option guide 2012 rtac alain - jp.trane.com · 1 rlc-prb030-e4 options guide air-cooled liquid...

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Options Guide

Air-cooled Liquid Chillers with Screw compressors Models RTAC 120 to 400

MAY 2012 RLC-PRB030-E4

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Table Of Contents

1. RANGE OVERVIEW ................................................................................................................................ 4

1.1. RTAC RANGE ........................................................................................................................................... 4

2. OPERATING MAP .................................................................................................................................. 5

2.1. STANDARD EFFICIENCY ............................................................................................................................... 5 2.2. HIGH AND XTRA EFFICIENCY ........................................................................................................................ 5

3. WATER PIPE CONNECTION FOR STANDARD UNITS ................................................................................ 6

4. COMPONENTS IN ELECTRICAL PANEL FOR STANDARD UNITS ................................................................. 7

4.1. PHASE 1 .................................................................................................................................................. 7 4.2. PHASE 2 .................................................................................................................................................. 7

5. COMPARISON FOR PHASE 1 UNITS AND PHASE 2 UNITS ........................................................................ 9

5.1. PHASE 1 .................................................................................................................................................. 9 5.2. PHASE 2 .................................................................................................................................................. 9

6. FREEZE PROTECTION DIGIT 15 ............................................................................................................. 10

6.1. WITH FREEZE PROTECTION DIGIT 15 = F OR G .............................................................................................. 10 6.2. WITHOUT FREEZE PROTECTION DIGIT 15 = C OR L ......................................................................................... 11 6.3. OIL COOLER ........................................................................................................................................... 11

7. EVAPORATOR INSULATION DIGIT 16 ................................................................................................... 12

7.1. WITH THERMAL INSULATION DIGIT 16 = X ................................................................................................... 12 7.2. WITHOUT THERMAL INSULATION DIGIT 16 = 2 ............................................................................................. 12 7.3. EXTRA PASS ............................................................................................................................................ 12 7.4. SPECIFIC TUBES FOR BRINE APPLICATIONS .................................................................................................... 13

8. CONDENSER TEMPERATURE RANGE DIGIT 17 ...................................................................................... 15

8.1. STANDARD DIGIT 17 = N .......................................................................................................................... 15 8.2. HIGH AMBIENT DIGIT 17 = H ..................................................................................................................... 15 8.3. LOW AMBIENT DIGIT 17 = L ...................................................................................................................... 15 8.4. WIDE AMBIENT DIGIT 17 = W ................................................................................................................... 15 8.5. SUMMARY ............................................................................................................................................. 15

9. CONDENSER FIN MATERIAL DIGIT 18 ................................................................................................... 16

9.1. STANDARD ALUMINUM SLIT FINS DIGIT 18 = X.............................................................................................. 16 9.2. COPPER SLIT FINS DIGIT 18 = 2 .................................................................................................................. 17 9.3. BLACK EPOXY FINS DIGIT 18 = 3................................................................................................................. 18

10. CONDENSER FAN MOTOR CONFIGURATION DIGIT 19 .......................................................................... 20

10.1. LOW NOISE DIGIT 19 = L .......................................................................................................................... 20 10.2. COMPARISON BETWEEN STANDARD NOISE AND LOW NOISE UNITS .................................................................... 20 10.3. NIGHT NOISE SETBACK DIGIT 19 = Q .......................................................................................................... 21 10.4. 100PA HIGH PRESSURE DROP DIGIT 19 = P ................................................................................................ 22

11. STARTER TYPE DIGIT 20 ...................................................................................................................... 24

11.1. ACROSS THE LINE STARTER/DIRECT ON LINE DIGIT 20= X ............................................................................... 24 11.2. SOLID‐STATE SOFT STARTER STAR ‐ DELTA STARTER DIGIT 20 = Y ...................................................................... 25 11.3. MORE DETAIL ......................................................................................................................................... 26

12. POWER LINE CONNECTION TYPE DIGIT 22 ........................................................................................... 27

12.1. TERMINAL BLOCK WITH FUSES DIGIT 22 = X ................................................................................................. 27 12.2. DISCONNECT SWITCH WITH FUSES DIGIT 22 = B ............................................................................................ 28

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13. REMOTE INTERFACE DIGIT 24 ............................................................................................................. 29

13.1. BCI‐C(BACNET) DIGIT 24 = B .................................................................................................................. 29 13.2. TRACER COMM 3 DIGIT 24 = C ................................................................................................................. 30 13.3. LCI‐C CARD (LONTALK COMMUNICATION INTERFACE) DIGIT 24 = L ................................................................. 31

14. CONTROL INPUT ACCESSORIES DIGIT 25 .............................................................................................. 33

14.1. REMOTE EXTERNAL CHILLED WATER SETPOINT (ECWS) AND REMOTE CURRENT LIMIT SETPOINT DIGIT 25 = B ....... 33

15. CONTROL OUTPUT ACCESSORIES DIGIT 26 .......................................................................................... 35

15.1. PROGRAMMABLE RELAYS DIGIT 26 = X ....................................................................................................... 35 15.2. CALMAC ICE‐MAKING DIGIT 26 = D ............................................................................................................ 36

16. ELECTRICAL PROTECTION DIGIT 27 ...................................................................................................... 37

16.1. DEAD FRONT DIGIT 27 = X ....................................................................................................................... 37 16.2. IP20 DIGIT 27 = 1 .................................................................................................................................. 37

17. PACKING & ELECTRICAL ACCESSORIES DIGIT 28 .................................................................................. 38

17.1. CONTAINER TRANSPORT WITH/WITHOUT FLOW SWITCH DIGIT 28 = G,H ........................................................... 38 17.2. CONTAINER 45 FT TRANSPORT WITH/WITHOUT FLOW SWITCH DIGIT 28 = J, K ................................................... 38 17.3. GROUND TERMINAL ................................................................................................................................ 39

18. CONTROL PANEL ACCESSORIES DIGIT 29 ............................................................................................. 40

18.1. UNDER/OVER VOLTAGE TRANSFORMER DIGIT 29 = 1 .................................................................................... 40 18.2. GROUND FAULT PROTECTION RELAY DIGIT 29 = 2 ......................................................................................... 41

19. SERVICES VALVES & GAUGES DIGIT 30 ................................................................................................ 42

19.1. GAUGES ................................................................................................................................................ 42 19.2. SUCTION VALVE ...................................................................................................................................... 43 19.3. DISCHARGE VALVE ................................................................................................................................... 43

20. COMPRESSOR SOUND ENCLOSURE DIGIT 31 = 1 .................................................................................. 44

21. APPEARANCE OPTIONS DIGIT 32 ......................................................................................................... 45

21.1. WITHOUT APPEARANCE OPTIONS DIGIT 32 = X ............................................................................................. 45 21.2. WHITE PAINT OVER SPRAY DIGIT 32 = P ...................................................................................................... 45 21.3. COIL PROTECTION DIGIT 32 = C ................................................................................................................. 46 21.4. COIL PROTECTION AND WHITE PAINT OVER SPRAY DIGIT 32 = H ....................................................................... 46 21.5. COIL PROTECTION AND EVAPORATOR PROTECTION DIGIT 32 = E ....................................................................... 46 21.6. COIL PROTECTION + WHITE PAINT OVER SPRAY + EVAPORATOR PROTECTION DIGIT 32 = L ............................... 47

22. INSTALLATION ACCESSORIES DIGIT 33 ................................................................................................. 48

22.1. NEOPRENE PADS DIGIT 33 = R .................................................................................................................. 48 22.2. NEOPRENE ISOLATORS DIGIT 33 = B‐D‐K‐P ................................................................................................. 49 22.3. GROOVED PIPE & VICTAULIC COUPLINGS DIGIT 33 = A ................................................................................... 50 22.4. SIDE VICTAULIC CONNECTION DIGIT 33 = U .................................................................................................. 51

23. LANGUAGE, DIGIT 35 AND DIGIT 23 .................................................................................................... 52

23.1. LANGUAGE AVAILABLE FOR (REGULATORY) MANDATORY DOCUMENTATIONS: IOM AND USER GUIDES...................... 52 23.2. LANGUAGE AVAILABLE FOR CH530 DISPLAY ................................................................................................. 52

24. DUAL DEVICES DIGIT 37 ...................................................................................................................... 53

24.1. DUAL SAFETY VALVE DIGIT 37 = 4 ............................................................................................................. 53 24.2. STANDARD CONFIGURATION (SINGLE SAFETY VALVE) DIGIT 37 = X ................................................................... 54

25. ACRONYMS ........................................................................................................................................ 55

26. ILLUSTRATION LIST ............................................................................................................................. 56

27. TABLE LIST .......................................................................................................................................... 57

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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. 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).

Illustration 1. RTAC range overview

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2. Operating Map

The unit condenser can operate in two conditions depending on the efficiency.

2.1. Standard Efficiency

2.2. 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

Standard ambient

°C

High ambient

°C

Low ambient

°C

Wide ambient

°C 7 7 -18 -18

40 46 40 46

Min. LWT °C -12 Max. LWT °C 18

Standard ambient

°C

High ambient

°C

Low ambient

°C

Wide ambient

°C 7 7 -18 -18

46 52 46 52

Min. LWT °C -12 Max. LWT °C 18

Illustration 2. Operating map for standard efficiency

Illustration 3. Operating map for high and xtra efficiency

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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

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4. Components in electrical panel for standard units

4.1. Phase 1

1.

4.2. Phase 2

Compressor fuses

Fan fusesCompressor contactor

Fan contactors and overload relays

Compressor fuses

Compressor contactors

Fan contactors

Fan fuses

Illustration 5. Electrical components for standard units

Illustration 6. Electrical components in phase 2

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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. Note : For fuse information, see the table in the Selection Data of RTAC.

Table 1. Fuse size in Amps

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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.

5.1. 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.

5.2. Phase 2

The electrical enclosure is mounted at the end of the unit, full part.

Illustration 8. Electrical enclosure in phase 1 Illustration 7. Additional box for fan inverters

Illustration 9. Electrical enclosure in Phase 2

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6. Freeze protection Digit 15

6.1. With freeze protection Digit 15 = F or G

6.1.1. Application

- When unit needs to be protected from freezing (no glycol in the water loop).

6.1.2. 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.

6.1.3. 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.

Circuit 1

Circuit 2

heater

heater

Illustration 10. Heater cables around the evaporator

Illustration 11. Heater in evaporator water box

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6.1.4. Benefits

- Components are protected from freezing.

6.1.5. Incompatibilities

- No incompatibility.

6.2. 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.

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.

No heater installed

Illustration 12. Evaporator without heater in water box

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7. Evaporator Insulation Digit 16

7.1. 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 .

7.2. Without thermal insulation Digit 16 = 2

Evaporator is not insulated.

7.3. Extra pass

7.3.1. 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.

7.3.2. 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 230-400.

Illustration 13. Evaporator insulation

Illustration 14. Evaporator without insulation

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7.3.3. 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.


- RTAC 120-200

7.4. Specific tubes for Brine applications

7.4.1. Application

- When the unit needs a very low leaving chilled water temperature (LCWT).

7.4.2. Description

- Specific tubes are used for water circuit in evaporator. - The type of tube is Gewa-BHV, it is a slotted tube.

R134a vapor outlet

R134a vapor outlet

R134a liquid inlet

R134a vapor outlet

R134a vapor outlet

R134a liquid inlet

Oil return Oil return

Evaporator entering water

Evaporator leaving water

Circuit 1 Circuit 2

Water box

Water box

Illustration 15. Evaporator water circuit in extra pass option

Illustration 16. Gewa-BHV slotted tube

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7.4.3. Operation

- Brine applications are compatible with RTAC 230-400 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.

7.4.4. 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


- RTAC 120-200

7.4.6. More detail

- For units with low leaving chilled water temperature (LCWT), some additionals enhancement in insulation for some components are provided by Trane.

Illustration 18. Insulation on expansion

device (EXV)

Illustration 17. Insulation on evaporator

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8. Condenser Temperature Range digit 17

To choose the unit configuration, refer to operating map.

8.1. 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.

8.2. 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.

8.3. 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.

8.4. 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.

8.5. Summary

Digit 17 Compressor Power

Wires oversized Variable speed

fan N standard

H high ambient L low ambient

W wide ambient

No Yes No Yes

No No Yes Yes

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9. Condenser fin material Digit 18

9.1. Standard aluminum slit fins Digit 18 = X

9.1.1. Applications

- When the chiller is installed in a non-polluted area.

9.1.2. Description

- Aluminum fin is a standard fin used on all air-chillers. - The slit is between the gap of two collar.

9.1.3. 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.

9.1.4. Benefits

- Increases the condenser and chiller performance.


- Not recommended when the chiller is installed in a polluted area or in a dusty area in order to avoid the clogging.

Slit

Illustration 19. Aluminum slit fin

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9.2. Copper slit fins Digit 18 = 2

9.2.1. Applications

- When chiller is installed in a non-polluted area - For marine application.

9.2.2. Description

- Slit is between the gap of two collar. - Condenser consists of all copper material.

9.2.3. Operation

- Slit increases the air turbulences. - Slit allows more heat transfers between both fluids.

9.2.4. 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.


- 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.

Illustration 20. Copper slit fin

slit

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9.3. Black epoxy fins Digit 18 = 3

9.3.1. Application

- For coastal or salt mist environments. - When the aluminum fin is exposed to hard weather conditions (acid rain,

moisture, pollution, salt …).

9.3.2. 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

9.3.3. 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.

9.3.4. 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.

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9.3.5. 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.


- Can not be used with lanced aluminum fins.

9.3.7. 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.

Resine Polyurethane, color black

Resine Black Epoxy

Phosphochromation

Aluminum 0.12 mm thick

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10. Condenser fan motor configuration Digit 19

10.1. Low noise Digit 19 = L

10.1.1. Application

- When unit needs to be installed in a sensitive area (where the noise is unbearable in a crowded place).

10.1.2. 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.


- 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.


- It can not be applied when the air ambient temperature is higher than 46°C.

10.2. 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

Illustration 23. Compressor and discharge lines insulation

Illustration 22. Suction lines and compressors insulation

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10.3. Night noise setback Digit 19 = Q

10.3.1. Application

- When the fan speed needs to be reduced at night.

10.3.2. 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..).

10.3.3. 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.

10.3.4. 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.


- Standard noise version units.

contactor

Clock as the external signal

Illustration 24. NNSB contactor and external signal diagram

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10.4. 100Pa High Pressure Drop Digit 19 = P

10.4.1. Application

- Used for specific application requiring a ducted air discharge. - When fans need to exhaust a higher volume of air flow.

10.4.2. Description

- Fans are mounted on top of the chiller and protected with fan guard (protection grill).

- For standard version units only.

10.4.3. 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.

Illustration 26. High static fans with fan motor Illustration 25. Standard fans

Illustration 28. The high static fans are easily recognizable because of the shape of the guard

Illustration 27. The shape of the guard for standard fans

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10.4.4. Benefits

- More air can be rejected outside the chiller. - 100Pa of Pressure Drop are available

10.4.5. Inconvenience

- Increase the sound level by 3 to 4 dB(A).


- Low noise version units.

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11. Starter type Digit 20

11.1. Across the Line Starter/Direct on Line Digit 20= X

11.1.1. Application

- To start the compressor.

11.1.2. Description

- This starter is factory-installed, located in electrical panel.

11.1.3. Operation

- Allow to start and stop compressors.

11.1.4. Benefits

- Low cost for component installation. - Simple system.


- Star-delta starter.

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11.2. Solid-state soft starter Star - delta starter Digit 20 = Y

11.2.1. Application

- To start the compressor. - To reduce inrush current.

11.2.2. Description

- Factory-installed, located in electrical panel.

11.2.3. 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 29. Y-delta starter installation circuit

Illustration 30. Star-delta stages

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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.

11.2.4. Benefits

- Motor starts with less inrush current than direct on line.


- Direct on line.

11.3. 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 100 100 < 0.5 Y-Delta 33 33 < 1

Table 2. Comparison of reduced inrush current

Illustration 31. % Run Load Amps(RLA) vs Times

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12. Power line connection type Digit 22

12.1. Terminal block with fuses Digit 22 = X

This is a standard component supplied by Trane.

12.1.1. Application

- Used to stop the chiller when there is a short circuit in the system.

12.1.2. 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.

12.1.3. 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.

12.1.4. Benefits

- Protects the unit from damages.



Copper blocks

Compressor fuses

Illustration 32. Terminal blocks with fuses

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12.2. Disconnect switch with fuses Digit 22 = B

12.2.1. 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.

12.2.2. Description

- Disconnect switch is factory-installed, located in electrical panel. - Used with a closed electrical panel (no electrical risk). - Fuses for unit components.

ill

12.2.3. 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.

12.2.4. Benefits

- Ensures the safety during the maintenance works. - Protects the unit from damages. - Provides a protection against excessive current by the fuses.



Compressor fuse

Illustration 33. Disconnect switch handle

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13. Remote Interface Digit 24

13.1. BCI-C (BACnet) Digit 24 = B

13.1.1. 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.

13.1.2. 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.


- Used with CH530 main processor (MP) 2.00 and TechView 12.1 SP2 or

higher.


- LCI-C. - Tracer Comm3 (Modbus).

Illustration 35. BCI-C layout Illustration 34. BCI-C

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13.2. Tracer Comm 3 Digit 24 = C

13.2.1. Application

- Allows Tracer CH530 to exchange information with a higher-level control device, such as Tracer Summit.

13.2.2. 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.

13.2.3. Operation/benefits

- Used with Tracer Summit™ and Tracer™ 100 systems.


- LCI-C.

Illustration 36. Tracer Comm 3 interface

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13.3. LCI-C Card (LonTalk Communication Interface) Digit 24 = L

13.3.1. 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).

13.3.2. Description

- The LCI-C is factory installed with the chiller controller, located in the control panel box.


- 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.

Illustration 37. LCI-C card

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RLC-PRB030-E4

- 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 network configuration input nvi network variable input nvo network variable output SNVT Standard Network Variable Type UNVT User-defined Network Variable Type

Table 3. Lontalk list

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- BCI-C. - Tracer Comm3 (Modbus).

14. Control Input Accessories Digit 25

14.1. Remote External Chilled Water Setpoint (ECWS) and Remote

Current Limit Setpoint Digit 25 = B

14.1.1. Application

- External signal used to set the chilled water setpoint. - External signal used to set the current limit setpoint.

14.1.2. 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.

14.1.3. 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.

Illustration 38. External current limit and chilled water setpoint card

Power port

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RLC-PRB030-E4

- 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.

14.1.4. 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.


- 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.

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RLC-PRB030-E4

15. Control Output Accessories Digit 26

15.1. Programmable Relays Digit 26 = X

15.1.1. Application

- When certain events or states of the chiller need to be remotely controlled.

15.1.2. Description

- Use 4 output relays as shown in the field wiring diagram.

15.1.3. 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 :

Table 4. Default assignments

Note : other events/states that can be assigned to the programmable relays can be found in Installation Operation Maintenance

15.1.4. Benefits

- Customers will be alerted if the events or states of the chiller occur. - Reduces maintenance work on the chiller.

Relay Alarm and status

Relay 1 terminals J2-12,11,10: Alarm

Relay 2 terminals J2-9,8,7: Chiller running

Relay 3 terminals J2-6,5,4: Maximum capacity

Relay 4 terminals J2-3,2,1: Chiller limit

Illustration 39. Alarm relay output card

Power port

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- No incompatibilitiy.

15.2. 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 www.calmac.com

15.2.1. 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.

15.2.2. 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.

15.2.3. Operation

- CH530 provides a “ Front Panel Ice Termination” settable and adjustable from - 6.7°C to - 0.5°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. - 6.7°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.

Illustration 40. Ice making card

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15.2.4. Benefits

- Reduces or even replaces mechanical cooling during the day. - Reduces the electricity consumption cost. - Ability to eliminate the chiller over sizing.



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.

16.1. Dead front Digit 27 = X

16.2. IP20 Digit 27 = 1

Front cover for IP20 is thicker than dead front. Note : The pictures of electrical protections are for the units in phase 2

Illustration 41. Dead Front

Illustration 42. IP20

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17. Packing & Electrical Accessories Digit 28

17.1. 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 120-200, the chillers can be transported also on 20 ft container. The coils are protected during the shipment.

17.2. 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. Metallic clog

Illustration 43. View of RTAC 400HE/XE for shipment

Additional box

Size of the electrical box reduced

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.

Coils protection

Illustration 44. Metallic clog

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RLC-PRB030-E4

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.

For a shipment with flow switch, it is placed in electrical panel. You will find more information in case 5082

Illustration 45. Location of the ground terminal

Illustration 47. Flow switch

Illustration 46. Ground terminal

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18. Control Panel Accessories Digit 29

18.1. Under/Over voltage transformer Digit 29 = 1

18.1.1. Application

- When unit needs to be protected from under/over voltage.

18.1.2. Description

- Factory installed, located in the electrical panel.


- 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.



Illustration 48. Under/over voltage transformer

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18.2. Ground fault protection relay Digit 29 = 2

18.2.1. Application

- When the electrical components need to be protected from a detectable current in the electrical panel.

18.2.2. 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.


- Protect an electrical distribution system from ground faults.



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

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19. Services Valves & Gauges Digit 30

19.1. Gauges

19.1.1. Application

- To give pressure information for each refrigerant circuit

19.1.2. Description

- Factory-installed, located near the compressor at the baseframe. - Consists of LP and HP gauges.


- Measures the pressure in the circuit.



19.1.5. Inconvenience

- Leakage source for refrigerant. - Higher cost for customers.

Reminder : Pressure information can be read directly on CH530

19.1.6. 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.

Illustration 52. LP and HP gauges

LP gauge HP gauge

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19.2. Suction valve

19.2.1. Application

- Used to isolate the refrigerant circuit.

19.2.2. Description

- Factory installed, located on suction line of the evaporator. - 2 positions, backseated (open) and frontseated (closed).

19.2.3. 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.



19.3. Discharge valve

It is a standard component. Located on the discharge line of the compressor.

Illustration 53. Suction valve

Illustration 54. Discharge valve

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20. Compressor sound enclosure Digit 31 = 1

20.1.1. Application

- Used to reduce the sound level emitted by compressor with a reduction of 1 dB(A).

20.1.2. Description

- Factory-installed. - Compressor is installed in a box - For standard unit.

20.1.3. Operation

- The box covers the compressor.

20.1.4. Benefits

- Reduces noise emissions from compressor. - Compressor is protected from outside elements. - Esthetics.



20.1.6. More detail

For standard unit, the compressor will be not covered

Illustration 55. Compressor enclosure

Illustration 56. Compressor without enclosure

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21. Appearance Options Digit 32

21.1. Without appearance options Digit 32 = X

The unit is without overspray, the coil and the equipment under the coil are not protected. 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)

21.2. 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 57. Chiller without appearance

Illustration 58. White paint over spray

Illustration 59. White paint over spray side view

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21.3. Coil protection Digit 32 = C

The coil is protected with access guards against outside elements.

21.4. Coil protection and white paint over spray Digit 32 = H

21.5. 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.

Access

Illustration 60. Coil protection with access guards

Illustration 61. Coil protection+white paint over spray

Illustration 62. Evaporator protection with access guards

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RLC-PRB030-E4

21.6. Coil protection + white paint over spray + evaporator protection

Digit 32 = L

The unit appears with full protection.

Illustration 63. Final phasing appearance

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22. Installation accessories Digit 33

22.1. Neoprene pads Digit 33 = R

22.1.1. Application

- Used to avoid direct contact of the chiller and the ground.

22.1.2. Description

- They are installed under the chiller. - Shipped in the control panel.


- Neoprene pad do not filter vibrations. - Avoid direct contact of the base frame with the ground.


- No incompatability.

Illustration 64. Neoprene pads

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RLC-PRB030-E4

22.2. Neoprene isolators Digit 33 = B-D-K-P

22.2.1. Application

- Used to minimize the vibrations transmitted to the building.

22.2.2. Description

- They are installed under the chiller. - Shipped with the chiller.

22.2.3. Operations/Benefits

- Eliminates vibration and noise transmission throughout the building.

Neoprene isolators deflection

Illustration 65. Neoprene isolators

Color Max. Load Deflection at max. Load

lbs kg inch mm

BROWN 1500 680

RED 2250 1020

GREEN 3000 1360

GRAY 4000 1815

0,5 12,7

Table 5. Neoprene isolators deflection

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RLC-PRB030-E4


- No incompatability.

22.3. Grooved pipe & victaulic couplings Digit 33 = A

Consiste of pipe stub and Victaulic couplings. Used when tube is welded. Tube cuff

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

Victaulic couplings Weld

sleeve

Illustration 66. Grooved pipe connection+victaulic couplings

Unit size φ Diametre (inche) A +/‐ 0,76 (mm) B +/‐ 0,76 (mm) L (mm)

120HE

120XE

130HE

130XE

140SE

140HE

140XE

155SE 4" 15,88 8,74 60

155HE

155XE

170SE

170HE

175XE

185SE

185HE

185XE

200SE

200HE

200XE

4"

6"

6" 15,88 8,74 80

15,88 8,74 60

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

8"

6" 15,88 8,74 80

10011,9119,05

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22.4. Side Victaulic connection Digit 33 = U

22.4.1. Application

- When the pipe connection between the building and the unit has to be joined directly.

22.4.2. 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.


- 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.


- Access guards at lower part of the unit (coil protection accepted)

Illustration 67. Side pipe ti

Table 6. Tube cuff dimensions

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23. Language, digit 35 and Digit 23

23.1. 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

23.2. Language available for CH530 display

And the CH530 can display messages in following languages: Digit 23 Language

A Dyna-view / English

F Dyna-view / French

G Dyna-view / German

H Dyna-view / Dutch

I Dyna-view / Italian

S Dyna-view / Spanish

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24. Dual Devices Digit 37

24.1. Dual Safety Valve Digit 37 = 4

24.1.1. 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.

24.1.2. 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.

24.1.3. 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.

3 way valve

Illustration 70. Dual safety valve layout

Valve port

3-way valve

Illustration 69. Dual safety valve on oil separator Illustration 68. Dual safety valve on evaporator

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RLC-PRB030-E4

24.1.4. Benefits

- Eliminates the need to shut down the unit and remove the refrigerant for servicing.

- Reduces maintenance work.



24.2. 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 72. Single safety valve on the evaporator

Illustration 71. Single safety valve on high pressure side of oil separator

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25. Acronyms

SE Standard Efficiency

HE High Efficiency

XE Xtra Efficiency

LCWT Leaving Chilled Water Temperature

MS/TP Master Slave Token Processing

BCI-C BACnet Communication Interface for Chiller

LLIDs Low Level Intelligent Devices

LCI-C LonTalk Communication Interface for Chiller

BAS Building Automation System

IPC3 Intra Processor Communication

ECWS External Chilled Water Setpoint

ECLS External Current Limit Setpoint

LP Low Pressure

HP High Pressure

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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 2 .......................................................... 7 Illustration 7. Additional box for fan inverters .............................................................. 9 Illustration 8. Electrical enclosure in phase 1 .............................................................. 9 Illustration 9. Electrical enclosure in Phase 2 ............................................................. 9 Illustration 10. Heater cables around the evaporator ................................................ 10 Illustration 11. Heater in evaporator water box ......................................................... 10 Illustration 12. Evaporator without heater in water box ............................................. 11 Illustration 13. Evaporator insulation ......................................................................... 12 Illustration 14. Evaporator without insulation ............................................................ 12 Illustration 15. Evaporator water circuit in extra pass option ..................................... 13 Illustration 16. Gewa-BHV slotted tube ..................................................................... 13 Illustration 17. Insulation on evaporator .................................................................... 14 Illustration 18. Insulation on expansion device (EXV) ............................................... 14 Illustration 19. Aluminum slit fin ................................................................................ 16 Illustration 20. Copper slit fin .................................................................................... 17 Illustration 21. Black epoxy fin .................................................................................. 18 Illustration 22. Suction lines and compressor’s insulation ......................................... 20 Illustration 23. Compressor and discharge lines insulation ....................................... 20 Illustration 24. NNSB contactor and external signal diagram .................................... 21 Illustration 25. Standard fans .................................................................................... 22 Illustration 26. High static fans with fan motor .......................................................... 22 Illustration 27. The shape of the guard for standard fans ......................................... 22 Illustration 28. The high static fans are easily recognizable because of the shape of the guard .................................................................................................................. 22 Illustration 29. Y-delta starter installation circuit ........................................................ 25 Illustration 30. Star-delta stages ............................................................................... 25 Illustration 31. % Run Load Amps(RLA) vs Times .................................................... 26 Illustration 32. Terminal blocks with fuses ................................................................ 27 Illustration 33. Disconnect switch handle .................................................................. 28 Illustration 34. BCI-C ................................................................................................ 29 Illustration 35. BCI-C layout ...................................................................................... 29 Illustration 36. Tracer Comm 3 interface ................................................................... 30 Illustration 37. LCI-C card ......................................................................................... 31 Illustration 38. External current limit and chilled water setpoint card ........................ 33 Illustration 39. Alarm relay output card ..................................................................... 35 Illustration 40. Ice making card ................................................................................. 36 Illustration 41. Dead Front ........................................................................................ 37 Illustration 42. IP20 ................................................................................................... 37 Illustration 43. View of RTAC 400HE/XE for shipment ............................................. 38 Illustration 44. Metallic clog ....................................................................................... 38 Illustration 45. Location of the ground terminal ......................................................... 39 Illustration 46. Ground terminal ................................................................................. 39

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Illustration 47. Flow switch ........................................................................................ 39 Illustration 48. Under/over voltage transformer ......................................................... 40 Illustration 49. Tore of the ground fault relay ............................................................ 41 Illustration 50. Name plate and port connection of the tore ...................................... 41 Illustration 51. Tore in a box for shipment ................................................................. 41 Illustration 52. LP and HP gauges ............................................................................ 42 Illustration 53. Suction valve ..................................................................................... 43 Illustration 54. Discharge valve ................................................................................. 43 Illustration 55. Compressor enclosure ...................................................................... 44 Illustration 56. Compressor without enclosure .......................................................... 44 Illustration 57. Chiller without appearance ................................................................ 45 Illustration 58. White paint over spray ....................................................................... 45 Illustration 59. White paint over spray side view ....................................................... 45 Illustration 60. Coil protection with acces guards ...................................................... 46 Illustration 61. Coil protection+white paint over spray ............................................... 46 Illustration 62. Evaporator protection with acces guards .......................................... 46 Illustration 63. Final phasing appearance ................................................................. 47 Illustration 64. Neoprene pads .................................................................................. 48 Illustration 65. Neoprene isolators ............................................................................ 49 Illustration 66. Grooved pipe connection+victaulic couplings .................................... 50 Illustration 67. Side pipe connection ......................................................................... 51 Illustration 68. Dual safety valve on evaporator ....................................................... 53 Illustration 69. Dual safety valve on oil separator ..................................................... 53 Illustration 70. Dual safety valve layout .................................................................... 53 Illustration 71. Single safety valve on high pressure side of oil separator ................. 54 Illustration 72. Single safety valve on the evaporator ............................................... 54

27. Table list

Table 1. Fuse sizes in Amps ....................................................................................... 8 Table 2. Comparison of reduced inrush current ........................................................ 26 Table 3. Lontalk list ................................................................................................... 32 Table 4. Default assignments ................................................................................... 35 Table 5. Neoprene isolators deflection ..................................................................... 49 Table 6. Tube cuff dimensions .................................................................................. 51

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Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, the leader in creating and sustaining safe, comfortable and energy efficient environments, Trane offers a broad portfolio of advanced controls and HVAC systems, comprehensive building services, and parts. For more information, visit www.Trane.com.

Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. © 2012 Trane All rights reserved RLC-PRB030-E4 May 2012

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