
USA
VENDORS
Riyadh
Dallah Trading Company

P O Box: 1438
Riyadh, Saudi Arabia 11431
PH:00966112104666
80

SECTION-03.08
HQ - CHILLERS
SPARE PARTS
81
SECTION 03.08 HQ – CHILLERS – SPARE PARTS
SN DESCRIPTION MODEL UNIT QTY

1 HELIOROTOR COMPRESSOR CHHWEN6DKD0N134A2 N 1
2 CONDESER FAN 45057 N 2
82

SECTION-03.09
HQ - CHILLERS
WARANATY CERTIFICATE
83
84
85
86

SECTION-04
CHILLED WATER PUMPS
87

SECTION-04
CHILLED WATER PUMPS

SECTION 04.05 Equipment Schedule.
SECTION 04.06 Control And Wiring Diagrams.
SECTION 04.08 Warranty Certificate
88

SECTION-04.01
HQ - CHILLED WATER PUMPS
89
SECTION 03.01 HQ – CHILLED WATER PUMP - DESCRPITION AND MODEL

The Primary chilled water pumps are five split coupled vertical inline,
Armstrong 4300 series with dimensions 6x6x8, while the secondary chilled water
pumps are three split coupled vertical inline, Armstrong 4300 series with
dimensions 8x8x10.
Armstrong 4300 Series has the greatest floor space savings result when
Vertical In-Line pumps are installed with Suction Guides and Flo-Trex valves.
Equivalent base mounted horizontal split case pumps may take 3 times more
floor space.
Vertical In-Line pumps, being integral components of the pipework, eliminate
need for inertia bases, inertia base
springs, flexible pipe connectors, field grouting and alignment. Pipe hangers, sized
for the weight of pump, piping and
fittings, are the only supports required. Pipe stools, with vibration isolating pads,
may be installed under each pipe leg.
The mechanical seal is the critical service item in any pump. Removal of the 4300
Series split spacer coupling
90
allows all mechanical seal components to be withdrawn for servicing, through the
resulting space between pump and
motor shafts, without disturbing other pump components or motor connection.
Re-installing the rigid coupling brings the unit rotating assembly back to factory
alignment specifications.
91

SECTION-04.02
NAME PLATE DATA
92
TAG PCHWP 1704 C/0-USA
MODEL 4300 SIZE 6X6X8
SERIAL NO 1019064042 IMP DIA 7.853”
CAPACITY 792.52 GPM 4.57 FT.HD
MOTOR 15 HP 1800 RPM
TAG SCHWP -1T02 C/0-USA
MODEL 4300 SIZE 8X8X10
SERIAL NO 1019064047 IMP DIA 9.677”
CAPACITY 1268.03 GPM 7.62 FT.HD
MOTOR 50 HP 1800 RPM
93

SECTION-04.03
GENERAL CATALOGUE
94
4300 Series
VERTICAL IN-LINE Pumps

FILE NO: 2-1
DATE: July 2010
SUPERSEDES: 2-1
DATE: December 2004
95

SECTION-04.04
96
Design Envelope
4300 & 4380
Vertical in-line pumping
unit with integrated
controls
Installation and
operating instructions
File No: 94.81 eu
Date: september 12, 2017
Supersedes: 94.81 eu
Date: may 10, 2017
Downloaded from www.Manualslib.com manuals search engine 97

contents
1.0 Introduction 4
1.1 Instructions for safe use 4
1. 2 Temperature 4
1.3 Noise levels 4
1. 4 Vibration levels 5
1.5 Storage 5
1.6 Uncrating 5
1.7 Handling Design Envelope
4300 & 4380 units 5
2 .0 Installation 6
2 .1 Location 6
2 . 2 Installation 6
2 .3 Pump piping – general 7
2 . 4 Alignment 8
2 .5 Starting pump 8
2 .6 General care 8
2 .7 Lubrication 9
2 . 8 System cleanliness 9
3 .0 ce conformities 13
4 .0 Mechanical installation 13
4 .1 Enclosure rating 13
4 . 2 Ambient temperature 13
5 .0 Electrical installation 13
5 .1 Earth leakage current 14
5 . 2 Earth leakage current 14
5 .3 Additional motor protection 14
5 . 4 Supply voltage 14
5 .5 Tools for installation 14
5 .6 Cable entry sizes 14
5 .7 Max. cable cross section 14
5 . 8 Mains supply connection 15
5 .9 Max. cable cross section 15

5 .9 .1 Connection examples 16 11. 4 Supply voltage 33
6.0 Programming, monitoring 11.5 Supply fusing 34
and diagnostics 17 11.6 Grounding and it mains 34
6.1 lcp functions and operation 18 11.7 Relay connections 35
6.1.1 Display 18 11. 8 Electrical installation and
6.1. 2 led's 18 control connections 37
6.1.3 Control keys 18 11. 8 .1 Access to terminals 38
6.1. 4 Display mode 19 11. 8 . 2 Control terminals 38
6.1.5 Quick menu 20 11. 8 .3 Connection examples 39
6.1.6 Menu mode 20 11. 8 . 4 Remote lcp
7.0 Sensorless operation 23 keypad wiring 40
7.1 Default operating mode - 12 .0 Programming, monitoring
quadratic pressure control 23 and diagnostics 41
7.1.1 Description of settings 23 12 .1 glcp functions and operation 41
7.1. 2 setting parameters for 12 . 2 Indicator lights (leds) 42
quadratic pressure 12 .3 Control keys 42
control 23 12 . 4 Programming 43
7. 2 Constant pressure control 23 12 . 4 .1 Parameter selection 43
7. 2 .1 Setting parameters 12 . 4 . 2 Changing data 44
for constant
13 .0 Sensorless operation 44
pressure control 24
13 .1 Default operating mode —
7.3 Proportional pressure control 2 4
quadratic pressure control 44
7.1.1 Setting parameters
13 .1.1 Settings for quadratic
for proportional
(control curve)
pressure control 24
pressure control 45
8 .0 Control using external feedback 24
13 . 2 Constant pressure control 45
8 .1 Parameter groups and
13 . 2 .1 Settings for constant
descriptions. 24
pressure control 45
9 .0 Warnings and alarms 29
13 .3 Changing control modes 45
9 .1 Internal led descriptions 30
13 .3 .1 Change to external
10.0 Integrated controls 33 sensor control 45
10.1 Enclosure rating 33 13 .3 . 2 Change to open loop
10. 2 Ambient temperature 33 (bas) control 46
11.0 Electrical installation 33 13 .3 .3 Change to sensorless
11.1 Ground leakage current 33 control 46
11. 2 Start / stop of pump 33 14 .0 Warnings and alarms 46
11.3 Additional motor protection 33 14 .1 Fault messages 47
15 .0 Acoustic noise and vibration 49

i nstallati on & Design Envelope 4300 and 4380 vertical in-line
op erat ing instru ction s pumping unit with integrated controls
1.0 introduction 1. 2 temper ature
This document contains specific information regarding the Install the Design Envelope unit with adequate access
safe installation, operating and maintenance of the Armstrong for routine maintenance. Adequate space, particularly
Design Envelope pumps and should be read and understood by at the fan inlet 2" (50 mm), is necessary to facilitate
installing, operating and maintenance personnel. The equipment airflow. Where several Design Envelope units are installed in
supplied has been designed and constructed to be safe and close proximity, care must be taken to ensure that there is no
without risk to health and safety when properly installed, oper- re-circulation of exhausted warm air.
ated and maintained. The instructions following must be strictly
Where under normal operating conditions the limit of
adhered to. If clarification is needed on any point please contact
68°c/155°f (Restricted Zone) for normal touch, or 80°c/176°f
Armstrong quoting the equipment serial number.
(Unrestricted Zone) for unintentional touch, may be experi-
enced, steps should be taken to minimize contact or warn opera-
tors/users that normal operating conditions will be exceeded.
1.1 instructions for safe use
In certain cases where the temperature of the pumped liquid
No installation of this equipment should take place exceeds the above stated temperature levels, pump casing tem-
unless this document has been studied and under- peratures may exceed 100°c/212°f and not withstanding pump
stood. Handling, transportation and installation of this insulation techniques appropriate measures must be taken to
equipment should only undertaken by trained personnel with minimize risk for operating personnel. The ambient temperature
proper use of lifting equipment. See later diagrams for lifting ad- for standard motors must be no greater than 40°c/104°f.
vice. Refer to the pump nameplate for pump speed, pressure and
temperature limitations. The limits stated must not be exceeded
without written permission from Armstrong.
1.3 noise levels

Typical Pumping Unit Sound Pressure Level, Decibels, A-Weighted, at 1 m (3 ft.) from unit.
1500 rpm 3000 rpm

frame fcm tefc fcm tefc
designation kW db-a kW db-a kW db-a kW db-a
80 0.55-0.75 55 0.55-0.75 47 0.55-0.75 55 0.55-1.1 58

90 1.1-1.5 60 1.1-1.5 49 1.1-1.5 60 1.5-2.2 62
100 2.2 59 2.2 53 2.2 59
100 3 62 3 53 3 62 3 64
112 4 64 4 54 4 63 4 66
132 5.5-7.5 62 5.5-7.5 60 5.5-7.5 62 5.5-7.5 69
160 11-15 63 11-18.5 74
180 18.5-22 65 22 75
200 30 65 30-37 78
225 37-45 66 45 78
250 55 67 55 81
280 75-90 70 75-90 81
315 110-132 78 110-132 82
315 160-200 83 160-200 86
355 250-315 85 250-315 89

Design Envelope 4300 and 4380 vertical in-line i nsta l l a t io n &
pumping unit with integrated controls oper a ti ng instr u cti o n s
1. 4 vibr ation levels
Armstrong Vertical In-Line pumps are designed to meet vibra-

tion levels set by Hydraulic Institute Standard hi Pump Vibration
9.6.4. Standard levels are as detailed below:
0.28
v ibr a tion – mm /sec r m s , unfilter e d
0.24 7.11 a
vibration – mm/sec rms, unfiltered

0.20 6.10
0.16 5.08
x y
0.12 4.06
0.08 3.04
0.04 2.03
0 1.01
1 10 100 1000
0
i npu t p ower @ test co nd ition s– b hp 0.75 7.5 75 750 vertical in - line
i n p u t p ow er @ test co n d i t i o n s – k w
1.5 stor age 1.7 handling design envelope 4300 & 4380 units
Pumps not immediately placed into service, or removed from To handle Design Envelope 4300 and 4380 units from shipment,
service and stored, must be properly prepared to prevent exces- secure the pallet following uncovering the unit, then place straps
sive rusting. Pump port protection plates must not be removed behind the integrated controls (around the motor feet) and
until the pump is ready to connect to the piping. carefully lift the pumping unit to stand the pump vertically up-
right. Lift only sufficiently to remove the pallet, then lower onto a
Rotate the shaft periodically (at least monthly) to keep rotating
flat surface. The pump and motor unit will free-stand on the cas-
element free and bearings fully functional.
ing ribs. Extra care is required to ensure the integrated controls
For long term storage (longer than three months), the pump do not get damaged during lifting and installation.
must be placed in a vertical position in a dry environment.
Internal rusting can be prevented by removing the plugs at the
top and bottom of the casing and drain or air blow out all water
to prevent rust buildup or the possibility of freezing. Be sure to
reinstall the plugs when the unit is made operational. Rustproof-
ing or packing the casing with moisture absorbing material and
covering the flanges is acceptable. When returning to service be
sure to remove the drying agent from the pump.
1.6 uncr ating
Armstrong Vertical In-Line pumps are thoroughly inspected be-

For Design Envelope 4300 units, remove the coupling guard and
fore shipment to assure they meet with your order requirements.
insert lifting straps through the pump/motor pedestal on either
After removing the pump from the crate, make sure the equip-
side of the coupling. For Design Envelope 4380 units, remove
ment is in good order and that all components are received as
the motor eye-bolt and install a swivel hoist ring tied to a lifting
called for on the packing list. Any shortages or damage should
strap. Place secondary lifting straps around the motor feet (and/
be reported immediately. Use extreme care in handling the
or spacers). As the lifting device is engaged (Using a spacer bar
unit, placing slings and hooks carefully so that stress will not be
if necessary) and the straps tighten ensure no part of the strap-
imposed on the integrated controls, pump or motor. Never place
ping is touching any part of the control or motor fan cover. Lift
cable slings around the pump shaft or integrated controls. The
the pumping unit carefully from the pallet in this manner and al-
eye bolts or lifting lugs on the motor are intended for lifting only
low the unit to stand upright on a flat surface and re-position the
the motor and not the complete unit.
straps, if necessary, to ensure safe and damage-free transporta-
tion into the pipe installation.

2 . 2 installation
When installing vertical in-line pumps, an important consider-

ation to accrue full added-value from the pump design is to en-
sure that the pump is pipe-mounted and free to ‘float’ with any
movement, expansion and contraction of the piping. Should any
vertical in-line pump use supports to the structure it is impera-
tive that no pipe strain is imposed on the pump flanges. Tell-tale
pieces of equipment such as springs or ‘waffle’ style neoprene
4300 4380
isolation pads that distort with pressure to indicate added piping
weight, should be used under pump supports should the pump
not be truly pipe mounted.
Remove coupling guard Remove the motor eye-bolt
and place lifting straps on and install a swivel hoist Design Envelope 4300 and 4380 cannot be mounted with shafts
each side of coupling, use ring tied to a lifting strap. in the horizontal position.
spacer bar if necessary to Place secondary lifting
protect the integrated con- straps securely around mo- Various installation arrangements are detailed on Pages 9–12
trols and motor fan cover. tor feet (and/or spacers). All Design Envelope 4300 pumps contain a tapped hole in the
motor bracket above the discharge flange to drain condensate
important: buildup of seal leakage. (fig. 2.14)
Do not run the pump for any length of time under very 2.2.1
low flow conditions or with the discharge valve closed. Vertical In-Line pumps may be installed directly in the system
To do so could cause the water in the casing to reach piping with no additional support. Pipe hangers are simply sized
super heated steam conditions and will cause premature failure for the additional weight of the pumping unit. Many pumps are
and could cause serious and dramatic damage to the pump and installed in this manner and can be mounted at sufficient height
surrounding area. to take zero floor space. (fig. 2.1)
2.2.2
2.0 installation Piping in many mechanical rooms is hung close to the ceiling
and larger pumps are mounted near ground level for ease of
2 .1 location maintenance. fig. 2.2 illustrates such an arrangement with the
piping supported at the ceiling and the vil unit installed with an
In open systems, locate the unit as close as practical to the Armstrong Suction Guide and Flo-Trex valve. Many very large
liquid being pumped, with a short, direct suction pipe. Ensure vil pumps are installed in this manner.
adequate space is left above and around the unit for operation,
maintenance, service and inspection of parts. 2.2.3
Should additional space saving be required the discharge spool
In closed systems, where possible, the pumps should be in-
piece may be replaced by a long-radius elbow.
stalled immediately downstream of the expansion tank /make-
up connection. This is the point of zero pressure change and is
2.2.4
necessary for effective pump operation. Do not install more than
fig 2.4 illustrates a similar arrangement to fig 2.2 with
one expansion tank connection into any closed hydronic system.
additional floor mounted pipe-stools isolated from the structure
Electric motor driven pumps should not be located in damp or
by ‘waffle’ style neoprene isolation pads under the Armstrong
dusty location without special protection.
Suction Guide and Flo-Trex valve.
Airflow into the motor and/or motor fan should not
be obstructed. 2.2.5
Floor mounted saddle supports (fig. 2.5) are typical for condens-
er water pumps where cooling tower base is at the mechanical
room elevation.
2.2.6
Where required, additional floor support may be used as shown
in Fig. 2.6. Note that the pump should not be rigidly attached to
the column. Leave a small gap between pump and column or
install a ‘waffle’ isolation pad under the pump. It is critical that
piping be installed in such a manner that the pump does not
become a pipe support.

2.2.7
fig. 2.7 illustrates stanchion plates at the pump inlet and outlet important:
ports that may be supplied for installation convenience. Isolation
pads must be used under the legs and monitored as pipe hang- All Design Envelope 4300 pumps contain a tapped hole in the
ers are adjusted to ensure the pump flanges are not support- motor bracket above the discharge flange (see fig. 2.14) for
ing the piping. Bolting to the floor or housekeeping pad is not draining the well. Pipe this drain hole to a floor drain to avoid
recommended. If the stanchions are bolted down the bolts must overflow of the cavity caused by collecting chilled water conden-
be isolated from the stanchion or an inertia base and flexible sate or from seal failure.
pipe connectors used.
2 .3 pump piping – gener al
2.2.8
fig. 2.8 illustrates installations with stanchion plates for seismi- Never connect a pump to piping, unless extra care is taken to
cally active regions. Seismically rated isolation pads or snubbers measure and align the piping flanges well. Always start piping
with bolts isolated from the stanchion plates are installed to from pump.
restrain the pump during a seismic event. Pipe hangers carry the
weight of the equipment as seismic components are designed Use as few bends as possible and preferably long radius elbows.
only to restrain the equipment during a seismic event. Do not use flexible connectors on the suction or discharge of a
vertical in-line pump, unless the pump is rigidly mounted to a
2.2.9 foundation.
Many Vertical In-Line pumps are piped successfully into Ensure piping exerts no strain on pump as this could distort
grooved piping systems. In-line pumps are supported well by the casing causing breakage or early failure due to pump
grooved piping however flange adapter locking devices or a misalignment.
welded flange at the pump should be used to prevent the pos-
sibility of pipe mounted pumps rotating in the piping. Armstrong All conecting pipe flanges must be square to the pipework and
offers grooved suction guides with cast-in outlet flanges and parallel to the pump flanges.
Flo-Trex valves with Armgrip™ fittings to prevent this Suction and discharge pipes may be increased or decreased at
possibility. (fig. 2.9) pump nozzle to suit pump capacity and particular conditions of
installation. Use eccentric reducers on suction connection with
2.2.10 flat side uppermost.
Do not support the unit by the motor eye bolts (fig. 2.10) or by
any other part of the motor. Layout the suction line with a continual rise towards the pump
without high points, thus eliminating possibility of air pockets
2.2.11 that may prevent the pump from operating effectively.
Connecting the pump to a permanent rigid base (fig. 2.11) is not A strainer of three or four times the area of the suction pipe,
recommended unless isolated from the piping by flexible con- installed in the suction line, will prevent the entrance of foreign
nectors and the base isolated from the building structure on an materials into the pump. V" (3 mm) diameter perforations in the
inertia base. (fig. 2.11 is generally acceptable when using strainer is typical.
plastic piping).
In open systems, test suction line for air leaks before starting;
2.2.12 this becomes essential with long suction line or static lift.
The motor and integrated control assembly can be rotated in Install, at the pump suction, a straight pipe of a length equiva-
90° increments to meet installation spacing requirements. lent to four or six times its diameter; this becomes essential
Where applicable, remove the coupling guard to access the when handling liquids above 120°f (49°c). Armstrong suction
motor bolts. Remove the motor bolts to rotate the motor and guides may be used in place of the straight pipe run and
integrated control assembly by hand. Larger motors may need in-line strainer.
strapping and slight lifting to break the contact with the ped-
estal. Care should be taken that the controls are not damaged Install an isolation valve in both suction and discharge lines on
during lifting and that the flushline, flushline accessories and the flooded suction application; these valves are used primarily to
coupling guard removal/seal service window are not compro- isolate the pump for inspection or repair.
mised following the turn (fig. 2.12). vil pumping units without Install a non-slam non-return check valve in discharge line
integrated controls can also be rotated in a similar manner to between pump and isolation valve to protect pump
facilitate access to the the motor terminal box. from excessive back pressure and to prevent water running back
through the pump in case of driver failure on open systems.
2.2.13
For d1 and d2 chassis Design Envelope units (110 kW–315 kW),
ensure adequate space is available for the access door to swing
open. (fig. 2.13)

2 . 4 alignment Do not run the pump against a closed discharge valve for an
extended period of time (a few minutes maximum.)
Design Envelope 4300 units are accurately aligned at the fac-
Should the pump be noisy or vibrate on start-up a common
tory prior to being shipped and do not need re-aligning when
reason is overstated system head. Check this by calculating the
installed. Alignment on a Design Envelope 4300 unit may be
pump operating head by deducting the suction pressure gauge
verified by assuring an equal and parallel gap between coupling
value from the discharge gauge reading. Convert the result into
halves on both sides of the coupling.
the units of the pump head as stated on the pump nameplate
and compare the values. The system designer or operator
should be made aware of this soon as some adjustment may be
oper ation
required to the drive settings to make the pump suitable for the
system as installed.
2 .5 starting pump
Check rotation arrow prior to operating the unit.
Ensure that the pump turns freely by hand, or with The rotation of all Armstrong Vertical In-Line units is
some gentle mechanical help such as a strap or Allen “clockwise” when viewed from the drive end.
key in coupling bolt. (Looking from on top of/behind the motor).
Ensure that all protective guarding is securely fixed in position.

2 .6 gener al care
The pump must be fully primed on start up. Fill the pump
casing with liquid and rotate the shaft by hand to remove any Vertical In-Line pumps are built to operate without periodic
air trapped in the impeller. On Design Envelope 4300 any air maintenance, other than motor lubrication on larger units. A
trapped in the casing as the system is filled must be removed by systematic inspection made at regular intervals, will ensure
the manual air vent in the seal flush line. Ensure entrained air is years of trouble-free operation, giving special attention to
removed from Design Envelope 4300 pumps, prior to starting, the following:
through the air vent on the seal flush line. Open vent until clear
of air. • Keep unit clean
Design Envelope 4380 units are fitted with seal flush/vent lines • Provide the motor with correctly sized overload protection
piped to the pump suction area. When these units operate, Keep moisture, refuse, dust or other loose particles away from
residual air is drawn out of the pump towards the suction piping. the pump and ventilating openings of the motor.
• Avoid operating the unit in overheated surroundings
(Above 100°f/40°c).
warning:
Whenever any service work is to be performed on
a pumping unit, disconnect the power source to the
driver, lock it off and tag with the reason. Any
possibility of the unit starting while being serviced
must be eliminated.
If mechanical seal environmental accessories are

installed, ensure water is flowing through the sight
flow indicator and that filter cartridges are replaced
Bump or energize the motor momentarily and check that the as recommended. (See Armstrong files 43.85 and
rotation corresponds with the directional arrow on the pump 43.86 for seal environmental instructions).
casing (clockwise when viewed from drive end.).
Start the pump with the discharge valve closed and the suction
valve open, then gradually open the discharge valve when the
motor is at operating speed. The discharge valve may be
cracked or open slightly at start up to help eliminate trapped air.
When stopping the pump: Close the discharge valve and de-
energize the motor.

2 .7 lubrication 2 .8 system cleanliness
Pump Before starting the pump the system must be thoroughly

Lubrication is not required. There are no bearings in the pump cleaned, flushed and drained and replenished with clean liquid.
that need external lubrication service.
Welding slag and other foreign materials, ‘Stop Leak’ and clean-
Large Design Envelope 4300 units are installed with a shaft ing compounds and improper or excessive water treatment are
bushing located beneath the impeller that is lubricated from the all detrimental to the pump internals and sealing arrangement.
pump discharge.
Proper operation cannot be guaranteed if the above conditions
are not adhered to.
Motor
Follow the lubrication procedures recommended by the mo-
note:
tor manufacturer. Many small and medium sized motors are
Particular care must be taken to check the following before the
permanently lubricated and need no added lubrication. Gener-
pump is put into operation:
ally if there are grease fittings evident the motor needs periodic
lubrication. None if not.
a Pump primed?
Check the lubrication instructions supplied with the motor for b Rotation OK?
the particular frame size indicated on the motor nameplate. c Lubrication OK?
d Pipe work properly supported?
Mechanical Seal e Voltage supply OK?
The mechanical seal is fitted with a flush line. The seal is flushed f Overload protection OK?
from discharge of the pump casing on Design Envelope 4300 g Is the system clean?
pumps and from the suction on Design Envelope 4380 pumps. h Is the area around the pump clean?
The Design Envelope 4300 pump is flushed from the pump
warr ant y
discharge because the mechanical seal chamber is isolated from
Does not cover any damages to the equipment resulting from
the liquid in the pump by a throttle bushing. Because the seal
failure to observe the above precautions. Refer to Armstrong
chamber is isolated, seal environmental controls such as filters
General Terms and Warranty sheet. Contact your local
and separators, when installed in the Design Envelope 4300
Armstrong representative for full information.
flush line are very effective, as only the seal chamber needs
cleansing, and will prolong seal life in hvac systems.
Do not run the pump unless properly filled with water as the
mechanical seals need a film of liquid between the faces for
proper operation.
Mechanical seals may ‘weep’ slightly at start-up. Allow the
pump to continue operating for several hours and the mechani-
cal seal to ‘seat’ properly prior to calling for service personnel.
The following Armstrong files are available for mechanical seal
replacement instructions:
• Series 4300: tc Motor Frame – File 43.88
• Series 4380: File 43.81

10
fig. 2.1 Hanger supported pipe mounted fig . 2 .3 Discharge elbow for minimum footprint
Hangers support the weight

Pipe hanger (typ.)
of the filled piping, pumps
See specification
and fittings
for size and type
System inlet System outlet
Split coupler
Flush line
Flo-Trex valve
Recommended field
pressure gauge piping
arrangement
Suction guide
Drain connection
Fig. 2.3 Discharge elbow for minimum footprint

Fig. 2.4 With a
fig . 2 . 2 Pipe mounted supported at ceiling fig . 2 . 4 With additional pipe supports
Hangers support the weight Pipe hanger (typ.)

Hangers support the weight Pipe hanger (typ.) of the filled piping, pumps See specification
of the filled piping, pumps See specification and fittings for size and type
and fittings for size and type

Split
Split coupler
coupler
Recommended field
Recommended field pressure gauge piping Flush line
pressure gauge piping Flush line arrangement
Flo-Trex valve
arrangement
Flo-Trex valve Suction Pet cock
Suction Pet cock guide (typ.)
guide (typ.)
Fig. 2.5 Floor saddle support

Pipe support
2" or 3"
2' or 3' Neoprene height above Fig. 2.6 Additi
height above isolation pad Drain connection finished floor
Drain connection finished floor
Fig. 2.3 Discharge elbow for minimum footprint
Fig. 2.4 With additional pipe supports
Fig. 2.7 With stanchion plates
Fig. 2.5 Floor saddle support Fig. 2.8 Seism
Fig. 2.6 Additional floor support
Downloaded from www.Manualslib.com manuals search engine Page 7 of 26 106

11
fig . 2 .5 Floor saddle support fig . 2 .7 With stanchion plates

Fig. 2.3 Discharge elbow for minimum footprint Fig. 2.5 Floor saddle support
Fig. 2.3 Discharge elbow for minimum footprint Fig. 2.6
Flo-Trex valve
Stanchion plates
Isolation pads
Fig. 2.5 Floor saddle support
Fig. 2.5 Floor saddle support Fig. 2.72.6
print fig . 2 .6 Additional floor support Fig. With stanchion
Additional plates
floor support
fig . 2 . 8 Seismic region installation
Fig. 2.4 With additional pipe supports Fig. 2.6 Additional floor support Fig. 2.8
Page 7 of 26
gap Stanchion
Seismically Rated Snubbers or plates
Pads and Concrete Foundation
Fig. 2.7 With stanchion plates Seismically
SeismicallyRated Snubbersoror
rated snubbers
Pads and Concrete Foundation
Fig. 2.7 With stanchion plates pads and concrete foundation
Fig. 2.6 Additional floor support Fig. 2.8 Seismic region installation
Fig. 2.8 Seismic region installation
fig . 2 .9 Mounting in grooved pipe systems
Page 7 of 26
Hangers support the weight Pipe hanger (typ.)
of the filled piping, pumps See specification
Page 7 of 26
and fittings for size and type

Gruvlok 7000 flex
7700 butterfly valve Split coupling (typ.)
coupler
Recommended field
Flush line
pressure gauge piping
arrangement Flo-Trex valve
Seismically Rated Snubbers or Pet cock
Pads and Concrete Foundation (typ.)
Suction
guide
Fig. 2.8 Seismic region installation
Drain connection
Fig. 2.10 Motor lifting hook supporte
Fig. 2.9 Mounting in grooved pipe systems
12
fig . 2 .10 Motor lifting hook supported fig . 2 .13 Clearance radius for d size chassis
Fig. 2.10 Motor lifting hook supported

29.5"typ
15.7
15.7
(399)
(399)
≤105,0°
20.7
(526)
Fig. 2.10 Motor lifting hook supported
Fig. 2.12 Motor and integrated controls assembly can be

rotated in 90° increments to meet installation spacing
fig . 2 .11 Mounted on rigid base without fig . 2 .14
requirements.Tapped collection well on series
43 0 0
Fig. 2.11 Mounted on rigid base without flexible connectors
flexible connectors Fig. 2.10 Motor lifting hook supported
29.50” (749)
Typical
45°
Series 4300 seal leaks or
15.70” condensate drain hole. Plumb to
(399) drain for area cleanliness.
Fig. 2.12 Motor and integrated controls assembly can be ≤105°

20.70”
requirements. (526)

Fig. 2.11 Mounted on rigid base without flexible connectors requirements.
Fig. 2.13 Clearance radius for D size chassis Fig. 2.14 Tapped collection well on Series 4300
fig . 2 .12 Motor and integrated controls assembly can be

rotated in 9 0° increments to meet
Fig. 2.10 Motor liftinginstallation spacing
hook supported Page 8 of 26
29.50” (749)
requirements Typical
45°
15.70”
(399)
≤105°
20.70”
Fig. 2.14 Tapped collection well on Series 4300 (526)
of 26
connectors Fig. 2.13 Clearance radius for D size chassis
requirements. Fig. 2.14 Tapped collection well on Series 4300
Page 8 of 26
Downloaded
(749) from www.Manualslib.com manuals search engine 108
13
3 .0 ce conformities 4 .0 mechanical installation

For Declaration of Conformity certificates please Install the Design Envelope unit with adequate access for routine
contact Armstrong. maintenance. Adequate space, particularly at the fan inlet (50
mm), is necessary to facilitate airflow. Where several Design En-
The Design Envelope product conforms to the requirements
velope units are installed in close proximity, care must be taken
in the following directive(s), standard(s) or other normative
to ensure that there is no re-circulation of exhausted warm air.
document(s):
With reference to fig. 3, the pump should not be
installed with the inverter in the underside position.
low voltage directive 2006/95/ec
This guidance pertains to all pump types and
emc directive 2004/108/ec
overrides any instruction in the particular pump
machinery directive 2006/42/ec
Installation, Operation and Maintenance Instruction.
ecodesign directive 2009/125/ec
fig. 3 Allowable Installation Orientation - On-board Inverter Position
integr ated controls 5 .0 electrical installation

Power Rating 0.55 kW - 7.5 kW All electrical connections should be carried out by a
qualified and authorised electrician in accordance with
local site regulations and the latest issue of the
4 .1 enclosure r ating iee regulations.
The standard enclosure rating for Design Envelope
pumps is ip55. If the pump is to be installed in a wet or safety, risk of death
dusty environment then a higher enclosure rating may
be required (ip56 or ip66 option). Before removing the inverter cover, the system must
be disconnected from the mains supply. After switch-
ing off wait for at least five minutes for the capacitors
4 . 2 ambient temper ature to discharge before opening the cover.
To avoid the inverter unit getting overheated, the

ambient temperature is not to exceed 40°c and the 24
hour average temperature is not to exceed 35°c. If the
ambient temperature is in the range of 40°c - 55°c, a
reduction of the service life of the inverter part is to be expected.

14
caution 5 .3 additional motor protection
High voltage testing (Megging) of the motor / inverter With the exception of supply fuses / mcb’s to protect the
may cause damage to the electronic components and installation, no additional overload or over-temperature
therefore should not be carried out. protection is required. Motor / inverter protection includes:
• Mains phase loss
5 .1 earth leak age current • Over voltage
• Under voltage
Earth leakage current is primarily caused by the ca- • Over current
pacitance between motor phases and the motor frame. • Short circuit
The rfi filter contributes additional leakage current, as • Over temperature
the filter circuit is connected to earth through capacitors.
The size of the leakage current to the ground depends of the 5 . 4 supply voltage
following factors, in order of priority:
The supply voltage details can be found on the motor
1 Switching frequency
nameplate. Please ensure that the motor is suitable for the
2 Motor grounded on site or not
electrical supply on which it is to be used. The mains supply
The leakage current is of importance to safety during handling / for Design Envelope pumps is as follows:
operation of the Design Envelope pump if (by mistake) the
3 × 380/400/415/440/460/480v ±10% Supply
on-board inverter has not been earthed.
frequency - 50/60hz
at tention:
Since the leakage current is >3.5 mA (approx 4 -20 mA), 5 .5 tools for installation
reinforced earthing must be established which is required if en
50178 is to be complied with. Never use elcb relays that are not One cross point screwdriver, one Large screwdriver,
suitable for dc fault currents (type a). one Small screwdriver
If elcb relays are used, they must be:
• Suitable for protecting equipment with a direct current 5 .6 cable entry sizes
content (dc) in the fault current (three-phase bridge rectifier)
0.55kW - 4.0kW: 3 × m20 × 1.5
• Suitable for power-up with short charging current to earth
5.5kW - 7.5kW: 1 × m25 × 1.5, 2 × m20 × 1.5
• Suitable for a high leakage current
One cable entry is factory fitted with a plug kit for external
keypad connection.
5 . 2 earth leak age current
The number of starts / stops via the mains voltage must not 5 .7 ma x. cable cross section
exceed one time per two mins.
Mains cable supply: 4.0mm 2
If a higher number of starts / stops is required then the start/
Control cable: 1.5mm 2
stop digital input must be used (mains voltage directly
connected). This is the preferred method of starting and Serial communication cable: 1.5mm 2
stopping Design Envelope Pumps.
The three phase mains must be isolated before

performing maintenance of the pump.

toronto
23 bertrand avenue
toronto, ontario
canada
m1l 2p3
+1 416 755 2291
buffalo
93 east avenue
north tonawanda, new york
u.s.a.
14120 -6594
+1 716 693 8813
birmingham
heywood wharf, mucklow hill
halesowen, west midlands
united kingdom
b62 8dj
+44 (0) 8444 145 145
manchester
wolverton street
manchester
united kingdom
m11 2et
+44 (0) 8444 145 145
bangalore
#59, first floor, 3rd main
margosa road, malleswaram
bangalore, india
560 003
+91 (0) 80 4906 3555
shanghai
unit 903, 888 north sichuan rd.
hongkou district, shanghai
china
200085
+86 (0) 21 5237 0909
são paulo
rua josé semião rodrigues agostinho,
1370 galpão 6
embu das artes
sao paulo, brazil
+55 11 4781 5500
a r m s t r o n g f lu i d t e c h n o lo g y
established 1934 a r m s t r o n g f lu i d t e c h n o lo g y. c o m
tm


SECTION-04.05
EQUIPMENT SCHEDULE
112
HQ- CHILLED WATER PUMPS SCHEDULE
FLOW TOTAL HEAD POWER DATA ELECTRICAL RATED SPEED
TAG NO. DUTY MAKE MODEL
GPM – LPS KPa-m KW - HP RATING RPM
PCHWP-1 TO 5 4 DUTY SERIES 4300

ARMSTRONG (793) 50 (147) 15 (11) 15 380/3/60 1800
(PRIMARY PUMP) 1 STANDBY SIZE 6X6X8
SCHWP-1 TO 3 2 DUTY SERIES 4300

ARMSTRONG (1,268) 80 (245) 50 (37) 50 380/3/60 1800
(SECONDARY PUMP) 1 STANDBY SIZE 8X8X10
113

SECTION-04.06
CONTROL AND WIRING DIAGRAM
114
15
fig. 4 Inverter Terminal Arrangement
led300
led304
led302
led303
led301
This switch is only used for
serial communications to
bms and should otherwise rs485
be left in the off position. switch
x100 x101
12 3 4 1 2 3 4 5 6 7 8 9
on x102
123
off 1 2
l1 l2 l3
e ar th gro un d vi Remove the middle e gland

arth plugg rou
and feed nd
the control cable
5 .8 mains supply connection
through the hole (see the section on control connections for
i Remove the inverter box cover, which is held by four screws wiring details).
(6 on 5.5 and 7.5 kW units), to obtain access to the terminals.
vii The third entry is fitted with a plug kit to facilitate keypad
ii Remove the detachable terminal plugs from the terminal connection. Do not remove the kit or wiring unless as serial
blocks x100 and x101 to obtain access to the mains terminals. communications link (to bms) is required.
iii Lift only the corner of the black plastic cover by the cable
You cannot change the rotational direction of the
entries to expose the mains terminals l1, l2 and l3.
pump by shifting around the input mains phases. The
DO NOT lift or remove the entire plastic cover. This is direction of rotation is factory set.
part of the inverters protective arrangements.
5 .9 control connections
Mains Terminals L1, L2 and L3 Terminal blocks x100, x101 and x102 are used for control
Make sure that your mains supply corresponds to the connections. Individual terminal allocation is as follows:
voltage required by the Design Envelope unit (see mo-
tor nameplate), tt and tn mains. x100 Terminals
The x100 terminals are used for data communications, either as
iv Remove the gland plug furthest from the drive end of the part of a serial communications network or for connection to the
motor (to the right in fig. 2) and feed the mains cable through cable gland mounted plug kit for key pad connection (Default).
the hole.
v Connect the three mains phases to terminals l1, l2 and l3 and x100 terminal wire color
the earth to the separate terminal provided.
1 2 3 4 1 Yellow
DO NOT over-tighten the mains terminals as this will 2 Green
damage the unit! 3 Red
0.55 - 4.0 kW torque - 0.5 to 0.6 Nm 4 Blue
5.50 - 7.5 kW torque - 1.2 to 1.5 Nm
Earth terminal - 3.4Nm

16
x101 Terminals - Control Terminals i Sensorless Pressure Control - Connection Details

The x101 terminals are used for analogue and digital signals that Design Envelope pumps are factory configured to be
will determine the operation of the pump(see the section on connected as shown below. For a description of sensorless
Control Modes). pressure control please refer to the programming section.
x101 running
com 1
n/o
x102
output 2
1 2 3 4 5 6 7 8 9 n/c 3
yw 1
gn 2
key pad
x100
rd 3
connection
• Terminal 1 - 4-20 mA input for a remote feedback device be 4
(when Sensorless control is not used).
• Terminal 2 - 0-10v input for a reference signal (when
x101
1
Sensorless control is not used). 2
• Terminal 3 - Digital input for a low water device (pump only low water device 3
start signal 4
runs if input is ‘logic 1’) - factory linked with zero ohm resistor
5
to terminal 6. 24vdc
6
• Terminal 4 - Digital input for pump start (pump enabled when 7
‘logic 1’). fault ov
8
• Terminal 5 - Digital input for pump mode (if left at ‘logic 0’ output 24vdc
9
then pump will be in sensorless mode).
• Terminal 6 - 24v dc supply for terminals 3 to 5 (max 150 mA). L1
3 phase + L2
• Terminal 7 - 10v dc supply for terminal 2 when used with a earth supply L3
potentiometer (max 15 mA).
PE
• Terminal 8 - 0v for terminals 1 to 7 and 9.
• Terminal 9 - Digital output for ‘pump fault’ connection to bms
(voltage level will be 24v dc when pump has a fault). ii Full speed overide
It may be required to run the pump at full speed without
at tention: automatic speed control (e.g. during system commissioning).
Terminal 9 is not a volt-free contact. Connection of an external This can be achieved without programming changes by
voltage will destroy the unit. making the control connections shown below.
x102 Terminals - Pump Running com 1

The x102 terminals provide a relay changeover contact for running n/o
x102
identification of pump running.

output n/c
2
3
yw 1
Terminals 1 - 2 will be made when the pump is running. gn
key pad 2
x100
Voltage level at contact/load (ac) 250v ac, 5a Voltage level rd 3

connection be
at contact/load (dc) 30v dc, 5a; 40v dc, 2a; 100v dc, 0.5a 4
1
x101
max speed referench 2

low water device 3
start signal 4
sensorless off 5
x102 24vdc 6
1 2 3 ov
7
fault 8
output 24vdc 9
L1
3 phase + L2
earth supply L3
5 .9 .1 connection ex amples PE
There are many ways that an Design Envelope pump can be

configured. The following is some examples of the most
common control configurations.

17
iii Constant curve mode - bms speed control iv Constant curve mode - Potentiometer speed control
Where the Building Management System is to be used for If a potentiometer is to be installed for manual control of
speed control it is necessary to disable sensorless control pump speed then the control connections will be as follows:
and provide the unit with a 0 - 10v dc speed reference signal.
com 1
com running n/o
x102
running 1 output 2
n/o n/c
x102
output 2 3
n/c 3 yw 1
yw 1 gn
key pad 2
x100
gn 2 rd
key pad
x100
connection 3
rd 3 be
connection 4
be 4
0v
x101
1
+0-10v
speed reference +0-10v
1
x101 2
2
low water device 3
low water device 3
start signal 4 start signal 4
sensorless off sensorless off 5
24vdc
5 24vdc
6 6
1-5 kΩ 10v 7
0v
7
fault 0v
fault 8 8
output 24vdc output 24vdc
9 9
L1 L1
3 phase + L2 3 phase + L2
earth supply L3 earth supply L3
PE PE
The recommended minimum speed for Design

As shown above, in Constant curve mode the pump will speed Envelope pumps is 580 rpm. Running for long periods
up and slow down according to the voltage level of the reference below this speed can damage the mechanical seal.
signal. On a unit configured for 50 hz pump speed the reference
signal is scaled (by default) so that 0v on x100 terminal 2 will
equate to 0 hz and 10v will equate to 50 hz. 6.0 progr amming, monitoring
and diagnostics
1450 rpm
120 51
62
1388 rpm 71
77
led300
led304
led302
100
led303
led301
81
1270 rpm
82
81 rs485
head kpa
80 1150 rpm
1040 rpm
77
switch
60 71
920 rpm x100 x101
12 3 4 1 2 3 4 5 6 7 8 9
40 801 rpm
750 rpm x102
123
20
580 rpm
l1 l2 l3
0
0 10 20 30 40 50 60 70 80
water, spgr= 1.0000 flow – L/s
A key pad tool (lcp) is available for Design Envelope Pumps as

an option. The lcp gives the user full programming and monitor-
ing capabilities and it is recommended that at least one lcp and
cable kit are purchased for each installation site.
The lcp is connected via a cable to the ‘plug kit’ mounted in one
of the inverter cable entries as shown above.

18
6.1 lcp functions and oper ation 1st line shows up to 3 measurements continuously in normal
operating status or a text which explains the 2nd line.
2nd line shows a measurement with related unit continuously,
regardless of status (except in the case of alarm/warning).
3rd line is normally blank and is used in the menu mode to show
the selected parameter number or parameter group number
and name.
4th line is used in operating status for showing a status text or
in data change mode for showing the value of the selected
parameter.
An arrow indicates the direction of rotation of the pump

(factory set). Furthermore, the Setup which has been
selected as the Active Setup in parameter 004 is shown.
When programming another Setup than the Active
Setup, the number of the Setup which is being programmed will
appear to the right. This second Setup number will flash.
6.1. 2 led's
At the bottom of the control panel is a red alarm led and a

red yellow green
The functions of the control panel can be divided into
three groups:
yellow warning led, as well as a green voltage led.
• Display If certain threshold values are exceeded, the alarm and/or

• Keys for changing program parameters warning lamp lights up together with a status and alarm text on
• Keys for local operation the control panel. The voltage led is activated when the Design
Envelope Pump receives voltage; at the same time the rear
All data is indicated by means of a 4 -line alphanumeric display, lighting of the display will be on.
which in normal operation is able show 4 measurements and 3
operating conditions continuously. During programming, all the
6.1.3 control keys
information required for quick, effective parameter Setup of the
Design Envelope Pump will be displayed. As a supplement to the The control keys are divided into functions. This means that
display, there are three leds for voltage, warning and alarm. the keys between display and indicator leds are used for
All program parameters of the Design Envelope Pump can be parameter Setup, including choice of display indication during
changed immediately from the control panel, unless this normal operation.
function has been blocked via parameter 018.
6.1.1 display
The lcd-display has rear lighting and a total of 4 alpha -

numeric lines together with a box that shows the direction of
rotation (arrow) and the chosen Setup as well as the Setup in
which programming is taking place if that is the case.
1st line
2nd line
Keys for local control are found under the indicator leds.
3rd line
4th line

19
Control key functions 6.1. 4 display mode

[display / status] is used for selecting the mode of
display or for changing back to Display mode from In normal operation, up to 4 different operating variables can be
either the Quick menu mode or the Menu mode. indicated continuously: 1,1 and 1,2 and 1,3 and 2, and in line 4 the
present operating status or alarms and warnings that have arisen.
[quick menu] is used for programming the param-
eters that belong under the Quick menu mode. It
is possible to switch directly between Quick menu
mode and Menu mode.
[menu] is used for programming all parameters. It is

possible to switch directly between Menu mode and
Quick menu mode.
[change data] is used for changing the parameter

selected either in the Menu mode or the Quick
menu mode.
There are three options in connection with the choice of read
[cancel] is used if a change of the selected -out state in the Display mode - I, II and III. The choice of read-
parameter is not to be carried out. out state determines the number of operating variables read out.
read-out
i ii iii
[ok] is used for confirming a change of the state:
parameter selected. Line 1 Description for Data value for 3 Description
operating vari- operating vari- for 3 operating
able in line 2 ables in line 1 variables in line 1
[+/-] is used for selecting parameter and for

changing the chosen parameter or for changing the The table below gives the units linked to the variables in the first
read out in line 2. and second line of the display (see parameter 009).
[<>] is used for selecting group and to move the operating variable unit
cursor when changing numerical parameters. Reference [%]
Reference [unit]*
[stop / reset] is used for stopping or for resetting Feedback [unit]*
the pump after a drop-out (trip). Can be selected Frequency [Hz]
via parameter 014 to be active or inactive. If stop is Frequency x scaling [-]
Motor current [A]
activated, line 2 will flash, and [start] must
Torque [%]
be activated.
Power [kW]
Power [HP]
at tention:
Motor voltage [V]
Pressing [stop/reset] will prevent the pump from running also
dc-link voltage [V]
with disconnected lcp. Restarting is only possible via the lcp
fc thermal [%]
[start] key. Hours run [Hours]
Input status, dig. Input [Binary code]
[jog] overrides the output frequency to a preset External reference [%]
frequency while the key is kept down. Can be Status word [Hex]
selected via parameter 015 to be active or inactive. Heat sink temp. [°c]
Alarm word [Hex]
[fwd / rev] changes the direction of rotation of the Control word [Hex]
motor, which is indicated by means of the arrow on Warning word 1 [Hex]
the display although only in Local. This key is Warning word 2 [Hex]
inactive by default. Analog input 1 [mA]
Analog input 2 [V]
[start] is used for starting the pump after stop via Sensorless power [W]
the [stop] key. Is always active, but cannot override Sensorless flow [l/s]
a stop command given via the terminal strip. Sensorless head [kPa]
* Select in parameter 416. The unit is shown in readout
state 1 line 1 otherwise ’U’ is shown.

20
Operating variables 1,1 and 1,2 and 1,3 in the first line, and operat-
ing variable 2 in the second line are selected via parameter 009,
010, 011 and 012.
Read-out state I:
This read-out state is standard after starting up or after
initialisation.
This is where parameter names and units for operating

variables in the first line are given - operating variable 2
remains unchanged .
6.1.5 quick menu
Quick menu gives access to a limited number of parameters

but does not include parameters that may need to be changed
Line 2 gives the data value of an operating variable with related when utilising sensorless control. It is therefore recommended
unit, and line 1 provides a text which explains line 2, cf. table. that parameter changes are made in the standard menu.
In the example, Frequency has been selected as variable via
parameter 009.
6.1.6 menu mode
During normal operation another variable can immediately
be read out by using the [+/-] keys. The Menu mode makes it possible to select and change all
parameters at the user’s option.
Read-out state II:
However, some parameters will be missing, depending on the
Switching between read -out states I and II is effected by
choice of configuration (parameter 100), e.g. open loop hides all
pressing the [display / status] key.
the pid parameters.
In addition to having a name, each parameter is linked up with a
number which is the same regardless of the programming mode.
In the Menu mode, the parameters are divided into groups, with
the first digit of the parameter number (from the left) indicat-
ing the group number of the parameter in question. Regardless
of the mode of programming, a change of a parameter will take
effect and be visible both in the Menu mode and in the Quick
menu mode.
The Menu mode is started by pressing the [menu] key, which
produces the following readout on the display:
In this state, data values for four operating values are shown at
the same time, giving the related unit, cf. table. In the example,
Reference, Torque, Current and Frequency are selected as
variables in the first and second line.
Read-out state III:

This read-out state can be held as long as the [display / status]
key is pressed. When the key is released, the system switches
back to Read-out state II, unless the key is pressed for less than
approx. 1 sec.
Line 3 on the display shows the parameter group number

and name.

21
Parameter Groups
This read-out state is standard after starting up or
after initialisation.
In the Menu mode the parameters are divided into groups. Se-
lection of parameter group is effected by means of the [<>] keys.
The following parameter groups are accessible:
group no. parameter group:

0 Operation & display
1 Load & motor The bottom display line shows the text value that will be
2 References & limits entered (saved) when acknowledgement is given [ok].
3 Inputs & outputs

Infinitely variable change of numeric data value
4 Special functions If the chosen parameter represents a numeric data value, a
5 Serial communication digit is first selected by means of the [<>] keys.
6 Technical functions
7 Sensorless control
When the desired parameter group has been selected, each

parameter can be chosen by means of the [+/-] keys:
Then the chosen digit is changed infinitely variably by means of

the [+/-] keys:
The 3rd line of the display shows the parameter number and
name, while the status/value of the selected parameter is shown
in line 4.
Changing Data
Regardless of whether a parameter has been selected under
the Quickmenu or the Menu mode, the procedure for changing
data is the same. Pressing the [change data] key gives access to
changing the selected parameter, following which the underlin- The chosen digit is indicated by the digit flashing. The bottom
ing in line 4 will flash on the display. The procedure for changing display line shows the data value that will be entered (saved)
data depends on whether the selected parameter represents a when signing off with [ok].
numerical data value or a text value.
Changing a Text Value

If the selected parameter is a text value, the text value is
changed by means of the [+/-] keys.

22
menu structure
display mode
menu mode quick menu mode
choice of choice of
parameter group
data mode
data change mode data change mode
choice of
data value

23
7.0 sensorless oper ation The probability of this occurring is remote but it is possible. One
answer to this is to move the sensor closer to the pump (two-
Sensorless control is an innovative concept in glanded circulat- thirds out in the system is a popular recommendation) although
ing pumps. Pump performance and characteristic curves for ten physically re-positioning the sensor at commissioning stage can
different speeds are embedded in the memory of the speed con- be a costly exercise. With Sensorless pump control it is possible
troller during manufacture. This data includes power, pressure to replicate the moving of a sensor by adjusting the head setting
and flow across the flow range of the pump. During operation, ‘Head Qmin’.
the power and speed of the pump are monitored, enabling the
controller to establish the hydraulic performance and position in
7.1.1 description of set tings
the pumps head-flow characteristic.
These measurements enable the pump to continuously identify The design duty head and flow of the pump (provided at time of
the head and flow at any point in time, giving accurate pressure order) is defined by the controller as ’head working point’ and
control without the need for external feedback signals. Patented ’flow working point’. The minimum head (Head Qmin) is defined
software technology within the controller ensures trouble-free as a percentage of the head working point. The maximum
operation in all conditions. Incorporating the pumps hydraulic controllable head (Head Qmax) is the head developed when the
data into the controller and removing sensors results in true pump reaches full speed and is calculated by the other two
integration of all components and removes the risk of head settings.
sensor failure.
7.1. 2 set ting par ameters for quadr atic
7.1 default oper ating mode - quadr atic pressure control
pressure control
• Parameter 716 - Enter the head (kPa) at design flow.
The default control mode for Design Envelope pumps ‘Quadratic • Parameter 717 - Enter the design flow (l/s).
Pressure Control’ where the controller is set to control the speed • Parameter 707 - Enter the minimum head requirement
according to a ‘control curve’ between max and min flow (as a percentage of p716).
• Parameter 705 - Quadratic Head should be set to ’on’.
Head working point (P716) • Parameter 798 - This is a calculated value from the
Flow working point (P717)
120
1450 rpm
51 settings above and should not be changed.
62
1388 rpm 71
77
100 81
Head Qmin (P798)
1270 rpm
82
7. 2 constant pressure control
head kpa
80 1150 rpm 1 81
2 77
1040 rpm 3
Control (QPC)
71
Design Envelope pumps can be configured to maintain a con-
60
920 rpm 4 stant pressure in a system as the demand varies. This effectively
5
40 801 rpm 6 simulates the mounting of a differential pressure sensor at, or
7
750 rpm near, the pump.
20
580 rpm
0 Head Qmin (P707)
Head working point (P716)
0 10 20 30 40 50 60 70 80 Flow working point (P717)
1450 rpm
120 51
62
water, spgr= 1.0000 flow – L/s 1388 rpm 71
77
100 1320 rpm 81
Head Qmin (P798)
1260 rpm 82
head kpa
(see above diagram). It is widely recognised that fitting a 80

1196 rpm 1 81
1185 rpm Control (QPC)
differential pressure sensor at the most remote load, across the 77
71
supply piping and return piping encompassing the valve & coil 60 Head Qmin (P707)
set, is the best installation scheme for energy efficiency.
40
Design Envelope pumps can replicate this control without the
20
need for the remote sensor. As the flow required by the system 580 rpm
is reduced, the pump automatically reduces the head developed 0
according to the pre-set control curve. It is often found that us- 0 10 20 30 40 50 60 70 80
ing a remote differential pressure sensor to sense the pressure water, spgr= 1.0000 flow – L/s
across a remote load could theoretically result in loads close to
the pump being underpumped.
The situation would be where the load at a loop extremity is
satisfied and the control valve closes while a load close to the
pump needs full flow.

24
7. 2 .1 setting par ameters for constant The parameter list following this section gives typical settings
pressure control for closed loop control.

• Parameter 717 - Enter the design flow (l/s). 8.1 par ameter groups and descriptions.
• Parameter 707 - Enter the minimum head requirement
(as a percentage of p716). which will be 100% for group 0 – oper ation and display.
constant pressure.
• Parameter 705 - Quadratic Head should be set to ’off’. Language/Local Control – Parameters 001,002, 003
• Parameter 798 - This is a calculated value from the Not normally changed.
settings above and should not be changed.
Active Set-up – Parameter 004
It is possible to program two separate sets of data for controlling
7.3 proportional pressure control the inverter.
Where a linear reduction in head is required with reducing flow Program Set-up – Parameter 005
then the quadratic curve should be turned off. The active set-up can be either set-up 1, set-up 2 or can be
remotely switched between the two.
Head working point (P716)
120
1450 rpm
51
Flow working point (P717) Copying of Set-ups – Parameter 006
62
1388 rpm 71 A copy is made from the set-up selected in parameter 005
77 Head Qmin (P798)
100 1290 rpm 81 and copied to the set-up selected in parameter 006.
82
head kpa
1190 rpm 1 81
80 2
1090 rpm 3 Control (QPC) 77 Copying of Set-ups Between Inverters – Parameter 007
4 71
60 990 rpm
5
894 rpm 6 • Connect key pad to the inverter from which the desired
40 7
set-up is to be copied.
20
750 rpm • Select 1 in parameter 007 to upload all parameters into the
580 rpm key pad.
0
Head Qmin (P707)
• Connect key pad to the inverter to which the desired set-up
0 10 20 30 40 50 60 70 80
is to be copied.
water, spgr= 1.0000 flow – L/s • Select 3 in parameter 007 to download all parameters into
the inverter.
• By selecting 3 in parameter 007, copying from one size of
inverter to a different size will not affect the power settings.
7.3 .1 set ting par ameters for
proportional pressure control Display Scaling – Parameter 008
Multiplication factor of frequency (normally set at 1).
• Parameter 717 - Enter the design flow (l/s).
Display Configuration – Parameters 009-012
• Parameter 707 - Enter the minimum head requirement
Allows choice of data to displayed in lines 1 and 2 of the key pad.
(as a percentage of p716).
• Parameter 705 - Quadratic Head should be set to ’off’. Local Operations – Parameters 013 -019
• Parameter 798 - This is a calculated value from the
Not normally changed.
settings above and should not be changed.
group 1 – load and motor.

8.0 control using external feedback
(closed loop control). Configuration – Parameter 100
Sets the configuration under which the inverter is controlled.
Design Envelope pumps can be configured (using the keypad) to
accept a feedback signal from a remote sensor (e.g. temperature
at tention:
transmitter for constant temperature). The connection of an
Set to Process Closed Loop for control via the 4 -20mA trans-
external device will depend on the device itself although typical
ducer feedback input set to Speed Open Loop for Potentiometer,
devices are 4-20mA, 2 wire where the supply will be provided by
bms or Sensorless control.
24v dc on terminal 6 of x101 and the output signal connected to
terminal 1 of x101.

25
Motor Settings – Parameters 101-141 Preset Reference 2 – Parameter 216

Set to 0% and not normally used.
at tention:
Are motor related parameters and are not normally changed. Catch Up/Slow Down – Parameter 219
Set to 0% and not normally used.
group 2 – reference and limits. Frequency Bypass Bandwidth – Parameter 229

If a skip frequency is entered at parameter 230 or 231 a %
Rotation Direction – Parameter 200
bandwidth either side of these frequencies can be defined in
this parameter.
at tention:
Sets rotation direction, normally set at 132 hz counter clockwise.
Frequency Bypass – Parameters 230-231
If resonance problems occur at particular frequencies, It is
Minimum Output Frequency – Parameter 201
possible to program two frequencies to be avoided.
Minimum output frequency is normally set at 0 to 21 hz
dependant on the mode of operation.
group 3 – inputs and outputs.
Maximum Output Frequency – Parameter 202
Maximum output frequency is normally set at 50 hz. This figure Inputs and Outputs – Parameters 317-340
should not be exceeded as the inverter could be overloaded. These parameters are not normally changed.
Reference Feedback – Parameter 203

Set to Min-Max and not normally changed. group 4 – special functions.
Special Functions – Parameters 400-446

Minimum Reference – Parameter 204
These parameters are not normally changed.
If operating in closed loop mode, set to minimum scale of the
feedback sensor, normally set to 0.0.
group 5 – serial communications.
note:
Units of measurement are selected in parameter 416. Bus Address – Parameter 500
This parameter allows specification of the address for each
If operating in open loop mode, the units can only be displayed inverter. Used in conjunction with plc/pc connection. Address
as hz, normally set to minimum speed 0.0 hz. 0 is used for the master unit, addresses 1-126 for slave units. A
repeater unit will be required if the total number of slave units
Ramp Up/Down Times – Parameters 207, 208, 211, 212 exceeds 30.
Ramp up times normally set to 10 seconds.
Baudrate – Parameter 501
at tention: Sets the speed of communication, set to a value that
Ramp down times normally set to 3 seconds. Longer times corresponds with the transmission speed of the plc/pc.
should be used with higher kW motors.
Drive Control – Parameters 502-508
Jog Frequency – Parameter 213 Allows control via terminal inputs and/or the Bus.
Normally set to 50 hz when the jog function is activated it will
override the normal reference input and run the pump at the Bus Jog Frequency – Parameters 509-510
preset jog reference. Activates the jog frequency via the Bus.
Reference Function – Parameter 214 Protocol – Parameter 512

Set to Sum. Not normally changed. Selects the control word profile 0=Profidrive, 1=fc Drive.
Preset Reference 1 – Parameter 215 Data Output – Parameters 513-635

(Set Point) if operating in closed loop mode, this parameter Read only values of various functions.
should be set to the required set point as a percentage of the
maximum range of the feedback sensor. i.e. Sensor range 0 -4.0 For further information on serial communication,
Bar, set point required 2.0 Bar, parameter would be set to 50%. If contact Armstrong.
operating in open loop mode or sensorless mode this parameter
should be set to 0%.

26
group 6 – technical functions. Quadratic Head – Parameter 705

Normally set to ‘on‘. In the ‘off’ position a linear curve between
Operating Hours – Parameter 600 Min/Max head is produced. In the ‘on’ position a quadratic
Readout of inverter operating time, updated hourly. curve between Min/Max head is produced.
Run Hours – Parameter 601 Head Minimum – Parameter 707

Readout of inverter running time, updated hourly. Normally set to 40%. This will provide a 60% reduction in head
at ‘No Flow’ conditions. Set to 100% if a constant head is
Power Ups – Parameter 603 required across the full flow range.
Readout of number of power-ups.
Power Consumption – Parameter 708
Over Temperatures – Parameter 604 Normally set to 0 option correction factor that mainly affects
Readout of temperature faults. the head reference at high flow values.
Over Voltages – Parameter 605 Temperature Rise Rated – Parameter 710

Readout of over-voltage faults. Normally set to 80°c. This specifies the estimated difference
in rotor temperature from idle running conditions to maximum
Fault Log – Parameter 615 loaded conditions.
Readout of last 10 trip codes, the lowest log number contains the
latest fault. (See Page 5 for Fault Code list). tau Therm. – Parameter 711
Normally set to 300 Seconds. This specifies the estimated time
Fault Log Time – Parameter 616 it will take the rotor temperature to rise from idle temperature to
Readout shows total number of operating hours before trip 67% of the maximum temperature, at maximum loaded
occurred. The lowest log number contains the latest data. conditions.
Fault Log Value – Parameter 617 Slip 0°C – Parameter 712

Readout shows current or voltage when the trip occurred. Normally set to 0%. This specifies the estimated change in
motor slip at the idle temperature compared with the nominal
Reset Hours Run Counter – Parameter 619 slip of the motor at idle load.
To reset the hours run counter in parameter 601 to zero select 1.
Slip 100°c – Parameter 713
Inverter Data – Parameters 620-635 Normally set to 0%. This specifies the estimated change in
Read only values of inverter identification numbers. motor slip at the temperature 100°c above the idle temperature,
compared with the nominal slip of the motor at maximum load.
group 7 – sensorless functions. Head Working Point - Parameter 716

Design duty head value (kPa)
Sensorless Control On/Off – Parameter 700
Set to ‘on’ for Sensorless control. For all other modes of control
Flow Working Point - Parameter 717
set to ‘off’.
Design duty flow value (l/s)
Power Error – Parameter 701
Head Maximum – Parameter 798
Normally set to 20W, this allows a fast but rough response to
Shows the maximum controlled head (at max speed). This
the output hz. Not normally changed.
parameter is automatically calculated using parameter 716, 717
and 707.
Delta Frequency – Parameter 702
Normally set to 0.2 hz, as parameter 701, this allows a fast but
Protocol – Parameter 561
rough response to the output hz. Not normally changed.
Fieldbus Communication: fc Protocol, Modbus rtu
Integral Power – Parameter 703
Normally set to 20, this allows more precise adjustments to the
output hz. Not normally changed.
Integral Frequency – Parameter 704

Normally set to 20, as parameter 703, this allows more precise
adjustments to the output hz. Not normally changed.

27
descrip tion par ameter sensorless open loop closed loop

Language 001 English English English
Local/remote control 002 Local Remote Remote
Local reference 003 0.000 0.000 0.000
Active setup 004 Multi setup Setup 1 Setup 1
Programming setup 005 Active setup Active setup Active setup
Copying of setups 006 No copy No copy No copy
lcp copy 007 No copy No copy No copy
Display scaling of motor frequency 008 1.00 1.00 1.00
Display line 2 009 Frequency [hz] Frequency [hz] Frequency [hz]
Display line 1.1 010 Sensorless head [kpa] Reference [%] Reference [Unit]
Display line 1.2 011 Sensorless power [W] Motor current [Amps] Feedback [Amps]
Display line 1.3 012 Sensorless flow [L/s] Power [kW] Power [kW]
Local control/configuration 013 lcp dig control/par 100 lcp dig control/Par 100 lcp dig control/par 100
Local stop 014 Enable Enable Enable
Local jog 015 Enable Disable Disable
Local reversing 016 Disable Disable Disable
Local reset of trip 017 Enable Enable Enable
Lock for data change 018 Not locked Not locked Not locked
Operating state at power up,
019 Auto restart Local = Stop Local = Stop
Local control
Configuration 100 Speed open loop Speed open loop Process closed loop
Torque characteristics 101 Constant torque Variable torque – med Variable torque – med
Motor power 102 Unit dependant Unit dependant Unit dependant
Motor voltage 103 Unit dependant Unit dependant Unit dependant
Motor frequency 104 Unit dependant Unit dependant Unit dependant
Motor current 105 Unit dependant Unit dependant Unit dependant
Rated motor speed 106 Unit dependant Unit dependant Unit dependant
Resonance damp 117 Off Off Off
dc braking time 126 10.0 seconds 10.0 seconds 10.0 seconds
dc brake cut -in frequency 127 Off Off Off
Motor thermal protection 128 Disable Disable Disable
dc braking voltage 132 Off Off Off
Start voltage 133 Motor dependant Motor dependant Motor dependant
Start compensation 134 100.0% 100.0% 100.0%
u/f ratio 135 Motor dependant Motor dependant Motor dependant
Slip compensation 136 0.00% 100.0% 100.0%
dc holding voltage 137 Off 0% 0%
Brake cut -out frequency 138 3.0hz 3.0hz 3.0hz
Brake cut -in frequency 139 3.0hz 3.0hz 3.0hz
Rotation direction 200 132hz ctr-clockwise 132hz ctr-clockwise 132hz ctr-clockwise

Minimum frequency 201 21hz 0hz 0hz
Maximum frequency 202 50hz (60 some models) 50hz (60 some models) 50hz (60 some models)
Reference/feedback range 203 Min- max Min- max Min- max
Minimum reference 204 0hz 0hz (Sensor min)
Maximum reference 205 50hz (60 some models) 50hz (60 some models) (Sensor max)
Ramp up time 1 207 10.00 seconds 10.00 seconds 10.00 seconds
Ramp down time 1 208 3.0 seconds 3.0 seconds 3.0 seconds
Ramp up time 2 209 3.0 seconds 3.0 seconds 3.0 seconds
Ramp down time 2 210 3.0 seconds 3.0 seconds 3.0 seconds
Jog ramp time 211 10.00 seconds 10.00 seconds 10.00 seconds
Quick stop ramp down time 212 3.0 seconds 3.0 seconds 3.0 seconds
Jog frequency 213 50hz 50hz 50hz
Reference function 214 Sum Sum Sum
Preset reference 1
215 000.00% 000.00% As required [%]
(copy of parameter 241)
Preset reference 2 216 000.00% 000.00% 000.00%
Catch up/slow down value 219 000.00% 000.00% 000.00%
Current limit for motor mode 221 100% 100% 100%
Frequency bypass bandwidth 229 Off Off Off
Frequency bypass 1 230 0.00 hz 0.00 hz 0.00 hz
Frequency bypass 2 231 0.00 hz 0.00 hz 0.00 hz
Preset reference 1
241 000.00% 000.00% As required [%]
(copy of parameter 215)
Preset reference 2 - 7 242 - 247 000.00% 000.00% 000.00%

28
descrip tion par ameter sensorless open loop closed loop

Time out 317 10 Seconds 10 seconds 10 seconds
Function after time out 318 Off Off Stop and trip
x102 relay function 323 Running Running Running
Pulse reference/feedback max frequency 327 5000hz 5000hz 5000hz
Terminal 1, analogue input current 331 No Operation Feedback Feedback
Terminal 2, digital input 332 Reference Reference Reference
Terminal 3, digital input 333 Quick Stop Inverse Quick stop inverse Quick stop inverse
Terminal 4, digital input 334 Stop Inverse Start Start
Terminal 5, digital input 335 Setup Select Setup Select Jogging
Terminal 1, minimum scaling 336 4.0mA 4.0mA 4.0mA
Terminal 1, maximum scaling 337 20.0mA 20.0mA 20.0mA
Terminal 2, minimum scaling 338 0.0v 0.0v 0.0v
Terminal 2, maximum scaling 339 10.0v 10.0v 10.0v
Output functions 340 Fault Fault Fault
Brake function 400 off off off

Sleep mode timer 403 off off off
Sleep frequency 404 0hz 0hz 0hz
Reset function 405 Automatic x 10 Automatic x 10 Automatic x 10
Boost setpoint 406 100% 100% 100%
Wake up frequency 407 50hz 50hz 50hz
Switching frequency 411 8000 hz 8000 hz 8000 hz
Variable switching frequency 412 Temp. dep. frequency Temp. dep. frequency Temp. dep. frequency
Overmodulation function 413 on on on
Minimum feedback 414 0.00 0.00 (Sensor min)
Maximum feedback 415 4.00 4.00 (Sensor max)
Reference/feedback unit 416 Bar Bar (Sensor unit)
Process pid normal/inverse control 437 n/a n/a Normal
Process pid anti-windup 438 n/a n/a Enable
Process pid start frequency 439 n/a n/a 20hz
Process pid proportional gain 440 n/a n/a 0.5
Process pid integral time 441 n/a n/a 1.00 second
Process pid differentiation time 442 n/a n/a 0.00 second
Process pid differentiation gain limit 443 n/a n/a 5.0
Process pid lowpass filter time 444 n/a n/a 0.50
Flying start 445 ok same direction ok same direction ok same direction
Switching pattern 446 sfavm sfavm sfavm
Feedback conversion 461 Linear Linear Linear
Bus address 500 1 1 1

Baudrate 501 9600 Baud 9600 baud 9600 baud
Coasting 502 Logic or Logic or Logic or
Quick stop 503 Logic or Logic or Logic or
dc-brake 504 Logic or Logic or Logic or
Start 505 Logic or Logic or Logic or
Reversing 506 Logic or Logic or Logic or
Selection of setup 507 Logic or Logic or Logic or
Selection of speed 508 Logic or Logic or Logic or
Bus jog 1 509 10.0hz 10.0hz 10.0hz
Bus jog 2 510 10.0hz 10.0hz 10.0hz
Telegram profile 512 fc drive profile fc drive profile fc drive profile
Bus time interval 513 1 Second 1 second 1 second
Bus time interval function 514 off off off
Serial communication parameters 515 – 543 Read out only parameters – not editable
Technical function parameters 600 – 635 Read out only parameters – not editable
Sensorless control 700 on off off

Power error 701 20w 20w 20w
Delta frequency 702 0.2hz 0.2hz 0.2hz
Integral power 703 20 20 20
Integral frequency 704 20 20 20
Quadratic head 705 on on on
Head Q min 707 40% 40% 40%
Power consumption 708 0W 0W 0W
Temperature rise rated 710 80°c 80°c 80°c
tau therm 711 300 seconds 300 seconds 300 seconds
Slip 0°c 712 0 0 0
Slip 100°c 713 0 0 0
Head working point 716 Default Default Default
Flow working point 717 Default Default Default
Head Q max 798 Default Default Default

29
9.0 warnings and alarms corrected. Reconnect the mains supply and reset (auto-reset by
default) the pump before starting. Wherever a cross is placed
There are two means of notification of warnings and alarms on under both Warning and Alarm, this can mean that a warning
an Design Envelope pump. The keypad tool (lcp) will display precedes the alarm. It can also mean that it is possible to
alarm information and in addition to this there are five status program whether a given fault is to result in a warning or an
led’s that can be viewed on removal of the inverter cover (see alarm. After a trip, alarm and warning will flash, but if the fault
figure 2, page 3). The table below gives the different warnings is removed, only alarm will flash. After a reset, the pump will be
andalarms and indicates whether the fault locks the pump. After ready to start operation again.
Trip locked, the mains supply must be cut and the fault must be
no. description warning trip alarm trip locked

2 Live zero fault (Live zero error) × ×
4 Phase loss (Mains phase loss) × × ×
5 Voltage warning high (dc Link voltage high) ×
6 Voltage warning low (dc Link voltage low) ×
7 Overvoltage (dc Link overvolt) × ×
8 Undervoltage (dc Link undervolt) ×
9 Inverter overload (Inverter time) × ×
11 Motor thermistor (Motor thermistor) ×
12 Current limit (Current limit) ×
13 Overcurrent (Over temperature) × ×
14 Earth fault (Earth fault) × ×
15 Supply fault (Switch mode fault) × ×
16 Short-circuit (Curr.short circuit) × ×
17 Standard bus timeout (std Bus timeout) × ×
18 Hpfb bus timeout (hpfb timeout) × ×
33 Out of frequency range (Out freq rng/rot lim) ×
34 hpfb error (hpfb alarm) × ×
35 Inrush fault (Inrush fault) × ×
36 Overtemperature (Over temperature) × ×
37 Internal error (Internal error) × ×
warnings
The display flashes between normal state and warning. A

warning comes up on the first and second line of the display.
wa r n i n g /a l a r m 2, Live zero fault (Live zero error):

The current signal on terminal 1 is less than 50% of the value set
in parameter 336 Terminal 1, min. scaling .
alarms
wa r n i n g /a l a r m 4 , Phase loss (Mains phase loss):
The alarm comes up in the 2. and 3. line of the display. Phase missing on the supply side. Check the supply voltage
to the inverter.
wa r n i n g 5 , Voltage warning high (d c link voltage high):

The intermediate circuit voltage (dc) is higher than the
overvoltage limit of the control system, see table on the next
page. The inverter is still active.

30
wa r n i n g 6, voltage warning low (dc link voltage low): a l a r m 16, Short-circuiting (Curr. short circuit):
The intermediate circuit voltage (dc) is below the undervolt- There is short-circuiting on the motor terminals or the motor
age limit of the control system, see table on the next page. The itself. Contact Armstrong.
inverter is still active.
a l a r m 17, Standard bus timeout (std Bus timeout):
a l a r m 7, overvoltage (dc over voltage): There is no communication to the inverter (when using serial
If the intermediate circuit voltage (dc) exceeds the inverter communications). The warning will only be active when
overvoltage limit (see table on the next page), the inverter parameter 514 has been set to another value than off. If param-
will trip. Furthermore, the voltage will be stated in the display. eter 514 has been set to stop and trip, it will first give a warning
and then ramp down until it trips, while giving an alarm.
a l a r m 8, Undervoltage (dc under voltage):
Parameter 513 Bus time interval could possibly be increased.
If the intermediate circuit voltage (dc) drops below the inverter
lower voltage limit (see table on this page), the inverter will trip
wa r n i n g 3 3 , Out of frequency range:
after 3 - 28 sec., depending on unit. Furthermore, the voltage
This warning is active if the output frequency has reached
will be stated in the display. Check whether the supply voltage
parameter 201 Output frequency low limit or parameter 202
matches inverter motor.
Output frequency high limit.
wa r n i n g /a l a r m 9, Inverter overload (Inverter time):

wa r n i n g /a l a r m 34, hpfb error (hpfb alarm):
The electronic, thermal inverter protection reports that the
The profibus communication is not working correctly.
inverter is about to cut out because of an overload (too high
current for too long). The counter for electronic, thermal inverter
a l a r m 3 5 , Inrush fault (Inrush fault):
protection gives a warning at 95% and trips at 100%, while giving
This warning occurs when the unit has been switched on too
an alarm. The inverter cannot be reset until the counter is
many times within one minute.
below 90%.
wa r n i n g /a l a r m 3 6 , Over temperature
trip/al arm/ warning limits: (Over temperature):
fc motor Series 3 × 380 - 480 A warning occurs at 78°c and the inverter trips at 90°c. The
Undervoltage 410[vdc] unit can be reset when the temperature is below 70°c.
Voltage warning low 440[vdc]
Voltage warning high 760[vdc]
a l a r m : 3 7 Internal error (Internal error):
Overvoltage 760[vdc]*
760v in 5 sec. or 800v immediately. An error has occurred in the system. Contact Armstrong.
The voltages stated are the intermediate circuit voltage of
the inverter.
9 .1 internal led descriptions
a l a r m 11, Motor thermistor (Motor thermistor):
The led’s (shown in figure 4, page 15) can be used to determine the
If a thermistor is mounted and parameter 128 is set to Enable [1],
status of the Design Envelope pump when an lcp is not available.
the fc motor will trip if the motor gets too hot..
wa r n i n g 12, Current limit (Current limit):

The current is higher than the value in parameter 221
safety, risk of death
(in motor operation).
To view the led’s the cover will need to be removed
with the power supply switched on. This is very dan-
a l a r m 13, Over Current (Over Current):
gerous and all necessary precautions should be taken
The inverter peak current limit (approx. 230% of the rated
to eliminate the risk of electrocution.
current) has been exceeded. The inverter will trip, while giving
an alarm. Turn off the inverter and check whether the motor
led 300 -304
shaft can be turned.
led 300 (red): Fault trip
led 301 (yellow): Warning
a l a r m 14, Earth fault (Earth fault):
led 302 (green): Power on
There is a discharge from the output phases to earth, either
led 303-304: Communication (lcp or rs485)
between the inverter and the motor or in the motor itself.
a l a r m 15, Supply fault (Switch mode fault): note:

Fault in the switch mode power supply (internal 24 v supply). If led301 flashes slowly then the pump has been given a stop
Contact Armstrong. command via an lcp (keypad) and can only be started by an lcp
start command.

31
fault finding chart - keypad available
Pump won’t
Start
no Is the Keypad yes

display and
on led lit?
Check 3 phase Is the

no - bms yes
mains supply pump being used
in Sensorless
Mode?
no Is the Link no Is the Link

made on x101 made on x101
t3 to t6? t3 - t6?
Connect x101 Connect x101

yes yes
t3 to t6 t3 to t6
no Is a start no Is a start
signal applied signal applied
to x101 t4? to x101 t4?
Check remote Check remote

start signal or yes start signal or yes
link x101 link x101
t4 to t6 t4 to t6
no yes
Is the reference
signal on x101 t2
>0vdc?
Check remote Has the keypad

reference stop key been
Yes-
signal from pressed?
Display
bms
Flashing
no
Press the Key
pad start key
yes Does the
display show
See the alarm an alarm?
descriptions on
page 17/18 no
Contact
Armstrong Service
Department

32
fault finding chart - no keypad available
Pump won’t
Start
no yes
Is led
302 lit?
Check 3 phase no - bms Is the pump yes

mains supply being used in
Sensorless
Mode?
no Is the Link no Is the Link

made on x101 made on x101
t3 - t6? t3 to t6?
Connect x101 Connect x101

yes yes
t3 to t6 t3 to t6
no Is a start no Is a start
signal applied signal applied
to x101 t4? to x101 T4?
Check remote Check remote

start signal or yes start signal or yes
link x101 link x101
T4 to T6 T4 to T6
no yes
Is the reference
signal on x101 t2
>0vdc?
Check remote Is led

reference 301 flashing
Yes slowly?
signal from
bms
no
Local Stop - A
keypad is
reqired to
start the unit yes
Is red led
300 lit?
There is a fault
- use a keypad
to diagnose no
Contact
Armstrong Service
Department

33
10.0 integr ated controls The leakage current is of importance to safety during
handling / operation of the Design Envelope pump if (by
mistake) the on-board inverter has not been grounded.
10.1 enclosure r ating ince the leakage current is >3.5ma (approx
S
4-20ma), reinforced grounding must be established
The standard enclosure rating for Design Envelope
which is required if en 50178 is to be complied with.
4300 and 4380 integrated controls is iec ip55. If the
Never use elcb relays that are not suitable for dc
pump is to be installed in a wet or dusty environ-
fault currents (type a).
ment then a higher enclosure rating may be required
If elcb relays are used, they must be:
(contact Armstrong)
• Suitable for protecting equipment with a direct current con-
tent (dc) in the fault current (three-phase bridge rectifier)
10. 2 ambient temper ature
• Suitable for power-up with short charging current
To avoid the inverter unit getting overheated, the to ground
ambient temperature is not to exceed 133°f (45°c). • Suitable for a high leakage current
Operating in higher ambient temperatures will re-
quire derating of the inverter.
11. 2 start / stop of pump
11.0 electrical installation The number of starts/stops via the mains voltage must not
exceed one-time per minute.
ll electrical connections should be carried out by
A If a higher number of starts/stops is required then the start/
a qualified and authorized electrician in accordance stop digital input must be used (mains voltage directly con-
with local site regulations and the latest issue of the nected). This is the preferred method of starting and stop-
iee regulations. ping Design Envelope pumps.
The three phase mains must be isolated before performing
safety, risk of death maintenance of the pump.
efore removing the controls cover, the system

B
must be disconnected from the mains supply. After 11.3 additional motor protection
switching off, wait for at least 15 minutes for the
With the exception of supply fuses / mcb’s to
capacitors to discharge before opening the cover.
protect the installation (for over-current and
short-circuit protection), no additional overload or
caution over-temperature protection is required (i.e. thermal
overloads). Protection features include:
igh voltage testing (Megging) of the motor/ con-
H
• Mains phase loss
trols may cause damage to the electronic compo-
• Over voltage
nents and therefore should not be carried out
• Under voltage
• Electronic thermal motor protection
11.1 ground leak age current
• Short circuit on motor terminals
Ground leakage current is primarily caused by the • Ground fault on motor terminals
capacitance between motor phases and the motor
• Over temperature
frame. The rfi filter contributes additional leakage
current, as the filter circuit is connected to ground
through capacitors. 11. 4 supply voltage
The size of the leakage current to the ground depends on the
The supply voltage details can be found on the inverter
following factors, in order of priority:
nameplate. Please ensure that the unit is suitable for the
1 Switching frequency electrical supply on which it is to be used. The mains supply
2 Motor grounded on site or not for Design Envelope pumps is as follows:
3 × 380-480v +/- 10%
Supply frequency - 50hz

34
11.5 supply fusing fig . 5 Mains and grounding connections for a5 units
( 38 0 -48 0v 7.5kW and below)
Branch circuit protection
In order to protect the installation against electrical and fire
95
hazard, all branch circuits in an installation, switch gear, ma-
chines etc., must be short-circuit and over-current protected
according to the national/international regulations.
Short circuit protection

The inverter must be protected against short-circuit to avoid
electrical or fire hazard. Armstrong recommends using the fuses
detailed in the separate ivs102 Operating Instructions to pro-
tect service personnel or other equipment in case of an internal
failure in the unit. The frequency converter provides full short fig . 6a Mains and grounding connections for b1 and b2 units
circuit protection in case of a short-circuit on the motor output. (380-480v – 11 to 30 kW)
11.6 grounding and it mains
he ground connection cable cross section must be

T
at least 10 mm 2 or two rated mains wires terminated
separately according to en 50178 or iec 61800-5-1
95
unless national regulations specify differently. Always
comply with national and local regulations on cable
cross sections.
he mains is connected to the main disconnect switch

T
if this has been included.
heck the mains voltage corresponds to the mains

C
voltage of the frequency converter name plate.
fig . 6b Mains and grounding connections for c1 and

it mains c2 units (380-480v – 37 to 90kW)
Do not connect frequency converters with rfi-filters

to mains supplies with a voltage between phase and
earth of more than 440v for 400v converters. For
440v it mains and delta earth (grounded leg), mains voltage 91 92 93
may exceed 440v between phase and earth. L1 L2 L3
95
fig . 4 Terminals for mains and grounding
Three phase 91 (l1)

power input 92 (l2)
93 (l3)
95 pe

35
fig . 4c Mains and grounding connections for d1 The following illustrations identify the location of the relays
and d2 units ( 38 0 -48 0v – 110 to 3 15kW) within specific inverter sizes:
The illustrations in fig. 6, 7 and 8 identify the location of the
relays within specific inverter sizes:
fig . 8 Relay connection: terminals for a5, b1 and b2 units

95
Figure 4c. Mains and Grounding Connections for D1 and D2 units (380-480V - 150 to 350HP, 525-600V - 150 to 350HP)
4.7 RELAY CONNECTIONS
The relays on the IVS are configured as follows:
Relay 1 - RUNNING
11.7 relay connections
Terminal 01: Common
Terminal 02: Normal Open 240V AC
Terminal 03: Normal Closed 240V AC
The relays on the Design Envelope are configured as follows:

Relay 2 - ALARM
Terminal 04: Common
Terminal 05: Normal Open 400V AC
Terminal 06: Normal Closed 240V AC
relay 1 – running
• Terminal 01: Common
Figure 5. Relay Contact Details
fig . 9 Relay connection terminals for c1 and c2 units
• Terminal 02: Normal open 240v ac Page 11 of 26
• Terminal 03: Normal closed 240v ac
relay 2 – alarm
• Terminal 04: Common
• Terminal 05: Normal open 400v ac
• Terminal 06: Normal closed 240v ac
fig . 7 Relay contact details
Relay 1
03
02 240v ac, 2a
01
Relay 2
06
240v ac, 2a
05
400v ac, 2a
04

36
fig . 8 Relay connection terminals for c 1 and c 2 units

Figure 6. Relay Connection Terminals for A5, B1 and Figure 7. Relay Connection Terminals for C1 and C2 Units
B2 Units
AUX RELAY
01 02 03
04 05 06
Figure 8. Relay Connection Terminals for D1 and D2 units

Page 12 of 26

37
11.8 electrical installation and control connections
fig . 9 Diagram showing all electrical connections

*Note: terminal 37 is not available on Design Envelope pumps
4.8 ELECTRICAL INSTALLATION AND CONTROL CONNECTIONS
Figure 9. Diagram Showing all Electrical Connections

*Note:Terminal 37 is not available on IVS Sensorless pumps

38
11.8.1 access to terminals Control terminal functions and factory settings are
4.8.1 ACCESS TO TERMINALS as follows:
Control terminal functions and factory settings are as follows:
Terminal No. Type / Description Factory Setting

terminal no. type / description factory setting
1,2,3 Relay 1 Running
4,5,6 1,2,3
Relay 2 Relay 1 Alarm Running
4,5,6 Relay 2 Alarm
12 Supply +24V DC
12 Supply +24v dc
13 Supply +24V DC
13 Supply +24v dc
18 Digital Input Start
18 Digital input Start
19 Digital Input Pump Operating Mode
19 Digital input Pump operating
20 Common 0V mode
4.8.1 ACCESS TO TERMINALS Control terminal functions and factory settings are as follows:
27 20 Common Low Water Interlock
Digital Input ok
Terminal No. Type / Description Factory Setting
27 Digital input Low water interlock
4.8.1 ACCESS TO TERMINALS Control terminal functions29 Digital Input
1,2,3
and factory settings are as follows: No1Operation Running
Relay
Terminal No. Type / Description 29

Factory Setting Digital input
4,5,6 Relay 2
NoAlarm
operation
32 Digital Input No Operation
12 Supply +24V DC
1,2,3 Relay 1 Running
32 Digital Input No operation
4,5,6 Relay 2 33 Alarm Digital Input
13 No Operation
Supply +24V DC
12 Supply +24V DC
33 Digital input
18 Digital Input
NoStart
operation
37 Digital Input No Operation
13 Supply +24V DC 37 Digital input
19 Digital Input NoPump
operation
Operating Mode
Remove front-cover to access control terminals. For D1 18 and 42 Analogue Output
20 Output
Frequency
Common 0V
Remove
D2 chassis IVS front-cover
units access toopen.
swings access(see
control terminals.
Fig. 2.13) .
Digital Input
For d1 and
Start
42 Analogue output Output
(4-20mA - 0-100Hz) frequency
When replacing the front
d2 chassis ivscover,
102 unitsplease
accessensure
swings open.19fasten-
proper Digital Input
(see Fig. 2.13). Pump Operating Mode 27 Digital Input (4-20mA
Low Water - 0-100Hz)
Interlock
53 Analogue Input Reference (0-10V)*
ing by applying a torque of 2 Nm.
When replacing the front cover, please ensure proper fastening
20 Common 0V 29 Digital Input No Operation
53 Analogue input Reference (0-10v)*
by applying a torque of 2 Nm. 27 54
Digital Input Low WaterAnalogue
Interlock Input
32 Feedback
Digital Input (0-10V)*
No Operation
4.8.2 CONTROL TERMINALS 54 Analogue input Feedback (0-10v)*
29 Digital Input No Operation 33 Digital Input No Operation
With reference to figure 10: *Note that Analogue inputs AI53 and AI54 can be either Volt-
32 Digital Input No Operation 37 Digital Input No Operation
age (0-10V) *Note or Current (4-20mA)
that Analogue input
inputs andand
ai53 by ai54
default
canboth
be either Voltage
Figure 10. Control Connections
Remove front-cover
33 to accessDigital
control inputs
Input are
terminals. set
ForNo
(0-10v) to Voltage.
D1Operation
and
or Current
42
(4-20ma)
Analogue Output
input and by
Output Frequency
default
D2 chassis IVS units access swings open. (see Fig. 2.13) . (4-20mAboth inputs
- 0-100Hz)
11.8. 2 control terminalsWhen replacing Switches S201
areNoset
and S202 (see figure 9) are used to configure
to Voltage.
37 the front cover,
Digitalplease
Input ensure proper 53Switches s201 and s202 (see figure 9) are
fasten-
Operation Analogue Input Reference (0-10V)*
ing by applying a torque of 2 Nm. the analogue inputs as follows:
Remove front-cover to access control terminals. For D1 and 42 Analogue Output used
OutputtoFrequency
configure 54 the analogue inputs
Analogue Inputas follows:
Feedback (0-10V)*
D2 chassis IVS units access swings open. (see Fig. 2.13) . 4.8.2 CONTROL TERMINALS (4-20mA - 0-100Hz)
When replacing the front
With cover, please
reference to ensure10:
figure proper fasten- 53 Analogue
S201
Input
(AI53)Reference
OFF =(0-10V)*
Voltage, ON = Current
With reference to figure 10: *Note that Analogue inputs AI53 and AI54 can be either Volt-
ing by applying a torque of 2 Nm. S202 (AI54) s201OFF = Voltage,
(ai53) ageON
off = Voltage, = Current
(0-10V) on = Current
or Current (4-20mA) input and by default both
54 Analogue Input Feedback (0-10V)*
4.8.2 CONTROL TERMINALS Figure 10. Control Connections s202 (ai54) off = Voltage,
inputs are seton = Current
to Voltage.
fig . 10 control connections Inserting Cables Switches S201 and S202 (see figure 9) are used to configure
With reference to figure 10: *Note that Analogue inputs AI53 and AI54 caninto Control
be either Volt- Terminals
the analogue inputs as follows:
1age10-way
(0-10V) orplug for
Current (4-20mA) input and by default both
inputs are set to Voltage.i) Strip 10mm of insulation
Figure 10. Control Connections digital i/0 from
S201 the
(AI53) OFFcable:
= Voltage, ON = Current
Inserting CablesS202
into(AI54)
Switches S201 and S202 (see figure 9) are used to configure Control Terminals
OFF = Voltage, ON = Current

2the3analogue
-way plug inputs as follows:
for ii) Insert a suitable terminal screwdriver
Inserting Cables intoas
Control Terminals

S201rs485 bus= Voltage,
(AI53) OFF ON = Current
shown andi Strip
then 10mm of insulation
push the cable into from the cable:
the terminal.
S202 (AI54) OFF = Voltage, ON = Current i) Strip 10mm of insulation from the cable:
3Inserting
6
-way plug for Terminals ii Insert a suitable terminal screwdriver
Iii) Remove as
Cables into Control theshown
terminal
andscrewdriver and
ii) Insert a suitable
then and push the terminal screwdriver as
cable into
analogue i/0 check the terminal shown
has gripped thethen push
cable the cable into the terminal.
the
i) Strip 10mm of insulation from the cable: terminal.
4ii) Insert
usb aconnection by gently pulling it. Iii) Remove the terminal screwdriver and
iii asRemove the terminal screwdriver and
suitable terminal screwdriver check the terminal has gripped the cable
shown and then push the cable into the terminal. by gently pulling it.
Note: Terminal check the can
plugs terminal has re-
be easily gripped the cable
moved for
Iii) Remove the terminal screwdriver by gently access
andimproved pulling it.Terminal
when
Note: making
plugs can be easily re-
check the terminal has gripped the cable moved for improved access when making
by gently pulling it. connections. connections.
Note: Terminal plugs can be easily removed
Note: Terminal plugs can be easily re-
moved for improved access when makingfor improved access when making connections.
connections.
1. 10 way plug for digital I/O
1. 10 way plug for digital I/O 2. 3 way plug for RS485 Bus
2. 1.3 10
way 3. 6 way plug for analogue I/O
wayplug for
plug for RS485
digital I/O Bus
4. USB Connection
3. 2.6 3way plug
way plug forfor analogue
RS485 Bus I/O
3. 6 way plug for analogue I/O Page 14 of 26
4. USB Connection
4. USB Connection
Page 14 of 26 Page 14 of 26
39
11.8.3 connection ex amples ii closed loop – with sensor feedback
Design Envelope pumps can be configured in four main ways: To control the pump based on a 4-20mA feedback signal
from a sensor use the following connection.
i Sensorless
12 (+24v )
ii Closed loop – with feedback sensor
24v 20 (0v )
iii Constant curve mode – Potentiometer Control
Start Signal 18 (d in)
iv Constant curve mode – bms signal
19 (d in)
iv.i Full speed override
27 (d in)
29 (d in)
i sensorless 32 (d in)
33 (d in)
Design Envelope pumps are factory configured to be Feedback from Sensor
connected as shown below. 4-20mA - Input t54
Power Supply (24 vdc) Pressure Sensor 50 (10v)
for sensor t13=24v
12 (+24v ) (0-10 bar / 4 -20ma)
53 (Ain)
20 (0v ) 54 (Ain)
55 (0v )
19 ( d in)
Output Fr equency 42 (Aout)
27 ( d in) 4-20mA Analog ue Out
39 (Aout)
29 (d in)
32 (d in) 3 (r1 n/c)

Running Output 2 (r1 n/o)
33 (d in)
1 (r1 com)
50 (10v)
53 (Ain) 6 (R2 N/C)

Alarm Output 5 (R2 N/ O)
54 (Ain)
4 (R2 COM)
55 (0v )
Output Fr equency 42 (Aout)

4-20mA Analog ue Out
39 (Aout)
3 (r1 n/c)
1 (r1 com)
6 (R2 N/C)
Alarm Output 5 (R2 N/ O)
4 (R2 COM)

40
iii constant curve mode – bms signal iv.i full speed over ride
When the Building Management System is to be used for It may be required to run the pump at full speed without
speed control it is necessary to disable sensorless control automatic speed control (eg during system commissioning).
and provide the unit with a 0-10vdc speed reference signal. This can be achieved without programming changes by
12 (+24v ) making the connections below.
20 (0v )
Start Signal 18 (d in) 12 (+24v )

19 (d in) 20 (0v )
Low Water Signal 27 (d in)
29 (d in)
19 (d in)
32 (d in)
Low Water Signal
27 (d in)
33 (d in)
29 (d in)
50 (10v) 32 (d in)
53 (Ain) 33 (d in)
0-10v Signal from bms
Input t53 (common t55) 54 (Ain)
55 (0v )
Link 10vdc (t50 ) into 50 (10v)
Analogue I nput t5 3 53 (Ain)
Output Frequency 42 (Aout)
4-20mA Analogue Out 54 (Ain)
39 (Aout)
55 (0 v)
3 (r1 n/c)
Running Output 2 (r1 n/o) 42 (Aout)
Output Frequency
1 (r1 com) 4-20mA Analogue Out
39 (Aout)
6 (r2 n/c)
Alarm Output 5 (r2 n/o) 3 (r1 n/c)
4 (r2 com)
1 (r1 com)
6 (r2 n/c)
Alarm Output 5 (r2 n/o)
iv constant curve mode – potentiometer 4 (r2 com)
To control the pump based on a 0-10v potentiometer signal

use the connections below.
11.8. 4 remote lcp keypad wiring
12 (+24v )
20 (0v )
For large Design Envelope units with remote lcp keypad, see
Start Signal 18 (d in) wiring arrangement below.
19 (d in))
Low Water Signal
27 (d in))
lc p w i r i n g a r r a n g e m e n t
29 (d in))
32 (d in))
33 (d in)) terminal wire color
50 (10v)
1 Green
0-10v Derived from 1k
Potentiometer into Input
53 (Ain) 2 Brown
t53 (common t55) 54 (Ain)
55 (0v )
3 Red
4 Yellow
Output Frequency 42 (Aout)
4-20mA Analogue Out 5 Black
39 (Aout)
6 Orange
3 (r1 n/c)
7 Blue
1 (r1 com) 8 Purple
9 Grey
6 (r2 n/c)
Alarm Output 5 (r2 n/o)
4 (r2 com)

41
12.0 p rogr amming, monitoring The number of the Active set-up (Sensorless mode being
and diagnostics setup 1) is shown.
Design Envelope pumps incorporate an integrated graphical The middle section (b) shows up to five variables with related
local control panel (glcp). unit, regardless of status. In case of alarm/warning, the
warning is shown instead of the variables.
The Bottom section (c) always shows the state of the inverter
12 .1 glcp functions and oper ation
in Status mode.
The glcp is divided into four functional groups:
It is possible to toggle between three status read-out displays
a by pressing the Status key.
Operating variables with different formatting are shown in
1 b
each status screen — see below.
c
Status display I:
2 This read-out state is standard after start-up or initialisation.
Use Info to obtain information about the value/measurement
linked to the displayed operating variables (1.1, 1.2, 1.3, 2 and
3). See the operating variables shown in the display in this
3 illustration. 1.1,1.2 and 1.3 are shown in small size. 2 and 3 are
shown in medium size.
Status display II:

4
See the operating variables (1.1, 1.2, 1.3 and 2) shown in the
display in this illustration.
1 Graphical display with status lines.

2 M
enu keys and indicator lights (leds) – selecting mode,
changing parameters and switching between
display functions.
3 N
avigation keys and indicator lights (leds).
4 O
peration keys and indicator lights (leds).
Graphical display:
The lcd-display is back-lit with a total of six alpha-numeric In the example, Speed, Motor current, Motor power and Fre-
lines. All data is displayed on the lcp which can show up to quency are selected as variables in the first and second lines.
five operating variables while in Status mode. 1.1, 1.2 and 1.3 are shown in small size. 2 is shown in large size.
Display lines: Display Contrast Adjustment
a S
tatus line: Status messages displaying icons
and graphics.
b L ine 1–2: Operator data lines displaying data and variables
de-fined or chosen by the user. By pressing the Status key,
up to one extra line can be added.
c Status line: Status messages displaying text.
The display is divided into three sections:

Top section (a) shows the status when in status mode or up Press Status and [p] for darker display
to two variables when not in status mode and in the case of Press Status and [q] for brighter display
alarm/warning.

42
12 . 2 indicator lights (leds) Alarm Log

Displays an Alarm list of the five latest alarms (numbered
If certain threshold values are exceeded, the alarm and/or
a1-a5). To obtain additional details about an alarm, use the
warning led lights up. A status and alarm text appear on the
arrow keys to manoeuvre to the alarm number and press ok.
control panel. The on led is activated when the frequency
Information is displayed about the condition of the frequency
converter receives power from mains voltage, a dc bus ter-
converter before it enters the alarm mode.
minal, or an external 24v supply. At the same time, the back
light is on. The Alarm log button on the lcp allows access to both Alarm
log and Maintenance log.
Back
Reverts to the previous step or layer in the
navigation structure.
Cancel
Last change or command will be cancelled as long as the
• Green led/on: Control section is working. display has not been changed.
• Yellow led/warn.: Indicates a warning.
Info
• Flashing Red led/alarm: Indicates an alarm.
Displays information about a command, parameter, or func-
tion in any display window. Info provides detailed information
12 .3 control keys when needed.
Menu keys
The menu keys are divided into functions. The keys below the
display and indicator lamps are used for parameter set-up, in-
Navigation Keys
cluding choice of display indication during normal operation.
The four navigation arrows are used to navigate between the
different choices available in Quick Menu, Main Menu and
Alarm Log. Use the keys to move the cursor.
OK
Status Is used for choosing a parameter marked by the cursor and
Indicates the status of the frequency converter and/or the for enabling the change of a parameter.
motor. Three different readouts can be chosen by pressing
Operation Keys for local control are found at the bottom of the
the Status key: five line readouts, four line readouts or Smart control panel.
Logic Control.
Use Status for selecting the mode of display or for changing
back to Display mode from either the Quick Menu mode, the
Main Menu mode or Alarm mode. Also use the Status key to
toggle single or double read-out mode.
Quick Menu
Allows quick set-up of the inverter by access to a limited
number of parameters. Quick Menu does not include all
Hand On
the parameters that may need to be changed when utilis-
ing Sensorless control and it is therefore recommended that Enables control of the pump via the glcp. It is possible to
parameter changes are made in Main Menu mode. enter the pump speed data by means of the arrow keys.
Main Menu
Is used for programming all parameters.

43
T
he low water device input must be made for the 12 . 4 .1 par ameter selection
pump to start in either hand mode or auto mode.
In the Main Menu mode, the parameters are divided into
groups. You select a parameter group by means of the navi-
Off gation key
Stops the pump. The following parameter groups are accessible:
Auto On group parameter group parameter

no. group no. group
Enables the pump to be controlled via the control terminals
and/or serial communication. When a start signal is applied 0 Operation/display 13 Smart Logic
on the control terminals the pump will start. 1 Load/motor 14 Special functions
F or the pump to operate in either Sensorless mode 2 Brakes 15 fc information

or any other automatic control mode it is neces- 3 References/ramps 16 Data readouts
sary to have pressed the Auto On button. 4 Limits/warnings 18 Data readouts 2
5 Digital in/out 20 Drive closed loop
Reset
6 Analog in/out 21 Ext. closed loop
Is used for resetting the frequency converter after an
8 Com. and options 22 Application functions
alarm (trip).
9 Profibus 23 Time-based
functions
12 . 4 progr amming 10 can Fieldbus 25 Cascade controller
Select the Main Menu mode by pressing the Main Menu 11 LonWorks 26 Analog i/0 option
mcb 109
key. The below read-out appears on the display. The middle
and bottom sections on the display show a list of parameter
groups which can be chosen by toggling the up and
down buttons.
Each parameter has a name and number which remain the

same regardless of the programming mode. In the Main
Menu mode, the parameters are divided into groups. The
first digit of the parameter number (from the left) indicates
the parameter group number.
After selecting a parameter group, choose a parameter by

means of the navigation keys.
The middle section on the display shows the parameter
number and name as well as the selected parameter value.
All parameters can be changed in the Main Menu. However,

depending on the choice of configuration (Par.1-00 Configu-
ration Mode), some parameters can be hidden.

44
12 . 4 . 2 changing data Readout and Programming of Indexed Parameters

Parameters are indexed when placed in a rolling stack.
The procedure for changing data depends on whether the
selected parameter represents a numerical data value or a Par.15-30 Alarm Log: Error code to Par.15-33 Alarm Log: Date
text value. and time contain a fault log which can be read out. Choose a
parameter, press OK, and use the up/down navigation keys
Changing a text value to scroll through the value log.
If the selected parameter is a text value, change the text
Use Par.3-10 Preset Reference as another example:
value by means of the [] [] navigation keys.
Choose the parameter, press OK, and use the up/down navi-
The up key increases the value, and the down key decreases
gation keys to scroll through the indexed values. To change
the value.
the parameter value, select the indexed value and press OK.
Place the cursor on the value you want to save and press OK. Change the value by using the up/down keys. Press OK to
accept the new setting. Press Cancel to abort.
Press Back to leave the parameter.
13 .0 sensorless oper ation

Sensorless control is an innovative concept in circulating
pumps. Pump performance and characteristic curves are
embedded in the memory of the speed controller during
Changing Numeric Data Values
manufacture. This data includes power, speed, head and flow
If the chosen parameter represents a numeric data value,
across the flow range of the pump. During operation, the
change the chosen data value by means of the [] [] navi-
power and speed of the pump are monitored, enabling the
gation keys as well as the [] [] navigation keys. .
controller to establish the hydraulic performance and posi-
tion in the pumps head-flow characteristic.
These measurements enable the pump to continuously iden-

tify the head and flow at any point in time, giving accurate
pressure control without the need for external feedback
signals. Patented software technology within the controller
ensures trouble-free operation in all conditions.
Incorporating the pumps hydraulic data into the controller
Use the [] [] navigation keys to move the and removing sensors results in true integration of all com-
cursor horizontally. ponents and removes the risk of sensor failure.
Use the [] []navigation keys to change the data value.
The up key enlarges the data value, and the down key re- 13 .1 d
efault oper ating mode —
duces the data value. Place the cursor on the value you want quadr atic pressure control
to save and press OK.
The default control mode for Design Envelope pumps is
‘Quadratic Pressure Control’ where the controller is set to
control the speed according to a ‘control curve’ between max
and min flow (see below diagram). It is widely recognised
that fitting a differential pressure sensor at the most remote
load, across the supply piping and return piping encompass-
ing the valve & coil set, is the benchmark scheme for
energy efficiency.

45
fig . 11 quadr atic control set tings parameters depending on whether the speed at the design duty
is known or unknown.
h (head)
Speed at Required System Design Point is known
(Refer to fig. 11):
a
hdesign
set point 1 Set the design head, hdesign, value in par. 20-21 (Setpoint 1),
p20-21 after setting unit of head in par. 20–12 (Reference/
n des
n r a t -86
ign
Feedback unit)
p
ed
hmin 22
p22-87 control curve 2 Set the speed of the pump at design head, hdesign, and design
flow using par. 22–86 (Speed at Design Point [Hz])
p22-89 q (flow)
3 Set the minimum head required, hmin, using par. 22–87
(Pressure at No-Flow Speed).
Design Envelope pumps can replicate this control without the 4 Adjust the shape of the control curve if required using par.
need for the remote sensor. As the flow required by the system 22–81 as shown in figure 12.
is reduced, the pump automatically reduces the head developed
according to the pre-set control curve.
13 . 2 constant pressure control
It is often found that using a remote differential pressure sensor
to sense the pressure across a remote load could theoretically Design Envelope pumps can be configured to maintain a con-
result in loads close to the pump being under-pumped. The stant pump head in a system as the demand varies. This effec-
situation would be where the load at a loop extremity is satis- tively simulates the mounting of a differential pressure sensor
fied and the control valve closes while a load close to the pump at, or near, the pump.
needs full flow. The probability of this occurring is remote but
it is possible. One answer to this is to move the sensor closer 13 . 2 .1 s et tings for constant pressure control
to the pump (two-thirds out in the system is a popular recom-
mendation) although physically re-positioning the sensor at 1 To revert to this mode of control simply follow these steps:
commissioning stage can be a costly exercise. With Sensorless Set the design head, hdesign, value in par. 20–21 (Setpoint 1).
pump control it is possible to replicate the moving of a sensor by In the units set in par.20–12 (Reference/feedback unit.)
increasing the head setting hmin . 2 Turn off flow compensation by setting par. 22-80 to
‘Disabled’ [0]
13 .1.1 s et tings for quadr atic (control curve)

pressure control 13 .3 changing control modes
The design duty head and flow of the pump (provided at time of
13 .3 .1 change to external sensor control
order) is shown as point ’A’ in figure 11 in column 1.
1 Change parameter 0-10 from 1 to 2
fig . 12 curve approximation set tings
2 Connect the sensor to terminals 54 (+) and 55 (-)
3 Move switch s202 (beside terminal input 54) to on if the
h (head)
speed command is 4-20mA, or leave it off if it’s 0-10Vdc
4 If the sensor signal is neither 0-10Vdc nor 4-20mA, enter the
correct voltage or input range in parameters 6-10 to 6-13
5 Enter the sensor and setpoint data in the parameters
0%
-81 listed below
p22
%
100
control curve
q (flow)
In order for the controller to determine the true fit and position
of the control curve it is necessary to set some specific param-
eters with data relating to specific points within the operating
range of the pump. There are two ways of programming the

46
param. name setup 2 (external sensor)

14 .0 warnings and alarms
0-10 Active set-up 2 A warning or an alarm is signalled by the relevant led on the
Terminal 54 low ref. front of the inverter and indicated by a code on the display.
6-24 Minimum sensor value
/feedback value A warning remains active until its cause is no longer present.
Terminal 54 high Under certain circumstances operation of the pump may still
6-25 Maximum sensor value
Ref./feedback value
be continued. Warning messages may be critical, but are not
Feedback 1 source
20-02
unit
Unit of external sensor necessarily so.
Reference/feed- In the event of an alarm, the inverter will have tripped. Alarms
20-12 Unit of external sensor
back unit
must be reset to restart operation once their cause has been
Minimum refer-
20-13 Low limit of sensor rectified. In many cases the auto reset function will restart the
ence/feedback
Maximum refer- pump. Alternatively, the Reset button on the control panel can
20-14 Upper limit of sensor
ence/feedback be pressed.
20-21 Setpoint 1 Design setpoint
pid proportional Needs to be fine tuned on Start After a manual reset using the Reset button on the
20-93
gain site at 2
control panel, the Auto On button must be pressed to
Needs to be fine tuned Start
20-94 pid Integral Time restart the pump.
on site at 1
Wake Up Speed Need to be fine tuned Start at
22-43
[Hz] on site 20 If an alarm cannot be reset, the reason may be that its cause has
not been rectified, or the alarm is trip-locked (see also table on
following page).
13 .3 . 2 change to open loop (bas) control
Alarms that are trip-locked offer additional protection, means
1 Change parameter 0-10 from 1 to 3 that the mains supply must be switched off before the alarm can
be reset. After being switched back on, the inverter is no longer
2 Connect the bas command on terminals 53 (+) and 55 (-)
blocked and may be reset as described above once the cause
3 Move switch s201 (beside terminal input 53) to on if the speed
has been rectified.
command is 4-20mA, or leave it off if it’s 0-10Vdc
Alarms that are not trip-locked can also be reset using the
4 If the reference signal is neither 0-10Vdc nor 4-20mA, enter
automatic reset function in par. 14–20 Reset Mode (Warn-
the correct voltage or input range in parameters 6-10 to 6-13
ing: automatic wake-up is possible!) If a warning and alarm is
5 The maximum speed (at 20mA or 10Vdc) can be adjusted in
marked against a code in the table on the following page, this
parameter 3-03
means that either a warning occurs before an alarm, or it can
6 The drive on/off status can be read as a dry contact between be specified whether it is a warning or an alarm that is to be
terminals 05 and 06 displayed for a given fault. This is possible, for instance, in par.
7 The drive alarm status can be read as a dry contact between 1–90 Motor Thermal Protection. After an alarm or trip, the mo-
terminals 01 and 02 tor carries on coasting, and the alarm and warning flash on the
8 Terminals 42(+) and 39(-) can provide a 0/4-20mA output inverter. Once the problem has been rectified, only the alarm
which by default is disabled, but can be configured to provide continues flashing.
speed feedback or sensorless flow
13 .3 .3 change to sensorless control
1 Change parameter 0-10 to 1

The unit will start controlling based on the pump design data
2 If the pump operation point needs to be changed, see the
parameters that need to be modified in Section 6.1 Sensorless

47
14 .1 fault messages wa r n i n g /a l a r m 11, Motor thermistor over temp:

The thermistor or the thermistor connection is disconnected.
wa r n i n g 1, 10 Volts low: You can choose if you want the inverter to give a warning or an
The 10 v voltage from terminal 50 on the control card is below alarm in par. 1-90 Motor Thermal Protection. Check that the
10 v. Remove some of the load from terminal 50, as the 10 v sup- thermistor is connected correctly between terminal 53 or 54
ply is over-loaded. Max. 15 ma or minimum 590 Ω. (analog voltage input) and terminal 50 (+ 10 Volts supply), or
wa r n i n g /a l a r m 2, Live zero error: between terminal 18 or 19 (digital input pnp only) and terminal
The signal on terminal 53 or 54 is less than 50% of the value set 50. If a kty sensor is used, check for correct connection between
in par.6–10 Terminal 53 Low Voltage, par. 6–12 Terminal 53 Low terminal 54 and 55.
Current, par.6–20 Terminal 54 Low Voltage, or par. 6–22 Termi- wa r n i n g /a l a r m 12, Torque limit:
nal 54 Low Current respectively. The torque is higher than the value in par. 4–16 Torque Limit Mo-
wa r n i n g /a l a r m 3 , No motor: tor Mode (in motor operation) or the torque is higher than the
No motor has been connected to the output of the inverter. value in par.4–17 Torque Limit Generator Mode (in regenerative
operation).
wa r n i n g /a l a r m 4 , Mains phase loss:
A phase is missing on the supply side, or the mains voltage im- wa r n i n g /a l a r m 13, Over Current:
balance is too high. This message also appears in case of a fault The inverter peak current limit (approx. 200% of the rated cur-
in the input rectifier on the inverter. Check the supply voltage rent) is exceeded. The warning will last approx. 8–12 sec., then
and supply currents to the inverter. the inverter trips and issues an alarm. Turn off the inverter and
check if the motor shaft can be turned and if the motor size
wa r n i n g 5 , d c link voltage high: matches
The intermediate circuit voltage (dc) is higher than the over- the inverter.
voltage limit of the control system. The inverter is still active.
a l a r m 14, Earth fault:
wa r n i n g 6, dc link voltage low: There is a discharge from the output phases to earth, either in
The intermediate circuit voltage (dc) is below the under voltage the cable between the inverter and the motor or in the motor
limit of the control system. The inverter is still active. itself. Turn off the inverter and remove the earth fault.
wa r n i n g /a l a r m 7, dc over voltage: a l a r m 15, In-complete hardware:
If the intermediate circuit voltage exceeds the limit, the inverter A fitted option is not handled by the present control board
trips after a time. (hardware or software).
wa r n i n g /a l a r m 8, dc under voltage: a l a r m 16, Short-circuit:
If the intermediate circuit voltage (dc) drops below the “voltage There is short-circuiting in the motor or on the motor terminals.
warning low” limit, the inverter checks if 24 v back-up supply is Turn off the inverter and remove the short-circuit.
connected. If no 24 v backup supply is connected, the inverter
trips after a given time depending on the unit. wa r n i n g /a l a r m 17, Control word timeout:
There is no communication to the inverter.The warning will only
wa r n i n g /a l a r m 9, Inverter overloaded: be active when par. 8–04 Control Timeout Function is not set to
The inverter is about to cut out because of an overload (too off. If par. 8–04 Control Timeout Function is set to Stop and Trip,
high current for too long). The counter for electronic, thermal a warning appears and the inverter ramps down to zero speed,
inverter protection gives a warning at 98% and trips at 100%, while giving an alarm. par. 8–03 Control Timeout Time could
while giving an alarm. You cannot reset the inverter until the possibly be increased.
counter is below 90%. The fault is that the inverter is overloaded
by more than nominal wa r n i n g 22, Hoist Mech. Brake:
Report value will show what kind it is.0 = The torque ref. was not
wa r n i n g /a l a r m 10, Motor etr over temperature: reached before timeout1 = There was no brake feedback
According to the electronic thermal protection (etr), the motor before timeout.
is too hot. You can choose if you want the inverter to give a
warning or an alarm when the counter reaches 100% in par. 1–90 wa r n i n g 23, Internal fans:
Motor Thermal Protection. The fault is that the motor is over- External fans have failed due to defect hardware or fans not
loaded by more than nominal current for too long. Check that mounted.
the motor par. 1–24 Motor Current is set correctly. wa r n i n g 24, External fan fault:
The fan warning function is an extra protection function that
checks if thefan is running / mounted. The fan warning can be
disabled in par.14–53 Fan Monitor, [0] Disabled.

48
wa r n i n g 25, Brake resistor short-circuited: wa r n i n g /a l a r m 36, Mains failure:

The brake resistor is monitored during operation. If it short- This warning/alarm is only active if the supply voltage to the
circuits, the brake function is disconnected and the warning inverter is lost and par. 14–10 Mains Failure is not set to off.
appears. The inverter still works, but without the brake function. Possible correction: check the fuses to the frequency converter
Turn off the inverter and replace the brake resistor (see par. 2–15
wa r n i n g /a l a r m 37, Phase Imbalance:
Brake Check).
There is a current imbalance between the power units.
a l a r m / wa r n i n g 26, Brake resistor power limit:
a l a r m 38, Internal fault:
The power transmitted to the brake resistor is calculated as a
Contact your local Armstrong supplier.
percentage, as a mean value over the last 120 s, on the basis of
the resistance value of the brake resistor (par. 2–11 Brake Resis- a l a r m 39, Heatsink Sensor:
tor (ohm)) and the intermediate circuit voltage. The warning is No feedback from the heatsink sensor.
active when the dissipated braking power is higher than 90%. If
wa r n i n g 40, Overload of Digital Output Terminal 27:
Trip [2] has been selected in par. 2–13 Brake Power Monitoring,
Check the load connected to terminal 27 or remove short-circuit
the inverter cuts out and issues this alarm, when the dissipated
connection. Check par. 5–00 Digital i/o Mode and par. 5–01
braking power is higher than 100%.
Terminal 27 Mode.
wa r n i n g /a l a r m 27, Brake chopper fault:
wa r n i n g 41, Overload of Digital Output
The brake transistor is monitored during operation and if it
Terminal 29:
short-circuits, the brake function disconnects and the warning
Check the load connected to terminal 29 or remove short-circuit
comes up. The inverter is still able to run, but since the brake
connection. Check par. 5–00 Digital i/o Mode and par. 5–02
transistor has short-circuited, substantial power is transmitted
Terminal 29 Mode.
to the brake resistor, even if it is inactive. Turn off the inverter
and remove the brake resistor. Warning: There is a risk of wa r n i n g 42, Overload of Digital Output On x30/6 :
substantial power being transmitted to the brake resistor if the Check the load connected to x30/6 or remove short-circuit
brake transistor is short-circuited. connection. Check par. 5–32 Term X30/6 Digi Out (mcb 101).
a l a r m / wa r n i n g 28, Brake check failed: wa r n i n g 42, Overload of Digital Output On x30/7 :

Brake resistor fault: the brake resistor is not connected/working. Check the load connected to x30/7 or remove short-circuit con-
nection. Check par. 5–33 Term x30/7 Digi Out (mcb 101).
wa r n i n g /a l a r m 2 9 , Drive over temperature:
If the enclosure isip00, ip20/Nema1 or ip21/type 1, the cut-out a l a r m 46, Pwr. card supply:
tem-perature of the heat-sink is 203°f +9°f (95°c +5°c). The The supply on the power card is out of range.
temperature fault cannot be reset, until the temperature of the wa r n i n g 47, 24 v supply low:
heatsink is below 158°f (70°c). The fault could be: -Ambient The external 24 v dc backup power supply may be overloaded,
temperature too high; -Too long motor cable otherwise contact your Armstrong supplier.
a l a r m 30, Motor phase U missing: a l a r m 48, 1.8 v supply low:
Motor phase U between the frequency converter and the motor Contact your Armstrong supplier.
is missing.Turn off the frequency converter and check motor
phase U. wa r n i n g 49, Speed limit:
The speed has been limited by range in par. 4–11 Motor Speed
a l a r m 31, Motor phase V missing: Low Limit [rpm] and par. 4–13 Motor Speed High Limit [rpm].
Motor phase V between the inverter and the motor is missing.
Turn off the inverter and check motor phase V. alarm 50, ama calibration failed:
Contact your Armstrong supplier.
a l a r m 32, Motor phase W missing:
Motor phase W between the inverter and the motor is missing. a l a r m 51, ama check Unom and Inom:
Turn off the frequency converter and check motor phase W. The setting of motor voltage, motor current, and motor power is
presumably wrong. Check the settings.
a l a r m 3 3 , Inrush fault:
Too many power ups have occured within a short time period. a l a r m 52, ama low Inom:
The motor current is too low. Check the settings.
wa r n i n g /a l a r m 34, Fieldbus a l a r m 53, ama motor too big:
communication fault: The motor is too big for the ama to be carried out.
The fieldbus on the communication option card is not working.

49
a l a r m 54, ama motor too small: a l a r m 69, Pwr. Card Temp:

The motor is too small for the ama to be carried out. Power card over temperature.
a l a r m 55, ama par. out of range: a l a r m 70, Illegal Frequency Converter Configuration:
The par. values found from the motor are outside Actual combination of control board and power board is illegal.
acceptable range.
a l a r m 90, Feedback Mon.:
a l a r m 56, ama interrupted by user:
The ama has been interrupted by the user. a l a r m 91, Analogue Input 54 Wrong Settings:
Switch s202 has to be set in position off (voltage input), when a
a l a r m 57, ama timeout:
kty sensor is connected to the analogue input terminal 54.
Try to start the ama again a number of times, until the ama is
carried out. Please note that repeated runs may heat the motor a l a r m 92, No Flow:
to a level where the resistance rs and rr are increased. In most A no load situation has been detected for the system.
cases, however, this is not critical. See parameter group 22–2*.
wa r n i n g /a l a r m 58, ama internal fault: a l a r m 93, Dry Pump:

Contact your Armstrong supplier. A no flow situation and high speed indicates that the pump has
run dry. See parameter group 22–2*.
wa r n i n g 59, Current limit:
The current is higher than the value in par. 4–18 Current Limit. a l a r m 94, End of Curve:
Feed back stays lower than the set point, which may be indicates
wa r n i n g 60, External Interlock:
a leak-age in the pipe system. See parameter group 22–5*.
External Interlock has been activated. To resume normal
operation, apply 24 v dc to the terminal programmed for Ex- a l a r m 95, Broken Belt:
ternal Interlock and reset the inverter (via Bus, Digital i/o or by Torque is below the torque level set for no load indicating a
pressing Reset). broken belt. See parameter group 22–6*.
wa r n i n g /a l a r m 61, Tracking Error: a l a r m 96, Start Delayed:

Tracking error. Contact your supplier. Start of the motor has been delayed due to short cycle protec-
tion is active. See parameter group 22–7*.
wa r n i n g 62, Output Frequency at Maximum Limit:
The output frequency is limited by the value set in par. 4–19 a l a r m 250, New Spare Part:
Max Output Frequency The power or Switch Mode Power Supply has been exchanged.
The inverter type code must be restored in the eeprom. Select
wa r n i n g 64, Voltage Limit:
the correct type code in par. 14–23 Type code Setting accord-
The load and speed combination demands a motor voltage
ing to the label on unit. Remember to select ‘Save to eeprom’ to
higher than the actual dc link voltage.
complete.
wa r n i n g /a l a r m / t r i p 65, Control Card Over Temperature:
a l a r m 251, New Type Code:
Control card over temperature: The cut-out temperature of the
The frequency converter has got a new type code.
control card is 176°f (80°c).
wa r n i n g 66, Heatsink Temperature Low:

The heat sink temperature is measured as 32°f (0°c). This could 15 .0 acoustic noise and vibr ation
indicate that the temperature sensor is defective and thus the
If the pump or the pipework close to the pump is making noise
fan speed is increased to the maximum in case the power part or
or vibrations at certain frequencies, try the following:
control card is very hot. If the temperature is below 59°f (15°c)
the warning will be present.
• Speed Bypass, parameters 4 – 6*
a l a r m 67, Option Configuration has Changed: • Over-modulation, parameter 14– 03 set to off
One or more options has either been added or removed since • Switching pattern and frequency parameters 14 – 0*
the last power-down. • Resonance Dampening, parameter 1–64
a l a r m 68, Safe Stop:
Safe Stop has been activated. To resume normal operation,
apply 24 vdc to terminal 37 then send a Reset signal (via Bus,
Digital i/o or by pressing Reset).

50
table 1 Alarm/warning code list
alarm alarm
no. description warning par ameter reference
/ trip / trip lock
1 10 volts low x
2 Live zero error (x) (x) Par. 6-01 Live zero
time-out function
3 No motor (x) Par. 1-80 Function at Stop
4 Mains phase loss (x) (x) (x) Par. 14-12 Function at mains
imbalance
5 dc link voltage high x
6 dc link voltage low x
7 dc over voltage x x
8 dc under voltage x x
9 Inverter overloaded x x
10 Motor etr over temperature (x) (x) Par. 1-90 Motor thermal
protection
11 Motor thermistor over termperature (x) (x) Par. 1-90 Motor thermal
protection
12 Torque limit x x
13 Over current x x x
14 Earth fault x x x
15 Incomp. hw x x
16 Short circuit x x
17 Control word timeout (x) (x) Par. 8-04 Control time-out
function
23 Internal fans
24 External fans
25 Brake resistor short circuited x
26 Brake resistor power limit (x) (x) Par. 2-13 Brake power monitoring
27 Brake chopper short circuited x x
28 Brake check (x) (x) Par. 2-15 Brake check
29 Power board over temp x x x
30 Motor phase U missing (x) (x) (x) Par. 4-58 Missing motor
phase function
31 Motor phase V missing (x) (x) (x) Par. 4-58 Missing motor
phase function
32 Motor phase W missing (x) (x) (x) Par. 4-58 Missing motor
phase function
33 Inrush fault x x
34 Fieldbus communication fault x x
36 Mains failure
38 Internal fault x x

51
alarm alarm
no. description warning par ameter reference
/ trip / trip lock
40 Overload t27
41 Overload t29
42 Overload x30/6-7
47 24v supply low x x x
48 1.8v supply low x x
49 Speed limit
50 ama calibration failed x
51 ama check Unom and Inom x
52 ama low Inom x
53 ama motor too big x
54 ama motor too small x
55 ama parameter out of range x
56 ama interrupted by user x
57 ama timeout x
58 ama internal fault x x
59 Current limit x
60 External interlock
62 Output frequency at x
maximum limit
64 Voltage limit x
65 Control board-over x x x
temperature
66 Heat sink temperature low x
67 Option configuration has x
changed
68 Safe stop activated x
70 Illegal fc configuration
80 Drive initialized to Default x
Value
92 No-flow x x Par. 22-2*
93 Dry pump x x Par. 22-2*
94 End of curve x x Par. 22-5*
95 Broken belt x x Par. 22-6*
96 Start delayed x Par. 22-7*
97 Stop delayed x Par. 22-7*
98 Clock fault x Par. 0-7*

52
table 2 ivs 102 parameter settings
setup 1 setup 2 setup 3

par. name
(sensorless) (external sensor) (external bms)
0-20 Display line 1.1 Small Reference [unit] Reference [unit] Reference [%]
0-21 Display line 1.2 Small Frequency Frequency Frequency
operation/ 0-22 Display line 1.3 Small Power (kW or hp Power (kW or hp Power (kW or hp
display depending on site) depending on site) depending on site)
0-23 Display line 2 large Feedback 1 [unit] Feedback 1 [unit] Feedback 1 [unit]
0-24 Display line 3 large Sensorless Readout Sensorless Readout No Function
1-00 Configuration mode Closed Loop Closed Loop Open Loop
1-03 Torque charasteristics Variable Torque Variable Torque Variable Torque
1-20 Motor power [kW] Motor nameplate power Motor nameplate power Motor nameplate power
load and 1-22 Motor voltage Motor nameplate Volts Motor nameplate Volts Motor nameplate Volts
motor 1-23 Motor frequency 60 or 50 per nameplate 60 or 50 per nameplate 60 or 50 per nameplate
1-24 Motor current FLA per nameplate FLA per nameplate FLA per nameplate
1-25 Motor nominal speed [rpm] Motor nameplate speed Motor nameplate speed Motor nameplate speed
1-73 Flying start Enabled Enabled Enabled
brakes 2-17 Over-voltage control Enabled Enabled Enabled
3-02 Minimum reference 0 No operation 0
3-03 Maximum reference Hdesign [in unit of No operation Max frequency of app
mapped perf data] (50 or 60Hz)
3-15 Reference 1 source No operation No operation Analog input 53
reference/ 3-16 Reference 2 source No operation No operation No operation
ramps 3-17 Reference 3 source No operation No operation No operation
3-41 Ramp up time Desired ramp time Desired ramp time Desired ramp time
(60s typical) (60s typical) (60s typical)
3-42 Ramp down time Desired ramp time Desired ramp time Desired ramp time
(60s typical) (60s typical) (60s typical)
4-10 Motor speed direction Clockwise Clockwise Clockwise
4-11 Motor speed low limit [rpm]
limits/ 4-12 Motor speed low limit [hz] Min frequency Min frequency Min frequency
of application of application of application
warnings
4-13 Motor speed high limit [rpm]
4-14 Motor speed high limit [hz] Max frequency Max frequency Max frequency
of application of application of application
5-01 Terminal 27 mode Input Input Input
5-10 Terminal 18 digital input Start Start Start
5-11 Terminal 19 digital input No operation No operation No operation
5-12 Terminal 27 digital input Run Permissive Run Permissive Run Permissive
5-13 Terminal 29 digital input Jog Jog Jog
digital 5-14 Terminal 32 digital input No operation No operation No operation
in/out 5-15 Terminal 33 digital input No operation No operation No operation
5-16 Terminal x30/2 digital input No operation No operation No operation
5-40 Function relay 1 No operation No operation Alarm
5-40 Function relay 2 No operation No operation Running

53
setup 1 setup 2 setup 3

par. name
(sensorless) (external sensor) (external bms)
6-00 Live zero timeout time No operation 1s No operation
6-01 Live zero timeout function No operation Stop No operation
6-10 Terminal 53 low voltage No operation No operation 0.07
6-11 Terminal 53 high voltage No operation No operation 10
6-12 Terminal 53 low current No operation No operation 4
6-13 Terminal 53 high current No operation No operation 20
6-14 Terminal 53 low ref./feedb. value No operation No operation 0
analog
6-15 Terminal 53 high ref./feedb. value No operation No operation 60
in/out
6-20 Terminal 54 low voltage No operation 0.07 No operation
6-21 Terminal 54 high voltage No operation 10 No operation
6-22 Terminal 54 low current No operation 4 No operation
6-23 Terminal 54 high current No operation 20 No operation
6-24 Terminal 54 low ref./feedb. value No operation minimum sensor value 0
6-25 Terminal 54 high ref./feedb. value No operation maximum sensor value 60
6-50 Terminal 42 output No operation No operation No operation
8-30 Protocol fc, mc Depends on controller Depends on controller
comm. 8-31 Address 1 Depends on controller Depends on controller
and option 8-32 Baud rate 9600 Depends on controller Depends on controller
8-33 Parity/stop bits Even Prity, 1 Stop bit Depends on controller Depends on controller
14-10 Mains failure [0] No function [0] No function [0] No function
14-11 Main voltage at mains fault Set to 83.5% of site voltage Set to 83.5% of site voltage Set to 83.5% of site
voltage
special 14-12 Function at mains imbalance [0] No function [0] No function [0] No function
functions 14-60 Function at over temperature [1] Derate [1] Derate [1] Derate
14-61 Function at inverter overload [1] Derate [1] Derate [1] Derate
14-62 Inverter overload derate 95 95 95
current (%)
20-00 Feedback 1 source Sensorless Pressure Analog input 54 No operation
20-02 Feedback 1 source unit Unit used for feedback 1 source Unit of external sensor No operation
20-12 Reference/feedback unit Unit of par 2021 (ex: ft WG) Unit of external sensor No operation
20-13 Minimum reference/feedback Low limit of sensor No operation
20-14 Maximum reference/feedback Max of head and flow mapped Upper limit of sensor No operation
drive 20-20 Feedback function Minimum Minimum No operation
closed
20-21 Setpoint 1 Design Head in unit in par 2012 Design setpoint No operation
loop
20-60 Sensorless unit Unit of par1850 (ex: GPM) not used No operation
20-70 Closed-loop type not used Fast Pressure No operation
20-71 pid performance not used Normal No operation
20-93 pid proportional gain Start at 0.05 Needs to be fine tuned on site No operation
20-94 pid integral time Start at 0.1 Needs to be fine tuned on site No operation
22-43 Wake up speed [hz] No operation Needs to be fine tuned on site No operation
22-50 End of curve function Off Off Off
22-80 Flow compensation Enabled No operation Disabled
22-81 Square-linear curve approximation 100% No operation 100%
application
functions 22-84 Speed at no-flow [hz] No operation Frequency at no flow No operation
and minimum head set
22-86 Speed at design point [hz] No operation No operation No operation
22-87 Pressure at no-flow speed 40% of maximum system head No operation No operation
22-89 Flow at design point Flow at Design Point No operation No operation


SECTION-04.07
HQ – CHILLED WATER PUMPS
154
SECTION 03.07 HQ – CHILLERS – MANUFACTURER/VENDORS
MANUFACTURER
93 East Avenue
North Tonawanda, New York - USA
14120-6594
Phone: +1 716 693 8813
VENDORS
ARABIAN A/C CO (CARRIER)
TEL 4911333
FAX 4916758
P.O BOX 9784
RIYADH 11423
PH:00966112104666
155

SECTION-04.08
HQ – CHILLED WATER PUMPS
WARANATY CERTIFICATE
156
157

SECTION-05
EXPANSION TANK AND AIR SEPARATOR
158

SECTION-05
EXPANSION TANK AND AIR SEPARATOR

159

SECTION-05.01
HQ - EXPANSION TANK AND AIR SEPARATOR
160
SECTION 03.01 HQ – EXP. TANK & AIR SEPARATOR - DESCRPITION AND MODEL

3 AIR SEPARATOR AMTROL 16-AS PUMP ROOM
EXPANSION TANK
pre-pressurized, diaphragm-design EXTROL 1000 L expansion tank was
designed to control system pressure and help reduce energy consumption of
heating and circulating operations. Today, AMTROL offers a broad range of both
bladder and diaphragm expansion tanks.
When the system is first filled with cold water, the EXTROL's pre-charge pressure,
which is equal to the fill pressure, keeps the diaphragm flush against the tank.
As the system water temperature increases, the expanded water is received by
the EXTROL tank.
As the system water temperature reaches its maximum, the EXTROL diaphragm
flexes against the air cushion to allow for the increased water expansion.
AIR SEPARATOR
Amtrol tangential air separators are designed to create a low velocity
vortex that separates and removes entrained air from circulating water or anti-
freeze in a closed, non-potable water system. Available in 1" to 24" connection
sizes with an optional stainless-steel strainer to collect unwanted system debris.
161

SECTION-05.02
NAME PLATE DATA
162
CERTIFIED BY AMTROL INC.
MAWP 125 P.S.I AT 240 F.
MDMT +18 F. AT 125 P.S.I
MFG. SER. NO. 400053 YEAR BUILT 2019
SIZE 1000
CERTIFIED BY AMTROL INC.
MAWP 125 P.S.I AT 240 F.
MDMT +18 F. AT 125 P.S.I
MFG. SER. NO. 400055 YEAR BUILT 2019
SIZE 1000
163

SECTION-05.03
GENERAL CATALOGUE
164
®
EXTROL ASME
EXPANSION TANKS
For Closed Hydronic Heating & Chilled Water Systems
165
Quality ASME Expansion Tanks
Table of Contents The First in the Industry

AMTROL® designed and patented the first EXTROL®
AMTROL Quality Expansion Tanks .... 2
expansion tank in 1954, redefining hydronic heating
How It Works....................................... 2 systems. For over four decades our unique, pre-pressurized,
diaphragm-design EXTROL has been the world's leading
Typical Commercial Installation .......... 2 expansion tank. EXTROL was designed to control system
pressure and help reduce energy consumption of heating
Commercial ASME Models ................ 3 and circulating operations. Today, AMTROL offers a broad
range of both bladder and diaphragm expansion tanks.
AX-Series EXTROL® Models............... 4
L-Series EXTROL® Models ................. 5

The AMTROL Advantage
• AMTROL and its subsidiaries offer a complete line of
LBC-Series EXTROL® Models ............ 6 quality engineered products for heating and water
systems throughout the world.
Sizing the EXTROL® ............................ 7
• ISO 9001-2000 Certification reflects AMTROL's
Typical Specification ........................... 8 worldwide vision and commitment to excellence.

• Full technical support is available.
How AMTROL Expansion Tanks Work
When the system is first filled with As the system water temperature As the system water temperature reaches
cold water, the EXTROL's pre-charge increases, the expanded water is its maximum, the EXTROL diaphragm
pressure, which is equal to the fill received by the EXTROL tank. flexes against the air cushion to allow
pressure, keeps the diaphragm flush for the increased water expansion.
against the tank.
2 166
The EXTROL® System
The Function of Hydro-Pneumatic Tank

Water Heating and Chilled Water Systems
The primary device in pressurizing and maintaining pressure control in a Superior Performance
closed system is the hydro-pneumatic tank, also known, traditionally, as with AMTROL's
the expansion tank. Heavy-Duty Butyl Bladder
Its function in the pressurization process is as follows:
Bladder Cross-Section Comparison
1. Through the use of a pneumatic cushion (air), it maintains positive
minimum pressure throughout the system when it is initially filled.
2. As temperature rises, it provides an additional space in the system for
the expanded volume of water that results. This is accomplished as
the pneumatic cushion is compressed as system pressure increases,
creating additional space for the increased volume of water. As the
system temperature drops, the compressed pneumatic cushion forces AMTROL Brand "X" Brand "Y"
water back into the system, maintaining a positive pressure on the
system during all temperatures in the system's operating range. THICKER IS BETTER!
3. Properly sized, the hydro-pneumatic tank will maintain maximum
system pressures within the working pressure limitations of the system L-Series and
equipment and components. LBC Series (Models 130-600)
4. By maintaining a positive pressure on the system throughout all the
operating temperature range, the hydro-pneumatic tank enables the
designer to constantly vent excess air through the use of automatically
operating float type air vents.
Typical Installation of Commercial Models
3
167
AX-Series EXTROL®
AX-Series EXTROL®
Horizontal & Vertical Models
• Proven diaphragm design since 1954

• Designed and constructed per ASME Section VIII,
Division 1 standards
• Horizontal models are available with optional saddles
• Factory pre-charged to 12 psig (0.83 bar)
• Maximum working pressure is 125 psig (8.6 bar)
• Maximum operating temperature is 240°F (115° C)
AX Vertical Series
AX-Series Specifications
Tank Max. A – Vert. C – Horiz. B System Ship Weight Ship Weight Vertical
Model Volume Accept. Height Length Diameter Conn.1 w/o saddles w/ saddles Ship.Wt.
Number Gallons Liters Gallons Liters Inches mm Inches mm Inches mm Inches lbs. kg lbs. kg lbs. kg
AX-15(V)* 8.0 30.3 2.4 9.1 19 1⁄2 495 19 1⁄4 489 12 305 ⁄
12 37 17 41 19 43 20
AX-20(V) 10.9 41.3 2.4 9.1 26 1⁄2 673 26 1⁄4 607 12 305 ⁄
12 46 21 50 23 45 21
AX-40(V) 21.7 82.2 11.3 42.8 29 1⁄2 749 29 737 16 1⁄4 356 1⁄2 82 37 96 44 90 41
AX-60(V) 33.6 127.2 11.3 42.8 45 1⁄8 1146 43 1073 16 1⁄4 356 1⁄2 103 47 116 53 110 50
AX-80(V) 44.4 168.1 22.6 85.5 29 737 28 9⁄16 725 24 610 1 127 58 104 47 146 66
AX-100(V) 55.7 211.8 22.6 85.5 33 11⁄16 856 33 840 24 610 1 137 62 114 52 167 76
AX-120(V) 68.0 257.4 34.0 128.7 47 3⁄8 1203 41 3⁄16 1051 24 610 1 210 95 235 107 224 102
AX-144(V) 77.0 291.5 34.0 128.7 52 1⁄4 1327 46 1170 24 610 1 240 109 246 112 244 111
AX-180(V) 90.0 340.7 34.0 128.7 59 5⁄8 1514 53 7⁄16 1357 24 610 1 242 110 248 113 266 121
AX-200(V) 110.0 416.4 34.0 128.7 66 1⁄8 1680 64 1624 24 610 1 275 125 306 139 296 134
AX-240(V) 132.0 500.0 46.0 174.0 57 7⁄8 1470 51 1295 30 762 1 398 181 428 194 427 194
AX-260(V) 159.0 600.0 56.0 212.0 64 3⁄4 1645 62 1⁄4 1581 30 762 11⁄4 449 204 480 218 476 216
AX-280(V) 211.0 800.0 84.0 318.0 81 3⁄4 2076 80 2032 30 762 11⁄4 630 286 660 299 645 293
1
System Connection for models AX-15 through AX-100 (vertical and horizontal) and models AX-120V through AX-240V are NPTF, models AX-260 through AX-280 (vertical and horizontal) and
AX-120 through AX-240 are NPTM.
*To specify vertical models AX -15V – AX-280V, include V after the model number; other options available on horizontal models: • Bulls Eye Sight Glass • Seismic Anchor Brackets
All dimensions and weights are approximate.
4 168
L-Series EXTROL®
L-Series EXTROL®
•Replaceable bladder design

•Designed and constructed per ASME
Section VIII, Division 1 standards
•Free-standing on integral floor stands
•Easily installed
•Factory pre-charged to 12 psig (0.83 bar)
•Maximum working pressure is 125 psig (8.6 bar)
•Available with optional 175 psig (12 bar) or 250 psig (17 bar)
for high-pressure applications “L” Series
•Maximum operating temperature is 240ºF (115°C)
L Series EXTROL
L-Series Specifications
Tank A B C System Shipping
Model Volume Height Diameter Standard Diameterr Conn.1 Weight
Number Gallons Liters Inches mm Inches mm Inches mm Inches mm lbs. kg
200-L 53 200 375⁄8 956 24 610 19 483 1 25 192 87
300-L 80 300 511⁄2 1308 24 610 19 483 1 25 268 122
400-L 106 400 657⁄16 1662 24 610 19 483 1 25 309 140
500-L 132 500 79 2006 24 610 19 483 1 25 328 149
600-L 158 600 633⁄4 1619 30 762 24 610 11⁄2 38 510 231
800-L 211 800 813⁄4 2076 30 762 24 610 11⁄2 38 565 256
1000-L 264 1000 731⁄2 1867 36 914 30 762 11⁄2 38 691 313
1200-L 317 1200 857⁄8 2181 36 914 30 762 11⁄2 38 779 353
1400-L 370 1400 981⁄4 2496 36 914 30 762 11⁄2 38 905 411
1600-L 422 1600 691⁄8 1756 48 1219 42 1067 11⁄2 38 1,183 537
2000-L 528 2000 84 2145 48 1219 42 1067 11⁄2 38 1,264 573
2500-L 660 2500 1007⁄8 2562 48 1219 42 1067 2 50 1,445 655
3000-L 792 3000 11818 3000 48 1219 42 1067 2 50 1,630 739
3500-L 925 3500 111 2820 54 1372 42 1067 2 50 2,110 957
4000-L 1057 4000 125 3175 54 1372 42 1067 2 50 2,230 1012
5000-L 1321 5000 128 3251 60 1524 42 1067 2 50 2,450 1111
1
System Connection is NPTF All dimensions and weights are approximate.
5
169
LBC-Series EXTROL®
LBC-Series EXTROL®
The LBC bottom connection bladder series incorporates a

partial acceptance replaceable bladder made of a heavy-
duty butyl material. The seamless bladder construction
and contoured bladder design ensures repeatable and
predictable long-life expectancy.
•Designed and constructed per ASME

Section VIII, Division 1 standards
•Replaceable bladder design
•Maximum working pressure is 125 psig (8.6 bar)
•Maximum operating temperature is 240ºF (115° C)
•Broad range of sizes from 10 gal. (35 lit.) to
158 gal. (600 lit.)
•Factory pre-charged to 12 psig (8.6 bar)
•Available with optional seismic restraints and site glass
Lifting Ring
Air Charge
Nut
Adapter
Lifting Ring
Diffuser
Bladder
Drain
Flange Ring
Stand
Blind Flange Elbow
LBC Series Tank
LBC-Series Specifications
Model Tank Volume Accept. Volume A Height B Diameter System Conn.1 Shipping Weight
Number Gallons Liters Gallons Liters Inches mm Inches mm Inches mm lbs. kg
35-LBC 10 35 10 35 3813⁄16 985 10 254 1 25 65 29
50-LBC 13 50 11 40 3813⁄16 985 12 305 1 25 72 33
85-LBC 22 85 11 40 377⁄16 951 16 406 1 25 88 40
100-LBC 26 100 11 40 421⁄8 1070 16 406 1 25 94 43
130-LBC 34 130 27 100 377⁄8 962 20 508 1 25 130 59
165-LBC 44 165 27 100 427⁄8 1089 20 508 1 25 140 64
200-LBC 53 200 27 100 407⁄8 1039 24 610 1 25 192 87
300-LBC 80 300 27 100 56 1423 24 610 1 25 230 104
400-LBC 106 400 53 200 685⁄8 1743 24 610 1 25 274 124
500-LBC 132 500 53 200 821⁄2 2096 24 610 1 25 308 140
600-LBC 158 600 53 200 67 1702 30 762 1 25 442 200 LBC Series EXTROL
1
System Connection is NPTF All dimensions and weights are approximate.
6 170
Sizing Commercial ASME Models
Precise Sizing of AX, L and LBC-Series EXTROL®s
Things you must know: Selection of EXTROL Model:
1. Total System Volume................................................(1)_____ gal. (lit.) 6. Find and enter "Net Expansion Factor".................... (6)_____ (see Table 1)
2. Minimum System Temperature................................(2)_____ °F (°C) 7. Amount of Expanded Water = line (1) x line (6) ...... (7)_____ gallon (lit.)
3. Maximum System Temperature ..............................(3)_____ °F (°C) 8. Find and enter "Acceptance Factor" ........................ (8)_____ (see Table 2)
4. Minimum Operating Pressure at EXTROL Tank .... (4)_____ psig(bar) 9. Minimum Total EXTROL Volume = line (7) ÷ line (8) (9)_____ gallons (lit.)
10.Using Specifications, select an EXTROL that is at least equal to line
5. Maximum Operating Pressure at EXTROL Tank .... (5)_____ psig(bar) (9) for "Total Volume" and line (7) for Max. Expanded Water
Acceptance Gallons.
Table 1. Net Expansion of Water

Max. System Temperature Minimum System Temperature
°F °C 40°F / 4°C 50°F / 10°C 60°F / 16°C 70°F / 21°C 80°F / 27°C 90°F / 32°C 100°F / 38°C
60°F 16 .0005 .0049 — — — — —
70°F 21 .00149 .00143 .00094 — — — —
80°F 27 .00260 .00254 .00204 .00111 — — —
90°F 32 .00405 .00399 .00350 .00256 .00145 — —
100°F 38 .00575 .00569 .00520 .00426 .00315 .00170 —
110°F 43 .00771 .00765 .00716 .00622 .00511 .00366 .00196
120°F 49 .0100 .0099 .0095 .0086 .0074 .0060 .0043
130°F 54 .0124 .0123 .0118 .0109 .0098 .0083 .0066
140°F 60 .0150 .0149 .0145 .0135 .0124 .0110 .0093
150°F 66 .0179 .0178 .0173 .0164 .0153 .0133 .0121
160°F 71 .0209 .0208 .0204 .0194 .0181 .0165 .0148
170°F 77 .0242 .0241 .0236 .0227 .0216 .0201 .0184
180°F 82 .0276 .0275 .0271 .0261 .0250 .0236 .0219
190°F 88 .0313 .0312 .0307 .0298 .0287 .0272 .0255
200°F 93 .0351 .0350 .0346 .0336 .0325 .0311 .0294
210°F 99 .0391 .0390 .0386 .0376 .0365 .0351 .0334
220°F 104 .0434 .0433 .0428 .0419 .0408 .0393 .0376
230°F 110 .0476 .0475 .0471 .0461 .0450 .0436 .0419
240°F 116 .0522 .0521 .0517 .0507 .0496 .0482 .0465
Note: For 50/50 ethylene glycol and for 50/50 propylene glycol contact AMTROL technical services.
Table 2. Acceptance Factors*

Maximum Operating Minimum Operating Pressure at Tank
Pressure at Tank
5 psig/0.34 bar 10 psig/0.68 bar 12 psig/0.82 bar 15 psig/1 bar 20 psig/1.37 bar 30 psig/2 bar 40 psig/2.8 bar 50 psig/3.44 bar 60 psig/4 bar 70 psig/4.8 bar 80 psig/5.5 bar
27 psig 1.8 bar 0.527 0.408 0.360 0.288 0.168 — — — — — —
30 psig 2.0 bar 0.560 0.447 0.403 0.336 0.224 — — — — —
35 psig 2.4 bar 0.604 0.503 0.463 0.403 0.302 0.101 — — — — —
40 psig 2.8 bar 0.640 0.548 0.512 0.457 0.366 0.183 — — — — —
45 psig 3.0 bar 0.670 0.586 0.553 0.503 0.419 0.251 0.084 — — — —
50 psig 3.4 bar 0.696 0.618 0.587 0.541 0.464 0.309 0.155 — — — —
55 psig 3.79 bar 0.717 0.646 0.617 0.574 0.502 0.359 0.215 0.072 — — —
60 psig 4.0 bar 0.736 0.669 0.643 0.602 0.536 0.402 0.268 0.134 — — —
65 psig 4.4 bar 0.753 0.690 0.665 0.627 0.565 0.439 0.314 0.188 0.062 — —
70 psig 4.8 bar 0.767 0.708 0.685 0.649 0.590 0.472 0.354 0.236 0.118 — —
75 psig 5.0 bar 0.780 0.725 0.702 0.669 0.613 0.502 0.390 0.279 0.167 0.056 —
80 psig 5.5 bar 0.792 0.739 0.718 0.686 0.634 0.528 0.422 0.317 0.211 0.106 —
90 psig 6.2 bar 0.812 0.764 0.745 0.716 0.669 0.573 0.478 0.382 0.287 0.191 0.096
100 psig 7.0 bar 0.828 0.785 0.767 0.741 0.698 0.610 0.523 0.436 0.347 0.261 0.174
110 psig 7.5 bar 0.842 0.802 0.786 0.762 0.723 0.642 0.561 0.481 0.401 0.321 0.241
* Acceptance factors based on EXTROL being charged while empty of liquid to minimum operating pressure.
7
171
Typical Specification for Extrol®
Hydronic Expansion Tank “Typical Specification ASME Vessels”
AX Series Expansion Tank (Diaphragm type pre-pressurized)

The pressurization system shall include an EXTROL®‚ diaphragm-type expansion tank which will accommodate
the expanded water of the system generated within the normal operating temperature range, limiting this
pressure increase at those components in the system to the maximum allowable pressure at those components.
It shall maintain minimum operating pressure necessary to eliminate all air. The only air in the system shall
be the permanent sealed-in air cushion contained in the diaphragm-type tank, Model No._____________.
Dimensions shall be as indicated on the drawings.
The expansion tank shall be welded steel, constructed, tested and stamped in accordance with Section VIII,
Division 1 of the ASME Code for a working pressure of (125 psig/8.6 bar) (________) and air pre-charged.
The tank shall be supported by steel legs or a base (integral ring mount) for a vertical installation or steel
saddles for horizontal installations. Each tank will have a heavy- duty butyl/EPDM diaphragm with code
approvals ANSI/NSF 61.
The manufacturer shall be AMTROL Inc. The manufacturer shall have at least five years experience in the
fabrication of diaphragm-type ASME expansion tanks.
L & LBC Series Expansion Tank (replaceable bladder-type pre-pressurized)

The pressurization system shall include an EXTROL®‚ replaceable bladder-type expansion tank which will
accommodate the expanded water of the system generated within the normal operating temperature range,
limiting this pressure increase at those components in the system to the maximum allowable pressure at
those components. It shall maintain minimum operating pressure necessary to eliminate all air. The only air
in the system shall be the permanent sealed-in air cushion contained in the replaceable bladder-type tank,
Model No._____________. Dimensions shall be as indicated on the drawings.
The expansion tank shall be welded steel, constructed, tested and stamped in accordance with Section VIII,
Division 1 of the ASME Code for a working pressure of (125 psig/86 bar) (175 psig/12 bar) (250 psig/17 bar)
(________) and air pre-charged.
The tank shall be supported by steel legs or a base (integral ring mount) for a vertical installation. Each tank
will have a heavy-duty replaceable butyl bladder (ANSI/NSF 61 “L” Series).
The manufacturer shall be AMTROL Inc. The manufacturer shall have at least five years experience in the
fabrication of bladder-type ASME expansion tanks.
*Refer to installation manual for warranty information or visit our website at www.amtrol.com
Corporate Headquarters
1400 Division Road, West Warwick, RI USA 02893
Telephone: 401-884-6300 • Fax: 401-884-5276
AMTROL Canada, Ltd.
275 Shoemaker Street, Kitchener, Ontario N2E 3B3
®
Telephone: 519-478-1138 • Fax: 519-748-4231

AMTROL Asia Pacific Ltd.
89 Owen Road, Singapore 218902
w w w . a m t r o l . c o m Telephone: 65-6294 4611 • Fax: 65-6294 3231
The AMTROL® logo and EXTROL® are registered trademarks of AMTROL Inc. In the interest of continuous development, AMTROL Inc. and it’s subsidiaries reserve the right to alter designs and specifications without prior notice.
Part # 9017-105 (08/04) MC# 2682 ©2004 AMTROL Inc.

Printed in USA
172
173
174
175
176

SECTION-05.04
177
TANGENTIAL AIR SEPARATORS
FOR CLOSED HYDRONIC HEATING AND CHILLED WATER SYSTEMS
INSTALLATION & OPERATION INSTRUCTIONS
Models 1-ASL through 24-AS(L)
NOTE: Inspect for shipping damage and notify freight carrier or store where purchased immediately if damage is present. To avoid risk of personal
injury and property damage, if the product appears to be malfunctioning or shows signs of corrosion, call a licensed professional immediately. Current
copies of the Product manual can be viewed at www.amtrol.com. Use proper safety equipment when installing.
THIS IS THE SAFETY ALERT SYMBOL. IT IS USED TO ALERT YOU TO POTENTIAL PERSONAL INJURY AND OTHER
HAZARDS. OBEY ALL SAFETY MESSAGES THAT FOLLOW THIS SYMBOL TO REDUCE THE RISK OF PERSONAL
INJURY AS WELL AS PROPERTY DAMAGE.
READ CAREFULLY THE PRODUCT Use only lead-free solder and flux for all sweat-
INSTALLATION & OPERATION INSTRUCTIONS. solder connections, as required by state and
FAILURE TO FOLLOW THE INSTRUCTIONS AND WARNINGS IN federal codes.
THE MANUAL MAY RESULT IN SERIOUS OR FATAL INJURY AND/ This Product, like most Products under pressure,
OR PROPERTY DAMAGE, AND WILL VOID THE PRODUCT may over time corrode, weaken and burst or
WARRANTY. THIS PRODUCT MUST BE INSTALLED BY A LICENSED explode, causing serious or fatal injury, leaking or flooding and/or
PROFESSIONAL. FOLLOW ALL APPLICABLE LOCAL AND STATE property damage. To minimize risk, a licensed professional must install
CODES AND REGULATIONS, IN THE ABSENCE OF SUCH CODES, and periodically inspect and service the Product. A drip pan connected
FOLLOW THE CURRENT EDITIONS OF THE NATIONAL PLUMBING to an adequate drain must be installed if leaking or flooding could cause
CODE AND NATIONAL ELECTRIC CODE, AS APPLICABLE. property damage. Do not locate in an area where leakage of the tank or
connections could cause property damage to the area adjacent to the
appliance or to lower floors of the structure.
EXPLOSION OR RUPTURE HAZARD. THE
EXPANSION TANK MUST BE OPERATED SO This product can expose you to chemicals including
THAT THE PRESSURE DOES NOT EXCEED THE MAXIMUM lead, which is known to the State of California to
WORKING PRESSURE. cause cancer and birth defects or other reproductive harm. For more
information go to www.P65Warnings.ca.gov.
178
PLEASE READ THE FOLLOWING INSTRUCTIONS CAREFULLY
IMPORTANT GENERAL SAFETY INFORMATION - ADDITIONAL SPECIFIC SAFETY ALERTS APPEAR IN THE FOLLOWING INSTRUCTIONS.
THIS PRODUCT MUST BE INSTALLED BY A

LICENSED PROFESSIONAL.
Suggested Piping Diagrams
Figure 1: AS Series
Installation Air
1. Refer to Figure 1 and 2 for proper installation of the Amtrol air separator. Vent
Shut Off
Wet weight of the separator can exceed AS
Series
Valve
strength of supports. Make sure provisions are AIR

SEPARATOR
made to support the wet weight and not just the dry weight (see System
Purge System
A
weight chart below). Failure to follow these instructions may result Clearance To Return
in serious or fatal personal injury and/or property damage.

Remove Strainer
Circulator Blow
Down
2. AS or ASL sizes through the 8-AS or 8-ASL can be supported in the Pressure-
piping system as long as pipe hangers are attached to the tangential Relief
nozzles as close to the unit’s shell as possible. Sizes larger than the
Valve
8-AS or 8-ASL must be supported by the stand. Factory installed EXTROL ®
Boiler
Expansion
seismic restraints are optional. Tank
Welding to the pressure vessel boundary will

void the ASME rating.
3. Model AS air separators have strainers, which must be removed and
cleaned after 24 hours of operation, 30 hours of operation and as required
to maintain proper air separation. Before installing the model AS, refer to Figure 2: AS-L Series
clearance chart for minimum distances to be maintained between the blind Pressure-
flange and any wall or other obstruction for strainer removal. Air
Vent
Reducing
Valve
Backflow
Preventer
4. A manual blowdown valve (MBV) can be added to the blowdown AS-L
Series
Water
Supply
connection at the bottom of the tank. The function of the MBV is to AIR
SEPARATOR
Shut Off
facilitate the purging of sediment from the vessel.

Valve
Shut Off System
System Valve Purge System
Supply Return
Maintenance Flow-Check
Valve
Circulator
licensed professional should check the complete system, including

A Pressure-
Relief
the air separator, yearly and more frequently as the system ages. Valve
Leakage, corrosion or indications of damage are EXTROL ®
Boiler
signs of an impending serious failure of the air Expansion
Tank
separator. Periodically inspect for damage and, if noted, the separator

must be serviced or replaced immediately. Failure to follow these
instructions may result in serious or fatal personal injury and/or
property damage.
The strainer in the AS series separator may need to be cleaned
periodically. This is particularly true during the initial start-up period. The
need to clean the strainer will be evidenced by a high pressure drop across Clearance Chart Weight Chart
the separator or by pump cavitation problems. To clean the strainer: Model A Model Dry Weight Wet Weight
Number (Inches) Number (lbs) (lbs)
1. Allow the system water temperature to cool below 100°F.
Water temperature above 100°F can be very 2-AS 12 1-ASL 15 20
hazardous. Allow system water temperature 2½-AS 13 2-AS(L) 70 100
to cool down below 100°F before blowing down the separator.
Failure to follow these instructions may result in serious or fatal 3-AS 15 2½-AS(L) 70 110
personal injury and/or property damage. 4-AS 17 3-AS(L) 75 140
2. Open the blowdown drain valve for a few seconds. This should
dislodge accumulated dirt from the strainer. If it does not, then the 5-AS 22 4-AS(L) 80 195
strainer must be removed from the separator for cleaning. Start by 6-AS 24 5-AS(L) 180 400
closing the isolation valve to isolate the separator from the system.
Next, open the blowdown valve on the bottom of the separator to drain 8-AS 30 6-AS(L) 250 575
the unit. Make sure that all of the flow from the blowdown valve has 10-AS 36 8-AS(L) 455 1,175
stopped. If water continues to flow, the isolation valve must be repaired
or replaced before proceeding. 12-AS 45 10-AS(L) 770 2,075
System fluid under pressure and/or high 14-AS 49 12-AS(L) 1,150 3,200
temperature can be very hazardous. Before 16-AS 59 14-AS(L) 2,200 4,800
proceeding to service the strainer, reduce system pressure to
zero and isolate the separator from the system. Allow system 18-AS 62 16-AS(L) 4,300 7,275
temperature to cool below 100°F. Failure to follow these 20-AS 70 18-AS(L) 4,900 10,300
instructions may result in serious or fatal personal injury and/or
property damage. 24-AS 80 20-AS(L) 5,600 12,375
3. Remove the flange bolts that hold the blind flange in place on the side 22-AS(L) 6,500 13,950
of the tank. Remove the blind flange and slide the strainer out of the
tank. Clean the strainer and reinstall in the separator. Replace the 24-AS(L) 8,000 23,250
flange gasket with a new one and reinstall blind flange making sure
that the flange bolts are tightened in a criss-cross pattern to 40-50 foot
pounds. Close the blowdown valve and open the isolation valves to
return to normal operation. Check the gasket for signs of leakage. If Warranty
found, additional slight tightening of bolts may be required. AS(L) Series Models: One (1) Year Limited Warranty
Visit www.amtrol.com for complete warranty details.
1400 Division Road, West Warwick, RI USA 02893

T: 800.426.8765 www.amtrol.com
© 2019 Worthington Industries Inc. Part #: 9017-111 (01/19)

One or more features of this product are covered by U.S. patents, visit www.amtrol.com/patents for more information.
179

SECTION-05.05
180
SECTION 03.07 HQ – EX. TANK & AIR SEPARATOR – MANUFACTURER/VENDORS
MANUFACTURER
Amtrol Inc, 1400 Division Rd, West Warwick, RI 02893,

United States
Phone: +1 (401) 884-6300
VENDORS
ARABIAN A/C CO (CARRIER)
TEL 4911333
FAX 4916758
P.O BOX 9784
RIYADH 11423
PH:00966112104666
181

SECTION-06
CHEMICAL DOSING SYSTEM
182

SECTION-06
CHEMICAL DOSING SYSTEM


SECTION-06.01
HQ – CHEMICAL DOSING SYSTEM
SECTION 06.01 HQ – CHEMICAL DOSING SYSTEM
sr ITEM MODEL Capacity QTY Manufacturer

1 Dosing pump 0704 PPE 3.9 L 2 ProMinent
2 Dosing Tank Polyethylene 200 L 2 Al zamil
A two-dosing pump solenoid driven diaphragm type metering pump, PP

and Acrylic liquid ends, low operation cost, compact construction, ideal for tank
bracket mounted installation, with a capacity 3.9 L/H @ 102 psi (7bar), with
220V/1ph/60Hz, with two polyethylene tanks with a capacity 200 Liters.

SECTION-06.02
NAME PLATE DATA
186
TYPE CNPB0704PVT200E010
SER. NO. / PN 2019264031 CNPB
POWER SUPPLY 100 – 230 VAC 50/60Hz
11,1W 0,43 – 0,20 A
DOSING RATE 3.9 l/h 07 bar
1,03gph 102psi
IP66/NEMA4X
TYPE CNPB0704PVT200E010
SER. NO. / PN 2019264040 CNPB
POWER SUPPLY 100 – 230 VAC 50/60Hz
11,1W 0,43 – 0,20 A
DOSING RATE 3.9 l/h 07 bar
1,03gph 102psi
IP66/NEMA4X
187

SECTION-06.03
GENERAL CATALOGUE
188
Concept PLUS Series
Economical metering pump solutions!
NSF 61/50
Approved
The ProMinent® Concept Plus series covers a capacity range of 0.19 to 4.33 GPH
(0.7 to 16.4 L/h) at pressures up to 232 psi (16 bar).
Its compact construction and features make it ideal for use in flow proportional or on/off
control applications. The Concept Plus mounts easily onto a tank or wall bracket.
Adjustment of the pump capacity is via the stroke length in the range of 10-100 % or can be
set at 1 of the 4 stroke frequency settings. This gives an adjustment ratio of 40:1.
Features & Benefits Applications

•• NSF 61/50 approved •• Swimming pools
•• Low cost opens up opportunities in the most basic •• Spas, fountains and spray pads
applications •• Cooling towers
•• PVDF wetted ends eliminate compatibility concerns •• Boiler feed applications
•• Integral bleed valve prevents “loss of prime” •• General Chlorination
•• Lowest maintenance costs in its class •• Municipal and industrial wastewater
•• External control via dry contact pulse (1:1) •• Water disinfection
•• Wetted end materials: PP, Acrylic/PVC or PVDF •• Biocide feed
•• “Pump on a drum” applications
1978
USA SINCE
| Metering Pumps | Process Instrumentation | Engineered Metering Systems |
189
Concept PLUS Series
Technical data
Capacity Data
Pump Version Capacity at Maximum mL/ Max. Pre-Primed Tubing Shipping Weight
Back Pressure stroke Stroking Rate Suction Lift Connectors (approx.)
O.D. x I.D.
psig (bar) GPH (L/h) spm ft. (m) (in.) lbs. (kg)
CNPb
1000 145 (10) 0.19 (0.7) 0.07 180 20 (6) 1/4 x 3/16 3.97 (1.8)
1601 232 (16) 0.29 (1.1) 0.10 180 20 (6) 1/4 x 3/16 3.97 (1.8)
1002 145 (10) 0.55 (2.1) 0.19 180 16 (5) 1/4 x 3/16 3.97 (1.8)
1003 145 (10) 0.79 (3.0) 0.21 240 16 (5) 1/4 x 3/16 3.97 (1.8)
0704 102 (7) 1.03 (4.0) 0.41 180 13 (4) 1/4 x 3/16 3.97 (1.8)
0705 102 (7) 1.37 (5.2) 0.36 240 13 (4) 1/4 x 3/16 3.97 (1.8)
0309 44 (3) 2.38 (9.0) 0.83 180 20 (6) 3/8 x 1/4 3.97 (1.8)
0215 22 (1.5) 4.33 (16.4) 1.45 180 5 (1.5) 3/8 x 1/4 3.97 (1.8)
External pulse contact retrofit available as an option (P/N 1022000)
NSF 50 certification only applies to NPB0 & NPB2 liquid ends
Identity code pump configuration

CNPb Concept PLUS
Version Capacity Version Capacity
1000 0.19 gph (0.7 l/h), 145 psi (10 bar) 0704 1.03 gph (4.0 l/h), 102 psi (7 bar)
1003 0.79 gph (3.0 l/h), 145 psi (10 bar) 0215 4.33 gph (16.4 l/h), 22 psi (1.5 bar)
Liquid end material:
PP Polypropylene
NP Acryllic/PVC
PV PVDF
O-rings:
B Viton® seals
E EPDM seals
T PTFE seals
Liquid end version:
0 Non-bleed version, no valve spring
1 Non-bleed version, with valve spring
2 With bleed valve, no valve spring (except 0704 models)
3 With bleed valve, with valve spring
Connection:
M 1/4" x 3/16"
N 3/8" x 1/4"
Logo:
0 With ProMinent® logo
Power Supply:
A 1 ph 230 V 50/60 Hz (Euro plug)
D 1 ph 115 V 50/60 Hz (US plug)
4 1 ph 230 V 50/60 Hz (US plug) (consult factory for pricing)
Control Option:
0 Standard (w/o external control)
B With external and level input retrofit kit, fitted, without level switch
Accessories:
1 With accessories (foot valve, injection valve, tubing)
Control Variant:
0 Standard
Approval:
01 CE
07 MET
11 MET + NSF 61
CNPb 1000 PP B 0 M 0 A 0 1 0 01
ProMinent Fluid Controls, Inc.

136 Industry Drive • Pittsburgh, PA 15275 USA © 2016 ProMinent Fluid Controls, Inc.
All Rights Reserved.
(412) 787-2484 • Fax: (412) 787-0704
PN: 7750012
1978
email: sales@prominent.us • www.prominent.us Concept_Plus.indd rev3 11/11/2016
USA SINCE
190

SECTION-06.04
HQ – CHEMICAL DOSING PUMP
191
Operating instructions
Solenoid Metering Pump

CONCEPTplus CNPb
EN
Please carefully read these operating instructions before use. · Do not discard.
The operator shall be liable for any damage caused by installation or operating errors.
The latest version of the operating instructions are available on our homepage.
Part no. 984976 Original Operating Instructions (2006/42/EC) BA CO 009 02/16 EN
192
Supplemental instructions
Supplementary information General user instructions

These operating instructions are only intended
for skilled users responsible for the operating of
oscillating metering pumps.
Fig. 1: Please read!

Read the following supplementary information
in its entirety! Should you already know this
information, you will benefit more from referring
to the operating instructions.
The following are highlighted separately in the
document:
n Enumerated lists
Operating guidelines
ð Outcome of the instructions
Information
This provides important information

relating to the correct operation of the unit
or is intended to make your work easier.
Safety notes
Safety notes are identified by pictograms - see
"Safety Chapter".
Validity
These operating instructions conform to current
EU regulations applicable at the time of publi‐
cation.
2
193
Table of contents
Table of contents
1 Identity code............................................................................................................................ 4
2 Overview of equipment .......................................................................................................... 6
3 Safety chapter......................................................................................................................... 7
4 Storage and Transport.......................................................................................................... 10
5 Assembly and Installation..................................................................................................... 11
6 Maintenance.......................................................................................................................... 14
7 Repairs.................................................................................................................................. 15
8 Faults.................................................................................................................................... 18
9 Decommissioning.................................................................................................................. 19
10 Technical data....................................................................................................................... 20
11 Accessories........................................................................................................................... 26
12 Dimensional drawings........................................................................................................... 27
13 EC / EU Declaration of Conformity for Machinery................................................................. 31
14 Installation instructions for External + Level retrofit kit CNPb (Part no. 1022099)................ 32
3
194
Identity code
1 Identity code
Product range CONCEPT plus, Version b
CNP Type
b
___ Performance data at maximum back pressure and type: refer to nameplate on the
_ pump housing
Material
PP Polypropylene
NP Clear acrylic/PVC
PV PVDF
Diaphragm and seal
E Standard with EPDM seals
B Standard with FPM seals
T Standard with PTFE flat seal
Dosing head design
0 Without bleed valve, without valve spring
1 Without bleed valve, with valve spring
2 With bleed valve, without valve spring
3 With bleed valve, with valve spring
Hydraulic connector
0 Standard connection
Design
0 with ProMinent logo
Electrical connections
A 100 - 230 V, standard European plug
B 100 - 230 V, Swiss plug
C 100 - 230 V, Australian plug
D 100 - 230 V, USA plug
Cable assembly
4
195
Identity code
Product range CONCEPT plus, Version b
0 Without cable and retrofit kit
A With external and level input retrofit

kit, loose, without level switch
B With external and level input retrofit

kit, fitted, without level switch
F With level input, fitted, with level

switch
G With external and level input, fitted,

with external cable and level switch
Accessories
0 without accessories
1 Supplied accessories
Control version
0 External contact
5
196
Overview of equipment
2 Overview of equipment
2 7
4
P_CO_0005_SW
5
6
Fig. 2: Overview of equipmentCONCEPT plus

1 Stroke length adjustment knob 5 "External control" terminal (in "External"
2 Fault / operating indicator (fault red / opera‐ operating mode, control via contact signal;
tion green) optional)
3 Multifunctional switch (stroke rates (in % of 6 "Level switch" terminal (for 1-stage level
180 or 240 strokes/min), Stop, "External" switch; optional)
operating mode (retrofit kit)) 7 Suction valve
4 Mains cable 8 Discharge valve
The leakage hole is between the suction valve and the drive housing.
6
197
Safety chapter
3 Safety chapter
Explanation of the safety information Intended use
The following signal words are used in these n Only use the pump to meter liquid feed
operating instructions to identify different chemicals.
severities of a hazard: n Only use the pump after it has been cor‐
rectly installed and started up in accord‐
ance with the technical data and specifica‐
tions contained in the operating
Signal Meaning instructions.
word n Observe the general limitations with regard
to viscosity limits, chemical resistance and
WARNI Denotes a possibly hazardous sit‐
density - see also ProMinent® resistance
NG uation. If this is disregarded, you
list in the Product Catalogue or at
are in a life-threatening situation
www.prominent.com!
and this can result in serious inju‐
ries. n All other uses or modifications are pro‐
hibited.
CAU‐ Denotes a possibly hazardous sit‐ n The pump is not intended for the metering
TION uation. If this is disregarded, it of gaseous media and solids.
could result in slight or minor inju‐ n The pump is not intended for the metering
ries or material damage. of flammable media without implementing
suitable protective measures.
n The pump is not intended to meter explo‐
sive media.
Warning signs denoting different types of
danger n The pump is not intended for operation in
areas at risk from explosion.
The following warning signs are used in these n The pump is not intended to meter radio‐
operating instructions to denote different types active media.
of danger:
n The pump is not intended for exterior
applications without the implementation of
Warning signs Type of danger suitable protective measures.
Warning – automatic n The pump is only intended for industrial
start-up. use.
n The pump should only be operated by
Warning – high- trained and authorised personnel.
voltage. Ensure that personnel are familiar with
Warning – danger oscillating metering pumps and their ope‐
zone. ration.
n Observe the information contained in the
operating instructions at the different
phases of the unit's service life.
7
198
Safety chapter
Safety notes
WARNING!
WARNING! Danger from hazardous substances!
Warning about personal and material Possible consequence: Fatal or very
damage serious injuries.
The pump can start to pump, as soon as it Please ensure when handling hazardous
is connected to the mains voltage. substances that you have read the latest
safety data sheets provided by the manu‐
– Install an emergency cut-off switch in facture of the hazardous substance. The
the pump power supply line or inte‐ actions required are described in the
grate the pump in the emergency cut- safety data sheet. Check the safety data
off management of the system. sheet regularly and replace, if necessary,
as the hazard potential of a substance can
be re-evaluated at any time based on new
findings.
WARNING! The system operator is responsible for
ensuring that these safety data sheets are
Danger of electric shock available and that they are kept up to date,
If there is a damaged housing or an as well as for producing an associated
opening is left open, the mains voltage hazard assessment for the workstations
inside is no longer sufficiently shielded. affected.
– Disconnect the pump from the mains

power supply if the housing is dam‐
aged or there is a gaping opening.
CAUTION!
Warning of feed chemical spraying around
Feed chemical can spray out of the
hydraulic components if they are manipu‐
lated or opened due to pressure in the
liquid end and adjacent parts of the
system.
power supply and ensure that it
cannot be switched on again by unau‐
thorised persons.
– Depressurise the system before com‐
mencing any work on hydraulic parts.
8
199
Safety chapter
Information in the event of an emergency
CAUTION! In an emergency, either pull out the mains plug,

turn the multifunctional switch to "Stop" or press
Warning of feed chemical spraying around the Emergency Stop switch installed on the
The metering pump can generate a mul‐ customer's side or disconnect the pump from
tiple of its rated pressure. Hydraulic parts the mains power supply in line with the emer‐
may burst if a discharge line is blocked. gency shut-down management guidelines for
your system!
– Correctly install a back pressure valve
in the discharge line behind the If feed chemical escapes, additionally ensure
metering pump. that the hydraulic system around the pump is at
atmospheric pressure. Adhere to the safety
data sheet for the feed chemical.
CAUTION!
Warning of excessive demand
The pump can meter too much if there is a
negative pressure difference between the
discharge and suction sides.
– For example with a free outlet, use a
back pressure valve with a minimum
opening pressure of 1.5 bar (not pos‐
sible with 0213).
CAUTION!
Danger of injury to personnel and material
damage
The use of untested third party compo‐
nents can result in injury to personnel and
material damage.
– Only fit parts to metering pumps that
have been tested and recommended
by ProMinent.
CAUTION!
Warning against illegal operation
Observe the regulations that apply where
the unit is installed.
9
200
Storage and Transport
4 Storage and Transport
WARNING!
Only return the metering pump for repair in a cleaned state and with a flushed liquid end - refer
to the section on decommissioning!
Only return metering pumps with a completed Decontamination Declaration form. The Decon‐
tamination Declaration constitutes an integral part of an inspection / repair order. We can only
inspect or repair a unit if a Decontamination Declaration is submitted that has been completed
correctly and in full by an authorised and qualified person on behalf of the pump operator.
The "Decontamination Declaration Form" can be found at www.prominent.com.
Ambient conditions
Data Value Unit
Minimum storage and transport temperature -10 °C
Maximum storage and transport temperature +50 °C
Maximum air humidity * 95 % rel. humidity
* non-condensing
10
201
Assembly and Installation
5 Assembly and Installation
CAUTION! CAUTION!
Warning of feed chemical spraying around Warning of destruction of the pump
The pipes can loosen or rupture if they are An incorrect mains voltage or mains fre‐
not installed correctly. quency can irreparably destroy the
metering pump.
– Route all hose lines so they are free
from mechanical stresses and kinks. – Check that the mains voltage and fre‐
– Only use original hoses with the quency agree with the values given
specified hose dimensions and wall on the nameplate.
thicknesses.
– Only use clamp rings and hose noz‐
zles that are intended for the hose
diameter in question to ensure the
long service life of the connections. CAUTION!
Possibility of your switching relay contacts
bonding
The high starting current can cause the
CAUTION! contacts of the switching relay to bond
together if the mains voltage switches a
Warning of feed chemical spraying around solenoid metering pump on and off in a
PTFE seals, which have already been process.
used / compressed, can no longer reliably – Use the switching options offered by
seal a hydraulic connection. the external contact to control the
– Always use new, unused PTFE seals. pump (functions: Pause or Contact).
– Use a starting current limiter (part no.
1059333 for 230 V) if it is impossible
to avoid switching the pump on and
off via a relay.
CAUTION!
Warning of excessive demand
The pump can meter too much if there is a
negative pressure difference between the
discharge and suction sides.
– For example with a free outlet, use a
back pressure valve with a minimum
opening pressure of 1.5 bar (not pos‐
sible with 0213).
11
202
Installing the hose line
CAUTION!
Material damage possible due to power
surges
Should the pump be connected to the
mains power supply in parallel to inductive 1
consumers (such as solenoid valves,
motors), inductive power surges can
damage the control when it is switched off.
– Provide the pump with its own con‐ 2
tacts (Phase) and supply with voltage
via a contactor relay or relay. 3
– Should this not be possible, then
switch a varistor (part no. 710912) or
an RC gate (0.22 µF/220 Ω, part no.
710802) in parallel.
4
CAUTION!
Warning against illegal operation
Observe the regulations that apply where 5
the unit is installed.
Capacity too low 6

The liquid end valves can be disturbed by
vibrations.
– Secure the metering pump so that no P_PNM_0008_SW
vibrations can occur.

Fig. 3
1. Assemble the metering pump on a
storage tank or a bracket using screws
and U-washers (Ø 6 mm).
Installation instructions for retrofit kit
2. Cut the pressure hose to the required
"Installation instructions for External + length.
Level retrofit kit CNPb (Part no. 1046731)"
- see Appendix. 3. Pull the union nut (5) and clamping ring
(4) over the hose line (6).
4. Push the shortened hose end up to the
stop over the nozzle (3).
5. Press the hose (6) on and tighten the
union nut (5).
12
203
6. Install the suction line.
To do this, shorten the free end of

the suction line so that the foot
valve hangs just above the base of
the storage tank.
With feed chemicals with impurities
or sediment, shorten the free end of
the suction line so that the foot
valve hangs at least 50 mm above
the base of the storage tank.
Keep the suction line and the suc‐

tion height as short as possible.
Route the suction line with an
upwards slope.
7. Install a foot valve.
13
204
Maintenance
6 Maintenance
Interval Maintenance work Personnel
Quarterly* n Check the metering diaphragm for damage** - refer to Technical personnel
"Repair".
n Check that the hydraulic lines are fixed firmly to the
liquid end.
n Check that the suction valve and discharge valve are
correctly seated.
n Check the leak-tightness of the entire liquid end - partic‐
ularly around the leakage hole.
n Check that the flow is correct: Allow the pump to prime
briefly - turn the multifunction switch briefly to "100 %".
n Check that the electrical connections are intact
n Check the integrity of the housing.
n Check that the dosing head screws are tight
* Under normal loading (approx. 30 % of continuous operation)

Under heavy loading (e.g. continuous operation): Shorter intervals.
** For feed chemicals which particularly load the diaphragm, e.g. those containing abrasive addi‐
tives, check the diaphragm frequently.
Tightening torque
Data Value Unit
Tightening torque for screws: 4.5 ... 5.0 Nm
14
205
Repairs
7 Repairs
Carry out repairs, which should be performed Replacing the diaphragm
by qualified technical personnel, in line with the
safety notes:
n Cleaning a valve
n Replacing the diaphragm
All other repairs: Contact your responsible
ProMinent branch!
P_CO_0015_SW
1 2 3 4 5 6
Fig. 4
n If necessary take protective measures.
n Adhere to the safety data sheet for the
feed chemical.
n Ensure that the system is at atmospheric
pressure.
1. Empty the liquid end (turn the liquid end
upside down and allow the feed chem‐
ical to run out; flush out with a suitable
medium; flush the liquid end thoroughly
when using hazardous feed chemicals!)
2. Turn the stroke adjustment dial as far as
0 % stroke length when the pump is run‐
ning (the drive axle is then difficult to
turn).
3. Switch off the pump.
4. Unscrew the hydraulic connectors on
the discharge and suction side.
5. Remove the screws (1).
6. Loosen the dosing head (2) and the
backplate (4) from the pump housing (6)
- but only loosen!
7. Hold the pump housing (6) with one
hand and clamp the diaphragm (3) with
the other hand between the dosing head
(2) and the backplate (4).
8. Loosen the diaphragm (3) from the drive
axle with a gentle backwards turn of the
dosing head (2), diaphragm (3) and
backplate (4) in an anticlockwise direc‐
tion.
15
206
Repairs
9. Unscrew the diaphragm (3) completely

from the drive axle.
CAUTION!
10. Remove the backplate (4) from the
pump housing (6). Leakage may become apparent at
a later stage.
11. Check the condition of the safety dia‐
phragm (5) and replace if necessary. – Make sure that the leakage
hole points downwards when
12. Push the safety diaphragm (5) onto the the pump is installed later -
drive axle only until it lies flush with the please refer to !
pump housing (6) and no further! – Place the backplate (4) imme‐
13. Tentatively screw the new diaphragm diately in the correct position
(3) onto the drive axle until it can go no on the pump housing (6)! Do
further. not twist the backplate on the
pump housing to prevent the
ð The diaphragm (3) is now sitting at safety diaphragm (5)
the stop of the thread. becoming warped!
14. Should this not work, remove dirt or
swarf from the threads and screw the 17. Place the diaphragm (3) into the back‐
diaphragm (3) onto the drive axle cor‐ plate (4).
rectly this time.
CAUTION!
Leakage may become apparent at
Ensure that the diaphragm is a later stage.
screwed exactly onto the drive axle
otherwise the pump will subse‐ – Do not over-tighten the dia‐
quently not meter accurately! phragm (3) in the following
step!
– Ensure that the backplate (4)
15. Unscrew the diaphragm (3) again. remains in its position so that
the safety diaphragm does not
16. Place the backplate (4) onto the pump become warped!
housing (6).
18. Hold the backplate (4) firmly and screw

the diaphragm (3) in a clockwise direc‐
tion until it is sitting tightly (the twisting
resistance of the return spring can be
felt).
19. Set the stroke length to 100 %.
20. Place the dosing head (2) with the
screws (1) onto the diaphragm (3) and
the backplate (4) - ensure that the suc‐
tion connector points downwards when
the pump is subsequently fitted.
16
207
Repairs
21. Gently tighten the screws (1) and then

tighten them diagonally. See below for – With PP and PV dosing heads, check
tightening torque. the tightening torque again after three
months!
CAUTION!
Leakage possible
– Check the tightening torque of the
screws after 24 hours of operation!
Tightening torque
Data Value Unit
17
208
Faults
8 Faults
Fault description Cause Remedy
Pump does not prime in Minor crystalline deposits on Take the suction hose out of the
spite of full stroke motion the ball seat due to the valves storage tank and thoroughly flush
and bleeding. drying out out the liquid end
Major crystalline deposits on Dismantle and clean the valves.

the ball seat due to the valves
drying out
Fluid is escaping from the The screws in the dosing head Tighten the screws in the dosing
backplate. are too loose head crosswise - see below for
the tightening torque.
The diaphragm is not tight. Replace the diaphragm - refer to

"Repair".
Fault/operating indicator The wrong mains voltage or no Connect the pump correctly to the
does not illuminate. mains voltage is connected. specified mains voltage -
according to the specification on
the nameplate
Fault/operating indicator is The fluid level in the storage Fill the storage tank.
red. tank has reached "Liquid level
low".
The multifunctional switch is Allow the multifunctional switch to

positioned between 2 selection lock into selection option 1.
options.
Electronics fault Return the pump.
Tightening torque
Data Value Unit
18
209
Decommissioning
9 Decommissioning
WARNING!
Danger from chemical residues
There is normally chemical residue in the
liquid end and on the housing after opera‐
tion. This chemical residue could be haz‐
ardous to people.
– It is mandatory that the safety infor‐
mation relating to the "Storage, trans‐
port and unpacking" chapter is read
before shipping or transporting the
unit.
– Thoroughly clean the liquid end and
the housing of chemicals and dirt.
Observe the safety data sheet for the
feed chemical.
CAUTION!
Environmental hazard due to electronic
waste
There are electronic components in the
pump, which can have a toxic effect on the
environment.
– Separate the electronic components
from the remaining parts.
– Note the pertinent regulations cur‐
rently applicable in your country!
19
210
Technical data
10 Technical data
CNPb performance table for 180 strokes/min
Type Minimum pump Minimum pump Connector Suc‐ Pri‐ Max.

capacity capacity size tion ming priming
lift* lift** pres‐
at maximum back at medium back pres‐ outside Æ sure on
pressure sure x inside Æ the
suction
side
bar l/h ml/ bar l/h ml/ mm m WS m WS bar

stroke stroke
concept plus
1000 10 0.74 0.07 5.0 0.97 0.09 6x4 6.0 1.8 8
1601 16 1.1 0.10 8.0 1.4 0.13 6x4 6.0 2.0 8
1002 10 2.1 0.19 5.0 2.6 0.24 6x4 5.0 2.5 5
0704 7 3.9 0.36 3.5 4.4 0.41 6x4 4.0 3.0 3
0309 3 9.0 0.83 1.5 13.0 1.20 8x5 2.0 2.0 1
0215 1.5 16.4 1.52 1.0 18.3 1.70 8x5 1.5 1.5 0.5
concept plus metering pumps with self-bleeding dosing head SER***
1002 10 1.8 0.17 5.0 2.7 0.2 6x4 1.8 1.8 5
0704 7 3.0 0.28 3.5 4.3 0.4 6x4 1.8 1.8 3
0309 3 9.0 0.83 1.5 13.6 1.3 8x5 1.8 1.8 1
0215 1.5 13.2 1.22 - - - 8x5 1.8 1.8 0.5
20
211
Technical data
CNPb performance table for 240 strokes/min
Type Minimum pump Minimum pump Con‐ Suc‐ Pri‐ Max.

capacity capacity nector tion ming priming
size lift* lift** pres‐
at maximum back at medium back pres‐ sure
pressure sure outside Æ on the
x inside Æ suction
side
bar l/h ml/ bar l/h ml/ mm m WS m WS bar

strok stroke
e
concept plus
1001 10 1.0 0.07 5.0 1.3 0.09 6x4 6.0 1.8 8
1602 16 1.5 0.10 8.0 1.9 0.13 6x4 6.0 2.0 8
1003 10 3.0 0.21 5.0 4.3 0.30 6x4 5.0 2.5 5
0705 7 5.2 0.36 3.5 5.9 0.41 6x4 4.0 3.0 3
0312 3 12.0 0.83 1.5 17.3 1.20 8x5 2.0 2.0 1
0223 1.5 21.9 1.52 1.0 25.2 1.75 8x5 1.5 1.5 0.5
concept plus metering pumps with self-bleeding dosing head SER***
1003 10 2.4 0.17 5.0 3.06 0.25 6x4 1.8 1.8 5
0705 7 4.2 0.29 3.5 5.2 0.36 6x4 1.8 1.8 3
0312 3 12.9 0.83 1.5 17.6 1.22 8x5 1.8 1.8 1
0223 1.5 18.6 1.29 - - - 8x5 1.8 1.8 0.5
* Suction lifts with a filled suction line and filled liquid end
** Priming lifts with clean and moist valves, feed chemical water (20 °C), at 100% stroke length,
max. stroke rate, free outlet or opened bleed valve and correctly installed piping.
**The given performance data constitutes guaranteed minimum values, calculated using medium
water at room temperature. The bypass connection with a self-bleeding dosing head is 6x4 mm.
21
212
Technical data
Material Specifications
Material type Dosing head Suction/pressure Seals Valve balls

connector
PPT Polypropylene Polypropylene PTFE Ceramic
PPE Polypropylene Polypropylene EPDM Ceramic
PPB Polypropylene Polypropylene FPM-B Ceramic
NPT Clear acrylic PVC PTFE Ceramic
NPE Clear acrylic PVC EPDM Ceramic
NPB Clear acrylic PVC FPM-B Ceramic
PVT PVDF PVDF PTFE Ceramic
Diaphragm: with a PTFE coating

Housing: PPE, fibreglass-reinforced
Electrical data
CNPb 100 ... 230 VAC ± 10%, 50 Hz/60 Hz
Specification 180 strokes/min 240 strokes/min
Nominal power 11.1 ... 10.5 W 14.3 ... 13.4 W
Current I eff 0.4 ... 0.2 A 0.46 ... 0.22 A
Peak current 1.5 A 1.5 A
Fuse* 1.6 AT 1.6 AT
* Fuses must have VDE, UL and CSA certification!
22
213
Technical data
Technical data for the inputs (contact input, level input)
Data Value Unit
Voltage with open contacts 5 ± 0.5 VDC
Input resistance 12 ± 0.5 ㏀
Short circuit current 0.5 ± 0.05 mA
Maximum level for "0" signal 1.0 V
Maximum level for "1" signal 3.5 V
Minimum closing time of contact input 20 ms
Reaction time of level input 2 s
Temperatures
CAUTION!
The 240 stroke version may fail
The 240 stroke version can overheat at ambient temperatures higher than 35 ℃.
– Only use the 240 stroke version at ambient temperatures of less than 35 ℃.
Data Value Unit
Storage and transport temperature -10 ... +50 °C
Ambient temperature during operation -10 ... +45 °C
Maximum permissible medium temperature
Dosing head material Long term For max. 15 min

at max. back pressure at max. 2 bar
PPE / PPB / PPT 50 °C 100 °C
NPE / NPB 45 °C 45 °C
NPT 45 °C 60 °C
PVT 60 °C 120 °C
23
214
Technical data
Climate
Data Value Unit
Maximum air humidity*: 95 % relative

humidity
*non-condensing
Enclosure rating and protection class

Protection against contact and humidity:
IP 65 in accordance with IEC 529, EN 60529,
DIN VDE 0470 Part 1
Degree of protection:
1 - mains power connection with protective
earth conductor
24
215
Technical data
Shipping weight
Specification Value Unit
Shipping weight 1.8 kg
Sound pressure level

Sound pressure level LpA < 75 dB in accord‐
ance with EN ISO 20361 (Type 1000)
Sound pressure level LpA < 70 dB in accord‐
ance with EN ISO 20361 (all other types)
at maximum stroke length, maximum stroke
rate, maximum back pressure (water)
25
216
Accessories
11 Accessories
Suction lances
Article Order no.
Suction lance for 200 l drum, storage tank opening 2“ DIN 570, PPE 1022511
Suction lance for 200 l drum, storage tank opening 2“ DIN 570, PCB 1022512
Suction lance for storage tank 5 - 50 l drum, storage tank opening d50, 1022645
PPE
Suction lance for storage tank 5 - 50 l drum, storage tank opening d50, 1022644
PCB
Variable suction lance with 1-stage level switch, closes when the chemical level is low.
Retrofit kits
Article Order no.
External + level input retrofit kit CNPb 1022099
Level input retrofit kit CNPb 1022115
26
217
Dimensional drawings
12 Dimensional drawings
Dimensions in mm
27
218
CONCEPT plus with bleed valve, PP and NP

85
D
C
E
132.5
29
6 10.5 34
80 31.5 56 A
92.5 108 B 12
P_CO_016_SW
Types A B C D E
0309-0213 79 112 90 178 176
1000-0704 76 110 70 162 170
28
219
CONCEPT plus without bleed valve, PP and NP

85
C
D
E
132.5
29
6 10.5 34
80 31.5 56 A
92.5 108 B 6.3
P_CO_017_SW
Types A B C D E
0309-0213 81 96 90 175 172
1000-0704 84 99 70 152 161
29
220
CONCEPT plus PV
85
D
C
E
132.5
29
6 10.5 34
80 31.5 56 A
92.5 108 B 29
P_CO_0018_SW
Types A B C D E
0309-0213 78 95 90 177 175
1000-0704 76 89 70 160 169
30
221
EC / EU Declaration of Conformity for Machinery
13 EC / EU Declaration of Conformity for Machinery

In accordance with DIRECTIVE 2006/42/EC OF THE EUROPEAN PARLIAMENT AND OF THE
COUNCIL, Appendix I, BASIC HEALTH AND SAFETY REQUIREMENTS, section 1.7.4.2. C.
We,
n ProMinent GmbH
n Im Schuhmachergewann 5 - 11
n D - 69123 Heidelberg,
hereby declare that the product specified in the following, complies with the relevant basic health
and safety requirements of the EC Directive, on the basis of its functional concept and design and in
the version distributed by us.
Any modification to the product not approved by us will invalidate this declaration.
Extract from the EC / EU Declaration of Conformity
Designation of Metering pump, CONCEPT plus product range

the product:
Product type: CNPb...
Serial number: see nameplate on the device
Relevant EC Machinery Directive (2006/42/EC)

directives:
Compliance with the protection targets of the Low Voltage Directive according
to Appendix I, No. 1.5.1 of the Machinery Directive 2006/42/EC
EU RoHS Directive (2011/65/EU)
up to 19.04.2016 from 20.04.2016

EMC Directive (2004/108/EC) EMC Directive (2014/30/EU)
Harmonised EN ISO 12100: 2010

standards
applied, in par‐ EN 809:1998 + A1:2009 + AC:2010
ticular: EN 61010-1:2010
EN 50581:2012
EN 61000-6-2:2005 + AC:2005
EN 61000-6-3:2007 + A1:2011 + AC:2012
Date: 26/01/2016
You will find the EC Declaration of Conformity to download on our homepage.
31
222
Installation instructions for External + Level retrofit kit CNPb (Part no. 1022099)
14 Installation instructions for External + Level retrofit kit

CNPb (Part no. 1022099)
Connector for external control (External oper‐ 1. Unscrew the cover at the bottom right
ating mode) on the front of the pump.
2. Punch open the marked openings.
Scope of delivery 3. Push the nut into each recess on the

inside of the cover and tighten the lower
1 cable, 2 m; 1 cable threaded connector; 1 part of the cable screw connectors to
nut; 2 plugs; 1 Torx key, TX9 make them watertight.
4. Thread the external cable and the suc‐
tion lance cable through a threaded
A contact or an electronic switch (contact con‐ cable connector.
trol, e.g. contact water meter) can be con‐
nected to the 3-wire cable for the external con‐ 5. Connect the plugs to the ends of the
trol of the pump. The pump reacts to the cables.
contact closing. The pump reacts to the contact To do so, push a screwdriver
opening with the Pause function. (0.4x2.5x75 mm) into the one hole and
guide the cable end into the other hole.
6. Insert the plugs into the respective
Installation recesses on the PCB in the pump.
7. Screw the cover back onto the pump
and tighten the threaded cable connec‐
WARNING! tors until they are watertight.
– Ensure that only trained and author‐
ised personnel install the retrofit kit.
power supply and secure to prevent
switching on again.
External control connectors

Niveau
GND
GND
Pause
Contact
Colour Function
P_CO_0014_SW
GND black
Fig. 5: View of the inserted plugs in the open
Contact blue pump - external control on the left, level alarm
on the right.
Pause brown
32
223
33
224
34
225
35
226
ProMinent GmbH
Im Schuhmachergewann 5-11
69123 Heidelberg
Germany
Telephone: +49 6221 842-0
Fax: +49 6221 842-419
Email: info@prominent.com
Internet: www.prominent.com
Heidelberg, 2, en_GB
© 2010
227
CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND

CAR PARKS FOR KACST BIOTECHNOLOGY RESEARCH FACILITY
AND HEADQUARTERS BUILDING AT KACST MAIN CAMPUS
SECTION-06.05
SECTION 03.07 HQ – EX. TANK & AIR SEPARATOR – MANUFACTURER/VENDORS
MANUFACTURER
136 Industry Dr, Pittsburgh, PA 15275
USA
Phone: +1 (412) 787-2484
VENDORS
WETICO Building Rabwa District, Al Nahdah Street P.O. BOX 9419, Riyadh, 11413, KSATEL 4911333
+966 11 240 9777 +966 11 240 9766
229

SECTION-07
MECHANICAL – HQ CHILLERS
TESTING AND COMISSIONING
230
Trane Inc of Delaware – Saudi Arabia Branch
P.O Box 15434, Al Mousa commercial complex
Olaya road, Riyadh 11444
Ph. +9661 4649735/5512/1336 fax +96614650331
Report #: Sarfaraz Chemma 3.554638
www.trane.com Job Number 220821
‫ ﻓـﺭﻉ ﺍﻟﺳﻌﻭﺩﻳﻪ‬-‫ﺗﺭﻳـــﻥ ﺃﻧــﻙ ﺃﻭﻑ ﺩﻳـﻼﻭﻳــﺭ‬ Job #: 176005018
11444 ، ‫ ﺍﻟﺭﻳﺎﺽ‬-15434 -‫ ﺏ‬. ‫ﺹ‬ Customer Ord.: -
‫ﻣﺟﻣﻊ ﺍﻟﻣﻭﺳﻰ ﺍﻟﺗﺟﺎﺭﻱ‬ Cust. Reference 1, Serial number U19C02728 Uni. RTAF500
Building name Hq Substation Customer company Dallah Trading Co - Jed

Building addr. King Abdulaziz City for Science and Technology Customer Nr NA
Building city Riyadh Job completed? Yes
Building # Chiller Plant 6 Must produce a quotation? No
Extra PPE required (specify which ones) Ergonomic (lifting, position, constrains) Low
Risk Evaluation Fall Low
Working Gloves
Confined spaces Low
Reason of call Start the unit

Unit & plant status on tech arrival Unit Stopped
Unit & plant status on tech leaving Unit Stopped
Job description
First Start-Up according to the manufacturer's instructions. The detailed description of activities and related results are described in annex, where
you can find the technical advice provided by Trane, which you must follow carefully for a safe, reliable and profitable use of your machine.
Technician
Date Trav. Start Job start Job end Travel end Pause Job & travel Travel mil. Overnight
name
8/22/2021 8:00 9:00 17:00 17:30 0:30 9:00 40 No
8/23/2021 8:00 9:00 19:00 19:30 0:30 11:00 40 No
Sarfaraz 8/24/2021 8:00 9:00 17:30 18:00 0:30 9:30 40 No
Chemma 8/25/2021 8:00 9:00 17:30 18:00 0:30 9:30 40 No
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
-
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
-
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
Unit starts & Unit run hour
Cmpr A Cmpr B Cmpr C Cmpr D Cmpr E Cmpr F
Starts 3 4 - 4 3 -
Hours 0.050694444 0.042361111 - 0.043055556 0.051388889 -
Conclusions:
Installation is acceptable, unit can be started without any reserve.
Suggested repair / upgrading
Pre Commissioning and Startup is completed as per Trane Standard.
8/29/2021
‫ ﻓـ ع اﻟﺴﻌﻮد ﻪ‬-‫ﺗ ــﻦ أﻧــﻚ أوف د ـﻼو ــﺮ‬

4650331 ‫ ﻓﺎ ﺲ‬-4649735/4645512/4641336: ‫ﻫﺎﺗﻒ‬
231
Ph. +9661 4649735/5512/1336 fax +96614650331
‫ ﻓـ ع اﻟﺴﻌﻮد ﻪ‬-‫ﺗ ــﻦ أﻧــﻚ أوف د ـﻼو ــﺮ‬ Job #: 176005018
11444 ، ‫ اﻟ ﺎض‬-15434 -‫ ب‬. ‫ص‬ Customer Ord.: -
‫ اﻟﺘﺠﺎري‬-‫ﻣﺠﻤﻊ اﻟﻤﻮ‬ Cust. Reference 1, Serial number U19C02728 Uni. RTAF500

Building # Chiller Plant 6 Customer Nr NA
Material Note
Part nr Description Q.ty Supplied by?
R134a Refrigerant 141 Dallah Trading Co - Jed
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -

4650331 ‫ ﻓﺎ ﺲ‬-4649735/4645512/4641336: ‫ﻫﺎﺗﻒ‬
232
Wednesday, August 25, 2021
04:41:30 PM Running Chiller Report
Prepared for: KACST
Technician: Sarfraz Ahmed Cheema
Chiller Name: 01
Model Number: RTAF500CUAGHXUA2N11
X3NHNXBW2CAXBXXXAX1T XXX0
Serial Number: U19B02728
Job Name: KACST
Work Order Number: 25082021
Location: Riyadh
Sales Office Name: Dallah Trading
Sales Order Number: 66O404A
Sales Office Address: Jeddah, Makkah,
Sales Office Phone Number: 966 12 6719222 Ext 232
Customer Name: STS
Customer Address:
Customer Phone Number: 966 112109853
Notes: Report A: 04:09:36 PM

Report B: 04:25:17 PM
Report C: 04:40:48 PM
Chiller Status
Reading 1: 04:09:36 PM Reading 2: 04:25:17 PM Reading 3: 04:40:48 PM
Chiller Modes
Top Level Mode Running Running Running
Sub Level Mode 1 Chilled Water Control Chilled Water Control Chilled Water Control
Sub Level Mode 2
Sub Level Mode 3
Sub Level Mode 4
Sub Level Mode 5
Sub Level Mode 6
Circuit 1 Modes
Top Level Mode Ckt1 Running Running Running
Sub Level Mode 1 Ckt1
Running Chiller Report Page 1
233
Circuit 2 Modes
Compressor 1A Mode
Top Level Mode Cprsr1A Running Running Running
Sub Level Mode 1 Cprsr1A
Compressor 1B Mode
Top Level Mode Cprsr1B Running Running Running
Sub Level Mode 1 Cprsr1B
Compressor 2A Mode
Compressor 2B Mode
234
Diagnostic Modes
Chiller Mode at Time of Last Diagnostic
Chiller Sub Mode 1 at Time of Last Diag
Top Level Mode at Last Diagnostic Ckt1
Submode 1 at Last Diagnostic Ckt1
Chiller
Active Chilled Water Setpoint 44.0 °F 44.0 °F 44.0 °F
Active Chilled Water Setpoint Source Front Panel Front Panel Front Panel
Active Demand Limit Setpoint 100.0% 100.0% 100.0%
Active Demand Limit Setpoint Source Front Panel Front Panel Front Panel
Actual Degrees of Chilled Water Reset 0.0 °F 0.0 °F 0.0 °F
Actual Evap Pool Temp Correction Ckt1 -1.0 °F -1.2 °F -1.5 °F
Arbitrated Chilled Water Setpoint 44.0 °F 44.0 °F 44.0 °F
BAS Chilled Water Setpoint 44.1 °F 44.1 °F 44.1 °F
BAS Demand Limit Setpoint 120.0% 120.0% 120.0%
BAS Interface BACnet BACnet BACnet
Chilled Water Softload Target 44.1 °F 44.0 °F 44.0 °F
Chiller Last Service 08/23/2021 03:10:43 08/23/2021 03:10:43 08/23/2021 03:10:43
Chiller Load Command 76.6% 75.6% 75.8%
Chiller Running Time 00:58 Hr:Min 01:14 Hr:Min 01:29 Hr:Min
Chiller Service Time Remaining 5999 Hr 5998 Hr 5998 Hr
Cooling Low Ambient Lockout Enable Enable Enable
Cooling Low Ambient Lockout Temperature -4.0 °F -4.0 °F -4.0 °F
Cooling Modulation Command 0.1 0.0 -0.1
Cooling Staging Accumulator 36.0 -37.3 -34.2
Demand Limit Softloading Target 100.0% 100.0% 100.0%
Desired Degrees of Reset 0.0 °F 0.0 °F 0.0 °F
235
Unfiltered Evap Water Flow Switch State Flow Flow Flow
Evaporator Water Flow Status Flow Flow Flow
Evaporator Entering Water Temperature 54.2 °F 53.8 °F 53.9 °F
Evaporator Leaving Water Temperature 44.1 °F 43.7 °F 43.9 °F
Evaporator Pump Command: Unit Off Off Off Off
Evaporator Pump Command: Unit On False False False
Evaporator Pump Off Delay Timer 00:00 Min:Sec 00:00 Min:Sec 00:00 Min:Sec
Evaporator Water Pump Command Pump 1 On On On
Evaporator Water Pump Command On On On
Front Panel Chilled Water Setpoint 44.0 °F 44.0 °F 44.0 °F
Front Panel Demand Limit Setpoint 100.0% 100.0% 100.0%
Leaving Water Temp Lead Filter Multiplier 1.5 1.5 1.5
Low Evaporator Water Temp Cutout 36.0 °F 36.0 °F 36.0 °F
Max Restart Time Remaining 0 0 0
Maximum Capacity Relay Inactive Inactive Inactive
Outdoor Air Temperature 112.1 °F 110.6 °F 109.7 °F
Power Up Delay Inhibit: 00:00 Min:Sec 00:00 Min:Sec 00:00 Min:Sec
Saved Evap Pool Temp Correction Ckt1 -0.9 °F -0.9 °F -0.9 °F
Setpoint Source Front Panel Front Panel Front Panel
Unit Running Indicator On On On
Unit Running Powered Indicator On On On
Variable Flow Filtered Result 10.0 °F 10.0 °F 10.1 °F
Evaporator Circuit 1
Calculated Chiller Capacity Ckt1 202.0 tons 201.5 tons 201.0 tons
Evaporator Approach Temperature Ckt1 1.3 °F 1.2 °F 1.2 °F
Evaporator Refrigerant Pool Temp Ckt1 45.1 °F 44.4 °F 44.0 °F
Evaporator Refrigerant Pressure Ckt1 52.5 PSIA 52.2 PSIA 52.4 PSIA
Evaporator Saturated Rfgt Temp Ckt1 42.8 °F 42.6 °F 42.7 °F
Evap Water Freeze Avoid Request Relay Open Open Open
External Circuit Lockout Status Ckt1 ------ ------ ------
EXV Command (%) Ckt1 51.2% 51.3% 52.1%
EXV Command (steps) Ckt1 3255 steps 3261 steps 3314 steps
EXV Flow Coefficient Ckt1 47.9% 48.0% 48.8%
EXV Flow Command Ckt1 1.026 1.016 1.046
EXV Maximum Steps Ckt1 6361 steps 6361 steps 6361 steps
EXV Percent Open Ckt1 51.2% 51.3% 52.1%
EXV Position Steps Ckt1 3255 steps 3262 steps 3315 steps
Front Panel Circuit Lockout Ckt1 Not Locked Out Not Locked Out Not Locked Out
LERTC Integral Ckt1 0.0 0.0 0.0
Measured Evap Rfgt Pool Temp Ckt1 46.1 °F 45.7 °F 45.5 °F
Oil Return Solenoid Valve Cprsr1A Open Open Open
Oil Return Solenoid Valve Cprsr1B Open Open Open
Running Indicator Ckt1 On On On
Running Powered Indicator Ckt1 On On On
Service Pumpdown Status Ckt1 Inactive Inactive Inactive
236
EXV Command (%) Ckt2 40.8% 41.1% 39.8%
Condenser Circuit 1
Air Flow Ckt1 100.0% 100.0% 100.0%
Cond Liquid Line Rfgt Saturated Temp Ckt1 132.8 °F 130.8 °F 132.5 °F
Condenser Liquid Line Rfgt Pressure Ckt1 221.6 PSIA 215.9 PSIA 220.7 PSIA
Cond Liquid Line Rfgt Subcooling Ckt1 12.7 °F 12.3 °F 13.6 °F
Condenser Liquid Line Rfgt Temp Ckt1 120.1 °F 118.5 °F 118.9 °F
Condenser Fan Board 1 Relay 1 Ckt1 On On On
Condenser Refrigerant Pressure Ckt1 250.4 PSIA 245.8 PSIA 250.5 PSIA
Condenser Refrigerant Tank Valve Ckt1 Open Open Open
Condenser Saturated Rfgt Temp Ckt1 142.0 °F 140.5 °F 142.0 °F
Condenser Subcooling Feedback Flow Fraction Ckt1 0.105 0.109 0.142
Condenser Temperature Target Ckt1 86.5 °F 86.3 °F 86.4 °F
Differential Refrigerant Pressure Ckt1 197.89 PSID 193.52 PSID 198.17 PSID
Fan Control Air Flow Goal Ckt1 100.0% 100.0% 100.0%
Fan Control Feedforward Flow Estimate Ckt1 100.0% 100.0% 100.0%
HPC Limit Boundary 298.5 PSIA 298.5 PSIA 298.5 PSIA
Predicted Condensing Temp Ckt1 141.8 °F 140.6 °F 142.1 °F
Condenser Circuit 2
Air Flow Ckt2 100.0% 100.0% 100.0%
237
Condenser Subcooling Feedback Flow Fraction Ckt2 -0.087 -0.080 -0.101
Motor 1A
Average Line Current % RLA Starter 1A 93.0% 91.3% 92.8%
Current Limit Setpoint Cprsr1A 120.0% 120.0% 120.0%
Motor Current L1 % RLA Starter 1A 93.8% 92.0% 93.2%
Motor Current L1 Starter 1A 248.0 A 243.0 A 246.0 A
Restart Inhibit Time Cprsr1A 00:00 Min:Sec 00:00 Min:Sec 00:00 Min:Sec
Winding Temp #1 Motor 1A ------ ------ ------
Motor 1B
Average Line Current % RLA Starter 1B 77.8% 75.6% 76.7%
Current Limit Setpoint Cprsr1B 120.0% 120.0% 120.0%
Motor Current L1 % RLA Starter 1B 78.2% 76.1% 77.4%
Motor Current L1 Starter 1B 207.0 A 201.0 A 204.0 A
Restart Inhibit Time Cprsr1B 00:00 Min:Sec 00:00 Min:Sec 00:00 Min:Sec
Winding Temp #1 Motor 1B ------ ------ ------
Motor 2A
238
Motor 2B
Compressor 1A
Cool Down Time Cprsr1A 00:00 Min:Sec 00:00 Min:Sec 00:00 Min:Sec
Differential Rfgt Pressure Cprsr1A 198.31 PSID 193.52 PSID 198.17 PSID
Discharge Superheat Cprsr1A 25.7 °F 26.1 °F 25.5 °F
Discharge Temperature Cprsr1A 167.8 °F 166.6 °F 167.5 °F
Economizer Discharge Pressure Cprsr1A 125.7 PSIA 124.4 PSIA 124.8 PSIA
Economizer Discharge Temperature Cprsr1A 108.3 °F 106.2 °F 108.0 °F
Economizer Superheat Cprsr1A 14.9 °F 13.5 °F 15.1 °F
Economizer Valve Percent Open Cprsr1A 15.1% 14.3% 14.8%
Last Service Cprsr1A 08/23/2021 03:11:03 08/23/2021 03:11:03 08/23/2021 03:11:03
Mass Flow Cprsr1A 392.643 391.757 391.625
Oil Loss Level Sensor Ckt1 Wet Wet Wet
Oil Pressure Cprsr1A 231.5 PSIA 227.1 PSIA 231.6 PSIA
Oil Temperature Cprsr1A 163.2 °F 161.8 °F 163.2 °F
Running Status Cprsr1A On On On
Running Time Cprsr1A 00:42 Hr:Min 00:57 Hr:Min 01:13 Hr:Min
Service Pumpdown Status Cprsr1A Not Available Not Available Not Available
Service Time Remaining % Cprsr1A 100.0% 100.0% 100.0%
Starts Cprsr1A 3 3 3
Suction Refrigerant Pressure Cprsr1A 52.5 PSIA 52.2 PSIA 52.4 PSIA
Tons Cprsr1A 110.8 tons 111.6 tons 111.3 tons
Compressor 1B
Cool Down Time Cprsr1B 00:00 Min:Sec 00:00 Min:Sec 00:00 Min:Sec
239
Differential Rfgt Pressure Cprsr1B 198.08 PSID 193.19 PSID 197.86 PSID
Discharge Superheat Cprsr1B 30.8 °F 30.1 °F 29.1 °F
Discharge Temperature Cprsr1B 172.9 °F 170.6 °F 171.1 °F
Economizer Discharge Pressure Cprsr1B 87.2 PSIA 83.8 PSIA 84.8 PSIA
Economizer Discharge Temperature Cprsr1B 119.7 °F 120.2 °F 118.8 °F
Economizer Superheat Cprsr1B 48.9 °F 51.7 °F 49.6 °F
Economizer Valve Percent Open Cprsr1B 0.0% 0.0% 0.0%
Last Service Cprsr1B 08/23/2021 03:12:44 08/23/2021 03:12:44 08/23/2021 03:12:44
Mass Flow Cprsr1B 321.410 313.617 314.408
Oil Pressure Cprsr1B 230.9 PSIA 226.1 PSIA 230.7 PSIA
Oil Temperature Cprsr1B 163.3 °F 161.9 °F 163.0 °F
Running Status Cprsr1B On On On
Running Time Cprsr1B 00:29 Hr:Min 00:45 Hr:Min 01:01 Hr:Min
Service Pumpdown Status Cprsr1B Not Available Not Available Not Available
Service Time Remaining % Cprsr1B 100.0% 100.0% 100.0%
Starts Cprsr1B 4 4 4
Suction Refrigerant Pressure Cprsr1B 52.7 PSIA 52.5 PSIA 52.7 PSIA
Tons Cprsr1B 90.7 tons 89.4 tons 89.4 tons
Compressor 2A
Mass Flow Cprsr2A 301.131 296.850 298.074
Compressor 2B
240
Mass Flow Cprsr2B 367.895 366.189 365.733
Chiller Setpoints
Chiller Setpoints
Capacity Control Softload Time 900 Sec 900 Sec 900 Sec
Chilled Water Reset Type Disable Disable Disable
Chiller Service Enable Enable Enable Enable
Chiller Service Interval Setpoint 6000 Hr 6000 Hr 6000 Hr
Compressor Service Enable Enable Enable Enable
Compressor Target Trip Setpoint 50.0% 50.0% 50.0%
Condenser Pressure Limit Setpoint 90.0% 90.0% 90.0%
Cooling Design Delta Temp (Waterside) 10.0 °F 10.0 °F 10.0 °F
Demand Limit Softload Time 600 Sec 600 Sec 600 Sec
Demand Limit Startup Target 44.0% 44.0% 44.0%
Differential to Start 10.0 °F 10.0 °F 10.0 °F
Differential to Stop 2.0 °F 2.0 °F 2.0 °F
Evap Flow Overdue Wait Time 1200 Sec 1200 Sec 1200 Sec
Evap Pool Temp Diagnostic Threshold Ckt1 8.0 °F 8.0 °F 8.0 °F
Evap Water Pump Service Enable Enable Enable Enable
Head Relief Relay Filter Time 600 Sec 600 Sec 600 Sec
Hot Start Threshold Temperature 80.0 °F 80.0 °F 80.0 °F
Local Atmospheric Pressure 14.7 PSIA 14.7 PSIA 14.7 PSIA
Oil Return Limit Enable Enable Enable Enable
Oil Return Valve Minimum On/Off Time 600 Sec 600 Sec 600 Sec
Outdoor Air Maximum Reset 5.0 °F 5.0 °F 5.0 °F
Outdoor Air Reset Ratio 10.0% 10.0% 10.0%
Outdoor Air Start Reset 90.0 °F 90.0 °F 90.0 °F
Power-Up Start Delay 0 Sec 0 Sec 0 Sec
Reset Chiller Service Time No No No
241
Return Water Maximum Reset 5.0 °F 5.0 °F 5.0 °F
Return Water Reset Ratio 50.0% 50.0% 50.0%
Return Water Start Reset 10.0 °F 10.0 °F 10.0 °F
Stage Off Control Level -65.0% -65.0% -65.0%
Stage On Control Level 65.0% 65.0% 65.0%
Staging Sequence Balanced Balanced Balanced
Variable Evap Water Flow Compensation Enable Enable Enable
Water Pump Service Interval Setpoint 20000 Hr 20000 Hr 20000 Hr
Feature Settings
Cooling Low Ambient Lockout Temperature -4.0 °F -4.0 °F -4.0 °F
Evaporator Water Pump Off Delay 1 Min 1 Min 1 Min
High Evaporator Water Temp Cutout 105.0 °F 105.0 °F 105.0 °F
Limit Relay Filter Time 600 Sec 600 Sec 600 Sec
Low Refrigerant Temperature Cutout 32.0 °F 32.0 °F 32.0 °F
Modulation Integral Time 60.0 Sec 60.0 Sec 60.0 Sec
Modulation Proportional Gain 0.500 0.500 0.500
Level 4 Gains and Start Sequence

Air Coil Correction 11.880 11.880 11.880
Chilled Water Control Feedforward Gain 100.000 100.000 100.000
Condenser Rfgt Tank Valve Open Delay 0 Sec 0 Sec 0 Sec
Condenser Subcooling Integral Time 60 Sec 60 Sec 60 Sec
Condenser Subcooling Proportional Gain 0.050 0.050 0.050
Condenser Subcooling Tracking Time 10 Sec 10 Sec 10 Sec
Control Staging Time 200 Sec 200 Sec 200 Sec
Current Limit Kp 0.500 0.500 0.500
Current Limit Ti 30.0 Sec 30.0 Sec 30.0 Sec
Damping Coefficient 10.0% 10.0% 10.0%
Economizer Superheat Proportional Gain 10.0 10.0 10.0
Economizer Superheat Reset Time 30 Sec 30 Sec 30 Sec
Economizer Superheat Setpoint 15.0 °F 15.0 °F 15.0 °F
EXV Pre-Position Hold Time 4 Sec 4 Sec 4 Sec
EXV Pre-Position Setpoint 90.0% 90.0% 90.0%
Fan Control Diff Pressure Setpoint 60.19 PSID 60.19 PSID 60.19 PSID
HPC Limit Integral Time 30 Sec 30 Sec 30 Sec
HPC Limit Proportional Gain 25.000 25.000 25.000
Inverted Water Temp Diagnostic Severity Warning Warning Warning
Low Disch Superheat Trip Setpt Cprsr1A 10.0 °F 10.0 °F 10.0 °F
Low Disch Superheat Trip Setpt Cprsr1B 10.0 °F 10.0 °F 10.0 °F
Low Rfgt Temp Limit Integral Time 30 Sec 30 Sec 30 Sec
Low Rfgt Temp Limit Proportional Gain 5.000 5.000 5.000
Operational Pumpdown Enable Enable Enable Enable
242
Restart Inhibit Diagnostic Disable Disable Disable
Restart Inhibit Free Starts 3 3 3
Restart Inhibit Start To Start Time 10 Min 10 Min 10 Min
User Cmd Min Capacity Cprsr1A Enable Enable Enable
User Cmd Min Capacity Cprsr1B Enable Enable Enable
User Cmd Min Capacity Delay Time Cprsr1A 30 Sec 30 Sec 30 Sec
User Cmd Min Capacity Delay Time Cprsr1B 30 Sec 30 Sec 30 Sec
Circuit 1
Reset Service Time Cprsr1A No No No
Reset Service Time Cprsr1B No No No
Circuit 2
Level 4 Timers
Set Cprsr1A Run Time 00:42 Hr:Min 00:57 Hr:Min 01:13 Hr:Min
Set Cprsr1A Starts 3 3 3
Set Cprsr1B Run Time 00:30 Hr:Min 00:45 Hr:Min 01:01 Hr:Min
Set Cprsr1B Starts 4 4 4
Alarms and Events

Date Time Active / Description Target Severity Persistence
Historic
8/25/2021 9:39 AM Historic Evaporator Water Flow Lost Chiller Immediate Shutdown Nonlatching
8/23/2021 3:44 PM Historic Evaporator Water Flow Overdue Chiller Normal Shutdown Nonlatching
8/23/2021 3:40 PM Historic Low Evaporator Rfgt Temp Ckt 2: Unit Off Chiller Warning Nonlatching
8/23/2021 3:37 PM Historic Starter Comm Loss: Main Processor - 2A Compressor 2A Immediate Shutdown Latching
8/23/2021 3:37 PM Historic Starter Comm Loss: Main Processor - 2B Compressor 2B Immediate Shutdown Latching
243
8/23/2021 3:26 PM Historic Comm Loss: Economizer Disch Temp - 2B Compressor 2B Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Slide Valve Load - 2B Compressor 2B Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Starter 2A Compressor 2A Immediate Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Liquid Line Temperature Circuit 2 Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Oil Pressure - 1B Compressor 1B Immediate Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Economizer Valve - 1B Compressor 1B Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Cprsr Disch Rfgt Temp - 1A Compressor 1A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Programmable Relay Board 1 Chiller Warning Latching
8/23/2021 3:26 PM Historic Comm Loss: Evap Leaving Water Temp Chiller Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Oil Return Solenoid Valve - 1A Compressor 1A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Oil Temperature - 2B Compressor 2B Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Suction Rfgt Pressure - 2B Compressor 2B Immediate Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Economizer Disch Press - 2B Compressor 2B Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Oil Pressure - 2A Compressor 2A Immediate Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Economizer Disch Press - 2A Compressor 2A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Evap Rfgt Pool Temp Circuit 2 Warning Latching
8/23/2021 3:26 PM Historic Comm Loss: Liquid Line Pressure Circuit 2 Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Cprsr Disch Rfgt Temp - 1B Compressor 1B Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Oil Temperature - 1A Compressor 1A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Suction Rfgt Pressure - 1A Compressor 1A Immediate Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Economizer Disch Press - 1A Compressor 1A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Economizer Disch Temp - 1A Compressor 1A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Slide Valve Unload - 1A Compressor 1A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Electronic Expansion Valve Circuit 1 Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Evap Rfgt Pool Temp Circuit 1 Warning Latching
8/23/2021 3:26 PM Historic Comm Loss: Liquid Line Pressure Circuit 1 Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Liquid Line Temperature Circuit 1 Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Condenser Rfgt Pressure Circuit 1 Immediate Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Evaporator Water Flow Switch Chiller Immediate Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Outdoor Air Temperature Chiller Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Evaporator Water Pump 1 Relay Chiller Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Starter 2B Compressor 2B Immediate Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Oil Temperature - 2A Compressor 2A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Cprsr Disch Rfgt Temp - 2A Compressor 2A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Suction Rfgt Pressure - 2A Compressor 2A Immediate Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Economizer Valve - 2A Compressor 2A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Condenser Rfgt Pressure Circuit 2 Immediate Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Economizer Valve - 1A Compressor 1A Normal Shutdown Latching
244
8/23/2021 3:26 PM Historic Comm Loss: Fan Board 2 Relay 4 Circuit 2 Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Oil Return Solenoid Valve - 2A Compressor 2A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Oil Return Solenoid Valve - 1B Compressor 1B Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: High Pressure Cutout Sw - 2A Compressor 2A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Economizer Disch Temp - 2A Compressor 2A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: High Pressure Cutout Sw - 1A Compressor 1A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Step Load - 2A Compressor 2A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: High Pressure Cutout Sw - 2B Compressor 2B Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Slide Valve Unload - 2A Compressor 2A Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Oil Loss Level Sensor Input Circuit 2 Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Oil Loss Level Sensor Input Circuit 1 Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Emergency Stop Feedback Input Chiller Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: External Auto/Stop Chiller Normal Shutdown Latching
8/23/2021 3:26 PM Historic Comm Loss: Cond Rfgt Tank Valve Ckt2 Circuit 2 Warning Latching
8/23/2021 3:26 PM Historic Comm Loss: Cond Rfgt Tank Valve Ckt1 Circuit 1 Warning Latching
8/23/2021 3:26 PM Historic Comm Loss: Oil Return Solenoid Valve - 2B Compressor 2B Normal Shutdown Latching
8/23/2021 3:25 PM Historic Comm Loss: Slide Valve Unload - 2B Compressor 2B Normal Shutdown Latching
8/23/2021 3:25 PM Historic Comm Loss: Slide Valve Load - 2A Compressor 2A Normal Shutdown Latching
8/23/2021 3:25 PM Historic Comm Loss: Electronic Expansion Valve Circuit 2 Normal Shutdown Latching
8/23/2021 3:25 PM Historic Comm Loss: Slide Valve Load - 1A Compressor 1A Normal Shutdown Latching
8/23/2021 3:25 PM Historic Comm Loss: Evap Entering Water Temp Chiller Normal Shutdown Latching
TU Configuration
Version Version - 11.2.23 Version - 11.2.23 Version - 11.2.23
245
PC Configuration
Operating System Microsoft Windows 10 Enterprise Microsoft Windows 10 Enterprise Microsoft Windows 10 Enterprise
System Architecture x64 x64 x64
Operating System Version 6.2 6.2 6.2
Chiller Configuration
Controller
Connected To Local USB Local USB Local USB
Firmware Version 4.45 4.45 4.45
Application Part Number 6200-0620-4.31 6200-0620-4.31 6200-0620-4.31
Hardware Serial Number 1183700086 1183700086 1183700086
Hardware Part Number X13651144-01 X13651144-01 X13651144-01
Build Part Number 6200-0619-4.45 6200-0619-4.45 6200-0619-4.45
Boot Part Number 6200-0446-1.00 6200-0446-1.00 6200-0446-1.00
Unit Sales Order Number 66O404A 66O404A 66O404A
Unit Model Number RTAF500CUA GHXUA2N11X RTAF500CUA GHXUA2N11X RTAF500CUA GHXUA2N11X
3NHNXBW2CA XBXXXAX1TX 3NHNXBW2CA XBXXXAX1TX 3NHNXBW2CA XBXXXAX1TX
XX0 XX0 XX0
Unit Serial Number U19B02728 U19B02728 U19B02728
Signed:
Date:
Copyright © 2021 Trane, Inc. All rights reserved. Trane, the Trane logo and Tracer TU are either registered trademarks or trademarks of Trane in the United
States and/or other countries.
Protected by U.S. Patents.
246
Ph. +9661 4649735/5512/1336 fax +96614650331

Working Gloves
Confined spaces Low

Job description
Technician
name
8/22/2021 8:00 9:00 17:00 17:30 0:30 9:00 40 No
8/23/2021 8:00 9:00 19:00 19:30 0:30 11:00 40 No
Sarfaraz 8/24/2021 8:00 9:00 17:30 18:00 0:30 9:30 40 No
Chemma 8/25/2021 8:00 9:00 17:30 18:00 0:30 9:30 40 No
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Starts 8 23 - 39 11 -
Hours 1.454166667 1.502083333 - 1.478472222 1.477777778 -
Conclusions:
Pre commissioning and Startup is completed as per Trane standard
8/29/2021

4650331 ‫ ﻓﺎ ﺲ‬-4649735/4645512/4641336: ‫ﻫﺎﺗﻒ‬
247
11:55:50 AM Running Chiller Report
Prepared for: KACST
Chiller Name: 02
Job Name: KACST
Location: Riyadh
Customer Name: STS
Customer Address: Riyadh,
Customer Phone Number: 966 11 2109853
Notes: Report A: 11:23:53 AM

Report B: 11:39:29 AM
Report C: 11:55:04 AM
Chiller Status
Reading 1: 11:23:53 AM Reading 2: 11:39:29 AM Reading 3: 11:55:04 AM
Chiller Modes
Top Level Mode Running Running - Limit Running
Sub Level Mode 1 Chilled Water Control Demand Limit Chilled Water Control
Sub Level Mode 2 Chilled Water Control
Sub Level Mode 3
Sub Level Mode 4
Sub Level Mode 5
Sub Level Mode 6
Circuit 1 Modes
248
Circuit 2 Modes
Compressor 1A Mode
Compressor 1B Mode
Compressor 2A Mode
Compressor 2B Mode
249
Diagnostic Modes
Chiller
Cooling Low Ambient Lockout Temperature 32.0 °F 32.0 °F 32.0 °F
Cooling Modulation Command 0.0 0.1 0.2
Cooling Staging Accumulator 58.0 63.4 38.5
250
EXV Command (%) Ckt1 61.4% 57.4% 58.3%
251
EXV Command (%) Ckt2 50.1% 48.4% 49.5%
Condenser Circuit 1
Air Flow Ckt1 100.0% 100.0% 100.0%
Condenser Circuit 2
Air Flow Ckt2 100.0% 100.0% 100.0%
252
Motor 1A
Motor 1B
Motor 2A
253
Motor 2B
Compressor 1A
Mass Flow Cprsr1A 399.519 397.461 398.283
Compressor 1B
254
Mass Flow Cprsr1B 399.728 397.773 353.033
Compressor 2A
Mass Flow Cprsr2A 363.049 363.075 324.865
Compressor 2B
255
Mass Flow Cprsr2B 363.153 362.971 365.805
Chiller Setpoints
Chiller Setpoints
256
Feature Settings

257
Circuit 1
Circuit 2
Level 4 Timers
Alarms and Events

Historic
8/22/2021 10:02 PM Historic Evaporator Water Flow Lost Chiller Immediate Shutdown Nonlatching
8/22/2021 9:05 AM Historic Phase Loss - 1B Compressor 1B Immediate Shutdown Latching
8/22/2021 8:58 AM Historic Starter Comm Loss: Main Processor - 2B Compressor 2B Immediate Shutdown Latching
8/22/2021 8:58 AM Historic Starter Comm Loss: Main Processor - 2A Compressor 2A Immediate Shutdown Latching
8/22/2021 8:58 AM Historic MP: Reset Has Occurred Platform Warning Nonlatching
8/22/2021 8:46 AM Historic Phase Loss - 1A Compressor 1A Immediate Shutdown Latching
258
8/22/2021 6:33 AM Historic Emergency Stop Feedback Input Chiller Immediate Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Cprsr Disch Rfgt Temp - 2B Compressor 2B Normal Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Economizer Disch Press - 2B Compressor 2B Normal Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Cprsr Disch Rfgt Temp - 2A Compressor 2A Normal Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Oil Pressure - 2A Compressor 2A Immediate Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Economizer Disch Press - 2A Compressor 2A Normal Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Economizer Valve - 2A Compressor 2A Normal Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Slide Valve Unload - 2A Compressor 2A Normal Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Slide Valve Load - 2B Compressor 2B Normal Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Starter 2A Compressor 2A Immediate Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Electronic Expansion Valve Circuit 2 Normal Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Evap Rfgt Pool Temp Circuit 2 Warning Latching
5/10/2021 6:16 AM Historic Comm Loss: Fan Board 1 Relay 1 Circuit 2 Normal Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: High Pressure Cutout Sw - 2B Compressor 2B Normal Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Slide Valve Unload - 2B Compressor 2B Normal Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Economizer Disch Temp - 2A Compressor 2A Normal Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Evaporator Water Pump 1 Relay Chiller Normal Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Oil Temperature - 2B Compressor 2B Normal Shutdown Latching
5/10/2021 6:16 AM Historic Comm Loss: Economizer Disch Temp - 2B Compressor 2B Normal Shutdown Latching
11/29/2020 12:22 PM Historic Emergency Stop Feedback Input Chiller Immediate Shutdown Latching
11/29/2020 12:21 PM Historic MP: Reset Has Occurred Platform Warning Nonlatching
259
11/25/2020 7:11 AM Historic Economizer Disch Press Sensor - 2A Compressor 2A Normal Shutdown Latching
11/25/2020 7:11 AM Historic Liquid Line Pressure Sensor Circuit 2 Normal Shutdown Latching
11/25/2020 7:10 AM Historic Very Low Evap Rfgt Pressure - 2B Chiller Immediate Shutdown Latching
11/25/2020 7:10 AM Historic Very Low Evap Rfgt Pressure - 2A Chiller Immediate Shutdown Latching
11/25/2020 7:10 AM Historic Comm Loss: Starter 2B Compressor 2B Immediate Shutdown Latching
11/25/2020 7:10 AM Historic Comm Loss: Oil Pressure - 2B Compressor 2B Immediate Shutdown Latching
11/25/2020 7:10 AM Historic Comm Loss: Suction Rfgt Pressure - 2B Compressor 2B Immediate Shutdown Latching
11/25/2020 7:10 AM Historic Comm Loss: Economizer Valve - 2B Compressor 2B Normal Shutdown Latching
11/25/2020 7:10 AM Historic Comm Loss: Oil Temperature - 2A Compressor 2A Normal Shutdown Latching
11/25/2020 7:10 AM Historic Comm Loss: Suction Rfgt Pressure - 2A Compressor 2A Immediate Shutdown Latching
TU Configuration
260
PC Configuration
Controller
Boot Part Number 6200-0446-1.00 6200-0446-1.00 6200-0446-1.00
XX0 XX0 XX0
Signed:
Date:
261
Ph. +9661 4649735/5512/1336 fax +96614650331

Working Gloves
Confined spaces Low

Job description
Technician
name
8/22/2021 8:00 9:00 17:00 17:30 0:30 9:00 40 No
8/23/2021 8:00 9:00 19:00 19:30 0:30 11:00 40 No
Sarfaraz 8/24/2021 8:00 9:00 17:30 18:00 0:30 9:30 40 No
Chemma 8/29/2021 8:00 9:00 17:30 18:00 0:30 9:30 40 No
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
-
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
-
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
Starts 7 8 - 7 7 -
Hours 0.201388889 0.2875 - 0.231944444 0.233333333 -
Conclusions:
8/29/2021

4650331 ‫ ﻓﺎ ﺲ‬-4649735/4645512/4641336: ‫ﻫﺎﺗﻒ‬
262
Prepared for: KACST
Chiller Name: 03
Job Name: KACST
Location: Riyadh
Customer Name: STS

Chiller Status
Chiller Modes
Top Level Mode Running - Limit Running - Limit Running
Sub Level Mode 1 Maximum Capacity Maximum Capacity Chilled Water Control
Sub Level Mode 2 Demand Limit Demand Limit
Sub Level Mode 3 Chilled Water Control Chilled Water Control
Sub Level Mode 4
Sub Level Mode 5
Sub Level Mode 6
Circuit 1 Modes
263
Circuit 2 Modes
Compressor 1A Mode
Compressor 1B Mode
Compressor 2A Mode
Compressor 2B Mode
264
Diagnostic Modes
Chiller
265
Maximum Capacity Relay Active Active Inactive
EXV Command (%) Ckt1 57.7% 55.6% 56.3%
266
EXV Command (%) Ckt2 48.6% 47.2% 47.9%
Condenser Circuit 1
Air Flow Ckt1 100.0% 100.0% 100.0%
Condenser Circuit 2
Air Flow Ckt2 100.0% 100.0% 100.0%
267
Motor 1A
Motor 1B
Motor 2A
268
Motor 2B
Compressor 1A
Mass Flow Cprsr1A 412.369 405.573 396.649
Compressor 1B
269
Mass Flow Cprsr1B 398.067 404.843 394.575
Compressor 2A
Mass Flow Cprsr2A 367.878 368.774 363.014
Compressor 2B
270
Mass Flow Cprsr2B 377.777 368.462 362.493
Chiller Setpoints
Chiller Setpoints
271
Feature Settings

272
Circuit 1
Circuit 2
Level 4 Timers
Alarms and Events

Historic
8/22/2021 9:25 AM Historic Low Oil Flow - 1A Compressor 1A Immediate Shutdown Latching
8/22/2021 9:21 AM Historic High Oil Temperature - 1B Compressor 1B Immediate Shutdown Latching
273
11/25/2020 6:55 AM Historic Very Low Evap Rfgt Pressure - 2B Chiller Immediate Shutdown Latching
11/25/2020 6:55 AM Historic Very Low Evap Rfgt Pressure - 2A Chiller Immediate Shutdown Latching
11/25/2020 6:54 AM Historic Comm Loss: Slide Valve Load - 2A Compressor 2A Normal Shutdown Latching
11/25/2020 6:54 AM Historic Comm Loss: Condenser Rfgt Pressure Circuit 2 Immediate Shutdown Latching
11/25/2020 6:54 AM Historic Comm Loss: Liquid Line Pressure Circuit 2 Normal Shutdown Latching
274
11/25/2020 6:54 AM Historic Comm Loss: Liquid Line Temperature Circuit 2 Normal Shutdown Latching
TU Configuration
275
PC Configuration
Controller
Boot Part Number 6200-0446-1.00 6200-0446-1.00 6200-0446-1.00
XX0 XX0 XX0
Signed:
Date:
276
Ph. +9661 4649735/5512/1336 fax +96614650331

Working Gloves
Confined spaces Low

Job description
Technician
name
8/22/2021 8:00 9:00 17:00 17:30 0:30 9:00 40 No
8/23/2021 8:00 9:00 19:00 19:30 0:30 11:00 40 No
Sarfaraz 8/23/2021 8:00 9:00 17:30 18:00 0:30 9:30 40 No
Chemma 8/25/2021 8:00 9:00 17:30 18:00 0:30 9:30 40 No
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
-
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
-
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
Starts 7 7 - 9 6 -
Hours 0.170138889 0.197916667 - 0.204166667 0.145833333 -
Conclusions:
Pre Commissioning and startup is completed as per Trane standard.
8/29/2021

4650331 ‫ ﻓﺎ ﺲ‬-4649735/4645512/4641336: ‫ﻫﺎﺗﻒ‬
277
Ph. +9661 4649735/5512/1336 fax +96614650331
‫ ﻓـ ع اﻟﺴﻌﻮد ﻪ‬-‫ﺗ ــﻦ أﻧــﻚ أوف د ـﻼو ــﺮ‬ Job #: 176005018
11444 ، ‫ اﻟ ﺎض‬-15434 -‫ ب‬. ‫ص‬ Customer Ord.: -
‫ اﻟﺘﺠﺎري‬-‫ﻣﺠﻤﻊ اﻟﻤﻮ‬ Cust. Reference 4, Serial number U19C02731 Uni. RTAF500

Building # Chiller Plant 6 Customer Nr NA
Material Note
Part nr Description Q.ty Supplied by?
R134a Refrigerant 68 Dallah Trading Co - Jed
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -
- - - -

4650331 ‫ ﻓﺎ ﺲ‬-4649735/4645512/4641336: ‫ﻫﺎﺗﻒ‬
278
Prepared for: KACST
Chiller Name: 04
Serial Number: U19C02731
Job Name: KACST
Location: Riyadh
Customer Name: STS
Customer Phone Number: 966 112109853

Chiller Status
Chiller Modes
Top Level Mode Running Running Running
Sub Level Mode 1 Chilled Water Control Chilled Water Control Chilled Water Control
Sub Level Mode 2
Sub Level Mode 3
Sub Level Mode 4
Sub Level Mode 5
Sub Level Mode 6
Circuit 1 Modes
279
Circuit 2 Modes
Compressor 1A Mode
Compressor 1B Mode
Top Level Mode Cprsr1B Running Auto Running
Compressor 2A Mode
Compressor 2B Mode
280
Diagnostic Modes
Chiller
281
EXV Command (%) Ckt1 45.2% 27.3% 47.9%
Oil Return Solenoid Valve Cprsr1B Open Closed Open
282
EXV Command (%) Ckt2 40.7% 44.6% 44.4%
Condenser Circuit 1
Air Flow Ckt1 100.0% 100.0% 100.0%
Condenser Circuit 2
Air Flow Ckt2 100.0% 100.0% 100.0%
283
Motor 1A
Motor 1B
Motor 2A
284
Motor 2B
Compressor 1A
Mass Flow Cprsr1A 373.910 364.822 381.267
Compressor 1B
285
Discharge Superheat Cprsr1B 37.0 °F ------ 34.7 °F
Mass Flow Cprsr1B 295.748 0.000 309.706
Running Status Cprsr1B On Off On
Compressor 2A
Mass Flow Cprsr2A 281.852 326.397 301.715
Compressor 2B
286
Mass Flow Cprsr2B 359.868 358.322 363.633
Chiller Setpoints
Chiller Setpoints
287
Feature Settings

288
Circuit 1
Circuit 2
Level 4 Timers
Alarms and Events

Historic
08/25/2021 12:28 Historic Comm Loss: Suction Rfgt Pressure - 2B Compressor 2B Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Economizer Valve - 2B Compressor 2B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Oil Pressure - 2A Compressor 2A Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Suction Rfgt Pressure - 2A Compressor 2A Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Economizer Disch Press - 2A Compressor 2A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Slide Valve Unload - 2A Compressor 2A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Liquid Line Pressure Circuit 2 Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Condenser Rfgt Pressure Circuit 2 Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Suction Rfgt Pressure - 1B Compressor 1B Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Economizer Valve - 1B Compressor 1B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Suction Rfgt Pressure - 1A Compressor 1A Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Economizer Disch Press - 1A Compressor 1A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Slide Valve Unload - 1A Compressor 1A Normal Shutdown Latching
289
08/25/2021 12:28 Historic Comm Loss: Electronic Expansion Valve Circuit 1 Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Liquid Line Pressure Circuit 1 Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Condenser Rfgt Pressure Circuit 1 Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Fan Board 2 Relay 3 Circuit 2 Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Step Load - 2A Compressor 2A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Oil Return Solenoid Valve - 1A Compressor 1A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Oil Pressure - 2B Compressor 2B Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Economizer Disch Press - 2B Compressor 2B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Economizer Disch Temp - 2B Compressor 2B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Slide Valve Unload - 2B Compressor 2B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: High Pressure Cutout Sw - 2A Compressor 2A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Economizer Disch Temp - 2A Compressor 2A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Economizer Valve - 2A Compressor 2A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Slide Valve Load - 2A Compressor 2A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Electronic Expansion Valve Circuit 2 Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Evap Rfgt Pool Temp Circuit 2 Warning Latching
08/25/2021 12:28 Historic Comm Loss: Liquid Line Temperature Circuit 2 Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Starter 1B Compressor 1B Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Oil Pressure - 1B Compressor 1B Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Economizer Disch Press - 1B Compressor 1B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Economizer Disch Temp - 1B Compressor 1B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Slide Valve Unload - 1B Compressor 1B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Slide Valve Load - 1B Compressor 1B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: High Pressure Cutout Sw - 1A Compressor 1A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Oil Pressure - 1A Compressor 1A Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Economizer Valve - 1A Compressor 1A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Liquid Line Temperature Circuit 1 Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Emergency Stop Feedback Input Chiller Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: External Auto/Stop Chiller Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Step Load - 1B Compressor 1B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Step Load - 1A Compressor 1A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Starter 2B Compressor 2B Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Starter 2A Compressor 2A Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Oil Temperature - 1B Compressor 1B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Starter 1A Compressor 1A Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Oil Temperature - 1A Compressor 1A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Economizer Disch Temp - 1A Compressor 1A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Programmable Relay Board 1 Chiller Warning Latching
08/25/2021 12:28 Historic Comm Loss: Evaporator Water Flow Switch Chiller Immediate Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Step Load - 2B Compressor 2B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: High Pressure Cutout Sw - 2B Compressor 2B Normal Shutdown Latching
290
08/25/2021 12:28 Historic Comm Loss: Cprsr Disch Rfgt Temp - 2B Compressor 2B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Oil Temperature - 2A Compressor 2A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Oil Loss Level Sensor Input Circuit 2 Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: High Pressure Cutout Sw - 1B Compressor 1B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Cprsr Disch Rfgt Temp - 1B Compressor 1B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Oil Loss Level Sensor Input Circuit 1 Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Evap Rfgt Pool Temp Circuit 1 Warning Latching
08/25/2021 12:28 Historic Comm Loss: Cond Rfgt Tank Valve Ckt1 Circuit 1 Warning Latching
08/25/2021 12:28 Historic Comm Loss: Oil Return Solenoid Valve - 2B Compressor 2B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Oil Return Solenoid Valve - 2A Compressor 2A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Oil Temperature - 2B Compressor 2B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Slide Valve Load - 2B Compressor 2B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Cprsr Disch Rfgt Temp - 2A Compressor 2A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Slide Valve Load - 1A Compressor 1A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Evap Leaving Water Temp Chiller Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Cond Rfgt Tank Valve Ckt2 Circuit 2 Warning Latching
08/25/2021 12:28 Historic Comm Loss: Oil Return Solenoid Valve - 1B Compressor 1B Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Cprsr Disch Rfgt Temp - 1A Compressor 1A Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Evap Entering Water Temp Chiller Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Outdoor Air Temperature Chiller Normal Shutdown Latching
08/25/2021 12:28 Historic Comm Loss: Evaporator Water Pump 1 Relay Chiller Normal Shutdown Latching
08/23/2021 13:53 Historic MP: Reset Has Occurred Platform Warning Nonlatching
08/22/2021 13:10 Historic Starter Comm Loss: Main Processor - 2B Compressor 2B Immediate Shutdown Latching
08/22/2021 13:10 Historic Starter Comm Loss: Main Processor - 2A Compressor 2A Immediate Shutdown Latching
08/22/2021 10:16 Historic Emergency Stop Feedback Input Chiller Immediate Shutdown Latching
TU Configuration
291
PC Configuration
Controller
Boot Part Number 6200-0446-1.00 6200-0446-1.00 6200-0446-1.00
XX0 XX0 XX0
Unit Serial Number U19C02731 U19C02731 U19C02731
Signed:
Date:
292
Ph. +9661 4649735/5512/1336 fax +96614650331

Working Gloves
Confined spaces Low

Job description
Technician
name
8/22/2021 8:00 9:00 17:00 17:30 0:30 9:00 40 No
8/23/2021 8:00 9:00 19:00 19:30 0:30 11:00 40 No
Sarfaraz 8/24/2021 8:00 9:00 17:30 18:00 0:30 9:30 40 No
Chemma 8/25/2021 8:00 9:00 17:30 18:00 0:30 9:30 40 No
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
-
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
-
- - - - - - - - -
- - - - - - - - -
- - - - - - - - -
Starts 7 7 - 7 5 -
Hours 0.478472222 0.477083333 - 0.475 0.235416667 -
Conclusions:
8/29/2021

4650331 ‫ ﻓﺎ ﺲ‬-4649735/4645512/4641336: ‫ﻫﺎﺗﻒ‬
293
Prepared for: KACST
Technician: SARFRAZ aHMED cHEEMA
Chiller Name: 05
Job Name: KACST
Location: Riyadh
Customer Name: STS
Customer Address:

Chiller Status
Chiller Modes
Top Level Mode Running - Limit Running - Limit Running - Limit
Sub Level Mode 1 Maximum Capacity Maximum Capacity Demand Limit
Sub Level Mode 2 Demand Limit Demand Limit Chilled Water Control
Sub Level Mode 3 Chilled Water Control Chilled Water Control
Sub Level Mode 4
Sub Level Mode 5
Sub Level Mode 6
Circuit 1 Modes
294
Circuit 2 Modes
Compressor 1A Mode
Compressor 1B Mode
Compressor 2A Mode
Compressor 2B Mode
295
Diagnostic Modes
Chiller
Cooling Modulation Command 0.5 0.2 -0.3
296
Maximum Capacity Relay Active Active Inactive
EXV Command (%) Ckt1 52.6% 52.7% 53.0%
297
EXV Command (%) Ckt2 46.6% 45.4% 45.7%
Condenser Circuit 1
Air Flow Ckt1 100.0% 100.0% 100.0%
Condenser Circuit 2
Air Flow Ckt2 100.0% 100.0% 100.0%
298
Motor 1A
Motor 1B
Motor 2A
299
Motor 2B
Compressor 1A
Mass Flow Cprsr1A 381.335 377.234 378.405
Compressor 1B
300
Mass Flow Cprsr1B 381.440 377.129 378.405
Compressor 2A
Mass Flow Cprsr2A 355.762 348.656 346.478
Compressor 2B
301
Mass Flow Cprsr2B 355.658 348.760 346.478
Chiller Setpoints
Chiller Setpoints
302
Feature Settings

303
Circuit 1
Circuit 2
Level 4 Timers
Alarms and Events

Historic
304
11/25/2020 6:52 AM Historic Comm Loss: Liquid Line Temperature Circuit 2 Normal Shutdown Latching
11/25/2020 6:52 AM Historic Comm Loss: Liquid Line Pressure Circuit 2 Normal Shutdown Latching
11/25/2020 6:52 AM Historic Comm Loss: Condenser Rfgt Pressure Circuit 2 Immediate Shutdown Latching
11/25/2020 6:52 AM Historic Comm Loss: Evap Leaving Water Temp Chiller Normal Shutdown Latching
11/25/2020 6:52 AM Historic Comm Loss: Evaporator Water Pump 1 Relay Chiller Normal Shutdown Latching
11/25/2020 6:52 AM Historic Comm Loss: Emergency Stop Feedback Input Chiller Normal Shutdown Latching
11/25/2020 6:52 AM Historic Comm Loss: External Auto/Stop Chiller Normal Shutdown Latching
11/25/2020 6:52 AM Historic Comm Loss: Programmable Relay Board 1 Chiller Warning Latching
11/24/2020 2:11 PM Historic Economizer Disch Press Sensor - 2B Compressor 2B Normal Shutdown Latching
305
3/1/2019 8:16 AM Historic Power Loss - 2A Compressor 2A Immediate Shutdown Nonlatching
3/1/2019 8:16 AM Historic Starter Did Not Transition - 1B Compressor 1B Immediate Shutdown Latching
3/1/2019 7:57 AM Historic High Pressure Cutout - 2A Compressor 2A Immediate Shutdown Latching
3/1/2019 7:57 AM Historic Excessive Condenser Pressure Circuit 2 Immediate Shutdown Latching
3/1/2019 7:28 AM Historic Inverted Evaporator Water Temperature Chiller Warning Nonlatching
2/28/2019 3:30 PM Historic Evaporator Water Flow Overdue Chiller Normal Shutdown Nonlatching
2/28/2019 10:14 PM Historic Very Low Evap Rfgt Pressure - 2B Chiller Immediate Shutdown Latching
2/28/2019 10:14 PM Historic Very Low Evap Rfgt Pressure - 2A Chiller Immediate Shutdown Latching
TU Configuration
306
PC Configuration
Controller
Boot Part Number 6200-0446-1.00 6200-0446-1.00 6200-0446-1.00
XX0 XX0 XX0
Signed:
Date:
307

SECTION-08
AS BUILT DRAWING LIST
308
SECTION 08 AS BUILT DRAWING LIST
Drawing Number Description

CPC/CP-06/M/001/X GENERAL NOTES, LEGENDS AND ABBREVIATIONS (MECHANICAL)
CPC/CP-06/M/002/X EQUIPMENT SCHEDULE
CPC/CP-06/MAC/101/X CHW PIPING GROUND FLOOR LAYOUT OF CHILLER YARD AND PUMP ROOM (MASTER)
CPC/CP-06/MAC/104/X HVAC GROUND FLOOR LAYOUT - MASTER
CPC/CP-06/MAC/107/X HVAC ROOF FLOOR LAYOUT - MASTER
CPC/CP-06/MAC/108/X HVAC ROOF FLOOR LAYOUT PART-1
309

SECTION-09
AS BUILT DRAWING HARD COPY
310

SECTION-10
AS BUILT DRAWING CD
311

SECTION-11
TRANE CHILLER CD
312

O&m HQ CHW System

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KING ABDULAZIZ CITY FOR SCIENCE AND TECHNOLOGY

GENERAL DIRECTORATE OF PROJECT

CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND CAR

OPERATION AND MAINTENANCE MANUAL

CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND CAR

OPERATION AND MAINTENANCE MANUAL

CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND CAR

CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND CAR

SECTION 01.01 Description of the HQ-Chilled water system

CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND CAR

Chilled water systems provide cooling to HQ building by using chilled water

CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND CAR

CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND CAR

Drawing Number Description

CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND CAR

SR ITEM MANUFACTURER MODEL LOCATION

CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND CAR

CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND CAR

SECTION 03.01 Description and model.

CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND CAR

SR ITEM MANUFACTURER MODEL LOCATION

CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND CAR

CONSTRUCTION OF CHILLER PLANTS, POWER PLANT AND CAR

Sintesis™ Air-Cooled Chillers

August 2015 RLC-PRC049B-EN

© 2015Trane All rights reserved RLC-PRC049B-EN

Capacity Control and Load Matching

Figure 1. Cutaway of a compressor

Close Spacing Installation

Factory Testing Means Trouble-Free Start-up

Microchannel Condenser Coils

Figure 2. Microchannel condensing coils

Microchannels Air Condenser Outlet

Figure 4. CHIL evaporator, 280 to 500 tons, 1-pass

Effect of Altitude on Capacity

Water Flow Limits

Flow Rates Out of Range

Figure 5. Flow rate out of range

Leaving-Water Temperature Out of Range

Figure 6. Leaving water temperature flow rate out of range

Series Chiller Arrangements

Figure 7. Typical series chiller arrangement

Typical Water Piping

Avoidance of Short Water Loops

Multiple Unit Operation

Ice Storage Operation

Isolation and Sound Emission

Figure 8. Installation example

Chilled water piping

Provide Sufficient Unit-to-Unit Clearance

Walled Enclosure Installations

Digit 38 — Unit Isolation

Table 1. General data table

Table 2. General data table

NO OBSTRUCTIONS ABOVE UNIT

Unit sizes 115 to 250 tons:

Unit sizes 280 to 500 tons:

Figure 20. RTAF unit dimensions - 150, 170, 180 ton

Figure 21. RTAF unit dimensions - 200, 215 ton

Figure 22. RTAF unit dimensions - 230, 250 ton

Figure 23. RTAF unit dimensions - 280 ton

Figure 24. RTAF unit dimensions - 310, 350 ton

Figure 25. RTAF unit dimensions - 410 ton