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September 2005 RTAA-SVX01A-EN © American Standard Inc. 2005 Models RTAA RTAA-70 RTAA-80 RTAA-90 RTAA-100 RTAA-110 RTAA-125 Installation Operation Maintenance Series R ® Air-Cooled Rotary Liquid Chillers Packaged Air-Cooled Chiller, RTAA 70-125 Remote Evaporator Air-Cooled Chiller, RTAA 70-125

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  • American Standard Inc. 2005

    Packaged Air-Cooled Chiller, RTAA 70-125

    Remote Evaporator Air-Cooled Chiller, RTAA 70-125

    Models RTAA

    RTAA-70RTAA-80RTAA-90

    RTAA-100RTAA-110 RTAA-125

    InstallationOperationMaintenance

    Series R Air-Cooled Rotary Liquid Chillers

    September 2005 RTAA-SVX01A-EN

  • Important Environmental Concerns!Scientific research has shown that certain man-made chemicals can affect the earths naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handling of all refrigerantsincluding industry replacements for CFCs such as and HCFCs and HFCs.

    Responsible Refrigerant Practices!Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified. The Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.

    WARNINGContains Refrigerant!System contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant additives.

    Failure to follow proper procedures or the use of non-approved refrigerants, refrigerant substitutes, or refrigerant additives could result in death or serious injury or equipment damage.

    NOTICE: Warnings and Cautions appear at appropriate sections through-out this literature. Read these carefully.

    WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

    CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

    CAUTION: Indicates a situation that may result in equipment or property-damage only accidents.

    2 RTAA-SVX01A-EN

  • Table of Contents

    General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Unit Identification - Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Loose Parts Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Model Number Coding System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

    Installation Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Installation Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Location Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Unit Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Unit Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Evaporator Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Evaporator Piping Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Entering Chilled Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Evaporator Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Chilled Water Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

    Installation Remote Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . 31System Configuration and Interconnecting Refrigerant Piping . . . . . . . . . 31Line Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Example Liquid Line Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Suction Line Sizing Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Piping Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Refrigerant Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Leak Test and Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Refrigerant and Additional Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Relief Valve Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

    Installation Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49General Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Installer-Supplied Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Power Supply Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Interlock Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Low Voltage Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Remote Clear Language Display Installation Procedure . . . . . . . . . . . . . . 62

    Operating Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Refrigeration (Cooling) Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Oil System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

    Controls Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Clear Language Display Keypad Overview . . . . . . . . . . . . . . . . . . . . . . . . 72Select Report Group and Select Settings Group Flowcharts . . . . . . . . . . 74Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Operational Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

    RTAA-SVX01A-EN 3

  • Table of Contents

    DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100IPC Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

    Pre-Start Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Unit Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Unit Voltage Imbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Unit Voltage Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Water System Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Water System Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Clear Language Display Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

    Start-Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108System Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111System Subcooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

    Unit Shutdown Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Temporary Shutdown and Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Extended Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112System Restart After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 113

    Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

    Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Coil Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1