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Installation Operation Maintenance: RTWB Helical-Rotary Chillers
Installation Operation Maintenance: RTWB Helical-Rotary Chillers
Installation Operation Maintenance: RTWB Helical-Rotary Chillers
Operation
Maintenance
RTWB Helical-Rotary
Chillers
200 to 700 kW
Sizes 207-224
RTWB-SVN01B-E4
Important
Notice
Hazardous voltage
C AUTION Disconnect and lockout or tagout all
electrical power, including
remote disconnects before
Risk of damage to equipment. servicing.
Trane assume no liability for
WARNING installation or service procedures
performed by unqualified personnel.
Risk for safety or health. Regulations on safety, construction,
and environment vary from one
country to another. Make sure that
the equipment complies with local
Pressure vessel regulations.
Do not attempt to remove In addition to this publication, read
fittings and covers or break carefully Société Trane’s and/or the
lines while the machine is Seller’s General Terms and
under pressure or while it is Conditions of Sale and any specific
running. instruction which you may have
received.
Do not weld or flamecut any vessel
or line until all refrigerant has been
removed.
Do not use oxygen to purge lines,
leak test, or pressurize a machine.
Do not pressure test any vessel at its
design pressure (found on the
equipment nameplate). Testing at the
pressures must be done in a special
enclosure or be using hydraulic,
refer to national regulation.
General Information 4
Literature change history
Unit inspection
Inspection checklist
Loose parts inventory
Unit description
Installation overview
Installation – Mechanical 9
Storage
Location requirements
Access restrictions
Moving and rigging
Lifting procedure
Isolation pads
Shipping items
Unit leveling
Water piping
Water pressure-drop data
Water treatment
Water pressure gauges and thermometers
Water pressure-relief valves
Flow sensing devices
Refrigerant pressure-relief valve venting
Thermal insulation
Installation – Electrical 18
General recommendations
Power supply wiring
Compressor-motor phase sequencing
Module and control panel connectors
Interconnecting wiring (field wiring required)
Periodic Maintenance 33
Overview
Weekly maintenance and checks
Maintenance Contract and Training
RTWB-SVN01B-E4 3
General
Information
4 RTWB-SVN01B-E4
General
Information
RTWB-SVN01B-E4 5
General
Information
Unit description
The RTWB units are helical-rotary 2
5
type, water-cooled, liquid chillers
designed for indoor installation . The 1
units have two independent 7
refrigerant circuits, with one 4 4
compressor per circuit.
8
Each RTWB unit is completely
assembled, wired, leak-tested,
dehydrated, charged, and tested for
proper control operation prior to
shipment. The chilled-water inlet and 3
outlet openings are covered for
shipment.
The RTWB series features Trane's
exclusive Adaptive Control™ logic Figure 2 -– Component location for typical RTWB unit
with Clear Language Display. It
monitors the control variables that 1 Starter panel
govern the operation of the unit. 2 Control panel
Adaptive Control logic can correct 3 Evaporator
these variables, when necessary, to 4 Oil separator
optimize operational efficiencies, 5 Helical-Rotary Compressor
avoid chiller shutdown, and keep 7 Condenser-water outlet
producing chilled water. 8 Condenser-water inlet
Compressor unloaders are oil
pressure operated. Each refrigerant
circuit is provided with filter,
electronic expansion valve, and
charging valves.
5 5
9
3
10
11 12
3 Evaporator
5 Helical-Rotary Compressor
6 Condenser
9 Evaporator-water outlet
10 Evaporator-water inlet
11 Electronic expansion valve
12 Filter dryer
6 RTWB-SVN01B-E4
General
Information
RTWB-SVN01B-E4 7
General
Information
8 RTWB-SVN01B-E4
Installation Mechanical
RTWB-SVN01B-E4 9
Installation Mechanical
Dimension of the
holes for the forklift
Figure 5 – Lifting and rigging
10 RTWB-SVN01B-E4
Installation Mechanical
Dimensions in mm
Size “A”
207 and 208 2880
210 to 224 4150
Isolation pads Evaporator water piping Provide shutoff valves in lines to the
The elastomeric pads shipped are Figure 7 illustrates typical gauges, in order to isolate them
adequate for most installations. For evaporator piping components. from the system when they are not
additional details on isolation Components and layout will vary in use. Use rubber vibration
practices, consult an acoustical slightly, depending on the location eliminators to prevent vibration
engineer for sensitive installations. of connections and the water transmission through the water
source. lines.
Water piping The chilled-water connections are If desired, install thermometers in
Piping connections on the back of the unit, when facing the lines to monitor entering and
the control panel. leaving-water temperatures. Install a
A vent is provided on the top of the balancing valve in the leaving-water
C AUTION line to control the balance of the
evaporator at the return end. Be
sure to provide additional vents at water flow. Install shutoff valves on
To prevent equipment damage, both the entering and leaving-water
bypass the unit if using an acidic high points in the piping to bleed air
from the chilled-water system. lines so that the evaporator can be
flushing agent. isolated for service.
Install necessary pressure gauges to
Make water piping connections to monitor the entering and leaving A pipe strainer should be installed in
the evaporator and condenser. chilled-water pressures. the entering water line to prevent
Isolate and support piping to water-borne debris from entering the
prevent stress on the unit. Construct To prevent damage to chilled-water
components, do not allow evaporator.
piping according to local and
national codes. Isolate and flush evaporator pressure (maximum
piping before connecting it to the working pressure) to exceed 10 bar.
unit.
RTWB-SVN01B-E4 11
Installation Mechanical
Manometer
Evaporator
Flow
switch
Air vent
Expansion joints
Thermometers
Stop valves
Filter
Drainage
12 RTWB-SVN01B-E4
Installation Mechanical
RTWB-SVN01B-E4 13
Installation Mechanical
Figure 9
1 = Customer controller
2 = Condenser water pump with VFD
3 = To/from cooling device
4 = Temperature sensor
1 = 3-way valve or 2 2-way valves Advantages:
2 = Customer controller • Pumping cost can be reduced.
3 = Condenser water pump Good cooling device temperature
4 = To/from cooling device control.
5 = Temperature sensor • Relatively low first cost.
Advantage: Disadvantages:
• Excellent control by maintaining • Increased rate of fouling due to
constant water flow through the lower water velocity in the
condenser. condenser.
Disadvantage:
• Higher cost because of the
dedicated pump required for each Water treatment
chiller if condenser pressure is the Do not use untreated or improperly
control signal. treated water. Use of untreated or
improperly treated water may result
in equipment damage.
The use of improperly treated or
untreated water in this equipment
may result in scaling, erosion,
corrosion, algae or slime. The
services of a qualified water-
treatment specialist should be
engaged to determine what
treatment, if any, is advisable. The
Trane Company warranty
specifically excludes liability for
corrosion, erosion or deterioration
of Trane equipment. Trane assumes
no responsibility for the results of
the use of untreated or improperly
treated water, or saline or brackish
water.
14 RTWB-SVN01B-E4
Installation Mechanical
RTWB-SVN01B-E4 15
Installation Mechanical
Sizes 210-224
Sizes 207-208
1: Evaporator drain
21: 1 pass condenser
22: condenser 2 passes right
23: condenser 2 passes left
16 RTWB-SVN01B-E4
Installation Mechanical
RTWB-SVN01B-E4 17
Installation Electrical
General recommendations All wiring must comply with Do not allow conduits to interfere
national electrical regulations. with other components, structural
For proper electrical component Electrical characteristics and other members, or equipment. All
operation, do not locate the unit in unit electrical data are on the unit conduits must be long enough to
areas exposed to dust, dirt, nameplate. Specific electrical allow compressor and starter
corrosive fumes, or excessive schematics and connection removal.
humidity. If any of these conditions diagrams are shipped with the unit.
exist, corrective action must be
taken. Use copper conductors only. Unit
terminals are not designed to accept
other types of conductors. Failure to
WARNING do so may cause damage to the
equipment.
Disconnect all electrical power,
including remote disconnects,
before servicing. Failure to
disconnect power before servicing
can cause severe personal injury or
death.
18 RTWB-SVN01B-E4
Installation Electrical
RTWB-SVN01B-E4 19
Installation Electrical
20 RTWB-SVN01B-E4
Installation Electrical
RTWB-SVN01B-E4 21
Installation Electrical
22 RTWB-SVN01B-E4
Installation Electrical
RTWB-SVN01B-E4 23
Installation Electrical
24 RTWB-SVN01B-E4
Installation Electrical
Isolated 4-20 mA current source Table 11: Input values vs. external current-limit setpoint
input Voltage (V (dc)) Current (mA) Resulting current-limit setpoint (% RLA)
2.0 4.0 40
Set dip switch SW1-1 of the option
3.0 6.0 50
module A9 to “ON.“ Connect the 4.0 8.0 60
current source terminals 4 (+) and 5.0 10.0 70
5 (-). CWS is now based on the 6.0 12.0 80
following equation: 7.0 14.0 90
8.0 16.0 100
Setpoint (°C) = (mA * 2.44) - 27.56 9.0 18.0 110
10.0 20.0 120
External current limit setpoint:
voltage source 2-10 V (dc)or current
source 4-20 mA.
This option allows the external
setting of the current limit setpoint, Outdoor air-temperature sensor Communication card
independent of the front panel This sensor is used for low ambient This option allows the Clear
current-limit setpoint, by one of the lockout and chilled-water reset by Language Display in the control
two means: outdoor air temperature. This sensor panel on RTWB units to exchange
is optional on the RTWB units. information (operating setpoints and
1 - an isolated voltage input 2-10 V Auto/Standby commands) with a
(dc) Remove the sensor from its
shipping location in the control higher-level control device, such as
2 - an isolated voltage input 4-20 mA panel and install it in the fresh-air Tracer. A shielded, twisted-pair
To enable external current-limit intake on the north wall of the connection establishes the
setpoint operation, external current- building. Protect the sensor from bidirectional communications link
limit setpoint (operator setting direct sunlight and shelter it from between the unit control panel and
menu) should be set to “E“ using the elements. the Tracer.
the clear language display. Connect leads to terminals 1 and 2
1- 2-10 V (dc) voltage source input from module A9 TB1. All wiring to C AUTION
Set dip switch SW1-2 of the option and from the remote sensor must be
module A9 to “OFF.“ Connect the made with shielded, twisted-pair Note: The shielded, twisted-pair
voltage source to terminals 7 (+) and conductors. Be sure to ground the conductors must run in a separate
8 (-) of the option module A9. CLS is shielding only at the UCM. Apply conduit.
now based on the following tape to the sensor end of the
equation: shielding to prevent it from
contacting the surface. C AUTION
CL Setpoint % = (V (dc)*10) + 20
Sample values for CLS vs. V To prevent control malfunction, do
(dc)signals are shown in Table 9. WARNING not run low-voltage wiring (<30V) in
conduits with conductors carrying
Minimum setpoint : 40% (2.0 V
To prevent injury or death, more than 30 volts.
(dc)input)
disconnect the electrical power
Maximum setpoint : 120% (10.0 V source before completing wiring
(dc)input) connections to the unit.
4-20 mA Current source input
Set dip switch SW1-2 of the option
module A9 to “ON.“ Connect the
C AUTION
current source to terminal 7 (+) and
To prevent overheating at the
8 (-) of option module A9. CLS is
terminal connections, use copper
now based on the following
conductors only.
equation:
CL Setpoint % = (mA * 5) + 20
Sample values for CLS vs mA
signals are shown in Table 9.
Minimum setpoint = 40% (4.0 mA)
Maximum setpoint = 120%
(20.0 mA)
RTWB-SVN01B-E4 25
Installation Electrical
26 RTWB-SVN01B-E4
Installation Electrical
C AUTION
If using an acidic, commercial flushing solution, construct a temporary
bypass around the unit to prevent damage to internal components of the
evaporator.
C AUTION
To avoid possible equipment damage, do not use untreated or improperly
treated system water.
[ ] Connect the water piping to the evaporator and condenser.
[ ] Install pressure gauges and shutoff valves on the water inlet and outlet, if
applicable.
[ ] Install a water strainer in the entering chilled-water line, if applicable.
[ ] Install a balancing valve and flow switch in the leaving chilled-water line,
if applicable.
[ ] Install a drain with shutoff valve or a drain plug on the evaporator, if
applicable.
[ ] Vent the chilled-water and condenser-water systems at high points in the
system piping, if applicable.
RTWB-SVN01B-E4 27
Operating Principles –
Mechanical
28 RTWB-SVN01B-E4
Unit Start-Up
Procedures
Pre-start checkout
WARNING C AUTION
General
When installation is complete, but Disconnect all electric power, Do not use untreated or improperly
prior to putting the unit into service, including remote disconnects, treated water. Equipment damage
the following pre-start procedures before servicing. Failure to may occur
must be reviewed and verified: disconnect power before servicing [ ] Close the fused disconnect
[ ] Inspect all wiring connections to can cause severe personal injury or switch that supplies power to the
be sure they are clean and tight. death. chilled-water pump starter and
[ ] Check the unit power phasing to the condenser pump starter.
be sure that it has been installed
WARNING in an “ABC“ sequence.
[ ] Start the chilled-water pump and
condenser-water pump to begin
Disconnect all electric power, circulation of the water. Inspect
including remote disconnects, WARNING all piping for leakage and make
before servicing. Failure to any necessary repairs.
disconnect power before servicing It is imperative that l1-l2-l3 in the [ ] With water circulating through
can cause severe personal injury or starter be connected in the A-B-C the system, adjust the water flow
death. phase sequence to prevent and check the water-pressure
equipment damage due to reverse drop through the evaporator and
rotation. condenser. Refer to Tables 5 and
C AUTION 6.
[ ] Fill the evaporator and condenser
Check the tightness of all chilled-water circuits. Refer to [ ] Adjust the chilled-water flow
connections in the compressor Table 2 for liquid capacities. Vent switch and the condenser-water
power circuit (disconnects, terminal the system while it is being filled. flow switch (if installed) for
block, contactors, compressor Open the vents on the top of the proper operation.
junction box terminals, …). Loose evaporator and condenser during [ ] Prove all interlock and
connections can cause overheating filling, and close them when interconnecting wiring interlock
at the connections and filling is completed as described in section 3.
undervoltage conditions at the The use of improperly treated or
compressor motor. [ ] Check and set, as required, all
untreated water in this equipment Clear Language Display menu
[ ] Verify that all refrigerant valves may result in scaling, erosion, items.
are open. corrosion, algae, or slime. The
services of a qualified water [ ] Stop the chilled-water pump and
treatment specialist should be the condenser-water pump.
C AUTION engaged to determine what
treatment, if any, is advisable. The
Do not operate the unit with the Trane Company warranty specifically
compressor, oil discharge, or liquid excludes liability of corrosion,
line valves closed. Failure to have erosion, or deterioration of Trane
these open may cause serious equipment. Trane assumes no
compressor damage. responsibilities for the results of the
[ ] Check the power supply voltage use of untreated or improperly
to the unit at the main-power, treated water or saline or brackish
fused disconnect switch. Voltage water.
must be within the voltage
utilization range, given in Table 7
and also stamped on the unit
nameplate. Voltage imbalance
must not exceed 2%
RTWB-SVN01B-E4 29
Unit Start-Up
Procedures
Unit voltage power supply Unit voltage phasing Water system flow rates
Voltage to the unit must meet the Establish a balanced chilled-water
criteria given in Table 7. Measure flow through the evaporator. The
each phase of the supply voltage at WARNING flow rates should be between the
the unit main-power, fused minimum and maximum values
disconnect. If the measured voltage It is imperative that L1-L2-L3 in the given in Table 4.
on any phase is not within the starter be connected in the A-B-C
phase sequence, to prevent The flow rates through the
specified range, notify the supplier condenser must also be balanced
of the power and correct the equipment damage due to reverse
rotation. according to the flow rates table
situation before operating the unit. (Table 4).
It is important that proper rotation of
the compressors be established Water system pressure drop
C AUTION before the unit is started. Proper Measure the water pressure drop
motor rotation requires confirmation through the evaporator and
Inadequate voltage to the unit can of the electrical phase sequence of condenser at the field-installed
cause control components to the power supply. The motor is pressure taps, on the system water
malfunction and shorten the life of internally connected for clockwise piping. Use the same gauge for each
relay contacts, compressor motors, rotation, with the incoming power measurement. Do not include
and contactors. supply phased A,B,C. valves, strainers, or fittings in the
Unit voltage imbalance pressure drop reading.
When rotation is clockwise, phase
Excessive voltage imbalance sequence is usually called “ABC;“
between the phases of a three-phase when counterclockwise, “CBA.“
system can cause motors to
overheat and eventually fail. The This direction may be reversed
maximum allowable imbalance is outside the alternator by
2%. Voltage imbalance is determined interchanging any two of the line
using the following calculations: wires. It is this possible interchange
of wiring that makes a phase
% imbalance =(Ux - U average) sequence indicator necessary if the
U average operator is to quickly determine the
U average = (U1 + U2 + U3) / 3 phase rotation of the motor.
Ux = phase with greatest difference
from U average (without regard
to sign).
For example, if the three measured
voltages are 401, 410, and 407 volts,
the average would be:
401 + 412 + 417 = 410
3
The percentage of imbalance is
then:
100 * ( 410 - 401) = 2.2%
410
This exceeds the maximum
allowable (2%) by 0.2%.
30 RTWB-SVN01B-E4
Unit Start-Up
Procedures
RTWB-SVN01B-E4 31
Unit Shutdown
Procedures
Unit shutdown procedures • Close all chilled-water supply • Check the oil-separator oil level.
valves and the condenser-water See the Maintenance paragraph.
Temporary shutdown and restart
To shut the unit down for a short supply valves. Drain the water • Fill the evaporator- and condenser-
time, use the following procedure: from the evaporator and the water circuits. Refer to Table 4 for
condenser. evaporator- and condenser-water
• Press the Stop key on the Clear content. Vent the system while it is
Language Display. The • Open the unit main electrical
disconnect and the unit-mounted being filled. Open the vents on the
compressors will continue to tops of the evaporator and
operate and, after unloading for 20 disconnect (if installed), and lock in
the “Open“ position. condenser during filling and close
seconds, will stop when the them when filling is completed.
compressor contactor de-
energizes. C AUTION
• Stop the water circulation by C AUTION
turning off both the chilled-water Lock the disconnects on the “Open“
pump and the condenser-water position to prevent accidental start- Do not use untreated or improperly
pump. up and damage to the system when treated water. Equipment damage
it has been set up for extended may occur.
To restart the unit after a temporary
shutdown, restart the chilled-water shutdown. • Close the fused disconnect
pump and the condenser-water At least every three months, check switches that provide power to the
pump, and press the Auto key. The the pressure in the unit to verify that chilled-water pump and the
unit will start normally if the the refrigerant charge is intact. condenser-water pump.
following conditions exist: System restart after extended • Start both the evaporator- and
• The UCM must receive a call for shutdown condenser-water pumps and, while
cooling and the differential-to-start water is circulating, inspect all
• Follow the procedures below to piping for leakage. Make any
must be above the setpoint. restart the unit after an extended necessary repairs before starting
• All system operating interlocks and shutdown: the unit.
safety circuits must be satisfied. • Verify that the liquid-line service • While the water is circulating,
Extended shutdown procedure valves, oil line, and compressor adjust the water flows and check
The following procedure is to be discharge service valves are open. the water pressure drops through
followed if the system is to be taken the evaporator and the condenser.
out of service for an extended Refer to “Water System Flow
period of time as a seasonal C AUTION
Rates“ and “Water System
shutdown: Pressure Drop.“
To prevent damage to the
Test the unit for refrigerant leakage compressor, be sure that all • Adjust the flow switch (s) on the
and repair as necessary. refrigerant valves are open before evaporator piping and the
Open the electrical disconnect starting the unit. condenser piping (if installed) for
switches for the chilled-water pump proper operation.
and the condenser-water pump. Lock • Stop both water pumps. The unit is
the switches in the “open“ position. now ready for the start-up
procedure.
C AUTION
Lock the chilled-water and
condenser-water pump disconnects
open, to prevent pump damage.
32 RTWB-SVN01B-E4
Periodic
Maintenance
RTWB-SVN01B-E4 33
Periodic
Maintenance
34 RTWB-SVN01B-E4
Periodic
Maintenance
1: Oil separator
2: Valve
3: ¼" refrigeration hose
4: Sight glass
5: Minimum oil level
6: Maximum oil level
RTWB-SVN01B-E4 35
Periodic
Maintenance
36 RTWB-SVN01B-E4
Periodic
Maintenance
To change the oil filter in the unit, 8. Install a new copper gasket
refer to Figure 14 and follow the under the bolt head that had one
steps listed below. at time of removal. Replace all
For units without the discharge other bolts and tighten to 89.5
valve option: Nm.
1. Shut off the compressor and 9. Vacuum the refrigerant circuit at
disconnect all electrical service 500 micron and isolate the
to the compressor. vacuum pump.
2. Vacuum the refrigerant out of 10. Confirm that no moisture or
the circuit. leaks are present by letting the
vacuum stand for 2 hours. The
3. Remove the seven bolts on the pressure should not raise more
oil filter cover. A pan may be than 250 microns.
necessary to catch any oil that is
released after the cover is 11. Charge the unit with oil, in a
loosened. quantity equal to what has been
removed, by using the charging
4. Remove the cover and the oil valve placed on the oil filter.
filter element.
Note: the oil is very sensitive to
5. Install the new filter element. moisture. Use the oil
6. Coat the new cover gasket with immediately after the oil can has
refrigerant oil. been opened.
7. Install the cover plate and cover 12. Charge the unit with refrigerant
plate gasket. R134a (refer to the charging
procedure)
RTWB-SVN01B-E4 37
Periodic
Maintenance
For units with the discharge valve 9. Install a new copper gasket
option: under the bolt head that had one
1. Closed the angle valve placed on at time of removal. Replace all
the refrigerant liquid line to store other bolts and tighten to 89.5
the refrigerant in the condenser. Nm.
1
2
38 RTWB-SVN01B-E4
Periodic
Maintenance
RTWB-SVN01B-E4 39
Maintenance Contract Training
It is strongly recommended that you The equipment described in this
sign a maintenance contract with manual is the result of many years
your local Service Agency. This of research and continuous
contract provides regular development. To assist you in
maintenance of your installation by obtaining the best use of it, and
a specialist in our equipment. maintaining it in perfect operating
Regular maintenance ensures that condition over a long period of time,
any malfunction is detected and the constructor have at your
corrected in good time and disposal a refrigeration and air
minimizes the possibility that conditioning service school. The
serious damage will occur. Finally, principal aim of this is to give
regular maintenance ensures the operators and maintenance
maximum operating life of your technicians a better knowledge of
equipment. We would remind you the equipement they are using, or
that failure to respect these that is under their charge. Emphasis
installation and maintenance is particularly given to the
instructions may result in immediate importance of periodic checks on the
cancellation of the warranty. unit operating parameters as well as
on preventive maintenance, which
reduces the cost of owning the unit
by avoiding serious and costly
breakdowns.