Library Service Literature

Product Section Refrigeration

Product Rotary liquid Chillers – Air-Cooled

Model RTAA

Literature Type Installation, Operation, Maintenance

Sequence 3

Date December 1991

File No. SV-RF-RLC-RTAA-IOM-3-1291

Supersedes

Installation RTAA-IOM-3OperationMaintenance

Since The Trane Company has a policy of continuous product improvement, it reserves the right to changespecifications and design without notice. The installation and servicing of the equipment referred in this bookletshould be done by qualified, experienced technicians.

Air-CooledSeries R®

Rotary LiquidChillers“CO” and Later Design Sequence

Packaged Air-Cooled Chiller,RTAA 130-400

Remote Evaporator Air-Cooled Chiller,RTAA 130-200

Models

RTAA-130 RTAA-170 RTAA-240 RTAA-340RTAA-140 RTAA-185 RTAA-270 RTAA-370RTAA-155 RTAA-200 RTAA-300 RTAA-400

Part No. X39560468-01

©American Standard Inc. 1991

3 RTAA-IOM-3

9 General Information9 Literature Change History9 Unit Identification9 Unit Inspection9 Inspection Checklist9 Loose Parts Inventory10 Unit Description10 Commonly Used Acronyms20 Warnings and Cautions20 Installation Responsibilities21 Nameplates21 — Outdoor Unit Nameplate21 — Compressor Nameplate21 — Remote Evaporator Nameplate23 Storage25 Installation - Mechanical, Packaged

Unit with Remote Evaporator25 General25 Pre-installation25 Location Requirements25 — Noise Considerations25 — Foundation25 — Clearances31 — Additional Location

Requirements for RemoteEvaporator Only

31 — Drainage32 Rigging32 Lifting Procedures36 Unit Isolation and Leveling36 Evaporator Water Piping41 — Evaporator Piping42 — Evaporator Piping Components42 — Entering Chilled Water Piping42 — Leaving Chilled Water Piping42 — Evaporator Drain42 — Evaporator Flow Switch44 — Water Treatment44 — Water Pressure Gauges44 — Water Pressure Relief Valves44 — Freeze Protection45 — Domestic Water Heater Piping45 — Domestic Water Heater Piping

Components45 — Entering Water Piping45 — Leaving Water Piping45 — Water Pressure Relief Valves45 — Freeze Protection

47 Installation - Mechanical,Remote EvaporatorInterconnecting RefrigerantPiping

47 General51 Line Sizing51 — Equivalent Line Length51 — Liquid Line Sizing53 —Suction Line Sizing54 Piping Installation Procedures54 Refrigerant Sensors56 Leak Test and Evacuation56 Refrigerant and Additional Oil

Charge56 — Refrigerant Charge

Determination56 — Oil Charge Determination

57 Installation - Electrical57 General Recommendations68 Installer-Supplied Components68 — Remote Evaporator Only68 Power Supply Wiring68 — General68 — Control Power Supply68 — Heat Tape Power Supply

(Packaged Units Only)68 — Water Pump Power Supply68 — Auxiliary Heat Tape Power

Supply69 Interconnecting Wiring69 — Chilled Water Pump Interlock

and External Auto/Stop69 — Chilled Water Pump Interlock69 — External Auto/Stop Wiring70 — Alarm/Running/Maximum

Capacity Outputs71 — Alarm/Running/Maximum

Capacity Indicator Wiring71 Low Voltage Wiring71 — Emergency Stop (Normal Trip)71 — External Circuit Lockout -

Circuit #171 — External Circuit Lockout -

Circuit #271 — Ice Making Option72 — External Chilled Water Setpoint

(CWS) Remote Resistor/Potentiometer, Voltage Source2-10 VDC or Current Source4-20 mA

73 — External Current Limit Setpoint(CLS) Remote Resistor/Potentiometer, Voltage Source2-10 VDC or Current Source4-20 mA

74 — Optional BidirectionalCommunication Link (BCL)

74 — General74 — Communication Link

Connection Procedure75 Installation Check List

Table ofContents

World environmental scientists haveconcluded, based on the best currentlyavailable evidence, that ozone in ourupper atmosphere is being reduceddue to release of CFC fully halogenatedcompounds.

Prior to installation, operation, serviceor maintenance on this equipment,refer to “Refrigerant Emission Control”in the Periodic Maintenance Section.

4RTAA-IOM-3

77 Operating Principles -Mechanical

77 General77 Refrigeration (Cooling) Cycle77 — Cycle Description77 — Compressor Description77 — Compressor Motor77 — Compressor Rotors77 — Compressor Loading Sequence82 Oil System Operation82 — Overview82 — Domestic Water Heater83 — Oil Separator83 — Compressor Bearing Oil Supply83 — Compressor Rotor Oil Supply84 — Slide Valve Movement84 — Oil Filter84 —Condenser Fans

87 Operating Principles -AdaptiveControl™ Microprocessor Logic

87 General87 Digital Display93 — Menus99 — Chiller Switch100 Menu Function Descriptions and

Selection100 — Selecting Variables and Options100 — Menu 0 - Operating Display100 — Menu 1 - Service #1 Display101 — Menu 2 - Service #2 Display101 — Menu 3 - Auxiliary Options102 — Menu 4 - Factory Display #1104 — Menu 5 - Factory Display #2105 Operational Features105 — Entering Evaporator Water

Temperature105 — Current Limit Setpoint105 — Low Ambient Lockout105 — Electronic Expansion Valve

(EXV) Test105 — Current Overload Protection105 — Leaving Chilled Water

Temperature Control106 — Chilled Water Reset (CWR)107 — Leaving Water Temperature

Cutout107 — Low Refrigerant Temperature

Cutout107 — Low Ambient Temperature Start107 — Low Refrigerant Temperature

Cutout Retry108 — Auto Lead/Lag108 — Phase Imbalance Protection108 —Reverse Rotation Protection108 DIP Switch Settings108 Compressor Overload DIP

Switches108 IPC Address108 — 2-10 VDC/4-20 mA Input for

(CWS) and (CLS)109 Diagnostics and Troubleshooting109 —Mechanical Control Settings

121 Pre-Start Check-out121 General122 Unit Voltage Power Supply122 Unit Voltage Imbalance123 Unit Voltage Phasing124 Water System Flow Rates124 Water System Pressure Drop124 UCM Set-up

125 Start-up Procedures125 General125 System Superheat125 System Subcooling

129 Unit Shutdown Procedures129 Temporary Shutdown and Restart129 Extended Shutdown Procedure130 System Restart After Extended

Shutdown

131 Periodic Maintenance131 General133 Refrigerant Emission Control133 Weekly Maintenance134 Monthly Maintenance134 Annual Maintenance

135 Maintenance135 General135 Coil Cleaning135 Chemically Cleaning the

Evaporator135 Domestic Water Heater –

Tube Cleaning136 Water Treatment136 Oil Separator Level Check

5 RTAA-IOM-3

37 Figure 18Spring Isolator Placement forTypical RTAA Packaged Unit- 130 to 200 Tons

38 Figure 19Spring Isolator Placement forTypical RTAA Packaged Unit -240 to 400 Tons

39 Figure 20Spring Isolator Placement forTypical RTAA Outdoor Unit withRemote Evaporator Option

40 Figure 21Spring Isolator Placement forTypical RTAA Unit with HeatRecovery Domestic Water Heater

41 Figure 22Suggested Piping for Typical RTAAEvaporator

43 Figure 23RTAA 130 thru 400 EvaporatorWater Pressure Drop

46 Figure 24Typical Domestic Water HeaterPiping

46 Figure 25RTAA 130 thru 400 DomesticWater Heater Water Pressure Drop

47 Figure 26Remote Evaporator Installation -No Elevation Difference

48 Figure 27Remote Evaporator Installation -Condenser and Compressor aboveEvaporator

49 Figure 28Restricted Installation -Evaporatoris More Than 1’8" Above Base ofOutdoor Unit.

49 Figure 29Restricted Installation -SuctionLine is on a Higher Plane than theOutdoor Unit.

50 Figure 30Refrigerant Circuit Identification

52 Figure 31Remote Evaporator PipingExample

55 Figure 32Customer Interconnect Wiring forRTAA Outdoor Unit with RemoteEvaporator -130 to 200 Tons

57 Figure 33Warning Label

58 Figure 34Typical Field Wiring for RTAAPackaged Unit - 130 to 200 Tons

61 Figure 35Typical Field Wiring for RTAAPackaged Unit - 240 to 400 Tons

List ofIllustrations

11 Figure 1Typical RTAA Packaged Unit -130 to 200 Tons (Front/sideExterior View)

12 Figure 2Typical RTAA Packaged Unit -130 to 200 Tons (Rear/side ExteriorView)

13 Figure 3Typical RTAA Packaged Unit -240 to 400 Tons (Front/sideExterior View)

14 Figure 4Typical RTAA Unit (Rear ExteriorView)

15 Figure 5Typical RTAA Unit with RemoteEvaporator Option (Rear ExteriorView)

18 Figure 6Remote Evaporator

21 Figure 7Nameplates

22 Figure 8Model Number Coding System

26 Figure 9Dimensions and Clearances forRTAA Packaged Unit - 130 to 200 Tons

27 Figure 10Dimensions and Clearances forRTAA Packaged Unit - 240 to 300 Tons

28 Figure 11Dimensions and Clearances forRTAA Packaged Unit - 340 to 400 Tons

29 Figure 12Dimensions and Clearances forRTAA Outdoor Unit with RemoteEvaporator Option

30 Figure 13Dimensions and Weights forRemote Evaporator

33 Figure 14Rigging and Lifting Weights forRTAA Packaged Unit- 130 to 200 Tons IncludingDomestic Water Heater

34 Figure 15Rigging and Lifting Weights forRTAA Packaged Unit- 240 to 300 Tons

34 Figure 16Rigging and Lifting Weights forRTAA Packaged Unit- 340 to 400 Tons

35 Figure 17Rigging and Lifting Weights forRTAA Outdoor Unit with RemoteEvaporator Option

6RTAA-IOM-3

64 Figure 36Typical Field Wiring for OutdoorUnit with Remote EvaporatorOption

70 Figure 37Alarm/Running/MaximumCapacity Contact Outputs

72 Figure 38Resistor and PotentiometerArrangement for External ChilledWater Setpoint

73 Figure 39Resistor and PotentiometerArrangement for External CurrentLimit Setpoint

78 Figure 40Refrigeration System and ControlComponents - Single Circuit

80 Figure 41Refrigeration System and ControlComponents - Duplex Circuit

81 Figure 42Typical RTAA Compressor

82 Figure 43RTAA Compressor Oil SystemSchematic

83 Figure 44Oil Separator

85 Figure 45Fan Configurations - RTAA 130 to200 Ton 15 F Minimum Ambient

86 Figure 46Fan Configurations - RTAA 130 to400 Ton 0 F Minimum Ambient

88 Figure 47RTAA Control Panel- 130 to 200 Tons

89 Figure 48RTAA Control Panel- 240 to 300 Tons

90 Figure 49RTAA Control Panel- 340 to 400 Tons

91 Figure 50RTAA Control Panel -130 to 200 Tons with RemoteEvaporator Option

92 Figure 51Operator Interface Controls

93 Figure 52Menu Formats

98 Figure 53Condition/Diagnostic Codes

107 Figure 54Low Refrigerant TemperatureCutout Ignore Time

123 Figure 55Associated Research Model 45Phase Sequence Indicator

126 Figure 56Unit Sequence of Operation- 240 to 400 Tons

128 Figure 57Unit Sequence of Operation-130 to 200 Tons

132 Figure 58Operator’s Log

135 Figure 59Chemical Cleaning Configuration

137 Figure 60System Oil Level Specification

7 RTAA-IOM-3

16 Table 1General RTAA MechanicalSpecifications

17 Table 2RTAA Refrigerant CircuitDesignations and Capacities

51 Table 3RTAA Circuit Capacities

51 Table 4Liquid Line Size for Horizontal and/or Downflow Lines

51 Table 5Equivalent Lengths of Non-FerrousValves and Fittings

53 Table 6Suction Line Size for Horizontaland/or Upflow Lines

53 Table 7Suction Line Size for Horizontaland/or Downflow Lines

56 Table 8System Refrigerant Charge

56 Table 9Field-installed Piping Charge

67 Table 10Electrical Data

70 Table 11Alarm/Running/MaximumCapacity Relay OutputConfigurations

70 Table 12Alarm/Running/MaximumCapacity Menu Settings

72 Table 13Input Values vs Extended ChilledWater Setpoint Inputs (Ohms)

73 Table 14Input Values vs External CurrentUnit Setpoint

102 Table 15Leaving Fluid TemperatureSetpoints

104 Table 16Compressor Overload DIP SwitchSettings

105 Table 17Compressor(s) Current LimitSetpoint vs. Chiller Current LimitSetpoint (CLS)

110 Table 18Diagnostic and TroubleshootingChart

List ofTables

8RTAA-IOM-3

9 RTAA-IOM-3

Literature Change HistoryRTAA-IOM-3 (October 1991)

Original manual. Covers installation,operation, and maintenance of “CO”design sequence RTAA-130 thruRTAA-400 units.

Unit IdentificationWhen the unit arrives, compare allnameplate data with ordering andshipping information.

Unit InspectionWhen the unit is delivered, verify that itis the correct unit and that it is propertyequipped. Compare the informationwhich appears on the unit nameplatewith the ordering and submittalinformation. Refer to “Nameplates”.

Note: If the Remote Evaporator Optionis ordered, the remote evaporator willbe shipped in a separate crate. Theserial number on the evaporatornameplate must match the serialnumber on the outdoor unitnameplate.

Caution: If the serial numbers onthe remote evaporator and theoutdoor unit do not match, do notproceed with the installation.Notify the appropriate Trane SalesOffice.

Inspect all exterior components forvisible damage. Report any apparentdamage or material shortage to thecarrier and make a “unit damage”notation on the carrier’s deliveryreceipt. Specify the extent and type ofdamage found and notify theappropriate Trane Sales Office.

Do not proceed with installation of adamaged unit without sales off iceapproval.

Inspection ChecklistTo protect against loss due to damageincurred in transit, complete thefollowing checklist upon receipt of theunit.

[ ] Inspect the individual pieces of theshipment before accepting the unit.Check for obvious damage to theunit or packing material.

[ ] Inspect the unit for concealeddamage as soon as possible afterdelivery and before it is stored.Concealed damage must bereported within 15 days.

[ ] If concealed damage is discovered,stop unpacking the shipment. Donot remove damaged material fromthe receiving location. Take photosof the damage, if possible. Theowner must provide reasonableevidence that the damage did notoccur after delivery.

[ ] Notify the carrier’s terminal of thedamage immediately, by phone andby mail. Request an immediate,joint inspection of the damage withthe carrier and the consignee.

[ ] Notify the Trane sales representativeand arrange for repair. Do not repairthe unit, however, until damage isinspected by the carrier’srepresentative.

Loose Parts InventoryCheck all the accessories and looseparts which are shipped with the unitagainst shipping list. Included in theseitems will be water vessel drain plugs,rigging and electrical diagrams, andservice literature, which are placedinside the control panel and/or starterpanel for shipment.

GeneralInformation

10RTAA-IOM-3

Commonly UsedAcronymsAcronyms used in this manual aredefined below.

OAT = Outdoor Air TemperatureBAS = Building Automation SystemBCL = Bidirectional Communications

LinkCAR = Circuit Shutdown, Auto ResetCLS = Current Limit SetpointCMR = Circuit Shutdown, Manual

ResetCWR = Chilled Water ResetCWS = Chilled Water SetpointDDT = Design Delta-Temperature

Setpoint (i.e., the differencebetween entering and leavingchilled water temperatures)

ENT = Entering Chilled WaterTemperature

EXV = Electronic Expansion ValveFLA = Full Load AmpsHGBP = Hot Gas BypassHVAC = Heating, Ventilating and Air

ConditioningIFW = Informational - Warning I/O

Input and Output WiringIPC = Inter-Processor

CommunicationsLRA = Locked Rotor Amps Leaving

Chilled Water TemperatureMAR = Machine Shutdown, Auto

ResetMMR = Machine Shutdown, Manual

ResetNEC = National Electric CodePCWS =Front Panel Chilled Water

SetpointPFCC = Power Factor Correction

CapacitorsPSID = Pounds-per-Square-inch

Differential (pressuredifferential)

PSIG = Pounds-per-Square-inch(gauge pressure)

RAS = Reset Action SetpointRLA = Rated Load AmpsRCWS =Reset Chilled Water Setpoint

(CWR)RRS = Reset Reference Setpoint

(CWR)SV = Slide ValveTracer® =Type of Trane Building

Automation SystemSCI = Serial Communications

InterfaceUCLS = Unit Current Limit SetpointUCM = Unit Control Module

(Microprocessor-based)UCWS= Unit Chilled Water Setpoint

Unit DescriptionThe 130 thru 400-ton Model RTAA unitsare helical-rotary type, air-cooled liquidchillers designed for installationoutdoors Depending upon ratedcapacity, the unit will have two, three orfour compressors. The compressorcircuits are completely assembled,hermetic packages that are factory-piped, wired, leak-tested, dehydrated,and tested for proper control operationbefore shipment.

Note: Packaged units are factorycharged with refrigerant and oil.Remote evaporator units are shippedwith a holding charge of nitrogen and apartial charge of oil.

Figures 1 thru 4 show typical RTAApackaged units and their components.Figures 5 and 6 show a typical RTAARemote Evaporator outdoor unit andevaporator. Tables 1 and 2 containgeneral RTAA mechanicalspecifications. Chilled water inlet andoutlet openings are covered forshipment. Each compressor has aseparate compressor motor starter.

The RTAA series features Trane’sexclusive Adaptive Control™ logic,which monitors the control variablesthat govern the operation of the chillerunit. Adaptive Control logic can correctthese variables, when necessary, tooptimize operational efficiencies, avoidchiller shutdown, and keep producingchilled water. An optional remotedisplay is available to monitor unitoperation from a remote location.

These units feature two independentrefrigerant circuits. Compressorunloaders are solenoid actuated and oilpressure operated. Each refrigerantcircuit is provided with filter drier, sightglass, electronic expansion valve, andcharging valves.

The shell-and-tube type evaporator ismanufactured in accordance withASME standards. Each evaporator isfully insulated and is equipped withwater drain and vent connections.Packaged units have heat tapeprotection to -200 F. Remoteevaporators do not have heat tape.

11 RTAA-IOM-3

Figure 1Typical RTAA Packaged Unit130 - 200 Ton(Front/Side Exterior View)

CondenserCoils

Connection Accessfor Control Voltage

and Interlocks

Starter and Power Panel

Nameplate

Control Panel

LineVoltageConnectionAccess

12RTAA-IOM-3

Figure 2Typical RTAA Packaged Unit130 - 200 Ton(Rear/Side Exterior View)

Chilled Water Outlet

Chilled Water Inlet

13 RTAA-IOM-3

Figure 3Typical RTAA Packaged Unit240-400 Tons

ControlPanel

Evaporator

Outlet

Inlet

14RTAA-IOM-3

Figure 4Typical RTAA Unit(Rear Exterior View)

Condenser Fans/Motors

Condenser

Liquid Line Filter

Electronic Expansion Valves

Liquid Line Filter

Condenser

15 RTAA-IOM-3

Figure 5Typical RTAA Unit(with Remote Evaporator Option)(Rear Exterior View)

CondenserFans/MotorsCircuit #1

CondenserFans/MotorsCircuit #2

CondenserCircuit #1

CondenserCircuit #2

Circuit #1Field RefrigerantPiping Connections

Circuit #2Field RefrigerantPiping Connections

16RTAA-IOM-3

Table 1General RTAA Mechanical Specifications

Size130 140 155 170 185 200

CompressorQuantity 2 2 2 2 2 2Nominal Size(1)(Tons) 70/70 70/70 85/70 100/70 100/85 100/100

EvaporatorWater Storage (Gallons) 49 46 73 69 62 61

(Liters) 184 175 277 261 234 231Min. Flow (GPM) 156 156 186 186 222 222

(L/Sec) 9.8 9.8 11.7 11.7 14.0 14.0Max. Flow (GPM) 504 504 612 612 720 720

(L/Sec) 31.8 31.8 38.6 38.6 45.4 45.4CondenserOty of Coils 4 4 4 4 4 4Coil Length (In) 214/214 214/214 240/214 240/214 240/240 240/240Coil Height (In) 42 42 42 42 42 42Number of Rows 3 3 3 3 3 3

Condenser FansQuantity 5/5 5/5 6/5 7/5 7/6 7/7Diameter (In) 30 30 30 30 30 30Total Airflow (CFM) 105,860 105,860 114,610 120,160 128,910 134,460Nominal RPM 1140 1140 1140 1140 1140 1140Tip Speed (Ft/Min) 8954 8954 8954 8954 8954 8954Motor HP (Ea) 1.5 1.5 1.5 1.5 1.5 1.5

Min Starting/Oper. Ambient (2)Std Unit (Deg. F) 15 15 15 15 15 15Low Amb. (Deg. F) 0 0 0 0 0 0

General UnitRefrigerant HCFC-22 HCFC-22 HCFC-22 HCFC-22 HCFC-22 HCFC-22No. of IndependentRefrigerant Circuits 2 2 2 2 2 2

% Min. Load (3) 10 10 10 10 10 10Refrig. Charge(1)(Lb) 130/130 130/130 165/130 170/130 170/165 170/170

(Kg) 59/59 59/59 75/59 77/59 77/75 77/77Oil Charge (Gal) 7/7 7/7 8/7 8/7 8/8 8/8(1,4,5) (L) 27127 27/27 31/27 31/27 31/31 31/31

17 RTAA-IOM-3

Table 1 (Continued from previous page)General RTAA Mechanical Specifications

Size240 270 300 340 370 400

CompressorQuantity (1) 2/1 1-1/1 2/1 2/2 1-1/2 2/2Nominal Size (1)(Tons) 70/100 100-70/100 100/100 70/100 100-70/100 100/100

EvaporatorWater Storage (Gallons) 151 143 135 124 116 108

(Liters) 572 523 511 470 439 407Min. Flow (GPM) 288 288 288 408 408 408

(L/Sec) 18.2 18.2 18.2 25.7 25.7 25.7Max. Flow (GPM) 1080 1080 1080 1440 1440 1440

(L/Sec) 68.1 68.1 68.1 90.8 90.8 90.8CondenserQty. of Coils 4/4 2-2/4 4/4 4/4 2-2/4 4/4Coil Length (In) 214/120 240-214/120 240/120 214/240240-214/240 240/240Coil Height (In) 42 42 42 42 42 42Number of Rows 3 3 3 3 3 3

Condenser FansQuantity (1) 10/7 12/7 14/7 10/14 12/14 14/14Diameter (In) 30 30 30 30 1 30 30Total Airflow (CFM) 173,090 187,390 201,690 240,320 254,620 268,920Nominal RPM 1140 1140 1140 1140 1140 1140Tip Speed (Ft/Min) 8954 8954 8954 8954 8954 8954Motor HP (Ea) 1.5 1.5 1.5 1.5 1.5 1.5

Min Starting/Oper. Ambient (2) 0 0 0 0 0 0(Deg. F)

General UnitRefrigerant HCFC-22 HCFC-22 HCFC-22 HCFC-22 HCFC-22 HCFC-22No. of IndependentRefrigerant Circuits 2 2 2 2 2 2

% Min. Load (3) 10 10 10 10 10 10Refrig Charge(1)(Lb) 276/180 318/180 360/180 276/360 318/360 360/360

(Kg) 125/82 144/82 163/82 125/163 144/163 163/163Oil Charge) (Gal) 15/8 16/8 17/8 15/17 16/17 17117(1.4,5) (L) 57/31 61/31 65/31 57/65 61/65 65/65

Notes:(1) Data containing information on two circuits shown as follows: ckt1/ckt2(2) Minimum start-up/operating ambient based on a 5 mph wind across the condenser.(3) Percent minimum load is for total machine, not each individual circuit.(4) Trane Part# OIL-15(5) Add 6 gal./circuit for domestic water heater.

18RTAA-IOM-3

Figure 6Remote Evaporator

RefrigerantSuction LineCircuit #1

RefrigerantSuction LineCircuit #2

Entering ChilledWater Temp. Sensors

Leaving Chilled WaterTemperature Sensor

EvaporatorRefrigerantTemperatureSensors

ElectronicExpansionValve

SightGlass

Filter/Dryer

Terminal Box

RefrigerantLiquid LineCircuit #1

19 RTAA-IOM-3

RTAA Model Circuit/Tons Compressor/Tons130 1 70 A 70

2 70 B 70140 1 70 A 70

2 70 B 70155 1 85 A 85

2 70 B 70170 1 100 A 100

2 70 B 70185 1 100 A 100

2 85 B 85200 1 100 A 101

2 100 B 100

RTAA Model Circuit/Tons Compressor/Tons240 1 140 A 70

B 702 100 C 100

270 1 170 A 100B 70

2 100 C 100300 1 200 A 100

B 1002 100 C 100

340 1 140 A 70B 70

2 200 C 100D 100

370 1 170 A 100B 70

2 200 C 100D 100

400 1 200 A 100B 100

2 200 C 100D 100

Table 2RTAA Refrigerant Circuit Designations and Capacities

Package Unit 130-200

Remote Evaporator Unit 130-200

PNL

COND 1 A

COND 2 B

ElectronicExpansionValves

PNL

COND 1EVAP 1

A

COND 2EVAP 2

B

EVAP 1

EVAP 2

240-300

PNL

COND 2

EVAP 2

EVAP 1COND 1

C A

B

340-400

PNL

COND 2EVAP 2

EVAP 1COND 1

C A

D B

20RTAA-IOM-3

Warnings and CautionsWarnings and Cautions appear inboldface type at appropriate points inthis manual.

Warnings are provided to alertpersonnel to potential hazards that canresult in personal injury or death; theydo not replace the manufacturer’srecommendations.

Cautions alert personnel to conditionsthat could result in equipment damage.

Your personal safety and reliableoperation of this machine depend uponstrict observance of these precautions.The Trane Company assumes noliability for installation or serviceprocedures performed by unqualifiedpersonnel,

InstallationResponsibilitiesGenerally, the contractor must do thefollowing when installing an RTAA unit:

[ ] Install unit on a flat foundation, level(within 1/4" [6.4 mm]), and strongenough to support unit loading.

[ ] Install unit per the instructionscontained in the InstallationMechanical and InstallationElectrical sections of this manual.

[ ] Install any optional sensors andmake electrical connections at theUCM.

Note: The standard leaving chilledwater sensor is factory installed in theevaporator leaving water outlet.

[ ] Where specified, provide and installvalves in water piping upstream anddownstream of evaporator waterconnections to isolate theevaporator for maintenance, and tobalance/trim system.

[ ] If desired, supply and install flowswitches in the chilled water piping;interlock each switch with properpump starter to ensure unit can onlyoperate if water flow is established.Chilled water flow protection isprovided by the UCM without theneed for a chilled water flow switch.A flow switch for chilled water isstrictly discretionary.

[ ] For Remote Evaporator units only,furnish and install refrigerant piping,refrigerant and oil, per theinstructions outlined in this manual.

[ ] Furnish and install pressure gaugesin inlet and outlet piping of theevaporator.

[ ] Furnish and install a drain valve tothe bottom of the evaporator.

[ ] Supply and install a vent cock to thetop of the evaporator.

[ ] Where specified, furnish and installstrainers ahead of all pumps andautomatic modulating valves.

[ ] Provide and install field wiring.

[ ] Start unit under supervision of aqualified service technician.

[ ] Install heat tape and insulate thechilled water lines and any otherportions of the system, as required,to prevent sweating under normaloperating conditions or freezingduring low ambient temperatureconditions.

21 RTAA-IOM-3

NameplatesThe RTAA outdoor unit nameplates areapplied to the exterior and interiorsurface of the Control Panel door(Figure 1). A compressor nameplate islocated on each compressor. Onremote evaporators, the nameplate islocated on the Terminal Box.

Outdoor Unit Nameplate

The outdoor unit nameplate providesthe following information:

– Unit model and size description.

– Unit serial number.

– Identifies unit electrical requirements.

– Lists correct operating charges of R-22 and refrigerant oil.

– Lists unit test pressures.

– Identifies installation, operation and maintenance and service data literature

– Lists drawing numbers for unit wiring diagrams.

Compressor Nameplate

The “compressor’ nameplate providesfollowing information:

– Compressor model number.

– Compressor serial number.

– Compressor electrical characteristics.

– Utilization Range.

– Recommended refrigerant.

Remote EvaporatorNameplate

The “evaporator” nameplate providesthe following information:

– RTAA outdoor unit to which the remote evaporator is designed to be connected.

– Evaporator serial number. This number and the serial number of the outdoor RTAA unit to which it is connected will be identical.

Figure 7Nameplates

22RTAA-IOM-3

Figure 8Model Number Coding System

RTA A 200 G X B0 1 A 0 D 0 B D E G0 1 2123 4 567 8 9 01 2 3 4 5 6 7 8 9 0 (Digit position for above)

Where digits are assigned the following meanings:

Digit CharacterNo. Value Description

1, 2, 3 Unit Type/FunctionRTA Rotary (Series “R”)

Air Cooled Chiller

4 Development SequenceA “A” Dev. Sequence

5, 6, 7 Unit Nominal Tons130 130 Tons140 140 Tons155 155 Tons170 170 Tons185 185 Tons200 200 Tons240 240 Tons270 270 Tons300 300 Tons340 340 Tons370 370 Tons400 400 Tons

8 Unit VoltageD 380/60/3G 200-230/60/3 Dual

Voltage1 346/50/3K 380-415/50/34 460/60/35 575/60/3S Special Customer Option

9 Compressor Starter TypeY Y-Delta

(Closed Transition)X X-Line

(Across the line)S Special Customer Option

10, 11 Design SequenceBO Second design.

Increment when partsare affected forservice purposes.

12 Evaporator Leaving Temp.1 Standard 40-60 F2 Low 20-40 F3 Ice making 20-60 FS Special Customer Option

13 Condenser Coil FinMaterial

A AluminumB Aluminum with

corrosion protectionS Special Customer Option

Digit CharacterNo. Value Description

14 Agency Listing0 No agency listing1 U.L. listed - Standard

where applicable2 C.S.A. listed3 *U.L./C.S.A. listedS Special Customer Option

15 Control InterfaceA Standard Control

No communicationmodule

B Standard ControlWith communicationmodule

C Deluxe ControlNo communicationmodule

D Deluxe ControlWith communication moduleDeluxe control option consistsof the following:A - Cycle counter and

hour meterB - Under/over voltage

protectionC - Remote alarm contacts

and compressor runindication

D - % volts

16 Chilled Water Reset0 None1 Return water temperature2 Outside air temperature3 Zone temperatureS Special Customer Option

17+ Add on OptionsA Architectural louvered

panelsB Control power transformerC Heat recoveryD Low ambient lockout

sensorE Suction service valvesF Power disconnectG Low ambient operationH *Unit sound attenuatorI Remote evaporatorS Special Customer Option

Note:1. Digits 17 and on may be multiple,

independent add on options.2. * Denotes that this option assignment has

been made but is not available now

Model NumberCoding System

The model numbers for the outdoorunit and the compressors arecomprised of numbers and letter whichrepresent features of the equipment.Shown on the chart in Figure 8 aresamples of typical unit and compressormodel numbers, followed by thecoding system for each.

Each position, or group of positions, inthe number is used to represent afeature. For example, in Figure 8,position 08 of the unit model number,Unit Voltage, contains the letter “G”.

From the chart, it can be seen that a“G” in this position means that the unitvoltage is 200-230/60/3 dual voltage.

23 RTAA-IOM-3

StorageExtended storage of the outdoor unitprior to installation requires thefollowing precautionary measures:

1. Store the outdoor unit in a securearea.

2. At least every three months(quarterly), check the pressure in therefrigerant circuits to verify that therefrigerant charge is intact. If it is not,contact a qualified serviceorganization and the appropriateTrane sales off ice.

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25 RTAA-IOM-3

GeneralThe following instructions are, for themost part, applicable to both packagedunits and units with the remoteevaporator option. Specific exceptionsare noted.

The most significant difference in theinstallation of the two systems is therequirement for interconnecting pipingwith the remote evaporator option. Forthis reason, these installationprocedures are covered separately inthe following section, Installation -Mechanical, Remote EvaporatorInterconnecting Piping.

Pre-installationReport any damage incurred duringhandling or installation to the Tranesales office immediately. An InstallationCheck Sheet is provided.

Location Requirements

Noise Considerations

Locate the outdoor unit away fromsound sensitive areas. If required,install rubber vibration isolators in allwater piping and use flexible electricalconduit. Refer to “Unit Isolation”.Consult an acoustical engineer forcritical applications. Also refer to TraneEngineering Bulletins for applicationinformation on RTAA chillers.

Installation - MechanicalPackaged Unit and Units withRemote Evaporator Option

Foundation

Provide rigid, non-warping mountingpads or a concrete foundation ofsufficient strength and mass to supportthe outdoor unit operating weight (i.e.,including completed piping, and fulloperating charges of refrigerant, oil andwater). Refer to Figures 18 thru 21 forunit operating weights. Once in place,the outdoor unit must be level within 1/4" (6.4 mm) over its length and width.The Trane Company is not responsiblefor equipment problems resulting froman improperly designed or constructedfoundation.

Clearances

Provide enough space around theoutdoor unit to allow the installationand maintenance personnelunrestricted access to all service points.Refer to submittal drawings for the unitdimensions. A minimum of four feet isrecommended for compressor service.Provide sufficient clearance for theopening of control panel doors. Referto Figures 9 thru 12 for minimumclearances. In all cases, local codeswhich require additional clearances willtake precedence over theserecommendations.

Note: If the outdoor unit configurationrequires a variance to the clearancedimensions, contact your Trane SalesOffice Representative. Also refer toTrane Engineering Bulletins forapplication information on RTAAchillers.

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Figure 9Dimensions and Clearances forRTAA Packaged Unit – 130 to 200 Ton

RTAA-SU-1000E

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Figure 10Dimensions and Clearances forRTAA Packaged Unit – 240 - 300 Ton

RTAA-SU-1001C

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Figure 11Dimensions and Clearances forRTAA Packaged Unit – 340 to 400 Ton

RTAA-SU-1002C

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Figure 12Dimensions and Clearances forRTAA Outdoor Unit with Remote Evaporator Option

RTAA-SU-1003A

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Figure 13Dimensions and Weights forRemote Evaporator Option

RTAA-SU-1004A

NOTES:1. TOLERANCE ± 1/8” UNLESS OTHERWISE SPECIFIED.2. ALLOW 8’-8” ON EITHER END FOR TUBE REMOVAL.

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Additional Location Requirementsfor Remote Evaporator Only

The remote evaporator must beinstalled indoors, unless:

– ambient temperatures are alwaysabove 32 F.

– the system circulating liquid is a non-freezing glycol-type solution, selectedfor the prevailing ambienttemperatures.

– the evaporator is protected fromfreezing by properly installed andapplied insulation and heat tape.

Caution: To prevent internaldamage due to freezing, do notinstall the outdoor unit withoutadequate freeze protection.

The remote evaporator should bemounted on a base of suitable strengthto support the operating weight.Remote evaporator weights andmounting locations are shown inFigure 13.

The remote evaporator must be levelwhen installed. Be sure to allow

adequate clearance for water andrefrigerant piping connections,performance of service procedures,reading of gauges and thermometers,and operation of valves. Space must beallowed at one end of the evaporator topull tubes, if required.

Drainage

Provide a large capacity drain for watervessel drain-down during shutdown orrepair. The evaporator is provided witha drain connection. Refer to“Evaporator Drain”. All local andnational codes apply. The vent on thetop of the evaporator is provided toprevent a vacuum by allowing air intothe evaporator for complete drainage.

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RiggingThe Model RTAA chiller should bemoved by lifting. Refer to Figures 14thru 17 for typical unit lifting andoperating weights. Refer to the riggingdiagram that ships with each unit forspecific “per unit” weight data.

WARNING: To prevent injury ordeath and unit damage, capacityof lifting equipment must exceedunit lifting weight by anadequate safety factor.

Lifting ProcedureCaution: To prevent damage do not usea forklift to lift the unit.

[ ] Install clevis connectors through thefour, six or eight lifting platesprovided on the unit (Figures 14thru 17).

WARNING: To prevent injury ordeath and unit damage, use thelifting method shown in Figures14 and 17.

[ ] Attach lifting chains or cables toclevis connectors. Each cable alonemust be strong enough to lift thechiller.

[ ] Attach cables to lifting beam. Totallifting weight, lifting weightdistribution and required liftingbeam dimensions are shown inFigures 14 thru 17 and on therigging diagram shipped with eachunit. Lifting beam crossbars must bepositioned so lifting cables do notcontact the sides of the unit.

Caution: To prevent unit damage,position lifting beam so that cablesdo not contact the unit.

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Figure 14Rigging and Lifting Weights forRTAA Packaged Unit

NOTES:1. LIFTING CHAINS (CABLES) WILL NOT BE THE SAME LENGTH. ADJUST TO

KEEP UNIT LEVEL WHILE LIFTING.2. DO NOT FORK LIFT UNIT.3. WEIGHTS ARE TYPICAL FOR UNITS WITH R-22 CHARGE.4. DEDUCT 740 FROM TOTAL WEIGHT FOR UNITS WITHOUT

ARCHITECTURAL LOUVER PANELS.

130-200 Tonswithout Domestic Water Heater

NOTES:1. LIFTING CHAINS (CABLES) WILL NOT BE THE SAME LENGTH. ADJUST TO

KEEP UNIT LEVEL WHILE LIFTING.2. DO NOT FORK LIFT UNIT.3. WEIGHTS ARE TYPICAL FOR UNITS WITH R-22 CHARGE.4. DEDUCT 740 FROM TOTAL WEIGHT FOR UNITS WITHOUT

ARCHITECTURAL LOUVERED PANELS.

130-200 Tonswith Domestic Water Heater

RTAA-SA-2001C

RTAA-SA-2007A

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Figure 15Rigging and Lifting Weights forRTAA Packaged Unit – 240-300 Tons

NOTES:1. LIFTING CHAINS (CABLES) WILL NOT BE THE SAME LENGTH.

ADJUST TO KEEP UNIT LEVEL WHILE LIFTING.2. DO NOT FORK LIFT UNIT.3. WEIGHTS ARE TYPICAL FOR UNITS WITH R-22 CHARGE.4. DEDUCT 1166 FROM TOTAL WEIGHT FOR UNITS WITHOUT

ARCHITECTURAL LOUVER PANELS.

NOTES:1. LIFTING CHAINS (CABLES) WILL NOT BE

THE SAME LENGTH. ADJUST TO KEEPUNIT LEVEL WHILE LIFTING.

2. DO NOT FORK LIFT UNIT.3. WEIGHTS ARE TYPICAL FOR UNITS

WITH R-22 CHARGE.4. DEDUCT 1480 FROM TOTAL WEIGHT

FOR UNITS WITHOUT ARCHITECTURALLOUVERED PANELS.

Figure 16Rigging and Lifting Weights for RTAAPackaged Unit – 340-400 Tons

RTAA-SA-2005B

RTAA-SA-2006B

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Figure 17Rigging and Lifting Weights forRTAA Outdoor Unit withRemote Evaporator Option

NOTES:1. LIFTING CHAINS (CABLES) WILL NOT BE

THE SAME LENGTH. ADJUST TO KEEPUNIT LEVEL WHILE LIFTING.

2. DO NOT FORK LIFT UNIT.3. WEIGHTS ARE TYPICAL FOR UNITS

WITH R-22 CHARGE.4. DEDUCT 740 FROM TOTAL WEIGHT FOR

UNITS WITHOUT ARCHITECTURALLOUVER PANELS.

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Unit Isolation andLevelingFor additional reduction of sound andvibration, use one of the two mountingmethods outlined below:

1. Construct an isolated concrete padfor the unit or provide concretefootings at each of the eight unitmounting points. Mount the unitdirectly to the concrete pads orfootings. Level the unit using thebase rail as a reference. The unitmust be level within 1/4" over theentire length. Use shims asnecessary to level the unit.

2. Install the optional spring isolators ateach of the eight/ten unit mountingpoints. Refer to Figures 18 thru 21 forisolator placement locations andloading information.

a. Secure the isolators to themounting surface, using themounting slots in the isolator baseplate. Do not fully tighten theisolator mounting bolts at thistime.

b. Positioning pins are located on thetop of each isolator, as shown inFigures 18 thru 21. Lower the uniton to the isolators so that the pinsregister with the unit mountingholes.

c. The weight of the unit will forcethe upper housing of each isolatordown. This may cause the upperhousing to contact the lowerhousing. As shown in Figures 18thru 21, the clearances betweenupper and lower housings must be1/4 to 1/2 inch. If the clearance onany isolator is greater than 1/2inch, it will be necessary to useshims or grout to achieve therequired clearance.

d. Minor adjustments can be madeto the clearance by turning theleveling bolt; clockwise to increasethe clearance andcounterclockwise to decrease theclearance. All eight isolators mustbe supporting the entire weight ofthe unit while these adjustmentsare being made.

Note: If proper clearances cannot beachieved using the leveling bolts, useshims or grouting under the isolators,as required. Isolators must not straddlesmall gaps in the shims or grout.

e. Before tightening the mountingbolts, level the unit using the unitbase rail as a reference. The unitmust be level within 1/4" over theentire length. Use the levelingbolts and/or additional shims orgrout to level the unit.

Evaporator Water PipingThoroughly flush all water piping to theunit before making the final pipingconnections to the unit.

Caution: If using an acidiccommercial flushing solution,construct a temporary bypassaround the unit to prevent damageto internal components of theevaporator.

Caution: To avoid possibleequipment damage, do not useuntreated or improperly treatedsystem water.

When completing the NPT-type waterconnections, apply a suitable pipesealant, or Teflon tape, to prevent waterleakage. To minimize heat gain and toprevent condensation, insulate allpiping.

Caution: Avoid overtightening andpossible damage of waterconnections. The lubricatingproperties of Teflon tape make thepossibility of overtightening morelikely.

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RTAA-SA-2000B

Figure 18Spring Isolator Placement forTypical RTAA Packaged Unit – 130 to 200 Tonswithout Domestic Water Heater

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RTAA-SA-2002C

Figure 19Spring Isolator Placement forTypical RTAA Packaged Unit – 240-400 Tons

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RTAA-SA-2003A

Figure 20Spring Isolator Placement forTypical RTAA Outdoor Unit withRemote Evaporator Option

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RTAA-SA-2008A

Figure 21Spring Isolator Placement forTypical RTAA Unit with Heat RecoveryDomestic Water Heater

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Evaporator Piping

Figure 22 illustrates typical evaporatorpiping components. Components andlayout will vary slightly, depending onthe location of connections and thewater source.

Caution: The chilled waterconnections to the evaporator areto be “victaulic” type connections.Do not attempt to weld theseconnections, as the heat generatedfrom welding can cause internaldamage to the evaporator.

The chilled water connections are onthe left side of the unit. If it is necessaryfor the chilled water piping to enter theunit from the right side, elbows can beused to route the piping 1800 over thetop of the evaporator, as shown inFigure 22, for RTAA 130-200 units only.

A vent is provided on the top of theevaporator at the return end. Be sure toprovide additional vents at high pointsin the piping to bleed air from thechilled water system. Install necessarypressure gauges to monitor theentering and leaving chilled waterpressures.

Caution: To prevent damage tochilled water components, do notallow evaporator pressure(maximum working pressure) toexceed 215 psig.

Provide shutoff valves in lines to thegauges to isolate them from thesystem when they are not in use. Userubber vibration eliminators to preventvibration transmission through thewater lines.

If desired, install thermometers in thelines to monitor entering and leavingwater temperatures. Install a balancingvalve in the leaving water line tocontrol water flow balance. Installshutoff valves on both the entering andleaving water lines so that theevaporator can be isolated for service.

A pipe strainer should be installed inthe entering water line to preventwaterborne debris from entering theevaporator.

Figure 22Suggested Piping forTypical RTAA Evaporator

VentsValved

PressureGauge

Drain Union

VibrationEliminator

FlowSwitch(Optional) Balancing Valve

Gate Valve

UnionWaterStrainer

VibrationEliminator

Gate Valve

RTAA 130-200with Opposite-Side Connections(View from end opposite control panel)

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Evaporator PipingComponents

“Piping components” include alldevices and controls used to provideproper water system operation andunit operating safety. Thesecomponents and their generallocations are given below.

Entering Chilled Water Piping

[ ] Air vents (to bleed air from system).

[ ] Water pressure gauges with shutoffvalves.

[ ] Vibration eliminators.

[ ] Shutoff (isolation) valves.Thermometers (if desired).

[ ] Clean-out tees.

[ ] Pipe strainer.

Caution: To prevent tube damageinstall strainer in evaporator waterinlet piping.

Leaving Chilled Water Piping

[ ] Air vents (to bleed air from system).

[ ] Water pressure gauges with shutoffvalves. Vibration eliminators.

[ ] Shutoff (isolation) valves.

[ ] Thermometers.

[ ] Clean-out tees.

[ ] Balancing valve.

[ ] Flow Switch (If desired)

Caution: To prevent evaporatordamage, do not exceed 215 psig(14.6 bar) evaporator waterpressure.

Evaporator Drain

A 3/4" drain connection is locatedunder the outlet end of the evaporator.This may be connected to a suitabledrain to permit evaporator drainageduring unit servicing. A shutoff valvemust be installed on the drain line.

Evaporator Flow Switch

Chilled water flow protection isprovided by the UCM without the needfor a chilled water flow switch. A flowswitch for chilled water is strictlydiscretionary but if not installed, asignal still must be sent to the chiller toindicate that water flow has beenestablished, e.g. chilled water pumpmotor starter auxiliary contacts.

If additional chilled water flowprotection is desired, use a field-installed flow switch or differentialpressure switch with the pumpinterlock to sense system water flow.Install and wire the flow switch in serieswith the chilled water pump motorstarter auxiliaries (refer to “ElectricalWiring”).

Specific connection and schematicwiring diagrams are shipped with theunit. Some piping and controlschemes, particularly those using asingle water pump for both chilled andhot water, must be analyzed todetermine how and or if a flow sensingdevice will provide desired operation.

Follow the manufacturer’srecommendations for selection andinstallation procedures. Generalguidelines for flow switch installationare outlined below

1. Mount the switch upright, with aminimum of 5 pipe diameters ofstraight horizontal run on each side.Do not install close to elbows,orifices or valves.

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

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

Note: The UCM provides a 6-secondtime delay after a “loss-of-flow”diagnostic before shutting the unitdown. Contact a qualified servicerepresentative if nuisance machineshutdowns persist.

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3. Adjust the switch to open whenwater flow falls below nominal.Evaporator data is shown in Figure23. Refer to Table 1 for minimumflow recommendations. Flow switchcontacts are closed on proof of waterflow.

4. Install a pipe strainer in the enteringevaporator water line to protectcomponents from waterbornedebris.

Figure 23RTAA 130 thru 400Evaporator Water Pressure Drop

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Water Treatment

Using untreated or improperly treatedwater in these units may result ininefficient operation and possible tubedamage. Consult a qualified watertreatment specialist to determinewhether treatment is needed. Thefollowing disclamatory label isprovided on each RTAA unit:

Customer NoteThe use of improperly treated oruntreated water in this equipment mayresult in scaling, erosion, corrosion,algae or slime. The services of aqualified water treatment specialistshould be engaged to determine whattreatment, if any, is advisable. TheTrane Company warranty specificallyexcludes liability for corrosion, erosionor deterioration of Trane equipment.Trane assumes no responsibilities forthe results of the use of untreated orimproperly treated water, or saline orbrackish water.

Caution: Do not use untreated orimproperly treated water.Equipment damage may occur.

Water Pressure Gauges

Install field-supplied pressure gauges(with manifolds, whenever practical) asshown in Figure 22. Locate pressuregauges or taps in a straight run of pipe;avoid placement near elbows, etc. Besure to install the gauges at the sameelevation on each shell if the shellshave opposite-end water connections.

To read manifolded pressure gauges,open one valve and close the other(depending upon the reading desired).This eliminates errors resulting fromdifferently calibrated gauges installedat unmatched elevations.

Water Pressure Relief Valves

Install a water pressure relief valve inthe evaporator inlet piping between theevaporator and the inlet shutoff valve,as shown in Figure 22. Water vesselswith close-coupled shutoff valves havea high potential for hydrostaticpressure buildup on a watertemperature increase. Refer toapplicable codes for relief valveinstallation guidelines.

Caution: To prevent shell damage,install pressure relief valves in theevaporator water system.

Freeze Protection

If the unit will remain operational atsubfreezing ambient temperatures, thechilled water system must be protectedfrom freezing, following the steps listedbelow

1. Heat tape is factory-installed on thepackaged unit evaporator and willprotect it from freezing in ambienttemperatures down to -20 F.

2. Install heat tape on all water piping,pumps, and other components thatmay be damaged if exposed tofreezing temperatures. Heat tapemust be designed for low ambienttemperature applications. Heat tapeselection should be based on thelowest expected ambienttemperature.

3. Add a non-freezing, low temperature,corrosion inhibiting, heat transferfluid to the chilled water system. Thesolution must be strong enough toprovide protection against iceformation at the lowest anticipatedambient temperature. Refer to Table1 for evaporator water storagecapacities.

Note: Use of glycol type antifreezereduces the cooling capacity of the unitand must be considered in the designof the system specifications.

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Domestic Water HeaterPiping

Figure 24 illustrates typical domesticwater heater piping components.Components and layout will varyslightly, depending on the location ofconnections and the water source. Seeunit submittals to insure identificationof water inlet and outlet connections.

Be sure to provide additional vents athigh points in the piping to bleed airfrom the water system.

Caution: To prevent damage tocomponents, do not allowdomestic water heater pressure(maximum working pressure) toexceed 150 psig.

Use rubber vibration eliminators toprevent vibration transmission throughthe water lines.

Install a balancing valve in the leavingwater line to control water flowbalance. Install shutoff valves on boththe entering and leaving water lines sothat the domestic water heater can beisolated for service.

The vent and drain can be used totemporarily install gauges anddetermine pressure drop at the heater.Water flow rates, as a function ofpressure drop, are charted in Figure 25,or pressure drop can be calculatedusing the following formula:

Pressure Drop (Ft. H20) = 2.31 (Drainpsig -Vent psig)

A pipe strainer should be installed inthe entering water line to preventwaterborne debris from entering thedomestic water heater.

Domestic Water HeaterPiping Components

“Piping components” include alldevices and controls used to provideproper water system operation andunit operating safety. Thesecomponents and their generallocations are given below.

Entering Water Piping

[ ] Drain

[ ] Vibration eliminators.

[ ] Shutoff (isolation) valves.

[ ] Pipe strainer.

Caution: To prevent tube damageinstall strainer in the water inletpiping.

Leaving Chilled Water Piping

[ ] Air vents (to bleed air from system)

[ ] Vibration eliminators.

[ ] Shutoff (isolation) valves.

[ ] Balancing valve.

Caution: To prevent damage, donot exceed 215 psig (14.6 bar)domestic water heater waterpressure.

Water Pressure Relief Valves

Install a water pressure relief valve inthe outlet piping between the domesticwater heater and the outlet shutoffvalve, as shown in Figure 24. Watervessels with close-coupled shutoffvalves have a high potential forhydrostatic pressure buildup on awater temperature increase. Refer toapplicable codes for relief valveinstallation guidelines.

Caution: To prevent shell damage,install pressure relief valves in theevaporator water system.

Freeze Protection

If water in the domestic water heaterwill be subjected to subfreezingambient temperatures, the watersystem must be protected fromfreezing, following the steps listedbelow:

1. Heat tape is factory-installed on thedomestic water heater and willprotect it from freezing in ambienttemperatures down to -20 F Insurethat electrical power is provided forthe heat tape.

2. Install heat tape on all water piping,pumps, and other components thatmay be damaged if exposed tofreezing temperatures. Heat tapemust be designed for low ambienttemperature applications. Heat tapeselection should be based on thelowest expected ambienttemperature.

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Figure 24Typical Domestic WaterHeater Piping

Figure 25Typical Domestic WaterHeater Piping

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Installation - MechanicalRemote Evaporator InterconnectingRefrigerant Piping.

GeneralThe RTAA outdoor unit with theRemote Evaporator option is shippedas two pieces: the outdoor unit(condensing) and the evaporator. Theoutdoor unit includes a suctionaccumulator line on each circuit andhas the field connections for therefrigerant at the end opposite thecontrol panel.

The evaporator is shipped completewith factory-mounted refrigerationspecialties (electronic expansionvalves, sight-glasses and removablecore filter-dryers). All evaporatorrefrigerant line connections are at oneend of the evaporator. The installingcontractor need only provide andinstall the refrigerant piping betweenthe evaporator and the outdoor unit.

System ConfigurationThe system may be configured ineither of the two primary arrangementsas shown in Figures 26 and 27. Theconfiguration and its associatedelevation, along with the total distancebetween the remote evaporator andthe compressor/condenser section,play a critical role in determiningsuction and liquid line sizes. This willalso affect field refrigerant and oilcharges. Consequently, there arephysical limits which must not beviolated if the system is to operate asdesigned. Please note the followingrestrictions:

Figure 26Remote Evaporator Installation –No Elevation Difference

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A. The line sizes established in thisinstallation manual are to be used onlyfor 40-50 F leaving water temperatureand full-load ice-making applications.

B. The evaporator can be mountedonly on the SAME PLANE OR LOWERPLANE than the outdoor unit. Figure 28illustrates what not to do. The elevationdifference is to not exceed 100 feet.

C. Piping between evaporator andoutdoor unit is to not exceed 200(linear) feet or an equivalent length(includes equivalent length pressuredrop of fittings) of 300 feet.

D. The suction line must never cross orbe above a plane that is 1’8" above thebottom of the outdoor unit. Figure 29illustrates what not to do.

Figure 27Remote Evaporator Installation –Condenser and Compressorabove Evaporator

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E. Horizontal portions of the suctionlines must be downward sloping to thecompressors. Suction lines must beinsulated.

F. Install an inverted trap in the liquidline when the evaporator is on a lowerplane than the outdoor unit. The apexof the trap should be at a height abovethe top of the condenser coils. SeeFigure 27.

G. Install a suction line trap at theevaporator when the evaporator is on alower plane than the outdoor unit. SeeFigure 27.

H. The evaporator MUST be matchedwith its respective outdoor unit. Thenameplate on the evaporator will havea serial number that is matched to theoutdoor unit’s serial number. SeeFigure 7.

Also the circuits on the outdoor unitmust match the circuits on theevaporator (I.E. circuit #1 on theoutdoor units must be connected withcircuit #1 on the evaporator).

Caution: If the circuits are crossed,serious equipment damage mayoccur.

See Figure 30 for circuit numberidentification.Figure 28

Restricted Installation –Evaporator is on a Higher Planethan the Outdoor Unit

Figure 29 – Restricted Installation -Suction Line is More Than 1’8"Above Base of Outdoor Unit

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Figure 30Refrigerant Circuit Identification

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Table 4Liquid Line Size for Horizontal and/or Downflow Lines

Circuit Size: Liquid Line Size (OD”)Total Equiv. Length (Ft) 100 Ton 85 Ton 70 Ton

25' 1 1/8 1 1/8 1 1/850' 1 3/8 1 1/8 1 1/875' 1 3/8 1 3/8 1 3/8100' 1 3/8 1 3/8 1 3/8125' 1 3/8 1 3/8 1 3/8150' 1 5/8 1 3/8 1 3/8175' 1 5/8 1 5/8 1 5/8200' 1 5/8 1 5/8 1 5/8225' 1 5/8 1 5/8 1 5/8250' 1 5/8 1 5/8 1 5/8275' 1 5/8 1 5/8 1 5/8300': 1 5/8 1 5/8 1 5/8

Table 5Equivalent Lengths of Non-Ferrous valves and Fittings

Line Size Globe Angle Short LongInches OD Valve Valve Radius ELL Radius ELL

1 1/8 87 29 2.7 1.91 3/8 102 33 3.2 2.21 5 /8 115 34 3.8 2.62 1/8 141 39 5.2 3.42 5/8 159 44 6.5 4.23 1/8 185 53 8.0 5.13 5/8 216 66 10.0 6.34 1/8 248 76 12.0 7.3

Reproduced by permission of Air conditioning and Refrigeration Institute.

Line Sizing

Equivalent Line Length

To determine the appropriate size forfield installed liquid and suction lines, itis first necessary to establish theequivalent length of pipe for each line.An initial approximation can be madeby assuming that the equivalent lengthof pipe is 1.5 times the actual length ofpipe. These assumed lengths can thenbe used with the appropriate tables inthe Liquid Line Sizing section and theSuction Line Sizing sections whichfollow.

It is also necessary to know thecapacity (tons) of each circuit. Circuitcapacities for each RTAA unit are listedin Table 3.

The following are examples of how todetermine line sizes.

Liquid Line Sizing

This example uses the unit installationshown in Figure 31 and assumes an 85ton circuit. The actual length of fieldinstalled piping is 117 feet (80 + 8 + 8 +21). Using the factor of 1.5, theequivalent line length is 175 feet.

From Table 4, for horizontal and/ordownflow liquid lines, and assumingan 85 ton circuit, 175 feet of equivalentline requires a liquid line with an OD of1 5/8 in.

There are 6 long-radius elbows in thisexample. Using Table 5 and the pipeOD of 1 5/8 in., these fittings represent15.6 feet (6 elbows @ 2.6 feet each).Therefore our new equivalent linelength is 132.6 feet (117 +15.6).

Referring back to Table 4, an 85 toncircuit with 132.6 feet of equivalent pipelength (use the dimension closest tothe calculated dimension) can use apipe O.D. of 1% in. rather than 1 5/8 in.From Table 5 we see that the 6 elbowsof 1 3/8 in. have an equivalent pipelength of 13.2 feet (6 elbows @ 2.2 feeteach). This further reduces theequivalent pipe length to 130.2 feet(117 + 13.2), and, as shown in Table 4,still allows the use of 1 3/8 in. O.D. pipe.

Table 3RTAA Circuit Capacities

Model Circuit 1 Circuit 2130 70 70140 70 70155 85 70170 100 70185 100 85200 100 100

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Figure 31Remote Evaporator Piping Example

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Suction Line Sizing

This example uses the unit installationshown in Figure 31 and assumes a 100ton circuit. As in the liquid line sizingexample, the equivalent pipe lengthmust first be determined. It must alsobe determined what portion of the pipeis “horizontal and/or downflowing”and what portion is “horizontal and/orupflowing.”

In Figure 31, the actual length of fieldinstalled piping is 100 feet (20 + 5 + 75).Using the factor of 1.5, the equivalentline length is 150 feet. The suction linehas an elevation of 20 feet and consistsof horizontal and vertical (upflowing)sections, which must be sizedseparately.

The two vertical sections are separatedby a small horizontal section. The totaldistance is 25 feet (20 +5). The firstapproximation of equivalent pipelength is 37.5 feet (1.5 times 25).Referring to Table 6 for a horizontaland/or upflow suction line on a 100 toncircuit with 37.5 feet of line, the pipeO.D. should be 3 1/8 in.

Add the 75 feet of horizontal and/ordownflow line to the 45.4 feet ofhorizontal and/or upflow line, resultingin 120.5 of equivalent pipe length. Table7 at 125 feet (use the dimension closestto the calculated dimension) indicatesthe use of 4 1/8 in. O.D. pipe. Therefore,the 4 1/8 in line will have to be reducedfor the vertical sections of the line andexpanded again for the horizontalsections.

There are four long-radius elbows inthis section of piping. Using Table 5and the pipe OD of 3 1/8 in., thesefittings represent 20.4 feet (4 elbows @5.1 feet each). Therefore our newequivalent line length is 45.4 feet (25 +20.4). Table 6 indicates that 45.4equivalent feet still permits the use of 31/8 in. O.D. pipe.

In sizing the horizontal and/ordownflow portion of the suction line, itis necessary to account for the totalequivalent length of the line.

Note: In this example, the horizontalline is pitched downward in thedirection of flow

Using Table 7 and 150 feet ofequivalent pipe length for a 100 toncircuit, a pipe O.D. of 4 1/8 in. isspecified. There are no fittings in the 75foot horizontal run, so no equivalentfitting lengths need to be determined.

Table 6Suction Line Size for Horizontal and/or Upflow Lines

Circuit Size: Suction Line Size (OD”)Total Vertical Equiv. Length (Ft) 100 Ton 85 Ton 70 Ton

50': 3 1/8 3 1/8 2 1/875': 3 1/8 3 1/8 2 1/8

100': 3 1/8 3 1/8 2 1/8

Table 7Suction Line Size for Horizontal and/or Downflow Lines

Circuit Size:Total Equiv. Length (Ft) Suction Line Size (OD”)

(Including vertical section, if any) 100 Ton 85 Ton 70 Ton50': 3 1/8 3 1/8 2 5/875': 3 1/8 3 1/8 2 5/8

100': 3 1/8 3 1/8 3 1/8125': 4 1/8 3 1/8 3 1/8150': 4 1/8 3 1/8 3 1/8175': 4 1/8 4 1/8 3 1/8200': 4 1/8 4 1/8 3 1/8225': 4 1/8 4 1/8 3 1/8250': 4 1/8 4 1/8 3 1/8275': 4 1/8 4 1/8 3 1/8300': 4 1/8 4 1/8 3 1/8

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Piping InstallationProceduresThe outdoor unit and the evaporatorare shipped with a 25 psig holdingpressure of dry nitrogen. Do not relievethis pressure until field installation ofthe refrigerant piping is to beaccomplished. This will require theremoval of the temporary pipe caps.

Note: Use Type L refrigerant-gradecopper tubing only.

The refrigerant lines must be isolatedto prevent line vibration from beingtransferred to the building. Do notsecure the lines rigidly to the buildingat any point.

All horizontal suction lines should bepitched downward, in the direction offlow, at a slope of 1/2 in. per 10 feet ofrun, This allows for larger line size,which will improve unit efficiency.

Do not use a saw to remove end caps,as this may allow copper chips tocontaminate the system. Use a tubingcutter or heat to remove the end caps.

When sweating copper joints, flow drynitrogen through the system. Thisprevents scale formation and thepossible formation of an explosivemixture of R-22 and air. This will alsoprevent the formation of toxicphosgene gas, which occurs whenrefrigerant is exposed to open flame.

WARNING: To prevent Injury ordeath, due to explosion and/orinhalation of phosgene gas,purge the system thoroughlywhile sweating connections. Usea pressure regulator in the linebetween the unit and the highpressure nitrogen cylinder toavoid over-pressurization andpossible explosion.

Refrigerant SensorsThe suction line refrigerant sensorsmust be installed by the contractorinstalling the refrigerant piping. Thesensors are pre-wired and each is“wire-tied” to its respective liquid line.Fittings and adapters for mounting ofthe sensors are located in the remoteevaporator terminal box. See Figure 32for mounting instructions.

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Figure 32Customer Interconnect Wiring forRTAA Outdoor unit with Remote Evaporator –130 to 200 Tons

2306-9133A

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Leak Test and EvacuationAfter installation of the refrigerantpiping, thoroughly test the system forleaks. Pressure test the system atpressures required by local codes.

Immediately before evacuation, installthe liquid line filter cores. These will beshipped with the evaporator.

Note: Do not install these before thecircuit is ready for evacuation, as thecores will absorb moisture from theatmosphere.

For field evacuation, use a rotary-typevacuum pump capable of pulling avacuum of 100 microns or less. Followthe pump manufacturer’s instructionsfor proper use of the pump. The lineused to connect the pump to thesystem should be copper and be thelargest diameter that can be practicallyused. A larger line size with minimumflow resistance can significantly reduceevacuation time.

Use the ports on the compressorsuction service valves and the liquidline shutoff valves for access to thesystem for evacuation. Insure that thecompressor suction service valve, theliquid line shutoff valve, the oil lineshutoff valve and any field installedvalves are open in the proper positionbefore evacuating.

Insulate the entire suction line and thesuction accumulator line. Where theline is exposed to the weather, wrap itwith weatherproof tape and seal withweatherproof compound.

Refrigerant andAdditional Oil Charge

Refrigerant ChargeDetermination

The approximate amount of refrigerantcharge required by the system must bedetermined by referring to Table 8 andmust be verified by running the systemand checking the liquid linesightglasses.

Table 8System Refrigerant Charge

Circuit Size Lbs. of R-2270 13085 165

100 170

To determine the appropriate charge,first refer to Table 8 to establish therequired charge required without thefield-installed piping. Next, determinethe charge required for the field-installed piping by referring to Table 9.

Table 9Field-installed Piping Charge

Pipe O.D. Suction Liquid(inches) Line Line

1 3/8 1.2 63.01 5/8 1.7 89.22 1/8 2.9 155.22 5/8 4.5 239.43 1/8 6.4 —4 1/8 11.3 —

Note: The amounts of refrigerant listedin Table 9 are based on 100 feet of pipe.Actual requirements will be in directproportion to the actual length ofpiping.

Note: Table 9 assumes:Liquid Temperature = 100 FSuction Temperature = 35 FSuction Superheat Temperature = 8 F

The approximate amount of refrigerantis therefore the sum of the valuesdetermined from Tables 8 and 9.

Example:Determine the approximate amount ofcharge required for an RTAA 200 tonunit with a remote evaporator that islocated 75 feet away (i.e. the actuallength of field installed pipe is 75 feetfor each suction line and liquid line).Assume that the suction lines havebeen previously determined to be 4 1/8in., O.D. and the liquid lines are 1 3/8 in.O.D.

A 200 ton unit has two 100 ton circuits.From Table 8 above, a 100 ton circuitrequires 170 lbs. of R-22. In addition,the 4 1/8 in. 0. D. suction line for the 100ton circuit will require 11.3 lbs. per 100feet of the 75 feet of line will thereforerequire 8.5 lbs. (11.3 times 75/100).

Similarly from Table 9, the 1 3/8 in. O.D.liquid line will require 47.3 lbs. of R-22(63 times 75/100). The total R-22 chargefor the 100 ton circuit will be 225.8 lbs.(170 + 8.5 + 47.3). And because theRTAA 200 has two 100 ton circuits, thetotal system charge will be twice asmuch, or 461.6 lbs.

Oil Charge Determination

The unit is factory charged with theamount of oil required by the system,without the field-installed piping. Theamount of additional oil required isdependent upon the amount ofrefrigerant that is added to the systemfor the field-installed piping.

Use the following formula to calculatethe amount of oil to be added:

Pints of Oil (Trane Oil-15) = lbs. ofrefrigerant added for field-installedpiping/18.375

From the example above, in which theweight of the additional refrigerantadded for the field-installed piping was55.8 lbs. (47.3 + 8.5), the amount of oilto be added equals 3 pints (55.8/18.375)per circuit.

57 RTAA-IOM-3

Installation –Electrical

Figure 33Warning Label

GeneralRecommendations

WARNING: The Warning Labelshown in Figure 33 is displayedon the equipment and shown onwiring diagrams and schematics.Strict adherence to thesewarnings must be observed.

All wiring must comply with localcodes and the National Electric Code.Typical field wiring diagrams areshown in Figures 34 thru 36. Minimumcircuit ampacities and other unitelectrical data are on the unitnameplate and are shown in Table 10.See the unit order specifications foractual electrical data. Specific electricalschematics and connection diagramsare shipped with the unit.

Caution: To avoid corrosion andoverheating at terminalconnections, use copperconductors only.

Do not allow conduit to interfere withother components, structural membersor equipment.

Control voltage (115V) wiring inconduit must be separate from conduitcarrying low voltage (<30V) wiring.

Caution: To prevent controlmalfunctions, do not run lowvoltage wiring (<30V) in conduitwith conductors carrying morethan 30 volts.

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(Continued on Next Page)Figure 34Typical Field Wiring forRTAA Packaged Unit –130 to 200 Tons

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See Notes on Next Page

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Figure 34 (Continued from Last Page)Typical Field Wiring forRTAA Packaged Unit –130 to 200 Tons

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Figure 35Typical Field Wiring forRTAA Packaged Unit –240-400 Tons

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Figure 35 (Continued from Previous Page)Typical Field Wiring forRTAA Packaged Unit –240-400 Tons

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See Notes on Previous Page

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See Notes on Page 61

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Figure 36Typical Field Wiring forRTAA With RemoteEvaporator Option

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See Notes on Page 61

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Figure 36 (Continued from Previous Page)Typical Field Wiring forRTAA With RemoteEvaporator Option

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Table 10Electrical Data

Unit Wiring Motor DataFans (Ea)

Rated MCA (3) Rec Time Comp. (Ea) Qty. Qty.Unit Size Voltage Ckt1/Ckt2(1) MOP(2) Delay or RDE4) Qty. RLA(5) LRA(8) (11) (12) kW FLA kW(7)RTAA 130 200 383/389 600/600 500/500 2 280/280 1689/1689 10 11 1.3 6.5 0.8

230 383/389 600/600 500/500 2 280/280 1689/1689 10 11 1.3 6.5 0.8460 306 400 350 2 122/122 633/633 10 11 1.3 2.8 0.8575 246 300 300 2 98/98 512/512 10 11 1.3 2.3 0.8

RTAA 140 200 383/389 600/600 500/500 2 280/280 1689/1689 10 11 1.3 6.5 0.8230 383/389 600/600 500/500 2 280/280 1689/1689 10 11 1.3 6.5 0.8460 306 400 350 2 122/122 633/633 10 11 1.3 2.8 0.8575 246 300 300 2 98/98 512/512 10 11 1.3 2.3 0.8

RTAA 155 200 422/389 700/600 500/500 2 306/280 2044/1689 11 12 1.3 6.5 0.8230 422/389 700/600 500/500 2 306/280 2044/1689 11 12 1.3 6.5 0.8460 322 450 400 2 133/122 766/633 11 12 1.3 2.8 0.8575 260 350 300 2 107/98 611/512 11 12 1.3 2.3 0.8

RTAA 170 200 515/389 800/600 700/500 2 375/280 2391/1689 12 13 1.3 6.5 0.8230 515/389 800/600 700/500 2 375/280 2391/1689 12 13 1.3 6.5 0.8460 363 500 450 2 163/122 896/633 12 13 1.3 2.8 0.8575 292 400 350 2 131/987 25/512 12 13 1.3 2.3 0.8

RTAA 185 200 515/428 800/700 700/600 2 375/306 2391/2044 13 14 1.3 6.5 0.8230 515/428 800/700 700/600 2 375/306 2391/2044 13 14 1.3 6.5 0.8460 376 500 450 2 163/133 896/766 13 14 1.3 2.8 0.8575 303 400 350 2 131/107 725/611 13 14 1.3 2.3 0.8

RTAA 200 200 514/514 800/800 700/700 2 375/375 2391/2391 14 14 1.3 6.5 0.8230 514/514 800/800 7001700 2 375/375 2391/2391 14 14 1.3 6.5 0.8460 406 500 450 2 163/163 896/896 14 14 1.3 2.8 0.8575 327 450 400 2 131/131 725/725 14 14 1.3 2.3 0.8

RTAA 240 460 303/224 400/350 350/300 3 122-122/163 633-633/896 N/A 17 1.3 2.8 1.0575 244/180 300/300 300/225 3 98-98/131 512-512/725 N/A 17 1.3 2.3 1.0

RTAA 270 460 360/224 500/350 450/300 3 163-122/163 896-633/896 N/A 19 1.3 2.8 1.0575 290/180 400/300 350/225 3 131-98/131 725-512/725 N/A 19 1.3 2.3 1.0

RTAA 300 460 406/224 500/350 450/300 3 163-163/163 896-896/896 N/A 21 1.3 2.8 1.0575 327/180 450/300 400/225 3 131-131/131 725-725/725 N/A 21 1.3 2.3 1.0

RTAA 340 460 303/406 400/500 350/450 4 122-122/163-163 633-633/896-896 N/A 24 1.3 2.8 1.0575 244/327 300/450 300/400 4 98-98/131-131 512-512/725-725 N/A 24 1.3 2.3 1.0

RTAA 370 460 360/406 500/500 450/450 4 163-122/163-163 896-633/896-896 N/A 26 1.3 2.8 1.0575 290/327 400/450 350/400 4 131-98/131-131 725-512/725-725 N/A 26 1.3 2.3 1.0

RTAA 400 460 406/406 500/500. 450/450 4 163-163/163-163 896-896/896-896 N/A 28 1.3 2.8 1.0575 327/327 450/450 400/400 4 131-131/131-131 725-725/725-725 N/A 28 1.3 2.3 1.0

Notes:(1) Low voltage units (200 & 230 volt) require separate power connections for each circuit.(2) MOP - Maximum Overcurrent Protection - may be either fused (UL/CSA) or with circuit breakers (CSA only).

MOP = 225 percent of the largest compressor RLA plus 100 percent of the second compressor RLA plus the sum of the condenser fansFLAs per NEC 440-22.

(3) MCA - Minimum Circuit Ampacity - 125 percent of largest compressor RLA plus 100 percent of second compressor plus the sum of thecondenser fans FLAs per NEC 440-33.

(4) RECOMMENDED TIME DELAY OR DUAL ELEMENT (RDE) FUSE SIZE: 150 percent of the largest compressor RLA plus 100 percent of thesecond compressor RLA and the sum of the condenser tan FLAs.

(5) RLA - Rated Load Amps - rated in accordance with UL Standard 465.(6) Local codes may take precedence.(7) Control kW includes operational controls only. Does not include heat tapes.(8) LRA - Locked Rotor Amps - based on full winding start units.(9) VOLTAGE UTILIZATION RANGE:

Rated Voltage Utilization Range200 180-220230 208-254460 414-506575 516.633

(10) A 11 5/60/1, 15 amp. customer provided power connection is required to operate the unit controls. A separate 115(60/1, 15 amp. customerprovided power connection is also needed to power the evaporator heat tape (RTAA 130-200 = 420 watts, RTAA 240-400 = 840 wafts @120 volts) and optional Domestic Water Heater (420 watts @ 120 volts.). If the optional control power is used, the customer needs only toprovide a power connection for the heat tapes.

(11) 15 F minimum starting/operating ambient.(12) 0 F minimum starting/operating ambient

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CAUTION:IT IS IMPERATIVE THATL1-L2-L3 IN THE STARTER BECONNECTED IN THE A-B-CPHASE SEQUENCE TOPREVENT EQUIPMENTDAMAGE DUE TO REVERSEROTATION.

Installer-SuppliedComponentsCaution: Customer wiring interfaceconnections are shown in theelectrical schematics andconnection diagrams that areshipped with the unit.

The installer must provide thefollowing components if not orderedwith the unit:

[ ] Power supply wiring (in conduit) forall field-wired connections.

[ ] All control (interconnecting) wiring(in conduit) for field supplieddevices.

[ ] Fused-disconnect switches.

[ ] Power factor correction capacitors.

Remote Evaporator Only:Control wiring between the outdoorunit and the evaporator terminal box.

Power Supply WiringGeneral

All power supply wiring must be sizedand selected accordingly by the projectengineer in accordance with NEC Table31016.

WARNING: To prevent injury ordeath, disconnect electricalpower source before completingwiring connections to the unit.

All wiring must comply with localcodes and the National Electrical Code.The installing (or electrical) contractormust provide and install the systeminterconnecting wiring, as well as-thepower supply wiring. It must beproperly sized and equipped with theappropriate fused disconnect switches.The type and installation location(s) ofthe fused disconnects must complywith all applicable codes.

Caution: Use only copperconductors for terminalconnections to avoid corrosion oroverheating.

Remove the plate on the lower rightside of the power connection panel andcut holes for the appropriately-sizedwiring conduits. The wiring is passedthrough these conduits and connectedto the terminal blocks or optional unit-mounted disconnect. Refer to Figure 1and Figures 34 thru 36.

To provide proper phasing of 3-phaseinput, make connections as shown inFigures 34 thru 36 and as stated on theyellow WARNING label in the starterpanel. For additional information onproper phasing, refer to “Unit VoltagePhasing Proper equipment groundmust be provided to each groundconnection in the panel (one on 460/575 volt units and two on 200/230 voltunits).

Control Power Supply

If the unit is equipped with the optionalcontrol power transformer, it is notnecessary to provide control powervoltage to the unit.

Caution: 200/230 volt units arefactory connected as 200 volt units.For 230 volt units, the leads mustbe moved to the appropriateterminals on the transformer (1T1).See Unit Wiring Diagrams.

If the transformer is not provided,connect control power (115V, 750VA, 15amp maximum fuse size) to terminals1TB3-1 and 1TB3-2, on 130-200 units.Use 1TB3-1 and 1TB4-1 on 240-400units.

Heat Tape Power Supply(Packaged Units Only)

Note: Units with the RemoteEvaporator option do not have heattape.

The evaporator shell and optionalDomestic Water Heater are insulatedfrom ambient air and protected fromfreezing temperatures by athermostatically-controlled heat tape.Whenever the water temperaturedrops to approximately 37 F, thethermostat energizes the heat tape. Theheat tape will provide protection fromambient temperatures down to -20 F.

Provide an independent power source(115V, 15 amp), with a fused-disconnect. The heat tape is factorywired back to the unit control panel.Customer connections are made onterminal strip 1TB3-11 and 1TB3-12 on130-200 units or 1TB3-10 and 1TB4-1 0on 240-400 units.

Water Pump Power Supply

Provide power supply wiring withfused disconnect for the chilled waterpump(s).

Auxiliary Heat Tape Power Supply

Provide power wiring and properlysized fused-disconnect for any electricalheat tape installed on the system waterpiping.

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Interconnecting WiringChilled Water Pump Interlockand External Auto/Stop forModel RTAA Air-CooledSeries R CenTraVac

Caution: The following must beadhered to or equipment damagemay occur.

The Model RTAA Series R chillerrequires a minimum of two field-supplied control inputs:

• Chilled water pump interlock (TB3-1, -2 on the 1U1 board).

• External Auto/Stop (T133-3, -4 on the1U1 board)

When there is a command to shutdown the chilled water system, thechilled water pump is required tooperate for a minimum of one minuteafter the External AUTO/STOP givesthe shutdown command.

Normally, when the compressors areterminating a cycle (via chiller Stop/Reset switch, loss of load, LowAmbient Run Inhibit or External Auto/Stop), the controller will initiate the“Run:Unload” mode. This operatingmode energizes the unload solenoidfor 20 seconds, to unload thecompressor so that it will be unloadedfor the next start-up. Then the masteroil solenoid is de-energized and closureof the master oil solenoid is verified.The entire process may take up to 40seconds.

If the chilled water pump interlock isused without the external Auto/Stopinput, the chiller will shut downimmediately upon the command forshut down, without initiating the“Run:Unload” mode. This isconsidered a “non-friendly” shut downand a “Machine Auto Reset” diagnosticwill be displayed on the LICK

Caution: The method in theprevious paragraph is not to beused as a normal means of cyclingthe chiller off, e.g. time clock,building automation system, etc.

The proper method for cycling thechiller off is to open a set of contactbetween TB3-3, -4 on the 1U1 board(External Auto/Stop). Then, following aone minute delay, the chilled waterpump is cycled off. Chilled water flowindication should be provided betweenTB3-1, -2 on the 1U1 board, e.g. waterpump motor starter auxiliaries and/orflow switch.

The wiring for this recommendation isshown in the furnished electricalschematics and connection diagrams.Relay 5DL1 is a normally-open,instantaneous close, timed open (1min.) time delay relay. An alternativesolution is to provide properprogramming in a building automationsystem.

Chilled Water Pump Interlock

The installer must provide leads 520and 521 from the chilled water pump(5B1) starter auxiliary (5K1) to theproper terminals of terminal strip 1U1TB3 on the UCM, as shown in Figures34 thru 36. Circuit requirement is 115VAC, with minimum contact rating @115 VAC of 6.9 VA inrush, 1.3 VA sealed.Refer to the field diagrams which areshipped with the unit.

The auxiliary contact of the chilledwater pump may be wired in serieswith an optional flow switch, as shown.The standard UCM provides internalprotection for the unit against loss ofchilled water flow. Also refer to“Evaporator Flow Switch.”

External Auto/Stop Wiring

If the unit requires the Auto/Stopfunction, the installer must provideleads 522 and 523 from the remotecontacts (5K5, 5K21) to the properterminals of the terminal strip 1U1 TB3on the UCM, as shown in Figures 34thru 36.

The chiller will run normally when thecontacts are closed. When eithercontact opens, the compressor(s), ifoperating, will go to the RUN:UNLOADoperating mode and cycle off. Unitoperation will be inhibited. Re-closureof the contacts will permit the unit toautomatically return to normaloperation.

Circuit requirements are 2-wire, 115VAC, with minimum contact rating @115 VAC of 6.9 VA inrush, 1.3 VA sealed.Refer to the field diagrams which areshipped with the unit.

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Alarm/Running/MaximumCapacity Outputs

Terminals 1 to 8 on terminal strip TB4of the 1U1 board provide a variety ofcontact outputs. These are dependentupon the setting of Menu Item 4E andits relationship to diagnostics,compressors operating and the systemoperating at full capacity.

Table 11Alarm/Running/MaximumCapacity Relay OutputConfigurationsRelay Output Configuration1: RLY 1 = Alarm

RLY 2 = Compressor RunningRLY 3 = Maximum Capacity

2: RLY 1 = Circuit I AlarmRLY 2 = Circuit 2 AlarmRLY 3 = Maximum Capacity

3: RLY 1 = AlarmRLY 2 = Circuit 1 RunningRLY 3 = Circuit 2 Running

As shown in Figure 37, there are threerelays. Relays 1 and 2 have SPDTcontacts. Relay 3 has SPST normallyopen contacts. The relays can providethree different output configurations, asshown in Table 11, and eachconfiguration offers four choices as tohow the alarm relay is to respond to aset of diagnostics.

Table 12 shows the twelve settingsavailable in Menu Item 4E and thediagnostics which are issued for eachset of conditions.

Figure 37Alarm/Running/MaximumCapacity Contact Outputs

Table 12Alarm/Running/Maximum Capacity Menu Settings

Diagnostics that theRelays Output Alarm Relay(s) is Active

Menu Item 4E Configuration MMR/ MAR/Setting (Table 11) CMR diag. CAR diag. IFW diag.

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

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

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

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Alarm/Running/MaximumCapacity Indicator Wiring

If the optional remote Alarm/Running/Maximum Capacity contacts are used,provide electrical power, 115 VAC(contact load not to exceed 1150 VAinrush, 115 VA sealed), with fused-disconnect to a customer-furnishedremote device. Also provide properremote device ground connection.

To install the available remote runningand alarm indication, the installer mustprovide leads 525 thru 532 from thepanel to the proper terminals ofterminal strip 1U1TB4 on the UCM, asshown in Figures 31 thru 32. Refer tothe field diagrams which are shippedwith the unit.

Low Voltage WiringThe remote devices described belowrequire low voltage wiring. All wiring toand from these remote input devices tothe UCM must be made with shielded,twisted pair conductors. Be sure toground the shielding only at the UCM.See Figures 34 thru 36 for therecommended conductor sizes.

Caution: To prevent controlmalfunctions, do not run lowvoltage wiring (<30 V) in conduitwith conductors carrying morethan 30 volts.

Emergency Stop (Normal Trip)

The UCM provides auxiliary control fora customer specified/installed latchingtripout. When this customer-furnishedremote contact (5K18) is provided, thechiller will run normally when thecontact is closed. When the contactopens, the unit will trip off on amanually resettable diagnostic. Thiscondition requires manual reset at thechiller switch on the front of the UCM.

To connect, first remove the jumperlocated between terminals 3 and 4 of1U1,TB1 on the UCM. Connect lowvoltage leads 513 and 514 to thoseterminals. Terminal strip locations areshown in Figures 34 thru 36. Refer tothe field diagrams which are shippedwith the unit.

Silver or gold-plated contacts arerecommended. These customer-furnished contacts must be compatiblewith 12 VDC, 45 mA resistive load.

External Circuit Lockout – Circuit #1

The UCM provides auxiliary control ofa customer specified or installedcontact closure, for individual operationof Circuit #1. If the contact is open, therefrigerant circuit will not operate.Upon closure, the refrigerant circuit willrun normally. This feature is used torestrict total chiller operation, e.g.during emergency generatoroperations.

External circuit lockout will onlyfunction if menu item 3b is enabled.

These customer-supplied contactclosures must be compatible with 12VDC, 45 mA resistive load. Silver orgold plated contacts arerecommended.

RTAA 130-200To install, cut, strip and wire-nutexisting wire loop #W59 on the P43connector of the 1U4 module to lowvoltage leads 45A and 45B.Connections are shown in the fielddiagrams which are shipped with theunit.

RTAA 240-400To install, cut, strip and wire-nutexisting wire loop #W53 on the P43connector of the 1U4 module to lowvoltage leads 568 and 569. Connectionsare shown in the field diagrams whichare shipped with the unit.

External Circuit Lockout – Circuit #2

The UCM provides auxiliary control ofa customer specified or installedcontact closure, for individual operationof Circuit #2. If the contact is open, therefrigerant circuit will not operate.Upon closure, the refrigerant circuit willrun normally. This feature is used torestrict total chiller operation, e.g.during emergency generatoroperations.

These customer-supplied contactclosures must be compatible with 12VDC, 45 mA resistive load. Silver orgold plated contacts arerecommended.

External circuit lockout will onlyfunction if menu item 3b is enabled.

RTAA 130-200To install, cut, strip and wire-nutexisting wire loop #W60 on the P53connector of the 1U5 module to lowvoltage leads 46A and 46B.Connections are shown in the fielddiagrams which are shipped with theunit.

RTAA 240-400To install, cut, strip and wire-nutexisting wire loop #W55 on the P63connector of the 1U6 module to lowvoltage leads 566 and 567. Connectionsare shown in the field diagrams whichare shipped with the unit.

Ice Making Option

Menu Item 32 must be Enabled. TheUCM provides auxiliary control for acustomer specified/installed contactclosure for ice making. When contact(5K20) is provided, the chiller will runnormally when the contact is open.Upon contact closure, the UCM willinitiate an ice-building mode, in whichthe unit runs fully loaded at all times.Ice-building shall be terminated eitherby opening the contact or based on theentering evaporator water temperature(Menu Item 33 = Setpoint). The UCMwill not permit the ice-building mode tobe reentered until the unit has beenswitched out of ice-building mode(open 5K20 contacts) and thenswitched back into ice-building mode(close 5K20 contacts.)

In ice-building, both the 1.5 F/min.pulldown rate limit and freezeavoidance will be ignored and thecurrent unit setpoint will be set at120%. For example, if the Front Panelor External Current Limit setpoint is setto 80%, in ice-building the ActiveCurrent Limit is 120%.

If, while in ice-building mode, the unitgets down to the freezestat setting(water or refrigerant), the unit will shutdown on a manually resettablediagnostic, just as in normal operation.

Connect leads 501 and 502 from 5K20to the proper terminals of 1U2,TB1 onthe UCM, as shown in Figures 34 thru36. Refer to the field diagrams whichare shipped with the unit.

Silver or gold-plated contacts arerecommended. These customerfurnished contacts must be compatiblewith 12 VDC, 45 mA resistive load.

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External Chilled WaterSetpoint (CWS):Remote Resistor/Potentiometer,Voltage Source 2-10 VDC, orCurrent Source 4-20 mA

This option allows the external settingof the Chilled Water Setpoint,independent of the Front Panel ChilledWater Setpoint, by one of three means:

1. A remote resistor/potentiometerinput (fixed or adjustable)

2. An isolated voltage input 2-10 VDC

3. An isolated current loop input4-20 mA

Methods 2 and 3 are usually used ininterfacing with a Generic BAS or aprocess controller to the chiller.

To enable external setpoint operation,Item 30 of Menu 3, “External ChilledWater Setpoint d/E”, should be set to“E” using the Front Panel OperatorInterface.

1. Remote Resistor/Potentiometer Input(fixed or adjustable)

Connect the remote resistor and/orpotentiometer to terminals TB1 -3and TB1 -5 of Options Module 1U2,as shown in Figure 38.

For units with 40 F to 60 F LCWSrange, a field-furnished 25 Kohmlinear taper potentiometer (±10%)and a fixed 5.6 Kohm (±10%) 1/4 wattresistor should be used.

For units with 20 F to 39 F LCWSrange, a field-furnished 25 Kohmlinear taper potentiometer (±1 0%)and a fixed 15 Kohm (±1 0%) 1/4 wattresistor should be used.

If the potentiometer is to be remotelymounted, it and the resistor must beconnected to the UCM prior tomounting. Then, with the UCMdisplay in Menu 0 and the displayadvanced to “Active Chilled WaterSetpoint”, the UCM can be used tocalibrate the positions of thepotentiometer to correspond withthe desired settings for the leavingwater temperature. External resistorinput values for various chilled watersetpoints are shown in Table 13.

Table 13Input Values Vs. External Chilled Water Setpoint

InputsResulting Chilled

Resistance (Ohms) Current (mA) Voltage (Vdc) Water Setpoint (F)94433 4.0 2.0 0.068609 5.2 2.6 5.052946 6.5 3.2 10.042434 7.7 3.9 15.034889 8.9 4.5 20.029212 10.2 5.1 25.024785 11.4 5.7 30.021236 12.6 6.3 35.018327 13.8 6.9 40.015900 15.1 7.6 45.013844 16.3 8.2 50.012080 17.5 8.8 55.010549 18.8 9.4 60.09050 20.0 10.0 65.0

Figure 38Resistor and PotentiometerArrangement for External ChilledWater Setpoint

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2. Isolated 2-10 VDC Voltage SourceInput

Set DIP Switch SW1-1 of OptionsModule 1U2 to “OFF”. Connect thevoltage source to terminals TB1 -4 (+)and TB1 -5 (-) on Options Module1U2. CWS is now based on thefollowing equation:

CW Setpoint 0 F = (VDC x 8.125) -16.25

Sample values for CWS vs. VDCsignals are shown in Table 13.

Minimum setpoint= 0 F (2.0 VDC input)

Maximum setpoint= 65 F (9.4 VDC input)

Maximum continuous input voltage= 15 VDC

Input impedance = 40.1 KohmsSW1 -1 off)

3. Isolated 4-20 mA Current SourceInput

Set DIP Switch SW1-1 of OptionsModule 1U2 to “ON”. Connect thecurrent source to terminals TB1-4(+)and TB1-5 (-). CWS is now basedon the following equation:

Setpoint °F = (mA x 4.0625) - 16.25

Sample values for CWS vs. mAsignals are shown in Table 13.

Minimum setpoint = 0 F (4.0 mA)Maximum setpoint = 65 F (18.8 mA)Maximum continuous = 30 mA

input currentInput impedance = 499 ohmsSW1 -1 on)

Note: The negative terminal TB1 -5 isreferenced to the UCM chassis ground.To assure correct operation, 2-10 VDCor 4-20 mA signals must be isolated or“floating” with respect to the UCMchassis ground. See Figures 34 thru 36.

External Current Limit Setpoint(CLS): Remote Resistor/Potentiometer, Voltage Source 2-10VDC or Current Source 4-20 mA

This option allows the external settingof the Current Limit Setpoint,independent of the Front Panel CurrentLimit Setpoint, by one of three means:

1. A remote resistor/potentiometerinput (fixed or adjustable)

2. An isolated voltage input 2-10 VDC

3. An isolated current loop input 4-20mA

Methods 2 and 3 are usually used ininterfacing with a Generic BAS.

To enable external Current LimitSetpoint operation, Item 31 of Menu 3,“External Current Limit Setpoint WE”,should be set to “E” using the FrontPanel Operator Interface.

1. Remote Resistor/Potentiometer Input

To cover the entire range of CurrentLimit Setpoints; (40 to 120%), a fieldfurnished 50 Kohm log taperpotentiometer (±10%) and a fixed820 ohm (±1 0%) 1/4 Waft resistorshould be wired in series andconnected to terminals TB1 -6 andTB1 -8, of options module 1U2, asshown in Figure 39.

Table 14Input Values Vs. External Current Limit Setpoint

InputsResulting Current

Resistance (Ohms) Current (mA) Voltage (Vdc) Limit Setpoint (% RLA)49000 4.0 2.0 4029000 6.0 3.0 5019000 8.0 4.0 6013000 10.0 5.0 709000 12.0 6.0 806143 14.0 7.0 904010 16.0 8.0 1002333 18.0 9.0 1101000 20.0 10.0 120

Figure 39Resistor and PotentiometerArrangement for ExternalCurrent Limit Setpoint

74RTAA-IOM-3

If the potentiometer is to be remotelymounted, it and the resistor must beconnected to the UCM prior tomounting. Then, with the UCM displayin Menu 0 and the display advanced to“Active Current Limit Setpoint”, theUCM can be used to calibrate thepositions of the potentiometer tocorrespond with the desired settingsfor the current limits. External resistorinput values for various current limitsetpoints are shown in Table 14.

2. 2-10 VDC Voltage Source Input

Set DIP Switch SW1-2 of OptionsModule 1U2 to “OFF”. Connect thevoltage source to terminals TB1 -7 (+)and TB1 -8 (-) of Options

Module 1U2. CLS is now based on thefollowing equation:

CL Setpoint % = (VDC x 10) + 20

Sample values for CLS vs. VDC signalsare shown below:

Minimum setpoint= 40% (2.0 VDC input)

Maximum setpoint= 120% (10.0 VDC input)

Maximum continuous input voltage= 15 VDC

Input impedance = 40.1 Kohms(SW1 -2 off)

3. 4-20 mA Current Source Input

Set DIP Switch SW1-2 of OptionsModule 1U2 to “ON”. Connect thecurrent source to terminals TB1 -7 (+)and TB1 -8 (-) of Options Module 1U2.CLS is now based on the followingequation:

CL Setpoint % = (mA x 5) + 20

Sample values for CLS vs. mA signalsare shown in Table 14.

Minimum setpoint = 40% (4.0 mA)Maximum setpoint = 120% (20.0 mA)Maximum continuous input current

= 30 mAInput impedance = 499 ohms(SW1 - 2 on)

Note: The negative terminal TB1 -8 isreferenced to the UCM chassis ground.To assure correct operation, 2-10 VDCor 4-20 mA signals must be isolated or“floating” with respect to the UCMchassis ground. See Figures 31 thru 32.

Optional BidirectionalCommunications Link (BCL)

This option allows the UCM in thecontrol panel to exchange information(e.g. operating setpoints and Auto/Standby commands) with a higherlevel control device, such as a Tracer, amultiple-machine controller or aremote display panel. A shielded,twisted-pair connection establishes thebidirectional communications linkbetween the unit control panel and theTracer, multiple-machine controller orremote display panel.

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

Caution: To prevent controlmalfunctions, do not run lowvoltage wiring (<30 V) in conduitwith conductors carrying morethan 30 volts.

General

Field wiring for the communication linkmust meet the following requirements:

1. All wiring must be in accordancewith the NEC and local codes.

2. Communication link wiring must be18 AWG shielded, twisted-pair wiring(Belden 8760, or equivalent).

3. The maximum total wire length foreach communication link is 5,000feet.

4. The communication link cannot passbetween buildings.

5. All UCM’s on the communication linkcan be connected in a “daisy chain”configuration.

Communication LinkConnection Procedure

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

2. Refer to RTAA-IOM-2 for installation/operation of Remote Display Panel.

3. Connect the shield of thecommunication link wiring to thedesignated shield terminal at theTracer unit.

4. Connect leads 561 and 562 from theproper terminals of 1U2,TB2 on theUCM to the Tracer, as shown inFigures 31 thru 33. There is nopolarity requirement for thisconnection.

5. At the UCM the shield should be cutand taped to prevent any contactbetween the shield and ground. SeeFigures 31 thru 33.

Note: On multiple-unit installations,splice the shielding of the twotwisted-pairs that come into eachUCM in the “daisy chain” system.Tape the spliced connections toprevent any contact between theshield and ground. At the last UCMin the chain, the shield should be cutand taped off.

6. For unit ICS address selection seemenu item “4C”.

75 RTAA-IOM-3

Installation Check ListComplete this checklist as the unit isinstalled, to verify that allrecommended procedures areaccomplished before the unit is started.This checklist does not replace thedetailed Instructions given in the“Installation -Mechanical” and“Installation -Electrical” sections of thismanual. Read both sectionscompletely, to become familiar with theinstallation procedures, prior tobeginning the work.

Receiving

[ ] Verify that the unit nameplate datacorresponds to the orderinginformation.

[ ] Inspect the unit for shippingdamage and any shortages ofmaterials. Report any damage orshortage to the carder.

Unit Location and Mounting

[ ] Inspect the location desired forinstallation and verify adequateservice access clearances.

[ ] Provide drainage for evaporatorwater.

[ ] Remove and discard all shippingmaterials (cartons, etc.)

[ ] Install optional spring isolators, ifrequired.

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

Unit Piping

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

Caution: If using an acidiccommercial flushing solution,construct a temporary bypassaround the unit to prevent damageto internal components of theevaporator.

Caution: To avoid possibleequipment damage, do not useuntreated or improperly treatedsystem water.

[ ] Connect the chilled water piping tothe evaporator.

[ ] Install pressure gauges and shutoffvalves on the chilled water inlet andoutlet to the evaporator.

[ ] Install a water strainer in theentering chilled water line.

[ ] Install a balancing valve and flowswitch (discretionary) in the leavingchilled water line.

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

[ ] Vent the chilled water system athigh points in the system piping.

[ ] Apply heat tape and insulation, asnecessary, to protect all exposedpiping from freeze-up.

Electrical Wiring

WARNING: To prevent injury ordeath, disconnect electricalpower source before completingwiring connections to the unit.

Caution: To avoid corrosion andoverheating at terminalconnections, use copperconductors only.

[ ] Connect the unit power supplywiring with fused-disconnect to theterminal block (or unit-mounteddisconnect) in the power section ofthe control panel.

[ ] Connect the control power supplywiring with fused-disconnect to theterminal strip in the power sectionof the control panel.

[ ] Connect power supply wiring to theevaporator heat tape. Connect leads551 and 552 to terminals 11 and 12of terminal strip 1TB3.

[ ] Connect power supply wiring to thechilled water pump.

[ ] Connect power supply wiring to anyauxiliary heat tapes.

[ ] Connect the auxiliary contact of thechilled water pump (5K1) in serieswith the optional flow switch, ifinstalled, and then connect to theproper terminals.

[ ] For the External Start/Stop function,install wiring from remote contacts(5K5, 5K21) to the proper terminalson terminal strip 1U1TB3.

Caution: Information inInterconnecting Wiring: ChilledWater Pump Interlock and ExternalAuto/Stop must be adhered to orequipment damage may occur.

[ ] If the remote alarm/running/maximum capacity contacts areused, install leads 525 thru 532 fromthe panel to the proper terminals onterminal strip 1U1TB4.

[ ] If the emergency stop function isused, install low voltage leads 513and 514 to terminals 3 and 4 of1U1TB1.

[ ] If indoor zone temperature is to beused, install leads 501 and 502 on6RT4 to the proper terminals on1U2TB1.

[ ] If the ice making-option is used,install leads 501 and 502 on 5K20 tothe proper terminals on 1U2TB1.

76RTAA-IOM-3

77 RTAA-IOM-3

OperatingPrinciples –Mechanical

GeneralThis section describes the mechanicaloperating principles of Series R air-cooled chillers equipped withmicrocomputer-based control systems.

The 130 thru 400-ton Model RTAA unitsare dual-circuited, helical-rotary typeair-cooled liquid chillers. The basiccomponents of an RTAA unit are:

- Unit Control Module (UCM)- Unit-mounted panel- Helical-rotary compressor- Direct Expansion evaporator- Air-cooled condenser- Oil supply system (hydraulic and lubrication)- Interconnecting piping

Components of a typical RTAA unit areidentified in Figures 1 thru 6.

Refrigeration(Cooling) CycleCycle Description

Figures 40 and 41 represent therefrigeration system and controlcomponents. Vaporized refrigerantleaves the evaporator and is drawn intothe compressor. Here it is compressedand leaves the compressor as amixture of hot gas and oil (which wasinjected during the compression cycle).

The mixture enters the oil separator atthe two in/out caps. The separated oilflows to the bottom of the separator,while the refrigerant gas flows out thetop and passes on to the tubes in thecondensing coils. Here circulating airremoves heat from the refrigerant andcondenses it.

The condensed refrigerant passesthrough the electronic expansion valveand into the tubes of the evaporator.As the refrigerant vaporizes, it cools thesystem water that surrounds the tubesin the evaporator.

Compressor Description

The compressors used by the ModelRTAA Series “R” Air-cooled chillerconsists of two distinct components:the motor and the rotors. Refer toFigure 42.

Compressor Motor

A two-pole, hermetic, squirrel-cageinduction motor directly drives thecompressor rotors. The motor is cooledby suction refrigerant gas from theevaporator, entering the end of themotor housing through the suctionline, as shown in Figures 40 and 41.

Compressor Rotors

The compressor is a semi-hermetic,direct drive helical rotary typecompressor. Each compressor has onlythree moving parts: Two rotors -“male” and ‘female” - providecompression, and a slide valve controlscapacity. See Figure 42. The male rotoris attached to, and driven by, the motor,and the female rotor is, in turn, drivenby the male rotor. Separately housedbearing sets are provided at each endof both rotors. The slide valve is locatedabove, and moves along, the top of therotors.

The helical rotary compressor is apositive displacement device. Therefrigerant from the evaporator isdrawn into the suction opening at theend of the motor barrel, through asuction strainer screen, across themotor, and into the intake of thecompressor rotor section. The gas isthen compressed and dischargeddirectly into the discharge line.

There is no physical contact betweenthe rotors and compressor housing.The rotors contact each other at thepoint where the driving action betweenthe male and female rotors occurs. Oilis injected along the top of thecompressor rotor section, coating bothrotors and the compressor housinginterior. Although this oil does providerotor lubrication, its primary purpose isto seal the clearance spaces betweenthe rotors and compressor housing.

A positive seal between these internalparts enhances compressor efficiencyby limiting leakage between the highpressure and low pressure cavities.

Capacity control is accomplished bymeans of a slide valve assemblylocated in the rotor section of thecompressor. Positioned along the topof the rotors, the slide valve is drivenby a piston/cylinder along an axis thatparallels those of the rotors.

Compressor load condition is dictatedby the position of the slide valve overthe rotors. When the slide valve is fullyextended over the rotors and awayfrom the discharge end, thecompressor is fully loaded. Unloadingoccurs as the slide valve is drawntowards the discharge end. Slide valveunloading lowers refrigeration capacityby reducing the compression surface ofthe rotors.

Compressor Loading Sequence

When there is a call for chilled water,the UCM will start the compressorwhich has the least number of starts. Ifthe first compressor cannot satisfy thedemand, the UCM will start anothercompressor and then balance the loadon all compressors by pulsing the load/unload solenoids.

The load on the compressors will bekept in balance, as load fluctuates, untilthe demand for chilled water is reducedto a level that can be handled by onecompressor. At this time, the UCM willdrop off the compressor that has thegreatest number of operating hoursand will adjust the load on the othercompressor, as required.

78RTAA-IOM-3

Figure 40Refrigeration System andControl ComponentsSingle Circuit

(Continued on Next Page)

79 RTAA-IOM-3

Figure 40(Continued from Previous Page)

1 Schrader valve2 Suction temperature sensor*3 Manufacturing process tube4 Suction service valve (optional)5 Motor winding thermostat*6 Discharge temperature sensor*7 Pressure relief valve (450 psi)8 High pressure cutout (405 psi)*9 Discharge check valve

10 Evaporator waterside vent11 Discharge line shutoff valve12 Oil separator in/out cap13 Saturated condensing temperature

sensor*14 Condenser header15 Subcooler header16 Liquid line shutoff valve

17 25 micron filter/drier18 Liquid line sight glass19 Electronic expansion valve20 Saturated evaporator temperature

sensor*21 Evaporator waterside drain22 Leaving water temperature sensor*23 Leaving water connection24 Entering water connection25 Entering water temperature sensor*26 Drain with Schrader valve27 Oil line28 Entering oil cooler header29 Leaving oil cooler header30 Schrader valve with stem depressor31 Oil line shutoff valve32 5 micron oil filter

33 Master solenoid valve*34 Oil line to load/unload slide valve

solenoids35 Injection oil check valve36 Heater37 Slide valve solenoids and orifices*38 Oil flow differential pressure switch*39 Compressor Drain Plug40 Domestic water heater (option)41 Oil line thermostat (option,

Domestic Water Heater)42 Oil line bypass solenoid valve

(option, Domestic Water Heater)

*UCM Input/Output Control

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Figure 41Refrigeration System andControl ComponentsDuplex Circuit

(Continued on Next Page)

81 RTAA-IOM-3

Figure 41(Continued from Previous Page)

1 Schrader valve2 Suction temperature sensor*3 Manufacturing process tube4 Suction service valve (optional)5 Motor winding thermostat*6 Discharge temperature sensor7 Pressure relief valve (450 psi)8 High pressure cutout (405 psi)*9 Discharge check valve

10 Evaporator waterside vent11 Discharge line shutoff valve12 Oil separator in/out cap13 Saturated condensing temperature

sensor*14 Condenser header15 Subcooler header16 Liquid line shutoff valve

17 25 micron filter/drier18 Liquid line sight glass19 Electronic expansion valve*20 Saturated evaporator temperature

sensor*21 Evaporator waterside drain22 Leaving water temperature sensor*23 Leaving water connection24 Entering water connection25 Entering water temperature sensor*26 Drain with Schrader valve27 Oil line28 Entering oil, cooler header29 Leaving oil cooler header30 Schrader valve with stem depressor31 Oil line shutoff valve32 5 micron oil filter

33 Master solenoid valve*34 Oil line to load/unload slide valve

solenoids35 Injection oil check valve36 Heater37 Slide valve solenoids and orifices*38 Oil flow differential pressure switch*39 Compressor Drain Plug40 Domestic water heater (optional)41 Oil line thermostat (option,

Domestic Water Heater)42 Oil line bypass solenoid valve

(option, Domestic Water Heater)

*UCM Input/Output Control

Figure 42Typical RTAA Compressor

REFRIGERATION SYSTEM AND CONTROL COMPONENTS

82RTAA-IOM-3

Figure 43RTAA Compressor Oil SystemSchematic

Oil System OperationOverview

Oil that collects in the bottom of the oilseparator is at condensing pressureduring compressor operation;therefore, oil is constantly moving tolower pressure areas. Refer toFigure 43.

As the oil leaves the separator, it passesthrough the air-cooled oil cooler at thetop of the condensing coils. It thengoes through the service valve andfilter. At this point, some of the oil isused to control the slide valvemovement in the compressor, via theload/unload solenoids. The remainingoil passes through the oil mastersolenoid valve and performs thefunctions of compressor bearinglubrication and compressor oilinjection. If the compressor stops forany reason, the master solenoid valvecloses, isolating the oil charge in theseparator and oil cooler during “off”periods.

To ensure proper lubrication andminimize refrigerant condensation inthe compressor, a heater is mountedon the bottom of the compressorhousing. A signal from the UCMenergizes this heater during thecompressor “Off” cycle to keeprefrigerant from condensing in thecompressor. The heater element iscontinuously energized.

Domestic Water Heater

The Domestic Water Heater optionutilizes available waste heat from thecompressor oil circuit, to heat domesticor process water. Normally, the excessheat is dissipated to the atmosphere byfans moving air over the oil cooler.

The high temperature oil that leavesthe oil separator enters the domesticwater heater. Heat is transferred fromthe oil to the cool water that enters theheater. The oil then passes eitherthrough the unit’s air-cooled oil cooler,where additional heat is removed, ifrequired, or through the air-cooled oilcooler bypass solenoid, that isoperated by a thermostat on the oilsupply line.

Water that is heated in the domesticwater heater exits the heater and flowsto the system.

83 RTAA-IOM-3

Oil Separator

The oil separator consists of a U-shaped tube, joined at the top by therefrigerant discharge line from thecompressor. As shown in Figure 44, thedischarge line is essentially tangentialto the U-tubes. This causes therefrigerant to swirl in the tubes andthrows the oil to the outside, where itcollects on the walls and flows to thebottom. The compressed refrigerantvapor, stripped of oil droplets, exits outthe top of the oil separator and isdischarged into the condensing coils.

Compressor Bearing Oil Supply

Oil is injected into the bearing housingslocated at each end of both the maleand female rotors. Each bearinghousing is vented to compressorsuction, so that oil leaving the bearingsreturns through the compressor rotorsto the oil separator.

Compressor Rotor Oil Supply

Oil flows through this circuit directlyfrom the master solenoid valvethrough the oil filter to the top of thecompressor rotor housing. There it isinjected along the top of the rotors toseal clearance spaces between therotors and the compressor housingand to lubricate the rotors.

Figure 44Oil Separator

84RTAA-IOM-3

Slide Valve Movement

Movement of the slide valve pistondetermines slide valve position which,in turn, regulates compressor capacity.Oil flow into and out of the cylindergoverns piston movement, and iscontrolled by the normally-closed, loadand unload solenoid valves.

The solenoid valves receivemomentary pulsating “load” and“Unload” voltage signals from theUCM based on system coolingrequirements. To load the compressor,the UCM opens the load solenoid valvewhile keeping the unload solenoidvalve closed. The pressurized oil flowthen enters the cylinder and forces theslide valve to move over the rotors.

The compressor is unloaded when theload solenoid valve is kept closed andthe unload solenoid valve is opened.Oil “trapped” within the cylinder isdrawn out into the lower-pressuresuction area of the compressor. As thepressurized oil leaves the cylinder, theslide valve gradually moves away fromthe rotors.

When both solenoid valves are closed,the present level of compressor loadingis maintained.

Just prior to a normal compressorshutdown, the unload solenoid valve isenergized and the slide valve moves tothe fully-unloaded position, so the unitalways starts fully unloaded.

Oil Filter

Each refrigerant circuit is equipped withreplaceable-element oil filters. Thefilter(s) remove any impurities thatcould foul the solenoid valve orificesand compressor internal oil supplygalleries. This also prevents excessivewear of compressor rotor and bearingsurfaces. Refer to the maintenanceportion of this manual forrecommended filter elementreplacement intervals.

Condenser Fans

The RTAA Series offers either the 15 For 0 F ambient fan configuration. Onthe 0 F ambient option, the lead fan(s)on each circuit is a half-airflow (half-pitch blade) fan(s). Half pitch fans havea blade pitch of 150 and full pitch fanshave a blade pitch of 27°.

Figures 45 and 46 show the number offans installed on each model, thedesignation of fan contactors and thestaging of fans as the UCM calls formore condenser cooling. Fan staging isa function of the difference betweenthe saturated condenser refrigeranttemperature and the saturatedevaporator refrigerant temperature,which in turn is a function of the loadand ambient temperature. Any numberof fans can be operating at a giventime, depending on these variables.

85 RTAA-IOM-3

Figure 45Fan Configurations – RTAA 130-200 Tons15 F Minimum Ambient

All fans will be Full Airflow (Full Pitch Blade) Fans:Circuit #1 is on the right side of the unit from the control panel.Circuit #2 is on the left side of the unit from the control panel.

# Of Fans # Of Fans UCM OutputsTons Circuit #1 Circuit #2 Per Circuit # Fan Steps/Circuit

130 5 5 4 5 & 5 respectively140 5 5 4 5 & 5 respectively155 6 5 4 6 & 5 respectively170 7 5 4 7 & 5 respectively185 7 6 4 7 & 6 respectively200 7 7 4 7 & 7 respectively

For STANDARD air-cooled (RTAA) Chillers, the mapping of UCM outputs to fan staging shall be as follows:

Fan Contactor 5 Fan Circuit 6 Fan Circuit 7 Fan Circuit

Circuit #1 K9 K10 K11 K12 K9 K10 K11 K12 K9 K10 K11 K12

Circuit #2 K13 K14 K15 K16 K13 K14 K15 K16 K13 K14 K15 K16

Number of Fan(s)/Contactor 1 1 1 2 1 1 2 2 1 1 2 3

Fan Steps0 – – – – – – – – – – – –1 x – – – x – – – x – – –2 x x – – x x – – x x – –3 x x x – x – x – x – x –4 x x – x x x x – x x – x5 x x x x x – x x x x – x6 – – – – x x x x x – x x7 – – – – – – – – x x x x

X = ON

86RTAA-IOM-3

Figure 46Fan Configurations - RTAA 130-400 Tons - 0 F Minimum Ambient

The 0 F AMBIENT OPTION will have Half Airflow (Half Pitch Blade) Fan.

# Of Fans # Of Fans UCM OutputsTons Circuit #1 Circuit #2 Per Circuit Fan Steps/Circuit130 5* 6* 4 9 & 10 respectively140 5* 6* 4 9 & 10 respectively155 6* 6* 4 10 & 10 respectively170 7* 6* 4 11 & 10 respectively185 7* 7* 4 11 & 11 respectively200 7* 7* 4 11 & 11 respectively215 7* 7* 4 11 & 11 respectively240 10** 7* 4 9 & 11 respectively270 12** 7* 4 10 & 11 respectively300 14** 7* 4 11 & 11 respectively340 10** 14** 4 9 & 11 respectively370 12** 14** 4 10 & 11 respectively400 14** 14** 4 11 & 11 respectively*The first fan on each single compressor circuit is a Half Airflow (Half Pitch Blade) Fan.

**The first two fans on each dual compressor circuit are Half Airflow (Half Pitch Blade) Fans.

For 0 F AMBIENT OPTION air-cooled (RTAA) Chillers, the mapping of UCM outputs to fan staging shall be as follows:

Fan Contactor 5 & 10 Fan Circuit 6 & 12 Fan Circuit 7 & 14 Fan Circuit

Circuit #1 K9 K10 K11 K12 K9 K10 K11 K12 K9 K10 K11 K12Circuit #2 K13 K14 K15 K16 K13 K14 K15 K16 K13 K14 K15 K16

Number ofFans/ContactorSingle Comp. Ckt. 1* 1 1 2 1* 1 2 2 1* 1 2 3Dual Comp. Ckt. 2* 2 2 4 2* 2 4 4 2* 2* 2 4 6* = Half AirFlow Fan

Fan StepsSingle DualCompr ComprCkt Ckt0.0 0.0 – – – – – – – – – – – –0.5 1 x – – – x – – – x – – –1 2 – x – – – x – – – x – –1.5 3 x x – – x x – – x x – –2 4 – x x – – – x – – – x –2.5 5 x x x – x – x – x – x –3 6 – x – x – x x – – – – x3.5 7 x x – x x x x – x – – x4 8 – x x x – – x x – x – x4.5 9 x x x x x – x x x x – x5.5 11 – – – – x x x x x – x x6.5 13 – – – – – – – – x x x xX = ON

87 RTAA-IOM-3

Operating Principles –Adaptive Control™Microprocessor Logic

GeneralThe exclusive Trane Adaptive Controllogic is comprised of a system ofindividual modules called the UnitControl Module (UCM), located in theControl Panel. The system consists offour types of microprocessor-basedcomponents and the operator interface,as shown in Figures 47 thru 51. Theprocessors are:

Chiller Module (Base or Deluxe) - 1U1Communication and Setpoint Reset

Option Module - 1U2Expansion Valve Module - 1U3Compressor Module (one per

compressor) - 1U4, 1U5, 1U6, 1U7Slave Expansion Valve Module

(240 -400 ton units) - 1U8

The Adaptive Control Chiller Module isavailable in two versions, a base modeland a deluxe model. The deluxe modeloffers the additional features of:

1. Under/Over Voltage Protection(Includes U/O voltage sensetransformer).

2. Display of Compressor Starts andHours

3. Display of % Line Volts

4. Alarm/Running/Max CapacityContacts

Local operator interface with thesystem is accomplished using the fourdisplay buttons on the LICK Datareadouts are shown on the seven-digit,digital display. The three-positionswitch is used to set chiller operation.

Digital DisplayThe digital display shows:

• both operating and diagnostic codes• compressor status indicators• settings of a local setpoints and

adjustments• actual controlling setpoints• specified temperatures• specified pressures• enable/disable status of features and

options• selection status of Sl units or English

units for display of temperatures andpressures

All display segments and any useddecimal points will be briefly turned onto provide a visual test of theiroperation , following a Power-On-Reset. The chiller operating codes (“A”prefix) will then be displayed. The datato be shown on the digital display isselected by using the Display Up andDisplay Down keys. Changing of thedisplay and menus is discussed below.

The digital display will light an indicatorat the bottom of the display, above the“A”, “B”, “C” or “D” and circuit 1 orcircuit 2. In Menu 0, these indicatorsshow which compressor/circuit isrunning. In Menu 2, these indicatorsshow which compressor/circuit isrelated to the displayed parameter.

A “Circuit Lockout” indicator will be litif either circuit is enabled (E) in Menu 1A (Circuit Lockout) or either circuit is“OFF” on its external Circuit Lockoutcontacts and Menu 3B, (External CircuitLockout) is enabled (E).

88RTAA-IOM-3

Figure 47RTAA Control Panel –130 to 200 Tons

LEGEND:

DeviceDesignation Description1F1-6 Fan Fuses, Circuit 11F7-12 Fan Fuses, Circuit 21F15 Control Circuit Fuse1F16, 1F17 Control Power

Transformer Fuses1K1, 1K5 Start Contactors1K2, 1K6 Run Contactors1K4, 1K8 Transition Contactors1K3, 1K7 Shorting Contactors1K9-12 Fan Contactors, Circuit 11K13-16 Fan Contactors, Circuit 21S1, 1S2 Non-fused Disconnect

Switch1T1 Control Power

Transformer1T2 Under/Over Voltage

Transformer1T3-5 Compressor Current

Transformer, Circuit 11T6-8 Compressor Current

Transformer, Circuit 21TB1,1TB2 Line Voltage Terminal

Blocks1TB3 Terminal Strip, 115 V1U1 Chiller Module1U2 Options Module1U3 Expansion Valve Module1U4 Compressor Protection

Module, Compressor A1U5 Compressor Protection

89 RTAA-IOM-3

Figure 48RTAA Control Panel –240 to 300 Tons

LEGEND:

DeviceDesignation Description1F1-6 Fan Fuses, Circuit 11F7-12 Fan Fuses, Circuit 21F15 Control Circuit Fuse1F16, 1F17 Primary Transformer

Fuses1K1, 1K2 Start Contactors, Circuit 11K3, 1K4 Start Contactors, Circuit 21K9-12 Fan Contactors, Circuit 11K13-16 Fan Contactors, Circuit 21S1, 1S2 Non-fused Disconnect

Switch1T1 Control Power

Transformer1T2 Under/Over Voltage

Transformer1T3-8 Compressor Current

Transformer, Circuit 11T9-14 Compressor Current

Transformer, Circuit 21TB1,1TB2 Line Voltage Terminal

Blocks1TB3,1TB4 Terminal Strip, 115 V1U1 Chiller Module1U2 Options Module1U3 Expansion Valve Module1U4 Compressor Protection

Module, Compressor A1U5 Compressor Protection

Module, Compressor B1U6 Compressor Protection

Module, Compressor C1U8 Slave Expansion Valve

Module

90RTAA-IOM-3

Figure 49RTAA Control Panel –340 to 400 Tons

LEGEND:

DeviceDesignation Description1F1-6 Fan Fuses, Circuit 11F7-12 Fan Fuses, Circuit 21F15 Control Circuit Fuse1F16, 1F17 Primary Transformer

Fuses1K1, 1K2 Start Contactors, Circuit 11K3, 1K4 Start Contactors, Circuit 21K9-12 Fan Contactors, Circuit 11K13-16 Fan Contactors, Circuit 21S1, 1S2 Non-fused Disconnect

Switch1T1 Control Power

Transformer1T2 Under/Over Voltage

Transformer1T3-8 Compressor Current

Transformer, Circuit 11T9-14 Compressor Current

Transformer, Circuit 21TB1,1TB2 Line Voltage Terminal

Blocks1TB3,1TB4 Terminal Strip, 115 V1U1 Chiller Module1U2 Options Module1U3 Expansion Valve Module1U4 Compressor Protection

Module, Compressor A1U5 Compressor Protection

Module, Compressor B1U6 Compressor Protection

Module, Compressor C1U7 Compressor Protection

Module, Compressor D1U8 Slave Expansion Valve

Module

91 RTAA-IOM-3

Figure 50RTAA Control Panel –130 to 200 Tonswith Remote Evaporator Option

LEGEND:

DeviceDesignation Description1F1-6 Fan Fuses, Circuit 11F7-12 Fan Fuses, Circuit 21F15 Control Circuit Fuse1F16, 1F17 Primary Transformer

Fuses1K1, 1K5 Start Contactors1K2, 1K6 Run Contactors1K4, 1K8 Transition Contactors1K5, 1K7 Shorting Contactors1K9-12 Fan Contactors, Circuit 11K13-16 Fan Contactors, Circuit 21S1, 1S2 Non-fused Disconnect

Switch1T1 Control Power

Transformer1T2 Under/Over Voltage

Transformer1T3-5 Compressor Current

Transformer, Circuit 11T6-8 Compressor Current

Transformer, Circuit 21TB1, 1TB2 Line Voltage Terminal

Blocks1TB3 Terminal Strip, 115 V1TB8, 1TB9 Terminal Strip, 24 V1U1 Chiller Module1U2 Options Module1U3 Expansion Valve Module1U4 Compressor Protection

Module, Compressor A1U5 Compressor Protection

Module, Compressor B

92RTAA-IOM-3

Figure 51Operator Interface Controls

93 RTAA-IOM-3

Figure 52Menu Formats

OPERATING DISPLAY - MENU 0Selected by setting the number 0 in the “P” menu item. Compressor/circuitindicators will be lit Continuously in this menu to indicate which compressors/circuits are running. All items of Menu 0 are display only. Setpoint changes mustbe made in other menus.

Display Code and Description

P Menu NumberA Operating Codeb Last Diagnostic CodeC Other Diagnostic Codesd Active Chilled Water Setpoint*E Evaporator Entering Water TemperatureF Evaporator Leaving Water TemperatureL Active Current Limit Setpoint

*Dashes are displayed for the setpoint when the chiller is either in the“Ice Building” or “Ice Building Complete” mode.

Menus

There are six menus, four of which areshown on the operator interface paneland two factory displays, which aredescribed later in this section. Themenus are numbered as follows:

Operating Display - Menu 0Service #1 Display - Menu 1Service #2 Display - Menu 2Auxiliary Options Display - Menu 3Factory Display - Menu 4Factory Display - Menu 5

Each menu can be considered to be apage of data, formatted as shown inFigure 52. The operator can view oneline of the menu at a time (menu item)on the digital display and can scrollthrough the menu by using the DisplayUp and Display Down keys. Forexample, when the digital displayshows “P 0”, the UCM is in the“Operating Display” menu. Bydepressing the Display Down key onetime, the next line of the menu,“Operating Code”, will be shown as an“A”, along with the current unitoperating status. All operating anddiagnostic codes are described on the“Condition Codes” label, as shown inFigure 53.

There are a few exceptions to thescrolling function. When a menuselection represents multiple pieces ofinformation:

“C” Menu Item - Other DiagnosticCodes”: When this menu item isselected, depressing the Display Downkey will display diagnostic history incode number sequence. Use theDisplay Up key to return to the top ofthe list. While in the “C” menu item,flashing indicates that the informationis currently “true”, whereas steady, ornon-flashing indicates historic dataonly. The digital display will notadvance to the next item (d) until alldiagnostics have been displayed. Ifthere are no diagnostics to display, thedata field will be blank for one keystroke.

Compressor/Circuit Parameters:Because the unit has two, three or fourcompressors and two refrigerantcircuits, items that refer to compressorsor circuits will remain selected untilinformation for all have beendisplayed. For example, assume a“29”, “Compressor Starts”, menuselection on a two compressor unit.The menu numbered “29” will bedisplayed and the indicator over the“A” compressor will be flashing. Bydepressing the Display Down key onetime, the “29” will remain but theindicator light over the “B” compressorwill be flashing. Another Display Down

key stroke will display menu “2A”,Compressor Hours, with compressor“A” indicator flashing. If either theDisplay Up or Display down keys areheld down, the scrolling will continueuntil the key is released, or untilreaching the top or bottom of themenu. In this case, the display willreturn to the “P” menu position andstop.

To change menus, scroll to the “P”menu position and use the Set PointUp or Set Point Down keys. Forexample, assume that the displayshows “P 0” and it is desired to viewthe Auxiliary Options on Menu 3.Depress the Set Point Up key threetimes and the “P 3” menu will bedisplayed. To return to Menu 0, depressthe Set Point Down key three times orSet Point Up key once (to wrap around)and “P 0” will be displayed. Thisprocedure will work for menus 0through 3.

A combination of key strokes isrequired to access menus 4 and 5. Withthe display in the “P” menu position(P), use the Set Point Up and Downkeys to display “0, 1, 2, 1, 2, 3, 2, 3, 4”.Once in the “P 4” menu, use the SetPoint Up key to access menu 5.

All menus are always accessible,whether the unit is in a “running” or‘stopped” mode.

94RTAA-IOM-3

Figure 52Menu Formats (Continued)

SERVICE #1 DISPLAY – MENU 1

Selected by setting the number 1 in the “P” menu item. The compressor circuit indicators will not be lit continuously in thismenu to indicate which compressors are running. As the menu is advanced, the appropriate compressor/circuit indicator willflash.

UCM Based SetpointDisplay Code and Description Defaults Range

P Menu Number10 Front Panel Chilled Water Setpoint 44 F 0 to 65 F11 Design Delta Temperature Setpoint 10 F 4 to 30 F12 Differential to Start Setpoint 2 F 2 to 30 F13 Front Panel Current Limit Setpoint 120% 40 to 120%14 Outdoor Air Temperature (Optional)15 Low Ambient Lockout - d/E (Optional) d16 Low Ambient Lockout Setpoint - d/E (Optional)* 20 F -20 to 40 F17 Cond. Entering Water Temperature (Optional) RTAA Non Applicable18 Cond. Leaving Water Temperature (Optional) RTAA = Non Applicable19 Service Pumpdown d/E (Stop/Reset only)** d1A Circuit Lockout d/E** d1b Circuit Diagnostics Reset** d

*Dashes are displayed for the setpoint when the Low Ambient Lockout (15) is disabled.**Displayed by Compressor/Circuit

SERVICE #2 DISPLAY - MENU 2

Selected by setting the number 2 in the “P” menu item. Compressor/Circuit indicators shall not be lit continuously in thismenu to indicate which compressors are running. As the menu is advanced, the appropriate compressor/circuit indicator willflash.

UCM Based SetpointDisplay Code and Description Defaults Range

P Menu Number20 Compressor Mode*21 Compressor Suction Refrigerant Temp.*22 Compressor Evap. Refrigerant Temp.*23 Evaporator Refrigerant Pressure*24 Saturated Condenser Refrigerant Temp.*25 Condenser Refrigerant Pressure*26 EXV Test - d/E (Only in STOP/RESET)* d27 Compressor % RLA (Highest leg)*28 % Line Volts (Optional)29 Compressor Starts (Optional)*2A Compressor Hours (Optional)*2b Compressor Test d/E d

*Displayed by compressor/circuit

Compressor Starts, Compressor Hours and % Line Volts will be displayed as dashes (e.g. “2A when this option is not installed.

After the EXV test has been completed, the “E” will be automatically reset to “d”.See “Electronic Expansion Valve (EXV) Test”.

The Condenser Refrigerant Pressure and the Evaporator Refrigerant Pressure, displayed on the UCM, are the saturatedcondenser and evaporator temperatures converted to R-22 pressure readings. The units are PSIG (Kilopascal gauge) andreferenced to an elevation of sea level or 14.6960 psia (101.3289 KPa absolute).

95 RTAA-IOM-3

Figure 52Menu Formats (Continued)

AUXILIARY OPTIONS – MENU 3Selected by setting the number 3 in the “P” menu number position. Compressor/circuit indicators will not be lit continuouslyin this menu to indicate which compressors/circuits are running.

UCM Based SetpointDisplay Code and Description Defaults Range

P Menu Number30 External Chilled Water Setpoint - d/E d31 External Current Limit Setpoint - d/E d32 Ice Machine Control - d/E d33 Active-Ice Termination Setpoint*34 Front Panel Ice Termination Setpoint 27 F 20 to 31 F35 Return Reset - d/E** d36 Zone Reset - d/E** d37 Outdoor Reset - d/E** d38 Reset Ratio Setpoint***

Return 50% 10 to 120%Zone 100% 50 to 300%Outdoor 10% -80 to 80%

39 Start Reset Setpoint***Return 10 F 4 to 30 FZone 78 F 55 to 85 FOutdoor 90 F 50 to 130 F

3A Maximum Reset Setpoint***Return 5 F 0 to 20 FZone 5 F 0 to 20 FOutdoor 5 F 0 to 20 F

3b External Circuit Lockout d/E d

*Dashes are displayed for the setpoint when the chiller is not in the “Ice Building” or “Ice Building Complete” mode.

**The UCM will permit only one type of reset (Return, Zone, or Outdoor) to be selected at one time. For example, if ReturnReset is enabled, an attempt to enable Zone Reset would disable RETURN RESET and enable Zone Reset automatically.

***The UCM contains setpoints for each of the types of reset. The setpoint displayed will be for the type of reset enabled.If no reset is enabled, dashes will be displayed.

96RTAA-IOM-3

Figure 52Menu Formats (Continued)

FACTORY DISPLAY #1 - MENU 4

Caution: Do not leave unit unattended while in Menu 4 or 5. Inadvertent unit safety setpoint changes could occur.

Selected by setting the number 4 in the “P” menu item. Unlike menus 0 through 3, the number 4 can only be set by entering acombination of numbers. This combination consists of a sequence of “P” menu numbers -0, 1, 2, 1, 2, 3, 2, 3. 4.

Compressor/circuit indicators will not be lit continuously in this menu to indicate which compressors are running. As themenu is advanced the appropriate compressor/circuit indicator will flash.

UCM Based SetpointDisplay Code and Description Defaults Range

P Menu Number40 Leaving water Temp. Cutout Setpoint 35 F -10 to 35 F41 Low Refrigerant Temp. Cutout Setpoint 22 F -39 to 35 F42 Condenser Limit Setpoint - % HPC 90% 80 to 120%43 Lead/Lag - d/E E44 SI Display Units - d/E d45 Unit Line Voltage* 460 V46 Under/Over Voltage Protection - d/E d47 Phase Imbalance Protection d/E E48 Phase Reversal Protection d/E E49 Superheat Setpoint 8 F 4 to 20 F4A EXV Control Response Setpoint** 20 2 to 2004b LWT Control Response Setpoint 40 2 to 2204C ICS Address (Optional)4d Fan Control Deadband Bias** 0 -50 to +504E Programmable Relay Setup 1 1 to 12

(see Alarm/Running/Maximum Capacity Contact Outputs)4F Restart Inhibit Timer 120 sec. 30 to 120 sec.

*Entry will be selected from 200, 220, 230, 346, 380, 415, 460, 500 or 575 volts. Dashes will be displayed if the Under/OverVoltage Protection option is not installed.

**Displayed by circuit.

97 RTAA-IOM-3

Figure 52Menu Formats (Continued)

FACTORY DISPLAY #2 - MENU 5

Caution: Do not leave unit unattended while in Menu 4 or 5. Inadvertent unit safety setpoint changes could occur.

Selected by setting the number 5 in the “P” menu item. Unlike menus 0 through 3, the number 5 can only be set after menu 4has been selected, as described on the previous page.

Compressor/circuit indicators will not be lit continuously in this menu to indicate which compressors are running. As themenu is advanced the appropriate compressor/circuit indicator will flash.

UCM Based SetpointDisplay Code and Description Defaults Range

P Menu Number50 Number of Compressors 1 1, 2, 3, 451 Compressor Tons* 100 25, 30, 40,50, 60, 70, 85, 10052 Low Water Temp EXV Gain Compensation d/e d53 Fan Control - d/E E54 Fans per Circuit** 7 4, 5. 6,7. 8, 10, 12, 1455 Reduced Inrush Starting - d/E d56 Compressor Current Overload Setting (to match DIP Switch)* 00 00 to 3157 GP Compressor Unit d/E d58 Low Ambient - Half Air Flow Fan d/E d59 LATSM d/E d5A NNS d/E d5b Number of EXV Valves per Circuit** 1 1. 25c Future Option** d

*Displayed by compressor.**Displayed by circuit

98RTAA-IOM-3

Figure 53Condition/Diagnostic Codes

UNIT OPERATING STATUS COMPRESSOR OPERATING STATUSCODE DESCRIPTION CODE DESCRIPTIONBlank UCM Power Off 00 Compressor Stop888888.8 UCM Paw Up 16 Compressor Lockout00 Unit Stop 17 Cprsr Service Pumpdown01 Auto-Local 70 Cprsr Restart Inhibit02 Auto-Remote 72 Cprsr Start17 Service Pumpdown 74 Run Normal70 Unit Restart Inhibit 75 Run: Current Limit72 Unit Start 76 Run: Condenser Limit74 Run:Normal 77 Run: Evaporator Limit75 Run:Current Limit 7E Run:Unload78 Run:Condenser Limit77 Run:Evaporator Limit7E Run:Unload88 Reset DIAGNOSTIC TYPES100 External Unit Stop101 Ice Building Complete MMR Machine Shutdown-Manual Reset118 EXV Test CMR Circuit Shutdown-Man Reset174 Ice Building; Normal MAR Machine Shutdown-Auto Reset175 Ice Building: Current Limit CAR Circuit Shutdown-Auto Reset176 Ice Building: Condenser Limit IFW Informational-Warning177 Ice Building: Evaporator Limit200 Low Ambient Run Inhibit

UNIT DIAGNOSTICS CONDITIONFLASHING DISPLAY: MEANS:A xxx A New CMR, CAR. or IFW Diagnostic Exists.A xxx ↔ C yyy Operating Code when MMR or MAR occurred. Diagnostic currently inhibiting operation.b yyy Manual reset required to restore full operation. This or other latching diagnostics exist.C yyy Condition creating MAR, CAR or IFW still exists. If MMR or CMR, manual reset required.10 uu The chilled water setpoint is too close to a cutout setpoint.DASHES: MEANS:d ---- The chiller is in either ice bldg or ice bldg compl; Ivg chld wtr stpt is not applicable.33 ---- The chiller is in normal cooling; the active ice termination setpoint is not applicable.Other (e.g. 14----) Option either not installed or not enabled.CODE DESCRIPTION TYPE CODE DESCRIPTION TYPE87 Chock External Chilled Water Stpt IFW 19F Phase Loss - Cprsr D CMR89 Check External Current Limit Stpt IFW 1AO Power Loss - Cprsr A CAR8A Chilled Water Flow (Ent Wtr Temp) MMR 1A1 Power Loss - Cprsr 8 CAR8E Evap Entering Water Temp Sensor MMR 1A2 Power Loss - Cprsr C CAR8F Cond Rfgt Tamp Sensor - Ckt I CMR 1A3 Power Loss - Cprsr D CAR90 Cond Rfgt Temp Sensor - Ckt 2 CMR 1A4 Remote communications Loss IFW93 Evap Rfgt Temp Sensor - Ckt I CMR 1A5 Oil Flow Control - Cprsr A CMR94 Evap Rfgt Tamp Sensor - Ckt 2 CMR 1A6 Oil Flow Control - Cprsr B CMRA0 Zone Temp Sensor IFW 1A7 Oil Flow Control - Cprsr C CMRA1 Outdoor Air Temp Sensor IFW 1A8 Oil Flow Control - Cprsr D CMRAb Evap Leaving Wtr Temp Sensor MMR 1A9 EXV Elec Drive Ckt - Rfgt Ckt I CMRbA Overload Trip - Cprsr A CMR 1AA EXV Elec Drive Ckt - Rfgt Ckt 2 CMRbb Overload Trip - Cprsr 0 CMR 1Ad Memory Error Type I (See Oper Manual) IFWbC Overload Trip - Cprsr C CMR 1AE Low Differential Press - Ckt I CMRbd Overload Trip - Cprsr D CMR 1AF Low Differential Press - Ckt 2 CMRbE High Pressure Cutout - Cprsr C CMR 1b2 Severe Phase Unbalance - Cprsr A CMRbF High Pressure Cutout - Cprsr D CMR 1b3 Severe Phase Unbalance - Cprsr B CMRC5 Low Chilled Water Temp (Unit off) IFW 1b4 Severe Phase Unbalance - Cprsr C CMRC6 Low Chilled Water Temp (Unit on) MAR 1b5 Severs Phase Unbalance - Cprsr 0 CMRCA Contactor - Cprsr A MMR 1b6 Compressor Overload Setting - Cprsr A IFWCb Contactor - Cprsr B MMR 1b7 Compressor Over load Setting - Cprsr B IFWcc Contactor - Cprsr C MMR 1b8 Compressor Overload Setting - Cprsr C IFWCd Contactor - Cprsr D MMR 1b9 Compressor Overload Setting - Cprsr D IFWd7 Over Voltage MAR 1bA Phase Unbalance - Cprsr A CMRd8 Under Voltage MAR 1bb Phase Unbalance - Cprsr 8 CMREd Chilled Water Flow Interlock MAR 1bC Phase Unbalance - Cprsr C CMRF5 High Pressure Cutout - Cprsr A CMR 1bd Phase Unbalance - Cprsr D CMRF6 High Pressure Cutout - Cprsr B CMR 1bE Winding Temp. - Cprsr A CMRFd Emergency Stop Input MMR 1bF Winding Temp. - Cprsr B CMR180 Starter Transition - Cprsr A CMR 1C0 Winding Temp. - Cprsr C CMR181 Starter Transition - Cprsr B CMR 1C1 Winding Temp. - Cprsr D CMR182 Starter Transition - Cprsr C CMR 1C2 Discharge Temp. - Cprsr A CMR183 Starter Transition - Cprsr D CMR 1C3 Discharge Temp. - Cprsr 8 CMR184 Phase Reversal - Cprsr A CMR 1C4 Discharge Temp. - Cprsr C CMR185 Phase Reversal - Cprsr 8 CMR 1C5 Discharge Temp. - Cprsr D CMR186 Phase Reversal - Cprsr C CMR 1C6 High Differential Pressure - Ckt I CMR187 Phase Reversal - Cprsr D CMR 1C7 High Differential Pressure - Ckt 2 CMR190 Low Superheat - Ckt I CMR 1d1 Memory Error Type 11 (See Oper Manual) IFW191 Low Superheat - Ckt 2 CMR 1d2 Memory Error Type III (See Oper Manual) IFW194 Low Evap Rfgt Tamp - Ckt I CMR 1d3 Cprsr Suction Temp. Sensor - Ckt 1 CMR195 Low Evap Rfgt Temp - Ckt 2 CMR 1d4 Cprsr Suction Temp. Sensor - Ckt 2 CMR198 Low Oil I Flow - Cprsr A CMR 1d7 Phase Reversal Prot. Lost - Cprsr A CMR199 Low 01 1 Flow - Cprsr B CMR 1d8 Phase Reversal Prot. Lost - Cprsr B CMR19A Low Oil Flow - Cprsr C CMR 1d9 Phase Reversal Prot. Lost - Cprsr C CMR19b Low Oil Flow - Cprsr D CMR 1dA Phase Reversal Prot. Lost - Cprsr D CMR19C Phase Loss - Cprsr A CMR 1db Slave-Exv Elec Drive Ckt - Rfgt Ckt 1 CMR19d Phase Lose - Cprsr B CMR 1dc Slave-Exv Elec Drive Ckt - Rfgt Ckt 2 CMR19E Phase Loss - Cprsr C CMR 4xy See Operator’s Manual – – –

X3956048201 Rev. B

Condition Codes

99 RTAA-IOM-3

Chiller Switch

The chiller switch has three positions:

Top Position AUTO REMOTEMiddle Position AUTO LOCALBottom Position STOP/RESET

With the switch in the AUTO REMOTEposition, the chiller will operatenormally using remote setpoints. Readand write remote communications maybe performed. Any call for coolingbased on Leaving Water Temperature(LWT) and the remote (e.g. Tracer)setpoints, will start the unit. The activechilled water setpoint (CWS) can be theremote CWS, a reset remote setpointbased on return, zone, or outdoortemperature reset, or a 4-20 mA/0-10VDC external CWS. The active CurrentLimit Setpoint (CLS) can be the RemoteCLS or a 4-20 mA/0-10 VDC ExternalCLS. If remote communication is lost,the UCM will revert to the Front Panel(or local) chiller settings.

When the chiller switch is in the AUTOLOCAL position, the chiller will operatenormally using Front Panel (or local)setpoints. Read and write remotecommunications may be performed,but remote setpoints cannot be usedfor control. The unit will run when thereis a call for cooling based on the LWTand the Front Panel or local setpoints.The active CWS can be the localsetpoint, a reset setpoint based onreturn, zone, or outdoor temperaturereset, or a 4-20 mA/0-10 VDC externalCWS. The active Current Limit Setpointcan be the local setpoint or a 4-20 mA/0-10 VDC External CLS. Remote (e.g.Tracer) setpoints communicated overthe serial communications link will beignored, but remote devices can stillread all unit control data.

In the STOP/RESET position, the UCMis powered but operation of the unit isprevented. All outputs are de-energizedand the chiller is stopped. The alarmrelay output may be energized if analarm condition exists.

If any of the chillers are running whenthe chiller is put into the STOP/RESETposition, the chiller will go into the Run:Unload mode for at least 20 secondsbefore shutting down the compressors.

Although not a “position” on the chillerswitch, it can be used to perform thefunction of manually resetting alllatching diagnostics and clearing allhistoric diagnostics. Latchingdiagnostics can be reset by manuallytoggling the chiller switch from theSTOP/RESET position to either AUTOposition.

Historic diagnostics (“C” menu item)can be cleared by depressing the“Display Down” key while manuallytoggling the chiller switch from theSTOP/RESET position to either AUTOposition (no compressor operating).

Moving the chiller switch from theSTOP/RESET position to either AUTOposition will reset the controls, withone exception. If the chiller operatingstatus is Run:Unload, this sequence willgo to completion before the reset isexecuted. During the completion of theRun:Unload, the reset is “queued up”and operated on only after completionof the Run:Unload. After reset iscompleted, the digital display willreturn to “A” Operating Code.

100RTAA-IOM-3

Menu FunctionDescriptions andSelectionSelecting Variables and Options

All variables and options will be set bydepressing the SET POINT UP and SETPOINT DOWN keys. The setpoints willbe increased or decreased by one leastsignificant digit (1 F, 0. 1 C, or 1 integervalue) with each key depression. If thekey is held down, the setpoint willcontinue to be increased or decreaseduntil the key is released. The minimumand maximum values of all setpointsare limited by system design and thesetting operation will stop when eitherthe minimum or maximum setpoint isdisplayed. See Figure 52 for setpointranges.

Options are also selected using the SETPOINT UP and SET POINT DOWN keys.Use the SET POINT UP key to select the“Enable” option and the letter “E” willappear on the display. Use the SETPOINT DOWN key to select the“Disable” option and the letter “d” willbe displayed. Certain items in Menus 4and 5 will be integers with variousendpoints and units. See Figure 52.

Menu 0 – Operating Display

A - Operating Code: This is the currentunit operating status, e.g. A 74, which,as shown in Figure 53, is Run:Normal.

b - Last Diagnostic Code: The lastdiagnostic detected by the UCM isstored and can be seen by displayingthis I item.

C - Other Diagnostics: All diagnosticsdetected by the UCM will be stored inpreprescribed code number sequence,as shown in Figure 53, rather than theorder in which they occurred. Allflashing codes found under this itemare currently active or “Latched”diagnostics. For additional information,see “Menus”.

Diagnostics will be stored only once,even though the diagnostic may haveoccurred several times. There is nochronological sequence to thediagnostics that may be in the “C”menu item.

d - Active Chilled Water Setpoint: Thesetpoint (display only) to which thechiller is controlling. This may be thesame as the Front Panel Chilled waterSetpoint (code 10 in Menu 1), but itmay also be a setpoint that is beingreset or loaded from a remotecontroller, such as a Tracer, multiple-machine controller, or a remote displaypanel.

E - Evap. Entering Water Temp.: Thetemperature of the water as measuredby the evaporator entering watertemperature sensor. F - Evap. LeavingWater Temp.: The temperature of thewater as measured by the evaporatorleaving water temperature sensor.

L - Active Current Limit Setpoint: Thecurrent limit setpoint (display only) towhich the chiller is controlled. This maybe the same as the Front Panel CurrentLimit setpoint (code 13 in Menu 1), butit may also be a setpoint that wasloaded from a remote controller, suchas a Tracer, multiple-machinecontroller.

Menu 1 – Service #1 Display

10 - Front Panel Chilled Water Setpoint:The temperature selected at the UCMfor the desired chilled water.

11 - Design Delta Temp. Setpoint: Thedifference between the entering andleaving chilled water temperatures atfull load. This will be a function of GPMthrough the evaporator.

12 - Differential To Start Setpoint: Thistemperature, when added to theleaving chilled water setpoint, is thetemperature at which the chiller will bestarted.

Note: 1.5 F below chill water setpoint,the UCM will initiate an integrator toshut off the last compressor on adecrease in cooling load.

13 - Front Panel Current Limit Setpoint,The percent of current limit selected atthe UCM for the system. Seediscussion in “Current Limit Setpoint”.

14 - Outdoor Air Temperature(Optional): The ambient temperature asmeasured by an outdoor temperaturesensor.

15 - Low Ambient Lockout (Optional): Ifthe unit is installed with optionalOutdoor Air Temperature Sensor, theentry in this code will enable or disablethe setpoint in code 16. See discussionin “Low Ambient Lockout”.

16 - Low Amb. Lockout Setpoint(Optional): The temperature of theoutside air below which the unit willnot be permitted to operate. Seediscussion in “Low Ambient Lockout”.

17 - Cond. Entering Wtr. Temp.: Notapplicable, with this air-cooledcondenser unit.

18 - Cond. Leaving Wtr. Temp.: Notapplicable, with this air- cooledcondenser unit.

19 - Service Pumpdown: Must bemanually “Enabled” by servicepersonnel from the UCM display. Theunit must be in STOP/RESET andservice pumpdown can be performedonly once for every power-up of theUCM. Restart inhibit will be ignored,the EXV will be prepositioned (20seconds) and the compressor selectedwill start and run for one minute.Manual closing of the liquid line anglevalve will be required.

Caution: Do not pumpdowncompressor more than once.

1A -Circuit Lockout: Allows servicepersonnel to set a lockout, preventing acircuit from operating. With the displayindicating the number of the circuit tobe locked out, change the display to“E” for circuit lockout. Once circuitlockout is enabled, the circuit willremain locked out even through a resetor power down. Entering a “d” willreturn the circuit to operational status.

1b - Circuit Diagnostic Reset: Allowsservice personnel to reset a CircuitManual Reset (CMR) diagnosticwithout having to terminate operationof the entire chiller via the STOP/RESETswitch. With the display indicating thenumber of the circuit to be reset,change the display to “E” to reset. Afterreset, the display will automaticallyreturn to “d”.

101 RTAA-IOM-3

Menu 2 - Service #2 Display

20 - Compressor Mode: The currentcompressor operating status, as shownin Figure 53, will be displayed whenthis menu item is selected.

21 - Compressor Suction Rfgt.Temperature: Temperature as read bythe suction temperature sensor (seeFigure 40).

22 - Saturated Evaporator RfgtTemperature: Temperature as read bythe saturated evaporator temperaturesensor (see Figure 40).

23 - Evaporator Refrigerant Pressure:The pressure displayed is theevaporator refrigerant temperatureconverted to an R-22 pressure. Unitsare PSIG (Kilopascal gauge), referencedto sea level (14.6960 psia or 101.3289KPa absolute).

24 - Saturated Condenser RfgtTemperature: Temperature as read bythe saturated condensing temperaturesensor (see Figure 40).

25 - Condenser Refrigerant Pressure:The pressure displayed is thecondenser refrigerant temperatureconverted to an R-22 pressure. Unitsare PSIG (Kilopascal gauge), referencedto sea level (14.6960 psia or 101.3289KPa absolute).

26 - EXV Test: EXV test will be initiatedwhen the unit is in STOP/RESET andEXV Test is set to the “Enable” mode.See “Electronic Expansion Valve (EXV)Test’. Mode will automatically be resetto “disable” upon completion of thetest.

27 - Compressor % RLA: Thepercentage of Rated Load Amps on thehighest leg of the compressor motor.See discussion in “Current OverloadProtection”.

28 - % Line Volts (Optional): If the unitis installed with the optional over/undervoltage transformer, the UCM willdisplay the percentage value of linevolts as based on the nominal linevoltage set in Menu 4, Item 45.

29 - Compressor Starts (Optional): Thisitem serves as a non-resettable, non-volatile accumulator of compressorstarts and is referenced by the UCM todetermine balancing of compressorstarts.

2A - Compressor Hours (Optional):This item serves as a non-resettable,non-volatile accumulator ofcompressor hours and is referenced bythe UCM to determine balancing ofcompressor hours.

2b - Compressor Test: Allows servicepersonnel to start a compressor andcheck its operation. This eliminates thetime of waiting for the UCM lead/lagfunction or load demand to start acompressor. With the display indicatingthe number of the circuit to be started,change the display to “E” to start thecompressor on that circuit. After start,the display will automatically return to“d” and the UCM will resume its lead/lag function of compressor control.

Menu 3 - Auxiliary Options

30 - External Chilled Water Setpoint:Enables or disables chilled watersetpoint from an external controlsystem. See discussion in “LeavingChilled Water Temperature Control”.

31 - External Current Limit Setpoint:Enables or disables current limitsetpoint for the system from anexternal control system. See discussionin “Current Limit Setpoint”.

32 - Ice Making Control: Enables ordisables the unit, when commanded bya contact closure, to run fully loadedand to stop, once ice terminationsetpoint has been reached, e.g. icestorage applications.

33 - Active Ice Termination Setpoint:The selected temperature, from aremote controller, such as a Tracer,multiple-machine controller, or aremote display panel, at which toterminate the ice building mode, basedon the evaporator entering watertemperature. If no remote controllersare connected, this setpoint shouldagree with the Front Panel icetermination setpoint. During normaloperation, this menu item will displaydashes, e.g. “33 -”.

34 - Front Panel Ice TerminationSetpoint: Established the temperatureof the entering chilled water at whichice making is terminated. This setpointis the active setpoint when the chiller isin the AUTO/LOCAL, ice mode.

35 - Return Reset: Enables or disablesReturn CWR, based on the currentDelta-T across the evaporator (e.g:Entering Chilled Water Temp. - LeavingChilled Water Temp.).

36 - Zone Reset: Enables or disablesZone CWR, based on a zonetemperature sensor.

37 - Outdoor Reset: Enables or disablesOutdoor CWR, based on an outdoortemperature sensor.

38 - Reset Ratio Setpoint: The resetratio, as a percent, to be used by theUCM to calculate a reset chilled watersetpoint. See discussion in “ChilledWater Reset”.

39 - Start Reset Setpoint: The startreset temperature to be used by theUCM to calculate a reset chilled watersetpoint. See discussion in “ChilledWater Reset”.

3A - Maximum Reset Setpoint: Themaximum reset temperature to beused by the UCM to calculate a resetchilled water setpoint. See discussionin “Chilled Water Reset”.

3b - External Circuit Lockout: Whenenabled, individual circuit operation iscontrolled by a remote, customerspecified/installed contact closure. SeeExternal Circuit Lockout -Circuit #1 andExternal Circuit Lockout -Circuit #2 inthe Installation - Electrical section.

102RTAA-IOM-3

Menu 4 – Factory Display #1

40 - Leaving Water Temp. CutoutSetpoint: Establishes a leaving chilledwater temperature, below which theUCM will begin unloadingcompressors and, if necessary,terminate unit operation. Seediscussion in “Leaving WaterTemperature Cutout”. See Table 15 forproper settings.

41 - Low Refrigerant Temp. CutoutSetpoint: Establishes a saturatedevaporator refrigerant temperature,below which the UCM will beginunloading compressors and, ifnecessary, terminate unit operation.See discussion in “Low RefrigerantTemperature Cutout”. See Table 15 forproper settings.

Table 15Leaving Fluid Temperature Setpoints

Chilled Leaving LowWater Water Temp Refrig Temp Recommended *** Solution Freeze

Setpoint - F Cut out - F Cut out - F % Ethylene Glycol Point - F40 35 22 0 3239 34 20 338 33 18 637 32 17 836 31 15 10 2535 30 14 1234 29 12 1433 28 11 15 2132 27 9 1731 26 7 1930 25 6 20 1629 24 4 2128 23 2 2327 22 0 25 1026 21 -1 2625 20 -3 2824 19 -5 2923 18 -6 30 422 17 -8 3121 16 -10 3320 15 -11 3419 14 -13 35 -318 13 -15 3617 12 -17 3716 11 -18 3815 10 -19 3914 9 -21 40 -1113 8 -23 4112 7 -24 4211 6 -26 4310 5 -27 439 4 -29 448 3 -31 45 -217 2 -32 466 1 -34 475 0 -35 474 - 1 -37 483 -2 -38 492 -3 -39 50 -321 -4 -39 500 -5 -39 50

***Recommended % Ethylene Glycol will give freeze protection consistent with otherchiller safety controls (solution freeze point is nominally 10 F above refrig temp cutout).

103 RTAA-IOM-3

42 - Condenser Limit Setpoint:Establishes a percentage of thecondenser high pressure cutout, abovewhich the UCM will begin unloadingcompressors and, if necessary,terminate unit operation.

43 - Lead Lag: Enables or disables theAuto Lead/Lag feature. See discussionin “Auto Lead/Lag”.

44 - SI Display Units: When set to“Enable”, the display units areconverted from OF to IC and PSIG toKilopascals Gauge.

45 -Unit Line Voltage (Optional):Establishes the line voltage cominginto the unit and calibrates the UCM forUnder/Over voltage protection anddisplay of % volts. See “Unit PowerSupply”.

46 - Under/Over Voltage Protection(Optional): Enables or disables theoptional under/over voltage protectionfeature, if installed.

47 - Phase Unbalance Protection:Enables or disables the phaseunbalance protection feature. Seediscussion in “Phase UnbalanceProtection”.

48 - Phase Reversal Protection:Enables or disables the phase reversalprotection feature. See discussion in“Reverse Rotation Protection”.

49 - Superheat Setpoint: Establishesthe temperature of the refrigerantsuperheat in the evaporator.

4A - EXV Control Response Setpoint:Establishes EXV controlresponsiveness. If the control appearsto be too responsive, decrease thesetpoint. Increase the setpoint if thecontrol appears to be sluggish. TheUCM-based default is designed tohandle most applications andadjustment is usually not necessary.

4b - LWT Control Response Setpoint:Establishes LWT controlresponsiveness. If the control appearsto be too responsive, decrease thesetpoint. Increase the setpoint if thecontrol appears to be sluggish. TheUCM-based default is designed tohandle most applications andadjustment is usually not necessary.

4C - ICS Address (Optional): Sets theaddress at which a remote controller,such as a Tracer, multiple-machine or aremote display panel, can find thechiller on a BidirectionalCommunications Interface. To use thisinterface, the optional 1U2 modulemust be installed. The Tracer will lookfor the chiller at addresses 55, 56, 57,58, 59 or 60. The UCM-based default isaddress 55. When multiple chillers areconnected to the BidirectionalCommunications Interface, each chillermust have a unique address, e.g. 55, 56and 57 for three chillers.

For chillers with the Remote DisplayPanel, set the address to “32”. SeeRTAA-IOM-2 for further information onRemote Display Panel.

4d - Fan Control Deadband BiasProvides sensitivity adjustment ofcondensing fan control logic. Must beset at “0”. Settings other than “0” arenot permitted.

4E - Programmable Relays Setup:Used for selection of the Alarm/Running/ Maximum Capacity contactoutputs. See Alarm/Running/MaximumCapacity Outputs in the Installation -Electrical section.

4F - Restart Inhibit Timer: Used toadjust the time (in seconds) betweenthe power-up of a unit (or the switchingfrom the STOP/RESET position) andthe initiation of the compressor startsequence, provided there is a call forcooling. The typical setting is 120seconds, but a time as short as 30seconds may be set.

Note: The anti-recycle timer, whichprovides 5 minutes between startcycles, is not affected by this menuitem.

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Menu 5 – Factory Display #2

50 - Number of Compressors: Set tothe number of compressor installed inthe unit.

51 - Compressor Tons: Set to the ratingin tons, of the each installedcompressor. See Table 2.

52 - Low Water Temperature EXV GainCompensation: Set to “E” if the unitwill ever operate with a leaving chilledwater temperature of 40 F or less.

53 - Fan Control: Set to “E”.

54 - Fans Per Circuit: Establishes thenumber of fans installed on eachcircuit. See Figures 45 and 46.

55 - Reduced Inrush Starting: Set to“d” if across-the-line wiring or to “E” ifWye-Delta wiring.

56 - Compressor Current OverloadSetting: Establishes the compressormotor current overload setting, whichmust agree with the DIP Switchsettings on the correspondingcompressor modules. See Table 16.

Compressor Compressor ModuleA ................................. 1U4B .................................. 1U5C .................................. 1U6D ................................. 1U7

57 - GP Compressor Unit: This menuitem must be set to “d”. The unit is notto be operated unless a “d” isdisplayed in this item.

58 - Low Ambient, Half Airflow Fan(Halfpitch Blades on Lead Fan(s): Setthis menu item per the following unitselections

RTAA 130 - 200 Standard Ambient = dRTAA 130 - 200 Low Ambient = ERTAA 240 - 400 All = E

59 - LATSM: Set this menu item to “d”.

5A - NNS: Set this menu item to “d”.

5b - Number of EXV Valves per Circuit:Set this menu item per the followingunit selections

RTAA 130 - 200 Circuit 1 = 1Circuit 2 = 1

RTAA 240 - 300 Circuit 1 = 2Circuit 2 = 1

RTAA 340 - 400 Circuit 1 = 2Circuit 2 = 2

5C - Future Option: Set this menu itemto “d” for both Circuit #1 and Circuit #2.

Table 16Compressor Overload DIP Switch Settings

Overload SettingCompressor CT DIP Sw/Decimal**Tons Volts.Hz RLA Ext* 1234570 200/230.60 280 -05 00100/04

460.60 122 -02 10000/16575.60 98 -01 11110/30

85 200/230.60 306 -05 01011/11460.60 133 -02 10110122575.60 107 -02 00110/06

100 200/230.60 375 -05 11010/26460.60 163 -03 10000/16575.60 131 -02 10110122

*The CT base part number is X13580253. The numbers in this column are suffixes to thebase number.

**On the DIP switch, 1= ON, O= OFF. The decimal number is the setting Menu Item 56. TheDIP switch setting and the decimal display of Item 56 comprise a redundant overloadsetting. If the values are not set to match, the related compressor(s) will continue to run,but a diagnostic will be initiated, both settings will be ignored, and the UCM will use thelowest possible trip setting value.

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Table 17Compressor(s) Current Limit Setpoint vs Chiller Current LimitSetpoint (CLS)

Number of Compressors on a UnitTwo (130-215) Three (240-300) Four (340-400)

Number of Number of Number ofcompressors compressors compressors

System in operation in operation in operationCLS One Two One Two Three One Two Three Four

120% 120 120 120 120 120 120 120 120 120100% 120 100 120 120 100 120 120 120 10080% 120 80 120 120 80 120 120 107 8060% 120 60 120 90 60 120 120 80 6040% 80 40 120 60 40 120 80 53 40

Operational FeaturesEntering Evaporator WaterTemperature

When one or more compressors arerunning, the UCM continually monitorsand compares the entering and leavingevaporator water temperatures. If thetemperature of the entering waterdrops more than 2 F below the leavingwater temperature for more than 100degree F seconds, the UCM uses this toindicate a loss of water flow throughthe evaporator, will shut down thechiller and will display an MMRdiagnostic. See Figure 53.

Current Limit Setpoint

The current limit setpoint (CLS) for thechiller (front panel or remote) is enteredthrough the UCM menu. The currentlimit setpoint for each compressor isshown in Table 17.

Based upon current levels received atthe UCM, the compressor slide valve ismodulated to prevent the actual chillercurrent from exceeding the CLS.

When a compressor is turned off, theCLS for the remaining runningcompressors shall be reset upwardimmediately. When a compressor isadded, the CLS for the runningcompressors shall ramped downwardat a rate not less than 10% RLA perminute to the new setpoint.

Low Ambient Lockout

The lockout provides a method forpreventing unit start-up when theoutdoor air temperature is below thesetpoint. If the outdoor temperaturegoes below the setpoint duringoperation, the UCM will go through anormal shutdown of the unit. If theoutdoor temperature subsequentlyincreases to 5 F above the setpoint, theUCM will automatically re-enable theunit.

Electronic Expansion Valve (EXV)Test

This test can be performed only whenthe chiller switch is in the STOP/RESETposition. It will confirm properoperation of the electronic expansionvalve and the EXV module.

Once the test has been initiated at theUCM, the UCM will:

1. Overdrive the EXV closed (1250steps)

2. Overdrive the EXV open (1250 steps)

3. Overdrive the EXV closed (1250steps) 4. Reset the display to disableand end the test

The EXV produces an audible clickingsound only when it is driven against itsend stops. Step 1 drives the EXV to itsclosed position, during which timeservice personnel can move from theUCM to the EXV.

Note: A tool may be needed to aid inhearing the clicking of the EXV, such asa screwdriver held between the EXVand the ear.

When Step 1 completes, the clickingstops and the UCM begins to open theEXV. When the EXV is fully opened, thevalve will begin to click against its endstop. The service personnel must beprepared to time the period betweenthe end of clicking in Step 1 and thebeginning of clicking in Step 2.

The time between the end of clicking inStep 2 and the beginning of clicking inStep 3 must also be recorded. The timefor the EXV to go from fully closed tofully open should be approximately 15seconds and the time to go back tofully closed is approximately 15seconds.

Current Overload Protection

The UCM continually monitorscompressor current to provide unitprotection in the event of anovercurrent or locked rotor condition.Protection is based on the phase withthe highest current and, if limits areexceeded, the UCM will shutdown thecompressor and will display an CMRdiagnostic. See Figure 53.

Leaving Chilled Water TemperatureControl

If the chiller switch is in the AUTOREMOTE position and a remote chilledwater setpoint has beencommunicated, the UCM will control tothat setpoint. Otherwise, it will controlto the front panel setpoint. Control isaccomplished by both stagingcompressors and modulating the slidevalves on each compressor.

Upon start-up, if the leaving watertemperature is dropping 1.5 F perminute or faster, the chiller will not loadfurther.

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Chilled Water Reset (CWR)

As an option, the UCM will reset thechilled water temperature setpoint,based on either the return watertemperature, zone air temperature, oroutdoor air temperature. The followingare selectable:

1. One of four RESET TYPEs, from topto bottom in order of reset:

no CWRRETURN WATERTEMPERATURE RESET ZONETEMPERATURE RESETOUTDOOR AIR TEMPERATURERESET

The UCM will not permit more thanone type of reset to be selected inMenu 3.

2. RESET RATIO Setpoints. ForOUTDOOR AIR TEMPERATURERESET, there are both positive andnegative reset ratios.

3. START RESET Setpoints.

4. MAXIMUM RESET Setpoints. Themaximum resets are with respect tothe chilled water setpoint.

No matter which type of reset isselected, all parameters are factory setto a predetermined set of values. Fieldadjustment of 2, 3, or 4, above, isusually not required.

The equations for each type of resetare:

RETURN WATER TEMPERATURERESET

CWS’= CWS + RESET RATIO[START RESET - (TWE - TWL)]

and CWS’> or = CWS

and CWS’- CWS < or = MAXIMUMRESET

ZONE TEMPERATURE RESET

CWS’= CWS + RESET RATIO[START RESET - TZONE]

and CWS’> or = CWS

and CWS’- CWS < or = MAXIMUMRESET

OUTDOOR AIR TEMPERATURE RESET

CWS’= CWS + RESET RATIO[START RESET - TOD]

and CWS’> or = CWS

and CWS’- CWS < or = MAXIMUMRESET

CWS’ is the new chilled water setpoint.

CWS is the active chilled water setpointbefore any reset has occurred.

RESET RATIO is a user adjustable gain.

START RESET is a user adjustablereference.

TZONE is the zone temperature.

TOD is the outdoor temperature.

TWE is the entering evaporator watertemperature.

TWL is the leaving evaporator watertemperature.

MAXIMUM RESET is a user adjustablelimit, providing the maximum amountof reset.

Note: When any type of CWR isenabled, the UCM will step the CWStoward the desired CWS’ (based on theabove equations and setupparameters) at a rate of 1 F every 5minutes. This applies when the chilleris both running and off. Normally thechiller will start at the Differential-to-Start value above a fully reset CWS orCWS’.

The values for RESET RATIO for each type of reset are:

Reset Increment FactoryReset Ratio English Increment DefaultType Range Units Sl Units ValueReturn 10 to 120% 1% 1% 50%Zone 50 to 300% 1 % 1 % 100%Outdoor 80 to -80% 1 % 1 % 10%

The values for START RESET for each type of reset are:

Start Increment FactoryReset Reset English Increment DefaultType Range Units Sl Units ValueReturn 4 to 30 F 1 F 0.1 C 10 F (5.6 C)

(2.2 to 16.7 C)Zone 55 to 85 F 1 F 0.1 C 78 F (25.6 C)

(12.8 to 29.4 C)Outdoor 50 to 130 F 1 F 0.1 C 90 F (32.2 C)

(10 to 54.4 C)

The values for MAXIMUM RESET for each type of reset are:

Maximum Increment FactoryReset Reset English Increment DefaultType Range Units Sl Units ValueReturn 0 to 20 F 1 F 0.1 C 5 F (2.8 C)

(-17.8 to -6.7 C)Zone 0 to 20 F 1 F 0.1 C 5 F (2.8 C)

(- 17.8 to -6.7 C)Outdoor 0 to 20 F 1 F 0.1 C 5 F (2.8 C)

(- 17.8 to -6.7 C)

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Leaving Water Temperature Cutout

This temperature cutout providesprotection against freezing caused bylow leaving water temperature. Thesetpoint is both factory set andadjustable from Menu 4. Temperaturesbelow the setpoint will cause the UCMto accelerate reduction of chillercapacity, even to the point ofcompressor shutdown. A non-latchingdiagnostic will be generated if the LWTis below the cutout for more than 30degree F seconds.

There must be a minimum of 5 Fbetween the cutout temperature andboth the front panel and active chilledwater setpoints. The UCM will notpermit setting of either the front panelor active chilled water temperaturesless than 5 F above this cutouttemperature and the display will flashthe last valid temperature.

If the leaving water temperature cutoutis set upward, the UCM will maintainthe 5 F minimum and will raise thesettings on the front panel and activechilled water setpoints, if necessary.

Low Refrigerant TemperatureCutout

Both circuits are protected from asaturated evaporator refrigeranttemperature that goes below thissetting. The cutout setpoint must be aminimum of 15 F lower than the frontpanel or active chilled water setpoints.

There must be a minimum of 15 Fbetween the cutout temperature andboth the front panel and active chilledwater setpoints. The UCM will notpermit setting of either the front panelor active chilled water temperaturesless than 15 F above this cutouttemperature and the display will flashthe last valid temperature.

If the leaving water temperature cutoutis set upward, the UCM will maintainthe 15 F minimum and will raise thesettings on the front panel and activechilled water setpoints, if necessary.

If the saturated evaporator refrigeranttemperature for a circuit drops belowthis setpoint for longer than 30 degreeF seconds, the circuit will be shutdownand a CMR diagnostic will bedisplayed.

Low Ambient Temperature Start

The Low Refrigerant TemperatureCutout (LRTC) on a circuit is ignored,briefly, each time the circuit is started.The “ignore time” is a function of theSaturated Condenser RefrigerantTemperature at the time thecompressor starts, as shown in Figure54.

Low Refrigerant TemperatureCutout Retry

If the LTRC trips despite the lowambient temperature start logic, thecircuit will be permitted to shutdownand retry one time

If the LRTC trips within the first 20minutes after initial start but after theLow Ambient ignore time (graceperiod), the compressor stopsimmediately and the Restart Inhibittimer is set to 1 minute. After timeexpires, the compressor will restart ifthere is a call for cooling.

If the LRTC trips again during the graceperiod, a CMR diagnostic will occur. Ifthere is an LRTC trip anytime after thegrace period, a CMR diagnostic willoccur.

Figure 54Low Refrigerant TemperatureCutout Ignore Time

Low Refrigerant Temperature Cutout Time - vs - Saturated Condenser Refrigeration Temperature

108RTAA-IOM-3

Auto Lead/Lag

This feature is enabled/disabled in code43, menu 4. When enabled, the UCMwill start the compressor with thefewest starts and stop the compressorwith the greatest hours, as determinedby the “Compressor Starts”accumulator (code 29, menu 2) and the“Compressor Hours” (code 2A, menu2). (Display is optional). This will tend tobalance out hours and starts equallyover all compressors. For efficiencyimprovement, when there are 2compressors operating, they will be onopposite circuits. When disabled thecompressors will start per the followingchart.

RTAA RTAA RTAA130-200 240-300 340-400

A A AAB AC AC

ABC ABC ABCD

Phase Imbalance Protection

The UCM monitors the current in eachphase and calculates the percentage ofimbalance as follows:

% Imbalance = (Ix - lave)

x 100lave

lave = (11 + 12 + 13) / 3

lx = phase with greatest difference fromlave (without regard to sign)

If code 47, menu 4, is enabled, and theaverage three phase current is greaterthan 80% RLA, and the percent ofimbalance is calculated to exceed 15%,the UCM will shutdown thecompressor and display a CMRdiagnostic.

In addition to the 15% criteria, the UCMhas a non-defeatable 30% criteriawhich has its own diagnostic. If the15% criteria is enabled, it will alwaysdisplay the 15% diagnostic first. The30% criteria is always active when acompressor is running, regardless of% RLA.

Reverse Rotation Protection

The UCM monitors incoming currentduring start-up and will shutdown thecompressor within one second, ifphase reversal is detected.

Caution: Phase relationships duringinstallation of unit power must becarefully controlled to assurecompressor protection againstreversed phase rotation. SeeInstallation - Electrical.

DIP Switch SettingsCompressor Overload DIPSwitches

The settings for these switches areshown in Table 16.

IPC Address

The [PC address set the address forInter-Processor Communications of theUCM modules. The following is the IPCDIP switch settings for the RTAA 130400 modules.

IPCDIP MODULE

SWITCH 1U3 1U4 1U5 1U6 1U7 1U81 OFF OFF OFF ON ON OFF2 OFF OFF ON OFF ON ON

2-10 VDC/4-20 made Input forExternal Chilled Water Setpoint(CWS) and Current Limit Setpoint(CLS)

When either external CWS or externalCLS is used on the optional Module1U2, DIP switch SW1 positions 1 and/or2 must be set to accommodate the typeof signal source the customer haschosen, either 2-10 VDC or 4-20 mA.SW1 - 1 sets 2-10 VDC/4- 20 mA forexternal CWS. SW1 -2 sets 2-10 VDC/4-20 mA for external CLS. The “OFF’setting configures the external input for2-10 VDC; the “ON” setting configuresthe external input for 4-20 mA.

109 RTAA-IOM-3

2. The display will flash the CurrentOperating Code “A”, followed by afully blank display for all otherdiagnostics (CMR, CAR, and IFWdiagnostics). This is to call attentionto the detection of some type offailure.

Depressing the Display Down key willadvance the display to the “Last (mostrecent) Diagnostic Code”. The displaywill “flash” if any diagnostic exists thatrequires a manual reset to restore fullunit operation. The display will becontinuous if no manual reset isrequired to restore full operation. The“Last Diagnostic Code” will be retaineduntil the unit control is reset or a newdiagnostic occurs.

Depressing the Display Down key willthen cause the display to show any“Other Diagnostic Codes” that haveoccurred since the “Other DiagnosticCodes” was last reset. Any specificdiagnostic will not be shown more thanonce, even if it has occurred more thanonce. No time sequence of occurrenceis provided. The display will “flash” ifthe current logical status of thecondition that caused the diagnosticstill exists or if it is an MMR or MARdiagnostic. Flashing means thecondition still exists if it is a MAR, CAR,or IFW diagnostic or that a manualreset is required if it is a MMR or CMRdiagnostic.

By depressing the Display Down keyafter the last of the “Other DiagnosticCodes”, the display can be advanced tosetpoint adjustment, unit temperature,and other data displays.

Depressing the Display Down keyfollowing the last data display in themenu (either operating, service,auxiliary options, or factory) will returnthe display to the top of the displaymenu, “P Menu Number”. If the menuselected is Menu 0 and either an MMRand MAR diagnostic is still active, whenselected again, the operating code will“alternate” with the highest priorityMMR or MAR, as in item 1. above.Otherwise, in all other cases, thecurrent operating code will bedisplayed continuously.

If any diagnostics have been detectedsince the last unit reset, the “LastDiagnostic Code” will be cleared whenthe chiller switch is moved from theSTOP/ RESET position to either of theAUTO positions. The display will show“A 88” for 0.5 to 5 sec. following thereset, before returning to the display ofthe operating code.

The above step will not clear the“Other Diagnostic Codes” menu item.To clear this, depress and hold theDisplay Down key while moving thechiller switch from the STOP/RESETposition to either of the AUTOpositions.

Mechanical Control Settings

The settings for the High Pressureswitch, Oil Pressure switch, andWinding Thermostat are shown below:

CLOSE OPEN

Compressor 300 ±20 405 ±7DischargeHigh PressureSwitch - PSIG

Compressor Oil 47 50 ±3Pressure Switch-PSID

Compressor 181 221Motor WindingThermostat - F

Domestic Water 115 130Heater SolenoidThermostat - F

Diagnostics andTroubleshootingIf no diagnostics exist, the selectedmenu item will be displayedcontinuously. When a diagnosticoccurs, the display will switch to theMenu “0” and, depending on thenature of the diagnostic, will do one ofthe following:

1. The display will “alternate” betweenthe Operating Code “A” at the timeof failure and the Diagnostic Code“C” for any condition that causes theentire shutdown (MMR and MARdiagnostics). The display willalternate between “A XX” and “CYY”, where YY is the MMR or MARdiagnostic that caused the machineto shutdown. If multiple MMR orMAR diagnostics occur, YY will bethe active diagnostic with thegreatest priority. Priority, from thehighest to lowest, shall be as follows:

Cd Contactor - Cprsr D (MMR)

CC Contactor - Cprsr C (MMR)

Cb Contactor - Cprsr B (MMR)

CA Contactor - Cprsr A (MMR)

413 CPM module indicates EXVmodule communications loss (MMR)

431 EXV Module indicates CPMmodule communications loss (MMR)

Fd Emergency Stop (MMR)

Ab Evaporator Leaving WaterTemperature Sensor (MMR)

8E Evaporator Entering WaterTemperature Sensor (MMR)

8A Chilled Water Flow (EnteringWater Temperature) (MMR)

d8 Under Voltage (MAR)

d7 Over Voltage (MAR)

Ed Chilled Water Flow Interlock(MAR)

C6 Low Chilled Water Temp.(Unit On) (MAR)

When multiple diagnostics exist and adiagnostic with a higher priority is nolonger active, the diagnostic with lowerpriority will replace it in the alternating“A XX” and “C YY” displays.

Note: MMR diagnostics only becomeinactive after a RESET MAR diagnosticsbecome inactive when the conditionthat caused them clears.

110RTAA-IOM-3

Table 18Diagnostics and Troubleshooting Chart

In the table below, a “LATCHING” diagnostic is a condition which shall cause the machine or a portion of the machine asnoted to shut down and shall require a manual reset to restore operation. A diagnostic that is non-latching shall resetautomatically when the condition causing the diagnostic goes away. A non-latching diagnostic shall shut down the machineor a part of the machine if so indicated. If a diagnostic is informative only, no machine or circuit action is taken except to load adiagnostic code into the last diagnostic register.

Diagnostic Types (And Action)MMR = Machine Shutdown, Manual ResetMAR = Machine Shutdown, Auto ResetCMR = Circuit Shutdown, Manual ResetCAR = Circuit Shutdown, Auto ResetIFW = Information/Warning

DIAG.ACTIVE

CODE DIAGNOSTIC DESCRIPTION TYPE MODES CAUSE

87 External Chilled Water IFW All a. Not “Enabled”: No Diagnostics Setpointb. “Enabled”: Out-of-Range Low, set diagnostic.

Out-of-Range Hi, no diagnostic.

89 External Current Limit IFW All a. Not “Enabled”: No Diagnostics Setpointb. “Enabled”: Out-of-Range Low, set diagnostic.

Out-of-Range Hi, no diagnostic.

8A Chilled Water Flow MMR Any Circuit a. The entering evaporator water fell (Ent. Wtr. Temp.)Energized below the leaving evap. water temp. by more than

2 F for 100 F-seconds.b. Causes to trip this diagnostic loss of chilled water

flow or a calibration shift in the evap. water temp. sensors.

8E Evap. Entering Water Temp. Sensor MMR All Open or Short

8F Cond. Rfgt. Temp. Sensor - Ckt 1 CMR All Open or Short

90 Cord. Rfgt. Temp. Sensor - Ckt 2 CMR All Open or Short

93 Evap. Rfgt. Temp. Sensor - Ckt 1 CMR All Open or Short

94 Evap. Rfgt. Temp. Sensor - Ckt 2 CMR All Open or Short

9A Cord. Entering Wtr. Temp. Sensor IFW All Shorted condenser temperature sensor(no diagnostic on open circuit).

9b Cond. Leaving Wtr. Temp. IFW All Shorted condenser temperature sensorSensor (no diagnostic on open circuit).

AO Zone Temperature Sensor IFW All Open or Shorta. Use end of range value (whatever value the open or

short gives).(Zone Reset Selected) b. Clear diag. when the resistance returns to normal

range.c. If Shorted, go into the ice making mode if

“Ice Machine Control” is enabled.

Zone Temperature Sensor None All a. If Open, do normal chiller control .(Zone Reset Not Selected) b. If Shorted, go into the ice making mode if “Ice

Machine Control” is enabled.

A1 Outdoor Air Temp. Sensor IFW All Open or Short(Either Outdoor Air Reset a. Use end of range value (whateveror Low Ambient Lockout value the open or short).Selected) b. Clear diag. when the resistance returns to

normal range.

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Table 18Diagnostics and Troubleshooting Chart (Continued)

DIAG. ACTIVECODE DIAGNOSTIC DESCRIPTION TYPE MODES CAUSE

NONE Outdoor Air Temperature None All Open or ShortSensor (Both Outdoor Air a. Display dashes e.g. 14 - - - - -”,Reset or Low Ambient LockoutNot Selected)

Ab Evap. Leaving Water Temp. Sensor MMR All Open or Short

bA Overload Trip - Compressor A CMR Compressor Energized Compressor current exceeded overloadtime vs. trip characteristic.

bb Overload Trip - Compressor B CMR Compressor Energized Compressor current exceeded overloadtime vs. trip characteristic.

bC Overload Trip - Compressor C CMR Compressor Energized Compressor current exceeded overloadtime vs. trip characteristic.

bd Overload Trip - Compressor D CMR Compressor Energized Compressor current exceeded overloadtime vs. trip characteristic.

bE High Pressure Cutout - Compressor C CMR All a. A high pressure cutout was detected onCompressor C; trip at 405 + or - 7 PSIG.

BF High Pressure Cutout - Compressor D CMR All a. A high pressure cutout was detected onCompressor D; trip at 405 + or - 7 PSIG.

NONE CWS/Leaving Water Temp. None All No diagnostic, display to flash andCutout Setpoint Overlap limit value to last legal value.

NOTE: The above is not a diagnostic because you don’t want the display vectoring you to a different display state when youare trying to set either the chilled water setpoint or the leaving water temp. cutout setpoint as it will in the case of a diagnostic.

C5 Low Chilled Water Temperature IFW No Circuits Energized a. The chilled water temp. fell below(Unit Off) the cutout setpoint while the

compressors were not running.

C6 Low Chilled Water Temperature MAR Any Circuit Energized a. The chilled water temp. fell below(Unit On) the cutout setpoint while the

compressors were running for 30 F - sec.

CA Contactor - Compressor A MMR Compressor a. Welded compressor contactor.Not Energized b. Detected a welded compressor contactor

off but the current does not go to zero.Detection time shall be 5 secondminimum and 10 seconds maximum.On detection, generate the diagnostic,energize the appropriate alarm relay,continue to command the affectedcompressor off, energize the affectedcompressors oil line solenoid, stop allother compressors, unload the runningcompressor with the welded contactor,open the EXV to it’s maximum openposition, and continue to do fan control.Do not exit this condition until thecontroller is manually reset.

Cb Contactor - Compressor B MMR Same as CA Same as diagnostic CA

CC Contactor - Compressor C MMR Same as CA Same as diagnostic CA

Cd Contactor - Compressor D MMR Same as CA Same as diagnostic CA

d7 Over Voltage MAR Pre-start and a. Line voltage above +10% of nominal.Any Circuit(s) (Must hold = +10% of nominal.Energized Must trip = +15% of nominal.)

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Table 18Diagnostics and Troubleshooting Chart (Continued)

DIAG. ACTIVECODE DIAGNOSTIC DESCRIPTION TYPE MODES CAUSE

d8 Under Voltage MAR Pre-start and a. Line voltage below -10% of nominalAny Circuit(s) Energized the Under/Over transformer is not

connected. (Must hold = -10% ofnominal Must trip = -15% of nominal).

Ed Chilled Water Flow Interlock MAR All Modes Except a. The chilled water flow switch inputSTOP (00) and was open for more than 6 seconds.EXTERNAL STOP (100)

F5 High Pressure Cutout - CMR All a. A high pressure cutout was detectedCompressor A on Compressor A; trip at 405 + or

- 7 PSIG.

F6 High Pressure Cutout - CMR All a. A high pressure cutout was detectedCompressor B on Compressor B; trip at 405 + or

- 7 PSIG.

Fd Emergency Stop MMR All a. EMERGENCY STOP input is open.An external interlock has tripped.Time to trip from input opening to unitstop shall be 0.1 to 1.0 sec.

180 Starter Transition CMR a. The UCM did not receive aCompressor A transition complete signal in the

designated time from the UCMcommand to transition. The musthold time from the UCM transitioncommand is 1 second. The Must triptime from the transition time is 6seconds.

b. The Transition Complete input wasfound to be shorted before thecompressor was started.

c. Active only if Reduced InrushStarting is enabled.

181 Starter Transition - Compressor B CMR Same as 180 Same as diagnostic 180.

182 Starter Transition - Compressor C CMR Same as 180 Same as diagnostic 180.

183 Starter Transition - Compressor D CMR Same as 180 Same as diagnostic 180.

184 Phase Reversal - Compressor A CMR a. A phase reversal was detected onthe incoming current. On acompressor start-up the phasereversal logic must detect and trip in amaximum of 1.0 second fromcompressor start.

185 Phase Reversal - Compressor B CMR Same as diagnostic 184.

186 Phase Reversal - Compressor C CMR Same as diagnostic 184.

187 Phase Reversal CMR Same as diagnostic 184.Compressor D

113 RTAA-IOM-3

Table 18Diagnostics and Troubleshooting Chart (Continued)

DIAG. ACTIVECODE DIAGNOSTIC DESCRIPTION TYPE MODES CAUSE

190 Low Superheat Circuit 1 CMR All Running Modes a. A low superheat condition existedfor an extended period of time. If asuperheat less than or equal to 2 F isdetected for more than 2400 Fseconds, the circuit shall be shutdown. The integrated area (2400 Fseconds) shall be only below 2 Fsuperheat.

191 Low Superheat - Circuit 2 CMR All Running Modes Same as diagnostic 190.

194 Low Evap. Rfgt. Temp. - Circuit 1 CMR Compressor Energized a. The Saturated Evaporator RefrigerantTemp.- Circuit 1 dropped below theLow Refrigerant Temp. Cutout Setpointwhen the circuit was running for30 F seconds.

b. See the low ambient ignore time onstart-up.

195 Low Evap. Rfgt. Temp. CMR Compressor Energized Same as diagnostic 194, but for Ckt 2.

198 Low Oil Flow - Compressor A CMR Compressor Energized a. The differential oil pressure switch remained open for more than 20 contiguous seconds on Compressor A.

199 Low Oil Flow - Compressor B CMR Compressor Energized Same as diagnostic 198, but for Cprsr B.

19A Low Oil Flow - Compressor C CMR Compressor Energized Same as diagnostic 198, but for Cprsr C.

19b Low Oil Flow - Compressor D CMR Compressor Energized Same as diagnostic 198, but for Cprsr D.

19C Phase Loss Compressor A CMR Compressor Energized a. No current was sensed on one or moreof the current transformer inputs. (Musthold = 20% RLA. Must trip = 5% RLA.)Time to trip shall be I second minimumand 3 seconds maximum.

19d Phase Loss Compressor B CMR Same as 19C Same as diagnostics 19C

19E Phase Loss Compressor C CMR Same as 19C Same as diagnostics 19C

19F Phase Loss Compressor D CMR Same as 19C Same as diagnostics 19C

1A0 Power Loss Compressor A CAR All Running Modes a. The compressor was running and allthree phases of current were lost.

b. There was an open Transition inputafter transition had been previouslyproven to have been complete.

c. There was an incomplete Transition onthe first check after transition and allthree phases of current here notpresent.

1A1 Power Loss - Compressor B CAR Same as 1A0 Same as diagnostic 1A0.

1A2 Power Loss - Compressor C CAR Same as 1A0 Same as diagnostic 1A0.

1A3 Power Loss - Compressor D CAR Same as 1A0 Same as diagnostic 1A0.

114RTAA-IOM-3

Table 18Diagnostics and Troubleshooting Chart (Continued)

DIAG. ACTIVECODE DIAGNOSTIC DESCRIPTION TYPE MODES CAUSE

1A4 Remote Communications Loss IFW All AUTO/REMOTE Modes a. While the chiller switch was in theAUTO/REMOTE the communicationbetween the CSR and the connectedremote device, e.g. a Tracer orRemote Display, had either neverbeen established for more than 15minutes after power up or was lost formore than 15 minutes after it hadbeen established; use the Front PanelSetpoints and the Default Chiller Auto/Stop.

All AUTO/LOCAL and all b. In AUTO/LOCAL communications hadSTOP/RESET modes been established and was then lost for

more than 15 minutes. Regardless ofthe remote communication status theUCM uses Front Panel setpoints.

NOTE: The active modes for diagnostic 1A4 follows the positions of the chiller switch which account for other chiller codes.

1A5 Oil Flow Control - Compressor A CMR Pre-Stop a. At the time the 20 second Run:Unload time times out, the UCM willde-energize the oil line solenoid andset a 10+ or -1 second timer. As soonas the differential pressure switchopens (0.8 to 1.2 sec.) the compressorwill be de-energized and the sequenceended. If the differential pressureswitch does not open within 10seconds, the compressor shall be de-energized and a CMR diagnosticgenerated not permitting thecompressor to restart. Whenever thefan control pressure differential isbelow 70 PSID, or if a diagnosticshutdown occurs, the aboveshutdown test will not be executed.The above test will serve to check thedifferential pressure switch, the switchwiring to the UCM, and closure of theoil line solenoid.

1A6 Oil Flow Control - CMR Pre-Stop Same as diagnostic 1A5. Compressor B

1A7 Oil Flow Control - CMR Pre-Stop Same as diagnostic 1A5. Compressor C

1A8 Oil Flow Control - CMR Pre-Stop Same as diagnostic 1A5. Compressor D

1A9 EXV Electrical Drive Circuit CMR Pre-Start and On Demand a. Wiring between the EXV and the UCM(Rfgt. Circuit 1) is “Open”. Check the connector for

proper termination.b. EXV motor is faulty.c. EXV drive circuits on Module 1U3 are

faulty.

1AA EXV Electrical Drive Circuit CMR Pre-Start and On Demand Same as diagnostic 1A9.(Rfgt. Circuit 2)

NOTE: For similar diagnostics for the Slaved EXV Drive Circuits see Codes 1 db and 1 dC.

115 RTAA-IOM-3

Table 18Diagnostics and Troubleshooting Chart (Continued)

DIAG. ACTIVECODE DIAGNOSTIC DESCRIPTION TYPE MODES CAUSE

1Ad Memory Error Type I IFW UCM Power Up or a. On UCM power up or following aFollowing a Type II Type II Memory Error a NOVRAMMemory Error memory error was detected. The UCM

is operating on all Engineering ROMdefaults for all setup parameters.Check all I setup parameters andcontinue to run chiller. Replace theChiller Module as soon as areplacement is available.

1AE Low Diff. Pressure - Circuit 1 CMR Compressor Energized a. The fan control algorithm detected alow differential temperature/ pressurecondition that existed for more than180 contiguous seconds. The trip-point is 40 PSID.

1AF Low Diff. Pressure - Circuit 2 CMR Compressor Energized Same as diagnostic 1AE.

1b2 Severe Phase Unbalance - CMR All Running Modes a. A 30% Phase Unbalance diagnosticCompressor A has been detected. The 15% Phase

Unbalance criteria has been defeated.Items to check are the CurrentTransformer Part Numbers (theyshould all match), The CurrentTransformer resistances, line voltagephase balance, all power wiringconnections, the contactor pole faces,and the motor.

1b3 Severe Phase Unbalance - CMR All Running Modes Same as diagnostic 1b2.Compressor B

1b4 Severe Phase Unbalance - CMR All Running Modes Same as diagnostic 1b2.Compressor C

1b5 Severe Phase Unbalance - CMR All Running Modes Same as diagnostic 1b2.Compressor D

1b6 Overload Setting - IFW All a. The CPM NovRam Based overloadCompressor A setting did not agree with the MCSP

Dip Switch overload setting for 30contiguous seconds. The affectedMCSP shall use the minimum (00000binary, 00 decimal) overload setting asa default until the UCM is reset whenthis diagnostic occurs.

1b8 Overload Setting - IFW All Same as diagnostic 1b6.Compressor C

1b9 Overload Setting - IFW All Same as diagnostic 1b6.Compressor D

1bA Phase Unbalance - CMR All Running Modes a. A 15% phase unbalance has beenCompressor A detected. Menu Item “47” is enabled.

1bb Phase Unbalance - CMR All Running Modes Same as diagnostic 1bA.Compressor B

1bC Phase Unbalance - CMR All Running Modes Same as diagnostic 1bA.Compressor C

1bd Phase Unbalance - CMR All Running Modes Same as diagnostic 1bA.Compressor D

116RTAA-IOM-3

Table 18Diagnostics and Troubleshooting Chart (Continued)

DIAG. ACTIVECODE DIAGNOSTIC DESCRIPTION TYPE MODES CAUSE

1bE Winding Temp.- Compressor A CMR All a. The motor winding temperature thermostat opened; nominally 221 F.

b. The motor temperature thermostat or wiring is open.

c. Time to trip from input open to compressor shutdown shall be 0.5 to 2.0 seconds.

1bF Winding Temp.- Compressor B CMR All Same as diagnostic 1bE.

1C0 Winding Temp.- Compressor C CMR All Same as diagnostic 1bE.

1C1 Winding Temp.- Compressor D CMR All Same as diagnostic 1bE.

1C2 Discharge Temp.- Compressor A CMR All a. The discharge temperature exceeded the trip value of 275 F.

b. The discharge temperature PTC or wiring is open.Note: on units built in 1992 and later,the discharge temp sensor will not bepresent.

1C3 Discharge Temp. - Compressor B CMR All Same as diagnostic 1C2.

1C4 Discharge Temp. - Compressor C CMR All Same as diagnostic 1C2.

IC5 Discharge Temp. - Compressor D CMR All Same as diagnostic 1C2.

1C6 High Diff. Pressure - Circuit 1 CMR Compressor Energized a. The difference between the condenserpressure and the evaporator pressureexceeded 350 PSID for 0.8 to 5.0seconds. 320 PSID must hold, 320+ totrip for 1 hour.

1C7 High Diff. Pressure - Circuit 2 CMR Compressor Energized Same as diagnostic 1C6.

1d1 Memory Error Type II IFW All a. A Shadow RAM memory error wasdetected. The UCM is operating on alllast valid values (pulled fromNOVRAM) for all setup parameters.No setup parameter changes werepending to be loaded into NOVRAM, acomplete recovery of all setupparameters was made and there is noneed to check unit setup parameters.Compressor starts and hours were lostfor not more than the last 24 hours.This is expected to be an isolatedevent and repair or replacement is notrequired.

1d2 Memory Error Type III IFW All a. A Shadow RAM memory error wasdetected. The UCM is operating on alllast valid values (pulled fromNOVRAM) for all setup parameters.Setup parameter changes less than 24hours old pending to be loaded intoNOVRAM were lost. Check all setupparameters made in last 24 hours.Compressor starts and hours were lostfor not more than 24 hours. This isexpected to be an isolated event andrepair or replacement is not required.

117 RTAA-IOM-3

Table 18Diagnostics and Troubleshooting Chart (Continued)

DIAG. ACTIVECODE DIAGNOSTIC DESCRIPTION TYPE MODES CAUSE

1d3 Comp. Suction Temp. Sensor - CMR All a . Open or Short in sensor electricalCircuit 1 circuitry.

1d4 Comp. Suction Temp. Sensor - CMR All a. Open or Short in sensor electricalCircuit 2 circuitry.

1d7 Phase Reversal Protection Lost - CMR Compressor Energized to a. The phase reversal protectionCompressor A To Transition Command Compressor A has become

inoperative. The phase rotationprotection system failed to detect twoin a row of one of the four phasecircuit states; Phase reversal, PhaseRotation OK, Phase A lost, Phase Blost.

1d8 Phase Reversal Protection Lost - CMR Compressor Energized to Same as diagnostic 1d7.Compressor B Transition Command

1d9 Phase Reversal Protection Lost - CMR Compressor Energized to Same as diagnostic 1d7.Compressor C Transition Command

1dA Phase Reversal Protection Lost - CMR Compressor Energized to Same as diagnostic 1d7.Compressor D Transition Command

1db Slaved EXV Elec. Drive Circuit - CMR On Demand and a. Wiring between the EXV and the UCMRefrigerant Circuit I Pre-Start is “Open”. Check the

connector for proper termination.b. EXV motor is faulty.c. EXV drive circuits on Module 1U3 are

faulty

1dC Slaved EXV Elec. Drive Circuit CMR On Demand and Same as diagnostic 1db. Also refer toRefrigerant Circuit 2 Pre-Start diagnostics 1A9 and 1AA.

412 1U1 Indicating IFW All The 1U1 Module has detected a loss of1U2 Communications inter-processor communications from

the 1U2 Module.

413 1U1 Indicating MMR All The 1U1 Module has detected a loss of1U3 Communications inter-processor communications from

the 1U3 Module.

414 1U1 Indicating CMR All The 1U1 Module has detected a loss of1U4 Communications inter-processor communications from

the 1U4 Module.

415 1U1 Indicating CMR All The 1U1 Module has detected a loss of1U5 Communications inter-processor communications from

the 1U5 Module.

416 1U1 Indicating CMR All The 1U1 Module has detected a loss of1U6 Communications inter-processor communications from

the 1U6 Module.

417 1U1 Indicating CMR All The 1U1 Module has detected a loss of1U7 Communications inter-processor communications from

the 1U7 Module.

418 1U1 Indicating CMR All The 1U1 Module has detected a loss of1U8 Communications inter-processor communications from

the 1U8 Module.

431 1U3 Indicating MMR All The 1U3 Module has detected a loss of1U1 Communications inter-processor communications from

the 1U1 Module.

434 1U3 Indicating CMR All The 1U3 Module has detected a loss of1U4 communications inter-processor communications from

the 1U4 Module.

118RTAA-IOM-3

Table 18Diagnostics and Troubleshooting Chart (Continued)

DIAG. ACTIVECODE DIAGNOSTIC DESCRIPTION TYPE MODES CAUSE

435 1U3 Indicating CMR All The 1U3 Module has detected a loss of1U5 Communications inter-processor communications from

the 1U5 Module.

436 1U3 Indicating CMR All The 1U3 Module has detected a loss of1U6 Communications inter-processor communications from

the 1U6 Module.

437 1U3 Indicating CMR All The 1U3 Module has detected a loss of1U7 Communications. inter-processor communications from

.the 1U7 Module.

441 1U4 Indicating CMR All The 1U4 Module has detected a loss of1U1 Communications inter-processor communications from

the 1U1 Module.

443 1U4 Indicating CMR All The 1U4 Module has detected a loss of1U3 Communications inter-processor communications from

the 1U3 Module.

445 1U4 Indicating CMR All The 1U4 Module has detected a loss of1U5 Communications . inter-processor communications from

the 1U5 Module.

451 1U5 Indicating CMR All The 1U5 Module has detected a loss of1U1 Communications inter-processor communications from

the 1U1 Module.

453 1U5 Indicating CMR All The 1U5 Module has detected a loss of1U3 Communications inter-processor communications from

the 1U3 Module.

454 1U5 Indicating CMR All The 1U5 Module has detected a loss of1U4 Communications inter-processor communications from

the 1U4 Module.

461 1U6 Indicating CMR All The 1U6 Module has detected a loss of1U1 Communications inter-processor communications from

the 1U1 Module.

463 1U6 Indicating CMR All The 1U6 Module has detected a loss of1U3 Communications inter-processor communications from

the 1U3 Module.

467 1U6 Indicating CMR All The 1U6 Module has detected a loss of1U7 Communications inter-processor communications from

the 1U7 Module.

471 1U7 Indicating CMR All The 1U7 Module has detected a loss of1U1 Communications inter-processor communications from

the 1U1 Module.

473 1U7 Indicating CMR All The 1U7 Module has detected a loss of1U3 Communications inter-processor communications from

the 1U3 Module.

476 1U7 Indicating CMR All The 1U7 Module has detected a loss of1U6 Communications inter-processor communications from

the 1U6 Module.

119 RTAA-IOM-3

Table 18Diagnostics and Troubleshooting Chart (Continued)

DIAG. ACTIVECODE DIAGNOSTIC DESCRIPTION TYPE MODES CAUSE

481 1U8 Indicating MMR All The 1U8 Module has detected a loss of1U1 Communications inter-processor communications from

the 1U1 Module.

483 1U8 Indicating CMR* All The 1U8 Module has detected a loss of1U3 Communications inter-processor communications from

the 1U3 Module.

484 1U8 Indicating CMR All The 1U8 Module has detected a loss of1U4 Communications inter-processor communications from

the 1U4 Module.

485 1U8 Indicating CMR All The 1U8 Module has detected a loss of1U5 Communications inter-processor communications from

the 1U5 Module.

486 1U8 Indicating CMR All The 1U8 Module has detected a loss of1U6 Communications inter-processor communications from

the 1U6 Module.

487 1U8 Indicating CMR All The 1U8 Module has detected a Ioss of1U7 Communications inter-processor communications from

the 1U7 Module.

*In the event of this communication diagnostic, CMR(s) will be generated for the circuit(s) which are using the Slaved EXV(i.e. those circuits which are employing a parallel valve arrangement).

120RTAA-IOM-3

121 RTAA-IOM-3

Pre-StartCheckout

GeneralWhen installation is complete, but priorto putting the unit into service, thefollowing pre-start procedures must bereviewed and verified correct:

[ ] Inspect all wiring connections to besure they are clean and tight.

WARNING: Disconnect all electricpower including remotedisconnects before servicing’Failure to disconnect powerbefore servicing can cause severepersonal injury or death.

Caution: Check the tightness of allconnections in the compressorpower circuits (disconnects,terminal block, contactors,compressor junction box terminals,etc.). Loose connections can causeoverheating at the connections andundervoltage conditions at thecompressor motor.

[ ] Verify that all refrigerant valves, asshown in Figure 37, are “OPEN”.

Caution: Do not operate the unitwith the compressor, oil dischargeand liquid line service valves“CLOSED”. Failure to have these“OPEN” may cause seriouscompressor damage.

[ ] Check the power supply voltage tothe unit at the main power fuseddisconnect switch. Voltage must bewithin the voltage utilization range,given in Table 10 and also stampedon the unit nameplate. Voltageimbalance must not exceed 2percent. Refer to “Unit VoltageImbalance”, below.

WARNING: Disconnect all electricpower including remotedisconnects before servicing.Failure to disconnect powerbefore servicing can cause severepersonal injury or death.

[ ] Check the unit power phasing to besure that it has been installed in an“ABC” sequence. Refer to “UnitVoltage Phasing”, below.

WARNING: It is imperative thatL1 -L2-L3 in the starter beconnected in the A-B-C phasesequence to prevent equipmentdamage due to reverse rotation.

[ ] Check the condenser fans to be surethat they rotate freely in the fanopenings and that each is securelyattached to its fan motor shaft.

WARNING: Disconnect all electricpower Including remotedisconnects before servicing.Failure to disconnect powerbefore servicing can cause severepersonal injury or death.

[ ] Energize the compressor sumpheaters by closing the unit maindisconnects. If unit-mounteddisconnects are used, they mustalso be closed. If the unit does nothave the optional control powertransformer, 115 VAC power mustbe field supplied to terminals 1TB3-1AND 1TB3-2. The Chiller Switchmust be in the STOP/RESETposition.

Caution: The compressor sumpheaters must be energized for aminimum of 24 hours prior to unitoperation, to prevent compressordamage caused by liquidrefrigerant in the compressor atstart-up.

122RTAA-IOM-3

[ ] Energize the evaporator andDomestic Water Heater heat tape.

[ ] Fill the evaporator chilled watercircuit. Refer to Table 1 forevaporator liquid capacities. Ventthe system while it is being filled.Open the vent on the top of theevaporator during filling and closewhen filling is completed.

Customer Note

The use of improperly treated oruntreated water in this equipment mayresult in scaling, erosion, corrosion,algae or slime. The services of aqualified water treatment specialistshould be engaged to determine whattreatment, if any, is advisable. TheTrane Company warranty specificallyexcludes liability for corrosion, erosionor deterioration of Trane equipment.Trane assumes no responsibilities forthe results of the use of untreated orimproperly treated water, or saline orbrackish water.

Caution: Do not used untreated orimproperly treated water.Equipment damage may occur.

Caution: Do not fill the watersystems unless the evaporator andDomestic Water Heater heat tapeshave been energized.

[ ] Close the fused-disconnectswitch(es) that supplies power tothe chilled water pump starter.

[ ] Start the chilled water pump tobegin circulation of the chilled water.Inspect all piping for leakage andmake any necessary repairs.

[ ] With chilled water circulatingthrough the system, adjust waterflow and check water pressure dropthrough the evaporator. Refer toFigure 23.

[ ] Adjust the chilled water flow switch(if installed) for proper operation.

[ ] Prove Chilled Water Pump Interlockand External Auto/Stop as describedin Interconnecting Wiring: ChilledWater Pump Interlock and ExternalAuto/Stop.

Caution: Chilled Water PumpInterlock and External Auto/Stopinformation must be adhered to orequipment damage may occur.

[ ] Check and set, as required, all UCMMenu items.

[ ] Stop the chilled water pump.

Unit VoltagePower SupplyVoltage to the unit must meet thecriteria given in Table 10. Measure eachleg of the supply voltage at the unitmain power fused-disconnect. If themeasured voltage on any leg is notwithin specified range, notify thesupplier of the power and correct thesituation before operating the unit.

Caution: Inadequate voltage to theunit can cause control componentsto malfunction and shorten the lifeof relay contact, compressormotors and contactors.

Unit Voltage ImbalanceExcessive voltage imbalance betweenthe phases of a three-phase system cancause Motors to overheat andeventually fail. The maximumallowable imbalance is 2 percent.Voltage imbalance is determined usingthe following calculations:

% Imbalance = (Vx - Vave) x 100

VaveVave = (V1 + V2 + V3) / 3

Vx = phase with greatest differencefrom Vave (without regard to sign)

For example, if the three measuredvoltages are 221, 230, and 227 volts, theaverage would be:

221 +230 +227 = 2263

The percentage of imbalance is then:

100 (221 - 226) = 2.2%226

This exceeds the maximum allowable(2%) by 0.2 percent.

123 RTAA-IOM-3

Unit Voltage PhasingIt is important that proper rotation ofthe compressors be established beforethe unit is started. Proper motorrotation requires confirmation of theelectrical phase sequence of the powersupply. The motor is internallyconnected for clockwise rotation withthe incoming power supply phasedA, B, C.

Basically, voltages generated in eachphase of a polyphase alternator orcircuit are called phase voltages. In athree-phase circuit, three sine wavevoltages are generated, differing inphase by 120 electrical degrees. Theorder in which the three voltages of athree-phase system succeed oneanother is called phase sequence orphase rotation. This is determined bythe direction of rotation of thealternator. When rotation is clockwisephase sequence is usually called“‘ABC”, when counterclockwise,“CBA”.

This direction may be reversed outsidethe alternator by interchanging any twoof the line wires. It is this possibleinterchange of wiring that makes aphase sequence indicator necessary ifthe operator is to quickly determine thephase rotation of the motor.

Proper compressor motor electricalphasing can be quickly determined andcorrected before starting the unit. Use aquality instrument, such as theAssociated Research Model 45 PhaseSequence Indicator shown in Figure 55,and follow this procedure.

WARNINGIT IS IMPERATIVE THAT L1-L2-L3IN THE STARTER BECONNECTED IN THE A-B-CPHASE SEQUENCE TO PREVENTEQUIPMENT DAMAGE DUE TOREVERSE ROTATION.

Figure 55Associated Research Model 45Phase Sequence Indicator

124RTAA-IOM-3

1. Turn the Chiller Switch on the UCMto the STOP/RESET position.

2. Open the electrical disconnect orcircuit protection switch thatprovides line power to the line powerterminal block(s) in the starter panel(or to the unit-mounted disconnect).

3. Connect the phase sequenceindicator leads to the line powerterminal block, as follows:

Phase Seq. Lead Terminal

Black (Phase A) ..................L1Red (Phase B) ....................L2Yellow (Phase C) ................L3

4. Turn power on by closing the unitsupply power fused- disconnectswitch.

5. Read the phase sequence on theindicator. The “ABC” LED on the faceof the phase indicator will glow ifphase is “ABC”.

WARNING: To prevent injury ordeath due to electrocution, takeextreme care when performingservice procedures with electricalpower energized.

6. If the “CBA” indicator glows instead,open the unit main power disconnectand switch two line leads on the linepower terminal block(s) (or the unitmounted disconnect). Reclose themain power disconnect and recheckthe phasing.

Caution: Do not interchange anyload leads that are from the unitcontactors or the motor terminals.

7. Reopen the unit disconnect anddisconnect the phase indicator.

Water SystemFlow RatesEstablish a balanced chilled water flowthrough the evaporator. The flow ratesshould fall between the minimum andmaximum values given in Table 1.Chilled water flow rates below theminimum values will result in laminarflow, which reduces heat transfer andcauses either loss of EXV control orrepeated nuisance, low temperaturecutouts. Flow rates that are too highcan cause tube erosion and damage tothe tube supports and baffles in theevaporator.

Caution: Once the evaporator andDomestic Water Heater (optional)are filled with water, the heat tapesmust be energized to protect theevaporator from freezing andbursting if the outdoor airtemperature drops below freezing.

Water SystemPressure DropMeasure chilled water pressure dropthrough the evaporator at the field-installed pressure taps on the systemwater piping. See Figure 22. Use thesame gauge for each measurement. Donot include valves, strainers fittings inthe pressure drop readings.

Measure the water pressure dropthrough the Domestic Water Heater atthe field installed vent and drainconnections. See Figure 24. Use thesame gauge for each measurement. Donot include valves, strainers, fittings inpressure drop readings.

Pressure drop readings should beapproximately those shown in thePressure Drop Charts, Figure 23 for theevaporator and Figure 25 for theDomestic Water Heater (optional).

UCM Set-upRefer to “Menu Function Descriptionsand Selection” for instruction on theset-up of the UCM.

125 RTAA-IOM-3

Start-UpProcedures

GeneralIf the pre-start checkout, as discussedabove, has been completed, the unit isready to start. UCM controls are shownin Figure 51 and UCM Sequence ofOperation is shown in Figures 56and 57. Complete each step, insequence, as follows:

[ ] Move the Chiller Switch on the UCMto the STOP/RESET position.

[ ] As necessary, adjust the setpointvalues in the UCM menus, asdescribed in “Menu FunctionDescriptions and Selections”.

[ ] Close the fused-disconnect switchfor the chilled water pump. Energizethe pump to start chilled watercirculation.

[ ] Check the service valves on thedischarge line, suction line, oil lineand liquid line for each circuit. Thesevalves must be open (backseated)before starting the compressors.

Caution: To prevent compressordamage, do not operate the unituntil all refrigerant and oil lineservice valves are opened.

[ ] Energize the compressor sumpheaters, if not already energized.Also close the unit-mounteddisconnect, if used.

Caution: The compressor sumpheaters must be energized for aminimum of 24 hours prior to unitoperation, to prevent compressordamage caused by liquidrefrigerant in the compressor atstart-up.

[ ] Verify that the evaporator heat tapeis energized.

[ ] Verify that the chilled water pumpruns for one minute after the chilleris commanded to stop (for normalchilled water systems). See page

[ ] Move the Chiller Switch to AUTOLOCAL. If the chiller control 1 U 1calls for cooling and all safetyinterlocks are closed, the unit willstart. The compressor(s) will loadand unload in response to thetemperature of the leaving chilledwater temperature.

If optional low-ambient is installed,outside air temperature must beabove the minimum startingambients, as shown in Table 1, forcontinued unit operation. Use Table1 to determine proper setpoints forthe optional low ambient lockoutsetpoint, if used. Also refer to thewiring diagrams in Figures 34thru 36.

Once the system has been operatingfor approximately 30 minutes and hasbecome stabilized, complete the start-up procedures, as follows:

[ ] Check the evaporator refrigerantpressure (23) and the condenserrefrigerant pressure (25) in Menu 2on the UCM. The pressures arereferenced to sea level (14.6960psia)

[ ] Check the liquid line sight glasses.The refrigerant flow past the sightglasses should be clear. Bubbles inthe refrigerant indicate either lowrefrigerant charge or excessivepressure drop in the liquid line. Arestriction in the line can sometimesbe identified by a noticeabletemperature differential betweenthe two sides of the restriction. Frostmay often form on the line at thispoint. Proper refrigerant charges areshown in Table 1.

Caution: A clear sight glass alonedoes not mean that the system isproperly charged. Also checksystem superheat, subcooling, andunit operating pressures.

[ ] Measure the system superheat.Refer to “System Superheat, below.

[ ] Measure the system subcooling.Refer to “System Subcooling”,below.

[ ] A shortage of refrigerant is indicatedif operating pressures are low andsubcooling is also low. If theoperating pressures, sight glass,superheat and subcooling readingsindicate a refrigerant shortage, gas-charge refrigerant into each circuit,as required. With the unit running,add refrigerant vapor by connectingthe charging line to the suctionservice valve and charging throughthe backseat port until operatingconditions become normal.

Caution: If both suction anddischarge pressures are low butsubcooling is normal, a problemother than refrigerant shortageexists. Do not add refrigerant, asthis may result in overcharging thecircuit.

Caution: Use only refrigerantsspecified on the unit nameplate, toprevent compressor damage andinsure full system capacity.

[ ] If operating conditions indicate arefrigerant overcharge, removerefrigerant at the liquid line servicevalve. Allow refrigerant to escapeslowly, to minimize oil loss. Do notdischarge refrigerant into theatmosphere.

WARNING: Do not allowrefrigerant to directly contactskin or injury from frostbite mayresult.

System SuperheatNormal superheat for each circuit isapproximately 8 F at full operatingload. Superheat temperature can beexpected to be moving around the 8 Fsetpoint when the chiller is pullingdown, the compressor slide valve isbeing modulated, or the fans arestaging on either the same or oppositecircuits. Superheat can be expected tosettle out at approximately 8 F whenthe above items stabilize.

System SubcoolingNormal subcooling for each circuitranges from 11 F to 20 F, depending onthe unit. If subcooling for either circuitdoes not approximate these figures,check the superheat for the circuit andadjust, if required. If superheat isnormal but subcooling is not, contact aqualified service technician.

126R

TAA

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Figure 56Unit Sequence of Operation – RTAA 240 to 400 Tons

(Co

ntin

ued

on

Next P

ag

e)

127 RTAA-IOM-3

(Continued from Previous Page)

2307-1

566C

128R

TAA

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Figure 57Unit Sequence of Operation – RTAA 130 to 200 Tons

2306-9122A

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Unit ShutdownProcedures

Temporary Shutdownand RestartTo shut the unit down for a short time,use the following procedure:

1. Move the Chiller Switch to STOP/RESET. The compressors willcontinue to operate and, afterunloading for 20 seconds, will stopwhen the compressor contactors de-energize. The condenser fans will bede-energized at this time.

2. The unit disconnect switch and unitmounted disconnect (if installed)should remain closed to keep thecompressor sump heaters energized.

3. Maintain power to keep theevaporator and Domestic WaterHeater heat tape(s) energized.

4. Stop the chilled water circulation byturning off the chilled water pump.

To restart the unit after a temporaryshutdown, restart the chilled waterpump and move the Chiller Switch toeither of the AUTO positions. The unitwill start normally, provided thefollowing conditions exist:

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

2. All system operating interlocks andsafety circuits must be satisfied.

Extended ShutdownProcedureThe following procedure is to befollowed if the system is to be taken outof service for an extended period oftime, e.g. seasonal shutdown:

1. Test the condenser and high-sidepiping for refrigerant leakage.

2. Open the electrical disconnectswitches for the chilled water pump.Lock the switch in the “OPEN”position.

Caution: Lock the chilled waterpump disconnect open to preventpump damage.

3. Close all chilled water supply valves.Drain the chilled water from theevaporator. If the unit will beexposed to freezing ambientconditions, flush the evaporator withan antifreeze solution and energizethe evaporator heat tape.

Caution: To prevent damage to theevaporator by freezing, flush theevaporator with an antifreezesolution and energize theevaporator heat tape.

4. Drain the Domestic Water Heater andany exposed system piping toprevent the possibility of freeze-up.Use the pressure tap on the wateroutlet to force compressed airthrough the water coils of the unitand assure that no water blocks anyof the tubes. Be certain that the drainvalve on the water inlet is openbefore applying compressed air tothe water coils. Energize theDomestic Water Heater heat tape.

Caution: To prevent damage to theDomestic Water Heater byfreezing, blow out water from coilsand energize the Domestic WaterHeater heat tape.

5. Open the unit main electricaldisconnect and unit-mounteddisconnect (if installed) and lock onthe “OPEN” position. If optionalcontrol power transformer is notinstalled, open and lock the 115 Vdisconnect.

Caution: Lock the disconnects onthe “OPEN” position to preventaccidental start-up and damage tothe system when it has been setupfor extended shutdown.

6. At least every three months(quarterly), check the pressure in theunit to verify that the refrigerantcharge is intact.

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System Restart AfterExtended Shutdown.Follow the procedures below to restartthe unit after extended shutdown:

1. Verify that the liquid line servicevalves, oil line, compressordischarge service valves and suctionservice valves (if installed) are open(backseated).

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

2. Close the main disconnect and unitmounted disconnect (if installed) toenergize the compressor sumpheaters. If the optional controltransformer is not installed, it will benecessary to close the disconnect for115 VAC power to 1TB3-1 and1TB3-2.

Caution: The compressor sumpheaters must be energized for aminimum of 24 hours prior to unitoperation, to prevent compressordamage caused by liquidrefrigerant in the compressor atstart-up.

3. Maintain power to the evaporatorheat tape connections.

4. Check the oil separator oil level. See“Oil Separator Level Check”.

5. Fill the evaporator chilled watercircuit. Refer to Table I for evaporatorliquid capacities. Vent the systemwhile it is being filled. Open the venton the top of the evaporator duringfilling and close when filling iscompleted.

Caution: Do not use untreated orimproperly treated water.Equipment damage may occur.

6. Close the fused-disconnect switchthat provides power to the chilledwater pump.

7. Start the chilled water pump and,while chilled water is circulating,inspect all piping for leakage. Makeany necessary repairs before startingthe unit.

8. While the chilled water is circulating,adjust the chilled water flow andcheck the chilled water pressure dropthrough the evaporator. Refer to“Water System Flow Rates” and“Water System Pressure Drop”.

9. Adjust the flow switch on theevaporator piping (if installed) forproper operation.

10. Stop the chilled water pump. Theunit is now ready for start-up asdescribed in “Start-Up Procedures”.

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PeriodicMaintenance

GeneralPerform all maintenance proceduresand inspections at the recommendedintervals. This will prolong the life ofthe equipment and minimize thepossibility of costly failures.

Use an “Operator’s Log”, such as thatshown in Figure 58, to record anoperating history for the unit. The logserves as a valuable diagnostic tool forservice personnel. By observing trendsin operating conditions, an operatorcan anticipate and prevent problemsituations before they occur.

If the unit does not operate properlyduring maintenance inspections, referto “Diagnostics and Troubleshooting”.

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Figure 58Operator’s Log

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Refrigerant EmissionControlEvidence from environmental scientistsindicates that the ozone in our upperatmosphere is being reduced, due tothe release of CFC fully halogenatedcompounds.

The Trane Company encourages everyeffort to eliminate, if possible, orvigorously reduce the emission of CFC,HCFC and HFC refrigerants into theatmosphere that result frominstallation, operation, routinemaintenance, or major services on thisequipment. Always act in a responsiblemanner to conserve refrigerants forcontinued use, even when acceptablealternatives are available.

Conservation and emission reductioncan be accomplished by followingrecommended Trane operation,maintenance and service procedures,with specific attention to the following:

1. Refrigerant used in any type of airconditioning or refrigeratingequipment should be recovered forreuse, recovered and/or recycled forreuse, reprocessed (reclaimed), orproperly destroyed, whenever it isremoved from equipment. Neverrelease refrigerant into theatmosphere.

2. Always determine possible recycle orreclaim requirements of therecovered refrigerant beforebeginning recovery by any method.Questions about recoveredrefrigerants and acceptablerefrigerant quality standards areaddressed in ARI Standard 700.

3. Use approved containment vesselsand safety standards. Comply withall applicable transportationstandards when shipping refrigerantcontainers.

4. To minimize emissions whilerecovering refrigerant, use recyclingequipment. Always attempt to usemethods which will pull the lowestpossible vacuum while recoveringand condensing refrigerant intocontainment.

5. When leak checking with tracerefrigerant and nitrogen, use HCFC-22 (R-22), rather than CFC-12 (R-12)or any other fully halogenatedrefrigerants. Be aware of any newleak test methods which eliminaterefrigerant as a trace gas.

6. When cleaning system componentsor parts, avoid using CFC-11 (R-11) orCFC-113 (R-113). Refrigerationsystem

cleanup methods which use filters anddryers are preferred. Do not usesolvents which have ozone depletionfactors. Properly dispose of usedmaterials.

7. Take extra care to properly maintainall service equipment that directlysupports refrigeration service work,such as gauges, hoses, vacuumpumps and recycling equipment.

8. Stay aware of unit enhancements,conversion refrigerants, compatibleparts and manufacturer’srecommendations which will reducerefrigerant emissions and increaseequipment operating efficiencies.Follow manufacturer’s specificguidelines for conversion of existingsystems.

9. In order to assist in reducing powergeneration emissions, alwaysattempt to improve equipmentperformance with improvedmaintenance and operations that willhelp conserve energy resources.

Weekly MaintenanceAfter the unit has been operating forapproximately 30 minutes and thesystem has stabilized, check theoperating conditions and complete theprocedures below:

[ ] Check the evaporator refrigerantpressure (23) and the condenserrefrigerant pressure (25) in Menu 2on the UCM. The pressures arereferenced to sea level (114.6960psia).

[ ] Check the liquid line sight glasses.The refrigerant flow past the sightglasses should be clear. Bubbles inthe refrigerant indicate either lowrefrigerant charge or excessivepressure drop in the liquid line. Arestriction in the line can sometimesbe identified by a noticeabletemperature differential betweenthe two sides of the restriction. Frostmay often form on the line at thispoint. Proper refrigerant charges areshown on Table 1.

Caution: A clear sight glass alonedoes not mean that the systemproperly charged. Also checksystem superheat, subcooling, andunit operating pressures.

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[ ] If operating pressures and sightglass conditions seem to indicaterefrigerant shortage, measure thesystem superheat and systemsubcooling. Refer to “SystemSuperheat” and “SystemSubcooling”.

[ ] If operating conditions indicate arefrigerant overcharge, removerefrigerant at the liquid line servicevalve. Allow refrigerant to escapeslowly, to minimize oil loss. Do notdischarge refrigerant into theatmosphere.

WARNING: Do not allowrefrigerant to directly contactskin or injury from frostbite mayresult.

[ ] Inspect the entire system forunusual conditions and inspect thecondenser coils for dirt and debris. Ifthe coils are dirty, refer to “CoilCleaning”.

Monthly Maintenance[ ] Perform all weekly maintenance

procedures.

[ ] Measure and record the systemsuperheat. Refer to “SystemSuperheat”.

[ ] Measure and record the systemsubcooling. Refer to “SystemSubcooling”.

[ ] Manually rotate condenser fans toinsure proper clearance on the fanopenings.

WARNING: Position all electricaldisconnects in the “OPEN”position and lock them, toprevent injury or death due toelectrical shock.

Annual Maintenance[ ] Perform all weekly and monthly

maintenance procedures.

[ ] Check the oil level and refrigerantcharge. Refer to “MaintenanceProcedures”.

[ ] Have a qualified laboratory performa compressor oil analysis todetermine system moisture contentand acid level. This analysis is avaluable diagnostic tool.

[ ] Contact a qualified serviceorganization to leak test the chiller,to check operating and safetycontrols, and to inspect electricalcomponents for deficiencies.

[ ] Inspect all piping components forleakage and damage. Clean out anyinline strainers.

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

[ ] Clean the condenser coils. Refer to“Coil Cleaning”.

[ ] Clean the Domestic Water Heater.Refer to Domestic Water Heater tubecleaning procedure.

WARNING: Position all electricaldisconnects in the “OPEN”position and lock them, toprevent injury or death due toelectrical shock.

[ ] Clean the condenser fans. Check thefan assemblies for proper clearancein the fan openings and for motorshaft misalignment, abnormalendplay, vibration and noise.

WARNING: Position all electricaldisconnects in the “OPEN”position and lock them, toprevent injury or death due toelectrical shock.

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Maintenance

GeneralThis section describes specificmaintenance procedures which mustbe performed as a part of the normalmaintenance program for this unit. Becertain that electrical power to the unitis disconnected before performingthese procedures.

WARNING: Position all electricaldisconnects in the “OPEN”position and lock them, toprevent injury or death due toelectrical shock.

Coil CleaningClean the condenser coils at least onceeach year, or more frequently if the unitis located in a “dirty” environment.This will maintain proper unit operatingefficiencies. Follow the detergentmanufacturer’s instructions as closelyas possible to avoid damage to thecoils.

To clean the coils, use a soft brush anda sprayer, either the garden, pump-uptype or a high-pressure type. A high-quality detergent, such as “Trane CoilCleaner, CHM-0002” is recommendedfor both standard and “Blue-Fin” coils.

Note: If the detergent mixture isstrongly alkaline (pH value greater than8.5), an inhibitor must be added.

Chemically CleaningThe EvaporatorThe chilled water system is a closed-loop and therefore should notaccumulate scale or sludge. If thechiller becomes fouled, first attempt todislodge the material by backflushingthe system. If unsuccessful after severalattempts, chemically clean theevaporator.

Caution: Do not use an acid typecleaning agent that will damagesteel, galvanized steel,polypropylene, or internal coppercomponents.

With this information, water treatmentfirms will be able to recommend asuitable chemical for use in thissystem.

A typical configuration for chemicalcleaning is shown in Figure 59. Thesupplier of the cleaning chemicals mustprovide or approve:

All of the materials used in thisconfiguration

The amount of chemicals used

The length of time the chemicals areused

Any safety precautions andhandling instructions

Domestic WaterHeater – Tube CleaningThe water tubes may be mechanicallycleaned with a wire brush. This can bedone by isolating the water supply tothe Domestic Water Heater, relievingthe water pressure, and removing theaccess plugs at the rear of the unit.Once the tubes have been brushed andscale has been loosened, flush thewater tubes with fresh water, reinstallthe access plugs and return to service.The circulator should be shut off duringthis operation and all air must be bledfrom the water circuit when returningthe unit to operation. Be certain to usean approved pipe sealant on thethreaded access plugs whenreinstalling to prevent water leaks.

Figure 59Chemical Cleaning Configuration

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Water TreatmentThe use of untreated or improperlytreated water in the unit may result inthe formation of scale, algae, or slime.It may also cause erosion or corrosion.It is recommended that a qualifiedwater treatment specialist providerecommendations for proper watertreatment. The Trane Companyassumes no responsibility forequipment failure caused by the use ofuntreated or improperly treated water.

Oil Separator LevelCheckFollow the steps listed below and referto the notes listed in Figure 60.

1. Turn off the unit,

2. Attach the hoses and sight glass tothe oil separator charging Schradervalve and the compressor dischargeline Schrader valve, as shown inFigure 60. Purge to remove non-condensibles.

It is advisable to use Schraderquickcoupler isolation valves at theends of the hoses. These will aid inthe installation and removal of thehoses and minimize oil andrefrigerant spray.

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

4. After the level has been determined,remove the sight glass and hoses.

Note: Routine changing of the oil orthe oil filter is not recommended. Theoil filter is oversized for this applicationand should not require replacement.

The oil and filter should be replacedonly if analysis reveals that the oil iscontaminated. Oil type and systemcapacities are shown in Table 1.

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Figure 60System Oil Level Specifications

Caution: Do not check oil level withmachine operating. Severe oil losswill occur.

Caution: When checking oil levelwear protective clothing since oilwill spray when discharged.

Insure that the apex of the line abovethe sight glass is as high as possible, toeliminate liquid traps which can giveerroneous readings.

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UNIT OPERATING STATUS COMPRESSOR OPERATING STATUSCODE DESCRIPTION CODE DESCRIPTIONBlank UCM Power Off 00 Compressor Stop888888.8 UCM Paw Up 16 Compressor Lockout00 Unit Stop 17 Cprsr Service Pumpdown01 Auto-Local 70 Cprsr Restart Inhibit02 Auto-Remote 72 Cprsr Start17 Service Pumpdown 74 Run Normal70 Unit Restart Inhibit 75 Run:Current Limit72 Unit Start 76 Run: Condenser Limit74 Run:Normal 1 77 Run:Evaporator Limit75 Run :Current Limit 7E Run:Unload78 Run ;Condenser Limit77 Run:Evaporator Limit7E Run:Unload88 Reset DIAGNOSTIC TYPES100 External Unit Stop101 Ice Building Complete MMR Machine Shutdown-Manual Reset118 EXV Test CMR Circuit Shutdown-Man Reset174 Ice Building; Normal MAR Machine Shutdown-Auto Reset175 Ice Building: Current Limit CAR Circuit Shutdown-Auto Reset176 Ice Building: Condenser Limit IFW Informational-Warning177 Ice Building: Evaporator Limit200 Low Ambient Run Inhibit

UNIT DIAGNOSTICS CONDITIONFLASHING DISPLAY: MEANS:A xxx A New CMR, CAR. or IFW Diagnostic Exists.A xxx ↔ C yyy Operating Code when MMR or MAR occurred. Diagnostic currently inhibiting operation.b yyy Manual reset required to restore full operation. This or other latching diagnostics exist.C yyy Condition creating MAR, CAR or IFW still exists. If MMR or CMR, manual reset required.10 uu The chilled water setpoint is too close to a cutout setpoint.DASHES: MEANS:d ---- The chiller is in either Ice bldg or ice bldg compl: Ivg chld wtr stpt is not applicable.33 ---- The chiller is in normal cooling; the active ice termination setpoint is not applicable.Other (e.g. 14----) Option either not installed or not enabled.CODE DESCRIPTION TYPE CODE DESCRIPTION TYPE87 Chock External Chilled Water Stpt IFW 19F Phase Loss - Cprsr D CMR89 Check External Current Limit Stpt IFW 1AO Power Loss - Cprsr A CAR8A Chilled Water Flow (Ent Wtr Temp) MMR 1A1 Power Loss - Cprsr 8 CAR8E Evap Entering Water Temp Sensor MMR 1A2 Power Loss - Cprsr C CAR8F Cond Rfgt Tamp Sensor - Ckt I CMR 1A3 Power Loss - Cprsr D CAR90 Cond Rfgt Temp Sensor - Ckt 2 CMR 1A4 Remote communications Loss IFW93 Evap Rfgt Temp Sensor - Ckt I CMR 1A5 Oil Flow Control - Cprsr A CMR94 Evap Rfgt Tamp Sensor - Ckt 2 CMR 1A6 Oil Flow Control - Cprsr B CMRA0 Zone Temp Sensor IFW 1A7 Oil Flow Control - Cprsr C CMRA1 Outdoor Air Temp Sensor IFW 1A8 Oil Flow Control - Cprsr D CMRAb Evap Leaving Wtr Temp Sensor MMR 1A9 EXV Elec Drive Ckt - Rfgt Ckt I CMRbA Overload Trip - Cprsr A CMR 1AA EXV Elec Drive Ckt - Rfgt Ckt 2 CMRbb Overload Trip - Cprsr 0 CMR 1Ad Memory Error Type I (See Oper Manual) IFWbC Overload Trip - Cprsr C CMR 1AE Low Differential Press - Ckt I CMRbd Overload Trip - Cprsr D CMR 1AF Low Differential Press - Ckt 2 CMRbE High Pressure Cutout - Cprsr C CMR 1b2 Severe Phase Unbalance - Cprsr A CMRbF High Pressure Cutout - Cprsr D CMR 1b3 Severe Phase Unbalance - Cprsr B CMRC5 Low Chilled Water Temp ( U n I t off) IFW 1b4 Severe Phase Unbalance - Cprsr C CMRC6 Low Chilled Water Temp (Unit on) MAR 1b5 Severs Phase Unbalance - Cprsr 0 CMRCA Contactor - Cprsr A MMR 1b6 Compressor Overload Setting - Cprsr A IFWCb Contactor - Cprsr B MMIR 1b7 Compressor Over load Setting - Cprsr B IFWcc Contactor - Cprsr C MMR 1b8 Compressor Overload Setting - Cprsr C IFWCd Contactor - Cprsr D MMR 1b9 Compressor Overload Setting - Cprsr D IFWd7 Over Voltage MAR 1bA Phase Unbalance - Cprsr A CMRd8 Under Voltage MAR 1bb Phase Unbalance - Cprsr 8 CMREd Chilled Water Flow Interlock MAR 1bC Phase Unbalance - Cprsr C CMRF5 High Pressure Cutout - Cprsr A CMR 1bd Phase Unbalance - Cprsr D CMRF6 High Pressure Cutout - Cprsr B CMR 1bE Winding Temp. - Cprsr A CMRFd Emergency Stop Input MMR 1bF Winding Temp. - Cprsr B CMR180 Starter Transition - Cprsr A CMR 1C0 Winding Temp. - Cprsr C CMR181 Starter Transition - Cprsr B CMR 1C1 Winding Temp. - Cprsr D CMR182 Starter Transition - Cprsr C CMR 1C2 Discharge Temp. - Cprsr A CMR183 Starter Transition - Cprsr D CMR 1C3 Discharge Temp. - Cprsr 8 CMR184 Phase Reversal - Cprsr A CMR 1C4 Discharge Temp. - Cprsr C CMR185 Phase Reversal - Cprsr 8 CMR 1C5 Discharge Temp. - Cprsr D CMR186 Phase Reversal - Cprsr C CMR 1C6 High Differential Pressure - Ckt I CMR187 Phase Reversal - Cprsr D CMR 1C7 High Differential Pressure - Ckt 2 CMR190 Low Superheat - Ckt I CMR 1d1 Memory Error Type II (See Oper Manual) IFW191 Low Superheat - Ckt 2 CMR 1d2 Memory Error Type III (See Oper Manual) IFW194 Low Evap Rfgt Tamp - Ckt I CMR 1d3 Cprsr Suction Temp. Sensor - Ckt 1 CMR195 Low Evap Rfgt Temp - Ckt 2 CMR 1d4 Cprsr Suction Temp. Sensor - Ckt 2 CMR198 Low Oil I Flow - Cprsr A CMR 1d7 Phase Reversal Prot. Lost - Cprsr A CMR199 Low 01 1 Flow - Cprsr B CMR 1d8 Phase Reversal Prot. Lost - Cprsr B CMR19A Low Oil Flow - Cprsr C CMR 1d9 Phase Reversal Prot. Lost - Cprsr C CMR19b Low Oil Flow - Cprsr D CMR 1dA Phase Reversal Prot. Lost - Cprsr D CMR19C Phase Loss - Cprsr A CMR 1db Slave-Exv Elec Drive Ckt - Rfgt Ckt 1 CMR19d Phase Lose - Cprsr B CMR 1dc Slave-Exv Elec Drive Ckt - Rfgt Ckt 2 CMR19E Phase Loss - Cprsr C CMR 4xy See Operator’s Manual – – –

X3956048201 Rev. B

Condition Codes

For further information on this product or other Trane products, refer to the “Trane Service LiteratureCatalog,” ordering number IDX-IOM-1. This catalog contains listings and prices for all service literaturesold by Trane. The catalog may be ordered by sending a $15.00 check to:The Trane Company, Service Literature Sales, 3600 Pammel Creek Road, La Crosse, WI 54601.

To help ensure optimum performance, be sure to specify quality Trane parts.

Printed by Production Services – La Crosse

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