Options Guide. Air-cooled Liquid Chillers with Screw compressors. Models RTAC 120 to 400 RLC-PRB030-E4

Transcription

1 Options Guide Air-cooled Liquid Chillers with Screw compressors Models RTAC 120 to 400 MAY

2 Table Of Contents 1. RANGE OVERVIEW RTAC RANGE OPERATING MAP STANDARD EFFICIENCY HIGH AND XTRA EFFICIENCY WATER PIPE CONNECTION FOR STANDARD UNITS COMPONENTS IN ELECTRICAL PANEL FOR STANDARD UNITS PHASE PHASE COMPARISON FOR PHASE 1 UNITS AND PHASE 2 UNITS PHASE PHASE FREEZE PROTECTION DIGIT WITH FREEZE PROTECTION DIGIT 15 = F OR G WITHOUT FREEZE PROTECTION DIGIT 15 = C OR L OIL COOLER EVAPORATOR INSULATION DIGIT WITH THERMAL INSULATION DIGIT 16 = X WITHOUT THERMAL INSULATION DIGIT 16 = EXTRA PASS SPECIFIC TUBES FOR BRINE APPLICATIONS CONDENSER TEMPERATURE RANGE DIGIT STANDARD DIGIT 17 = N HIGH AMBIENT DIGIT 17 = H LOW AMBIENT DIGIT 17 = L WIDE AMBIENT DIGIT 17 = W SUMMARY CONDENSER FIN MATERIAL DIGIT STANDARD ALUMINUM SLIT FINS DIGIT 18 = X COPPER SLIT FINS DIGIT 18 = BLACK EPOXY FINS DIGIT 18 = CONDENSER FAN MOTOR CONFIGURATION DIGIT LOW NOISE DIGIT 19 = L COMPARISON BETWEEN STANDARD NOISE AND LOW NOISE UNITS NIGHT NOISE SETBACK DIGIT 19 = Q PA HIGH PRESSURE DROP DIGIT 19 = P STARTER TYPE DIGIT ACROSS THE LINE STARTER/DIRECT ON LINE DIGIT 20= X SOLID STATE SOFT STARTER STAR DELTA STARTER DIGIT 20 = Y MORE DETAIL POWER LINE CONNECTION TYPE DIGIT TERMINAL BLOCK WITH FUSES DIGIT 22 = X DISCONNECT SWITCH WITH FUSES DIGIT 22 = B

3 13. REMOTE INTERFACE DIGIT BCI C(BACNET) DIGIT 24 = B TRACER COMM 3 DIGIT 24 = C LCI C CARD (LONTALK COMMUNICATION INTERFACE) DIGIT 24 = L CONTROL INPUT ACCESSORIES DIGIT REMOTE EXTERNAL CHILLED WATER SETPOINT (ECWS) AND REMOTE CURRENT LIMIT SETPOINT DIGIT 25 = B CONTROL OUTPUT ACCESSORIES DIGIT PROGRAMMABLE RELAYS DIGIT 26 = X CALMAC ICE MAKING DIGIT 26 = D ELECTRICAL PROTECTION DIGIT DEAD FRONT DIGIT 27 = X IP20 DIGIT 27 = PACKING & ELECTRICAL ACCESSORIES DIGIT CONTAINER TRANSPORT WITH/WITHOUT FLOW SWITCH DIGIT 28 = G,H CONTAINER 45 FT TRANSPORT WITH/WITHOUT FLOW SWITCH DIGIT 28 = J, K GROUND TERMINAL CONTROL PANEL ACCESSORIES DIGIT UNDER/OVER VOLTAGE TRANSFORMER DIGIT 29 = GROUND FAULT PROTECTION RELAY DIGIT 29 = SERVICES VALVES & GAUGES DIGIT GAUGES SUCTION VALVE DISCHARGE VALVE COMPRESSOR SOUND ENCLOSURE DIGIT 31 = APPEARANCE OPTIONS DIGIT WITHOUT APPEARANCE OPTIONS DIGIT 32 = X WHITE PAINT OVER SPRAY DIGIT 32 = P COIL PROTECTION DIGIT 32 = C COIL PROTECTION AND WHITE PAINT OVER SPRAY DIGIT 32 = H COIL PROTECTION AND EVAPORATOR PROTECTION DIGIT 32 = E COIL PROTECTION + WHITE PAINT OVER SPRAY + EVAPORATOR PROTECTION DIGIT 32 = L INSTALLATION ACCESSORIES DIGIT NEOPRENE PADS DIGIT 33 = R NEOPRENE ISOLATORS DIGIT 33 = B D K P GROOVED PIPE & VICTAULIC COUPLINGS DIGIT 33 = A SIDE VICTAULIC CONNECTION DIGIT 33 = U LANGUAGE, DIGIT 35 AND DIGIT LANGUAGE AVAILABLE FOR (REGULATORY) MANDATORY DOCUMENTATIONS: IOM AND USER GUIDES LANGUAGE AVAILABLE FOR CH530 DISPLAY DUAL DEVICES DIGIT DUAL SAFETY VALVE DIGIT 37 = STANDARD CONFIGURATION (SINGLE SAFETY VALVE) DIGIT 37 = X ACRONYMS ILLUSTRATION LIST TABLE LIST

4 1. Range Overview 1.1. RTAC range Before explaining the different options and accessories available, let s first take a look at the current range and review the definition of the RTAC chiller. Illustration 1. RTAC range overview RTAC family covers a cooling capacity range from 400 kw to 1500 kw. The numbers above the circles define the unit size. Units in Phase 1 have a range from 400 kw to 750 kw which contain 7 sizes ( except for RTAC Standard Efficiency ). Units in Phase 2 have a range between 850 kw and 1500 kw which contain 6 sizes ( except for RTAC Standard Efficiency ). All units have 2 circuits and installed with 2 compressors for units in Phase 1 and 3 or 4 compressors for units in Phase 2. RTAC Xtra Efficiency is the latest version of the unit which meets class A efficiency in all range (EER > 3.1). 4

5 2. Operating Map The unit condenser can operate in two conditions depending on the efficiency Standard Efficiency Standard ambient C High ambient C Low ambient C Wide ambient C Min. LWT C -12 Max. LWT C 18 Illustration 2. Operating map for standard efficiency 2.2. High and Xtra Efficiency Standard ambient C High ambient C Low ambient C Wide ambient C Min. LWT C -12 Max. LWT C 18 Illustration 3. Operating map for high and xtra efficiency In High and Xtra efficiency, the condenser fans temperature range for low noise option are limited. Standard ambient C 40 High ambient C 46 5

6 3. Water pipe connection for standard units For standard units, Trane supplies the grooved pipe connection without victaulic coupling. Water connection needs to be done on site. Grooved pipe Illustration 4. Evaporator water connection 6

7 4. Components in electrical panel for standard units 4.1. Phase 1 Fan contactors and overload relays Compressor fuses 1. Illustration 5. Electrical components for standard units Compressor contactor Fan fuses 4.2. Phase 2 Fan contactors Fan fuses Compressor fuses Compressor contactors Illustration 6. Electrical components in phase 2 7

8 Component in blue circle is disconnect switch handle position. The fuses and contators for all components have differents sizes and types for each unit size. See table below for fuse size and type of contactor. Table 1. Fuse size in Amps Note : For fuse information, see the table in the Selection Data of RTAC. 8

9 5. Comparison for Phase 1 units and Phase 2 units As mentioned above, there are some differences between Phase 1 and Phase 2 of the chiller. Another difference between both phase is the installation of the electrical enclosure Phase 1 The electrical enclosure is installed at the end of the unit, at the lower part. For low ambient units, an additional box is installed for the fan inverters at the side of the unit. Illustration 8. Electrical enclosure in phase 1 Illustration 7. Additional box for fan inverters 5.2. Phase 2 The electrical enclosure is mounted at the end of the unit, full part. Illustration 9. Electrical enclosure in Phase 2 9

10 6. Freeze protection Digit With freeze protection Digit 15 = F or G Application - When unit needs to be protected from freezing (no glycol in the water loop) Description - Heaters cables are installed on the evaporator and all water piping. - A heater is installed in evaporator water box at each end of the evaporator. Circuit 2 Circuit 1 Illustration 10. Heater cables around the evaporator heater heater Illustration 11. Heater in evaporator water box Operation - Freeze protection via the CH530 control turns on the heater based on ambient temperature. - Power of heater cables is 420 W per circuit. - Power of each heater in water box is 600 W. 10

11 Benefits - Components are protected from freezing Incompatibilities - No incompatibility Without freeze protection Digit 15 = C or L For this option, the evaporator is still covered by the heater cables but without the heater in water box. Thus, the evaporator is provided with less power in resistance againts freezing. No heater installed Illustration 12. Evaporator without heater in water box 6.3. Oil cooler When leaving water temperature is below +4 C we add an oil cooler. If LWTE < +4 C digit 15 = L If LWTE > +4 C digit 15 = C in this case we don t add oil cooler. 11

12 7. Evaporator Insulation Digit With thermal insulation Digit 16 = X The evaporator is insulated with foam insulation. This insulation prevents heat in evaporator from escaping in order to maintain the heat exchange between the fluids. The thickness of the foam insulation is 19 mm and 32 mm on waterboxes for phases 2 chiller. Illustration 13. Evaporator insulation 7.2. Without thermal insulation Digit 16 = 2 Evaporator is not insulated. Illustration 14. Evaporator without insulation 7.3. Extra pass Application - Evaporator with extra pass is better when the evaporator leaving water temperature needed is below +4 C. - Used when the water flow is low Description - Evaporator is comprised of 3 passes instead of 2 passes in standard units. - Water box at both end side consiste a grooved pipe. - Extra pass is compatible only in RTAC

13 Water box R134a vapor outlet R134a vapor outlet R134a liquid inlet R134a vapor outlet R134a vapor outlet R134a liquid inlet Evaporator leaving water Circuit 1 Circuit 2 Evaporator entering water Water box Oil return Oil return Illustration 15. Evaporator water circuit in extra pass option Operation/Benefits Evaporator extra pass provides a long water pass in order to increase heat exchange between the water and the refrigerant. Water flows inside the tube mounted in evaporator which the interior and exterior of the tube is slotted. The purpose is to enhance more heat exchange by creating a turbulence flow of the fluids around the tube Incompatibilities - RTAC Specific tubes for Brine applications Application - When the unit needs a very low leaving chilled water temperature (LCWT) Description - Specific tubes are used for water circuit in evaporator. - The type of tube is Gewa-BHV, it is a slotted tube. Illustration 16. Gewa-BHV slotted tube 13

14 Operation - Brine applications are compatible with RTAC with ambient temperature 35 C. - The slots around these tubes are designed to have a better heat transfer between both fluids as more turbulence flow of the fluids are created Benefits - The units are able to reach ELWT of -12 C for ethylene glycol and -9 C for propylene glycol. - In market opportunities, the unit can be used for food and beverage applications and ice rink applications. - Always check with Topss if standard tubes can be used before to use tubes for brine application Incompatibilities - RTAC More detail - For units with low leaving chilled water temperature (LCWT), some additionals enhancement in insulation for some components are provided by Trane. Illustration 17. Insulation on evaporator Illustration 18. Insulation on expansion device (EXV) 14

15 8. Condenser Temperature Range digit 17 To choose the unit configuration, refer to operating map Standard digit 17 = N Standard efficiency standard ambient units : 7 C <= Air temperature <= 40 C High efficiency standard ambient units: 7 C <= Air temperature <= 46 C For Standard ambient electrical components are designed to resist up to 70 C in the electrical panel High ambient digit 17 = H Standard efficiency high ambient: 7 C <= Air temperature <= 46 C High efficiency high ambient: 7 C <= Air temperature <= 52 C The difference between standard and high ambient units are: Power wires are oversized to resist up to 55 C Low ambient digit 17 = L Standard efficiency low ambient units: -18 C <= Air temperature <= 40 C High efficiency low ambient units: -18 C <= Air temperature <= 46 C For RTAC chillers running in low ambient, we add a speed inverter on one fan per circuit to control the condensing pressure. This fan is able to run between 10% and 100%. So the air flow is adapted in function of the condensing pressure Wide ambient digit 17 = W Standard efficiency wide ambient units: -18 C <= Air temperature <= 46 C High efficiency wide ambient units: -18 C <= Air temperature <= 52 C We combine features of High and low ambient, so the units can work on both ranges Summary Digit 17 N standard H high ambient L low ambient W wide ambient Compressor Power Wires oversized No Yes No Yes Variable speed fan No No Yes Yes 15

16 9. Condenser fin material Digit Standard aluminum slit fins Digit 18 = X Applications - When the chiller is installed in a non-polluted area Description - Aluminum fin is a standard fin used on all air-chillers. - The slit is between the gap of two collar. Slit Illustration 19. Aluminum slit fin Operation - The aluminum fins increase the capacity of heat exchange between the refrigerant and the ambient air flow. - Slit increases the air turbulences. - It allows more heat transfers with fluids than non-lanced aluminum fins Benefits - Increases the condenser and chiller performance Incompatibilities - Not recommended when the chiller is installed in a polluted area or in a dusty area in order to avoid the clogging. 16

17 9.2. Copper slit fins Digit 18 = Applications - When chiller is installed in a non-polluted area - For marine application Description - Slit is between the gap of two collar. - Condenser consists of all copper material. slit Illustration 20. Copper slit fin Operation - Slit increases the air turbulences. - Slit allows more heat transfers between both fluids Benefits - Increases resistance againts corrosion in harsh coastal environment. - Eliminates the galvanic corrosion at the collar between the copper fin and the copper tube because the galvanic corrosion would occur at the collar when using two diffenrent materials such as aluminum fins and copper tube Incompatibilities - It is not recommended when the chiller is installed in a polluted coastal applications or industrial applications. - Not available for 4 rows coil, RTAC 240 and RTAC Xtra Efficiciency. 17

18 9.3. Black epoxy fins Digit 18 = Application - For coastal or salt mist environments. - When the aluminum fin is exposed to hard weather conditions (acid rain, moisture, pollution, salt ) Description - Aluminium pre-coated fin is a standard non-lanced fin used on all air cooled chillers. - Condenser black epoxy coated. - Edges treated. Illustration 21. Black epoxy fin Operation - Black epoxy slows down the corrosion process on the aluminum fins. - When the unit is installed on sea side or in a polluted area Benefits - This option allows installation near the sea and avoids aluminum corrosion. - Trane coating also includes edges of the fins. If edges are not treated, then the corrosion starts at this point and the coil is quickly destroyed. - The black epoxy also provides a barrier protection at the fin collar to stop galvanic corrosion action between the aluminum fins and the copper tubes. 18

19 Incovenience - Aluminum fin is painted with black epoxy, it is covered by 3 layers of protection.thus, this action will decrease slightly the capacity of heat transfer ( 2%) between the refrigerant and the ambient air. Resine Polyurethane, color black Resine Black Epoxy Phosphochromation Aluminum 0.12 mm thick Incompatibilities - Can not be used with lanced aluminum fins More detail The installation of fins for condenser is depending on the number of rows coil mounted in the unit. For 3 rows coil, there are 192 fins per foot and for 4 rows coil, there are 180 fins per foot. 19

20 10. Condenser fan motor configuration Digit Low noise Digit 19 = L Application - When unit needs to be installed in a sensitive area (where the noise is unbearable in a crowded place) Description - Fans consist of 7 polypropylene dynamically balanced crenellated blades fitted on a flat motor. - Compressor is isolated with sound attenuator. - Suction and discharge lines are isolated with acoustical insulation. Illustration 22. Suction lines and compressors insulation Illustration 23. Compressor and discharge lines insulation Operation/Benefits - The unit operates with the speed of fans at 690 RPM. - Provides a noise reduction of 7dB(A) compared to standard units. - Fans are fitted on a rigid structure attached to the unit baseframe in order to absorb vibrations instead of transmitting them to roof and panels with amplification Incompatibilities - It can not be applied when the air ambient temperature is higher than 46 C Comparison between Standard noise and Low noise units Standard Noise units Low Noise units Fan speed 915 RPM 690 RPM Compressor Non-insulated Insulated Suction and discharge lines Non-insulated Insulated 20

21 10.3. Night noise setback Digit 19 = Q Application - When the fan speed needs to be reduced at night Description - Used on low noise version units only. - Fan speed is controlled by contactors. - An external signal must be provided by customers (e.i. thermostat,clock..). contactor Clock as the external signal Illustration 24. NNSB contactor and external signal diagram Operation - Fan speeds on low noise version is 690 RPM meanwhile with night noise setback option, the unit is running with low speeds of fans at 560 RPM. - The switching between high and low speeds is done by the means of an external signal (provided by customers). - When the external signal is switched on (closed), the contactors are energized and switch the fans for low speeds Benefits - Reduces the global sound level by 1 db(a). - Most of the units can operate at full load up to 30 C ambient temperature with a water rate 12/7 C. - Customers get an additional noise reduction during a big part of operating time of the unit Incompatibilities - Standard noise version units. 21

22 Pa High Pressure Drop Digit 19 = P Application - Used for specific application requiring a ducted air discharge. - When fans need to exhaust a higher volume of air flow Description - Fans are mounted on top of the chiller and protected with fan guard (protection grill). - For standard version units only. Illustration 25. Standard fans Illustration 26. High static fans with fan motor Illustration 27. The shape of the guard for standard fans Illustration 28. The high static fans are easily recognizable because of the shape of the guard Operation - The unit operates with the speed of fans increased to 935 RPM instead of 915 RPM for standard fans. - Fans provide a pressure drop in ducted air discharge resulting an increase of air flow. 22

23 Benefits - More air can be rejected outside the chiller Pa of Pressure Drop are available Inconvenience - Increase the sound level by 3 to 4 db(a) Incompatibilities - Low noise version units. 23

24 11. Starter type Digit Across the Line Starter/Direct on Line Digit 20= X Application - To start the compressor Description - This starter is factory-installed, located in electrical panel Operation - Allow to start and stop compressors Benefits - Low cost for component installation. - Simple system Incompatibilities - Star-delta starter. 24

25 11.2. Solid-state soft starter Star - delta starter Digit 20 = Y Application - To start the compressor. - To reduce inrush current Description - Factory-installed, located in electrical panel. Illustration 29. Y-delta starter installation circuit Operation - Technical explanation Three contactors are used to first connect the motor in star and then to delta. TRANE units use Y-Delta starter with the following phase : 1.1. Illustration 30. Star-delta stages 25

26 In phase 1, the contactors are energized or closed. This connects the motor winding in the Y-configuration. Connecting the motor in star reduces the voltage applied to each winding to about 1/ 3 of the line voltage. This reduces the starting torque and the starting current (1/ 3 of nominal current). Phase 2 is the first step in the transition to delta connection. In this configuration, the resistors are connected parallel to the motor windings. In phase 3, the motor windings are connected in series with the resistors. Phase 4, the resistors are out and the motor is switched to the delta connection and runs as if direct on line Benefits - Motor starts with less inrush current than direct on line Incompatibilities - Direct on line More detail Differences between across direct line starter and Y-delta.(see table below) Starter type Inrush current %LRA % lock torque motor Acceleration time(s) Across direct line < 0.5 Y-Delta < 1 Table 2. Comparison of reduced inrush current Illustration 31. % Run Load Amps(RLA) vs Times 26

27 12. Power line connection type Digit Terminal block with fuses Digit 22 = X This is a standard component supplied by Trane Application - Used to stop the chiller when there is a short circuit in the system Description - Factory-mounted, located in electrical panel. - 3 copper blocks. - Fuses for chiller components. - Requires a switch to be installed before the installation of terminal block. Copper blocks Compressor fuses Illustration 32. Terminal blocks with fuses Operation - The copper blocks is used to connect the fuses with unit power supply as the current can go through the copper blocks. - If there is a short circuit in the system, an excessive current occurs,then the fuse will interrupt excessive current to stop the unit Benefits - Protects the unit from damages Incompatibilities - No incompatibility. 27

28 12.2. Disconnect switch with fuses Digit 22 = B Application - Used to stop the unit power supply for emergency/maintenance. - Used to stop the chiller when there is a short circuit in the system Description - Disconnect switch is factory-installed, located in electrical panel. - Used with a closed electrical panel (no electrical risk). - Fuses for unit components. Compressor fuse ill Illustration 33. Disconnect switch handle Operation - A disconnect switch is a switch which has the capability to interrupt power to an electrical circuit or to a group of electrical circuits. - During maintenance works, the disconnect switch is used to stop the unit power supply as it will deenergize electrical circuits. - It is possible to swith off the unit even it is still running Benefits - Ensures the safety during the maintenance works. - Protects the unit from damages. - Provides a protection against excessive current by the fuses Incompatibilities - No incompatibility. 28

29 13. Remote Interface Digit BCI-C (BACnet) Digit 24 = B Application - Allows RTAC chiller to communicate with BACnet systems and devices. - Allows heating,ventillation and air-conditioning equipment to communicate on a BACnet communications network Description - Factory-installed in the chiller control panel. - It is a BACnet MS/TP protocol. MS/TP means Master Slave Token Passing is the rules for the BACnet messages to move from device to device. - There are three rotary switches on the front of the BCI-C device that are used to define a three-digits address when the BCI-C is installed on a BACnet communications network. Illustration 34. BCI-C Illustration 35. BCI-C layout Operation/Benefits - Used with CH530 main processor (MP) 2.00 and TechView 12.1 SP2 or higher Incompatibilities - LCI-C. - Tracer Comm3 (Modbus). 29

30 13.2. Tracer Comm 3 Digit 24 = C Application - Allows Tracer CH530 to exchange information with a higher-level control device, such as Tracer Summit Description - Tracer Comm 3 is a Trane proprietary communication protocol. - Tracer Comm 3 interface LLID (Low Level Intelligent Devices) is installed in the chiller control panel. Illustration 36. Tracer Comm 3 interface Operation/benefits - Used with Tracer Summit and Tracer 100 systems Incompatibilities - LCI-C. 30

31 13.3. LCI-C Card (LonTalk Communication Interface) Digit 24 = L Application - Provides a communication interface between a Tracer CH530 controller and a LonTalk network. - Allows communication between the chiller and a building automation system (BAS) Description - The LCI-C is factory installed with the chiller controller, located in the control panel box. Illustration 37. LCI-C card Operation/Benefits - The hardware of an LCI-C consists of a low-level intelligent device (LLID), which is an electronic board that allows the Tracer CH530/531 controller to communicate on a LonTalk network. - LCI-C shall be used to provide gateway functionality between the LonTalk protocol and the IPC3 (Intra Processor Communication) protocol. - The LCI-C LLID and CH530 Main Processor shall collaborate to ensure that data synchronization is maintained under reasonable failure modes, which include: Message loss or corruption between the BAS and the LCI-C LLID. Message loss or corruption between the LCI-C LLID and the CH530 Main Processor. Temporary power loss/brownout conditions on the LCI-C LLID, CH530 Main Processor, or both simultaneously. 31

32 - The LLID is designed to be mounted in an enclosure so that it is protected from the environment. The chiller control panel box, where the other Tracer CH530/531 LLIDs reside, provides a convenient place for the LCI-C. Lontalk points list All the points list can be referred in Installation Operation Maintenance (IOM) of RTAC, RLC-SVX02G-E4 for update views. nci nvi nvo SNVT UNVT Table 3. Lontalk list network configuration input network variable input network variable output Standard Network Variable Type User-defined Network Variable Type 32

33 Incompatibilities - BCI-C. - Tracer Comm3 (Modbus). 14. Control Input Accessories Digit Remote External Chilled Water Setpoint (ECWS) and Remote Current Limit Setpoint Digit 25 = B Application - External signal used to set the chilled water setpoint. - External signal used to set the current limit setpoint Description - The external signal input provided by CH530 to both functions is either a 2-10 V or 4-20 ma. - There is one input to set the chilled water setpoint and one input to set the current limit setpoint. Power port Illustration 38. External current limit and chilled water setpoint card Operation - External chilled water and current limit setpoint set via the Dynaview. - For chilled water setpoint, an input signal of 2-10 V or 4-20 ma each correspond to 12 C to 18 C. 33

34 - For input signals beyond the 2-10 V or 4-20mA range, the end of range value shall be used. For example, if the customer inputs 21 ma, the external chilled water setpoint limit itself to the corresponding 20 ma external chilled water setpoint. - For current limit setpoint, an input signal of 2-10 V or 4-20 ma each correspond to 60% to 120% RLA (Run Load Amps). - For input signals beyond the 2-10 V or 4-20mA range, the end of range value shall be used. For example, if the customer inputs 21 ma, the external current limit setpoint limit itself to the corresponding 20 ma external current limit setpoint Benefits - Energy savings: client does not have to go to the site job to set the applications. - Provides an external signal from remote location to set chilled water and current limit setpoints Incompatibilities - Impossible to send both signals at one time. - BCI-C. Note : Both functions, the external chilled water setpoint (ECWS) and the external current limit setpoint (ECLS) can work at the same time. 34

35 15. Control Output Accessories Digit Programmable Relays Digit 26 = X Application - When certain events or states of the chiller need to be remotely controlled Description - Use 4 output relays as shown in the field wiring diagram. Power port Illustration 39. Alarm relay output card Operation - Factory installed, located in control panel. - The relay will be energized when the event or state occurs. - CH530 (TechView) is used to install the Alarm and Status Relay Option package and assign any of the above list of events or status to each of the four relays provided. - The default assignments for the four available relays of the RTAC Alarm and Status Package Option : Relay Relay 1 terminals J2-12,11,10: Relay 2 terminals J2-9,8,7: Relay 3 terminals J2-6,5,4: Relay 4 terminals J2-3,2,1: Alarm and status Alarm Chiller running Maximum capacity Chiller limit Table 4. Default assignments Note : other events/states that can be assigned to the programmable relays can be found in Installation Operation Maintenance Benefits - Customers will be alerted if the events or states of the chiller occur. - Reduces maintenance work on the chiller. 35

36 Incompatibilities - No incompatibilitiy Calmac Ice-making Digit 26 = D Calmac is Trane s supplier for providing the additional ice bank tank for chillers with ice-building option. For futher information concerning Calmac Manufacturing Corporation, visit Application - When the evaporator leaving water temperature is in a range of 8 C to 15 C. - When the chiller is used to produce ice Description - Requires a glycol solution in the chilled water system for freeze protection. - Requires the additional ice storage tanks (tested by Calmac). - Also known as thermal ice storage. Illustration 40. Ice making card Operation - CH530 provides a Front Panel Ice Termination settable and adjustable from C to C. - The minimum setpoint of entering chilled water temperature in ice storage is 6.7 C. - Generates ice at night when utility rates are low (off-peak period) and uses ice for cooling during the day when utility rates are high (on-peak period). - During the night the chiller cools the mixture of glycol/water to a very low leaving water temperature (i.e C) which is then circulated through coils inside a tank containing water to create ice. - During the day, heat load is carried through the chilled water system to the ice storage tanks. The ice melts and cools the glycol/water mixture (i.e. 5 C), then is routed to the cooling coils and cools the building. 36

37 Benefits - Reduces or even replaces mechanical cooling during the day. - Reduces the electricity consumption cost. - Ability to eliminate the chiller over sizing Incompatibilities - No incompatibility. 16. Electrical Protection Digit 27 The electrical protection is used to provide a protection against direct contacts to the power line connection inside the electrical panel Dead front Digit 27 = X Illustration 41. Dead Front IP20 Digit 27 = 1 Front cover for IP20 is thicker than dead front. Illustration 42. IP20 Note : The pictures of electrical protections are for the units in phase 2 37

38 17. Packing & Electrical Accessories Digit Container transport with/without Flow switch Digit 28 = G,H All units of RTAC can be shipped on 40 ft container except RTAC 400 HE/XE. For units size , the chillers can be transported also on 20 ft container. The coils are protected during the shipment Container 45 ft transport with/without Flow switch Digit 28 = J, K For shipment of RTAC 400 HE/XE, the unit is shipped on a 45 ft container. In order to ensure the unit can be fitted in the container, the length of the unit is reduced by reducing the length between the 2 condensers and the size of electrical box at the side of the unit and adding a box which assembles all the electrical components at each circuit. Illustration 43. View of RTAC 400HE/XE for shipment Coils protection Size of the electrical box reduced Additional box Metallic clog Metallic clog is fixed at the base frame of the unit. It prevents all mark and a direct contact between the chiller and the container while loading it in container. Illustration 44. Metallic clog 38

39 17.3. Ground Terminal The ground terminal is located on the base frame of the chiller. It can not be seen when a metallic clog is installed at the base frame as it is hidden behind the metallic clog. The terminal is threaded. Illustration 45. Location of the ground terminal Illustration 46. Ground terminal For a shipment with flow switch, it is placed in electrical panel. You will find more information in case 5082 Illustration 47. Flow switch 39

40 18. Control Panel Accessories Digit Under/Over voltage transformer Digit 29 = Application - When unit needs to be protected from under/over voltage Description - Factory installed, located in the electrical panel. Illustration 48. Under/over voltage transformer Operation/Benefits - If the value of voltage exceeds the minimum or maximum value in the unit, the unit will be shut down. - Unit receives protection against variation in voltage Incompatibilities - No incompatibility. 40

41 18.2. Ground fault protection relay Digit 29 = Application - When the electrical components need to be protected from a detectable current in the electrical panel Description - The relay which is used to connect the tore is factory-installed, located in the electrical panel. - The tore is installed at site, shipped in a box located in the electrical panel. For fixation of the tore Illustration 49. Tore of the ground fault relay Illustration 50. Name plate and port connection of the tore Illustration 51. Tore in a box for shipment Operation/Benefits - Protect an electrical distribution system from ground faults Incompatibilities - No incompatibility. 41

42 19. Services Valves & Gauges Digit Gauges Application - To give pressure information for each refrigerant circuit Description - Factory-installed, located near the compressor at the baseframe. - Consists of LP and HP gauges. HP gauge LP gauge Illustration 52. LP and HP gauges Operation/Benefits - Measures the pressure in the circuit Incompatibilities - No incompatibility Inconvenience - Leakage source for refrigerant. - Higher cost for customers. Reminder : Pressure information can be read directly on CH More detail - When there are 2 compressors manifolded on the same refrigerant circuit, there is only one set of gauges will be installed on this circuit. 42

43 19.2. Suction valve Application - Used to isolate the refrigerant circuit Description - Factory installed, located on suction line of the evaporator. - 2 positions, backseated (open) and frontseated (closed). Illustration 53. Suction valve Operation/benefits - Isolates the refrigerant flow in the compressor. - By closing the suction valve, the back flow refrigerant from the compressor is prevented when the compressor stops. - Ease of compressor servicing Incompatibilities - No incompatibility Discharge valve It is a standard component. Located on the discharge line of the compressor. Illustration 54. Discharge valve 43

44 20. Compressor sound enclosure Digit 31 = Application - Used to reduce the sound level emitted by compressor with a reduction of 1 db(a) Description - Factory-installed. - Compressor is installed in a box - For standard unit Operation - The box covers the compressor. Illustration 55. Compressor enclosure Benefits - Reduces noise emissions from compressor. - Compressor is protected from outside elements. - Esthetics Incompatibilities - No incompatibility More detail For standard unit, the compressor will be not covered Illustration 56. Compressor without enclosure 44

45 21. Appearance Options Digit Without appearance options Digit 32 = X The unit is without overspray, the coil and the equipment under the coil are not protected. Illustration 57. Chiller without appearance The base frame is grey color (RAL 7012) Compressor is slight grey color (RAL 7003) Panels and unit frame parts are painted with polyurethane, beige color (RAL 1019) White paint over spray Digit 32 = P The unit body is painted with white color (RAL 9002) as well as the unit equipment (compressor, oil separator, etc..). The sprayed color will prevent the unit and the equipment surface from corrosion. Illustration 58. White paint over spray Illustration 59. White paint over spray side view 45

46 21.3. Coil protection Digit 32 = C The coil is protected with access guards against outside elements. Illustration 60. Coil protection with access guards Access Coil protection and white paint over spray Digit 32 = H Illustration 61. Coil protection+white paint over spray Coil protection and evaporator protection Digit 32 = E The equipment under the condenser are also protected with access guards (evaporator,oil separator, etc..). By installing the access guards at the lower part, the equipment is safe from outside elements such as animals. Illustration 62. Evaporator protection with access guards 46

47 21.6. Coil protection + white paint over spray + evaporator protection Digit 32 = L The unit appears with full protection. Illustration 63. Final phasing appearance 47

48 22. Installation accessories Digit Neoprene pads Digit 33 = R Application - Used to avoid direct contact of the chiller and the ground Description - They are installed under the chiller. - Shipped in the control panel. Illustration 64. Neoprene pads Operation/Benefits - Neoprene pad do not filter vibrations. - Avoid direct contact of the base frame with the ground Incompatibilities - No incompatability. 48

49 22.2. Neoprene isolators Digit 33 = B-D-K-P Application - Used to minimize the vibrations transmitted to the building Description - They are installed under the chiller. - Shipped with the chiller. Illustration 65. Neoprene isolators Operations/Benefits - Eliminates vibration and noise transmission throughout the building. Neoprene isolators deflection Color Max. Load Deflection at max. Load lbs kg inch mm BROWN RED ,5 12,7 GREEN GRAY Table 5. Neoprene isolators deflection 49

50 Incompatibilities - No incompatability Grooved pipe & victaulic couplings Digit 33 = A Consiste of pipe stub and Victaulic couplings. Used when tube is welded. Weld sleeve Victaulic couplings Tube cuff Illustration 66. Grooved pipe connection+victaulic couplings Tube cuff is connected to the grooved pipe of evaporator. The length of the tube depends on its diameter. Below is the table mentioning the length of the tube in each unit size Unit size φ Diametre (inche) A +/ 0,76 (mm) B +/ 0,76 (mm) L (mm) 120HE 120XE 130HE 4" 15,88 8, XE 140SE 140HE 140XE 6" 15,88 8, SE 4" 15,88 8, HE 155XE 170SE 170HE 175XE 185SE 185HE 185XE 200SE 200HE 200XE 6" 15,88 8,74 80 Unit size φ Diametre (inche) A +/ 0,76 (mm) B +/ 0,76 (mm) L (mm) 230SE 240SE 250SE 250HE 255XE 275SE 275HE 275XE 300SE 300HE 300XE 350SE 350HE 355XE 375SE 375HE 375XE 400SE 400HE 400XE 6" 8" 15,88 19,05 8,74 11,

51 Table 6. Tube cuff dimensions Side Victaulic connection Digit 33 = U Application - When the pipe connection between the building and the unit has to be joined directly Description - The tube can be connected either with Victaulic couplings or by welding. - It is stainless steel tube. - In case of welding, victaulic weld-sleeves are provided Operation/Benefits Illustration 67. Side pipe ti - Reduces installation time and cost. - Ease of installation at jobsite. - Safety improvement by reducing the risks of injury - the person in charge at the jobsite does not have to cut and weld the tubes to connect the tubes inside the unit Incompatibilities - Access guards at lower part of the unit (coil protection accepted) 51

52 23. Language, digit 35 and Digit Language available for (regulatory) mandatory documentations: IOM and user guides Digit 35 Language F French D German E English I Italian H Dutch C Spanish T Czech U Greek P Polish M Swedish R Russian V Portuguese 6 Hungarian 2 Romanian 8 Turkish Language available for CH530 display And the CH530 can display messages in following languages: Digit 23 A F G H I S Language Dyna-view / English Dyna-view / French Dyna-view / German Dyna-view / Dutch Dyna-view / Italian Dyna-view / Spanish 52

53 24. Dual Devices Digit Dual Safety Valve Digit 37 = Application - When a pressure exceeds its limit in the evaporator and oil separator. - When a safety valve needs to be replaced while unit is operating Description - Factory-installed at the low pressure side and high pressure side. - 2 safety valves are mounted on a 3-way valve (each safety valve has a port). - Stem is mounted at the bottom of both safety valves. 3 way valve Illustration 68. Dual safety valve on evaporator Illustration 69. Dual safety valve on oil separator Operation - Used to relieve a pressure on a gas when the equipment experiences overpressure. - Only one safety valve works at a time and the other acts as a standby allowing for replacement of the safety valve while unit is operating. - Stem is used to direct the gas flow to one of the two ports. Valve port 3-way valve Illustration 70. Dual safety valve layout 53

54 Benefits - Eliminates the need to shut down the unit and remove the refrigerant for servicing. - Reduces maintenance work Incompatibilities - No incompatibility Standard configuration (Single safety valve) Digit 37 = X The single safety valve is also installed on a low and high pressure side. It operates to relieve the overpressure in the evaporator and oil separator. During the maintenance work or when the valve needs to be replaced, the unit needs to be stopped first from operating and the client has to drain the refrigerant in the circuit for servicing. Illustration 71. Single safety valve on high pressure side of oil separator Illustration 72. Single safety valve on the evaporator 54

55 25. Acronyms SE HE XE LCWT MS/TP BCI-C LLIDs LCI-C BAS IPC3 ECWS ECLS LP HP Standard Efficiency High Efficiency Xtra Efficiency Leaving Chilled Water Temperature Master Slave Token Processing BACnet Communication Interface for Chiller Low Level Intelligent Devices LonTalk Communication Interface for Chiller Building Automation System Intra Processor Communication External Chilled Water Setpoint External Current Limit Setpoint Low Pressure High Pressure 55

56 26. Illustration list Illustration 1. RTAC range overview... 4 Illustration 2. Operating map for standard efficiency... 5 Illustration 3. Operating map for high and xtra efficiency... 5 Illustration 4. Evaporator water connection... 6 Illustration 5. Electrical components for standard units... 7 Illustration 6. Electrical components in phase Illustration 7. Additional box for fan inverters... 9 Illustration 8. Electrical enclosure in phase Illustration 9. Electrical enclosure in Phase Illustration 10. Heater cables around the evaporator Illustration 11. Heater in evaporator water box Illustration 12. Evaporator without heater in water box Illustration 13. Evaporator insulation Illustration 14. Evaporator without insulation Illustration 15. Evaporator water circuit in extra pass option Illustration 16. Gewa-BHV slotted tube Illustration 17. Insulation on evaporator Illustration 18. Insulation on expansion device (EXV) Illustration 19. Aluminum slit fin Illustration 20. Copper slit fin Illustration 21. Black epoxy fin Illustration 22. Suction lines and compressor s insulation Illustration 23. Compressor and discharge lines insulation Illustration 24. NNSB contactor and external signal diagram Illustration 25. Standard fans Illustration 26. High static fans with fan motor Illustration 27. The shape of the guard for standard fans Illustration 28. The high static fans are easily recognizable because of the shape of the guard Illustration 29. Y-delta starter installation circuit Illustration 30. Star-delta stages Illustration 31. % Run Load Amps(RLA) vs Times Illustration 32. Terminal blocks with fuses Illustration 33. Disconnect switch handle Illustration 34. BCI-C Illustration 35. BCI-C layout Illustration 36. Tracer Comm 3 interface Illustration 37. LCI-C card Illustration 38. External current limit and chilled water setpoint card Illustration 39. Alarm relay output card Illustration 40. Ice making card Illustration 41. Dead Front Illustration 42. IP Illustration 43. View of RTAC 400HE/XE for shipment Illustration 44. Metallic clog Illustration 45. Location of the ground terminal Illustration 46. Ground terminal

57 Illustration 47. Flow switch Illustration 48. Under/over voltage transformer Illustration 49. Tore of the ground fault relay Illustration 50. Name plate and port connection of the tore Illustration 51. Tore in a box for shipment Illustration 52. LP and HP gauges Illustration 53. Suction valve Illustration 54. Discharge valve Illustration 55. Compressor enclosure Illustration 56. Compressor without enclosure Illustration 57. Chiller without appearance Illustration 58. White paint over spray Illustration 59. White paint over spray side view Illustration 60. Coil protection with acces guards Illustration 61. Coil protection+white paint over spray Illustration 62. Evaporator protection with acces guards Illustration 63. Final phasing appearance Illustration 64. Neoprene pads Illustration 65. Neoprene isolators Illustration 66. Grooved pipe connection+victaulic couplings Illustration 67. Side pipe connection Illustration 68. Dual safety valve on evaporator Illustration 69. Dual safety valve on oil separator Illustration 70. Dual safety valve layout Illustration 71. Single safety valve on high pressure side of oil separator Illustration 72. Single safety valve on the evaporator Table list Table 1. Fuse sizes in Amps... 8 Table 2. Comparison of reduced inrush current Table 3. Lontalk list Table 4. Default assignments Table 5. Neoprene isolators deflection Table 6. Tube cuff dimensions

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