Trane RTWA 70-125 TON - Manuals

RLC-SVD03A-EN 7 General Information Real time data for temperatures, diagnostics and control algorithms etc. are made available to the CPM and the other modules for display and for input to higher level functions. See Electronic Expansion Valve Module (EXV) (1U3) on page 58 for details. Options Modu...

8 RLC-SVD03A-EN Interprocessor Communications The respective modules communicate with each other via an InterProcessor Communication link (IPC). The IPC allows the modules to work in a coordi-nated manner with the CPM directing overall chiller operation while each module handles specific subfunction...

RLC-SVD03A-EN 9 Interprocessor Communication from the Options Module. When some problem exists with the IPC link or a module fails, it is not uncommon for more than one of these IPC diagnostics to be displayed. Note that only those diagnostics that are indicated to be active currently exist. All oth...

10 RLC-SVD03A-EN Interprocessor Communication Figure 1 IPC Link Order For 70-125 Ton RTAA *#,$5 *-3#0"5 *-3#0!5 *#325 *)0#"5 2%-/4%#,$ *%86-!34%25 *#0-5 *,#)#5 /R 5AND5AREMUTUALLYEXCLUSIVEOPTIONS4HE2EMOTE#,$ISNOTAVAILABLEIFTHE5OPTIONISINSTALLED

RLC-SVD03A-EN 11 Interprocessor Communication . 3. Loss of power to a module: Generally a power loss to a particular module will only affect communica-tions with that module. The module can usually be identified by analysis of the IPC diagnostics. (When the display is blank, check power at the CLD)....

12 RLC-SVD03A-EN Interprocessor Communication 5. Improper connections to terminal J2: Jack J2, present on all modules except CLD, should have no connections. This input is for manufacturing test purposes only and any connections, shorts, etc. will potentially cause the module to not respond, respond...

14 RLC-SVD03A-EN Interprocessor Communication The CPM has detected loss of communications with MCSP A, MCSP B, and EXV. Suspect an open early in the IPC link between the CPM and MCSP B. There are a large number of possible combinations of diagnostics. One must deduce what is causing the problem usin...

RLC-SVD03A-EN 15 Temperature Sensor Checkout With the exception of the thermostats located in the motor windings of the screw compressors, all the temperature sensors used on the UCMs are negative temperature coefficient (NTC) thermistors. The thermistors employed all have a base resistance of 10 Ko...

16 RLC-SVD03A-EN Temperature Sensor Checkout 4. Again measure the temperature at the sensor with an accurate thermom-eter; record the temperature reading observed. 5. Remove the sensor leads from the terminal strip or unplug the respective MTA. Measure the resistance of the sensor directly or probe ...

RLC-SVD03A-EN 17 Temperature Sensor Checkout . 1. Overall accuracy for any of the sensors is at least + 2 F over the range shown. Accuracy of matched sensors is + 1 F over specific ranges.2. As you compare a thermistor resistance (or input voltage) reading with the “actual” temperature indicated by ...

18 RLC-SVD03A-EN Temperature Sensor Checkout 1. Overall accuracy for the sensor is at least + 2 F over the range shown.2. As you compare a thermistor resistance (or input voltage) reading with the “actual” temperature indicated by the thermometer, be sure to consider the location and precision of th...

RLC-SVD03A-EN 19 Compressor Operation This feature is called the Auto Lead/Lag and can be found in the Service Settings Group, under the “Balanced CPRSR Starts and Hours” menu. When this function is disabled, the UCM always starts compressor “A” first. When this function is enabled, the following oc...

20 RLC-SVD03A-EN Compressor Start/Stop To start a compressor after either a “normal' shutdown, a Diagnostic reset, or power-on-reset, the following sequence will occur: 1. On a call for a compressor, the Restart Inhibit Timer will time out, if any time remains. 2. The EXV is positioned to the initia...

RLC-SVD03A-EN 23 Current Transformer Each compressor motor has all three of its line currents monitored by torroid (doughnut) current transformers. While the MCSP utilizes all three of the signals, it only displays the maximum phase at any given time. These currents are normalized with respect to th...

RLC-SVD03A-EN 25 Current Transformer WARNING Hazardous Voltage w/Capacitors! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy stor...

26 RLC-SVD03A-EN Current Transformer essar y to remove a cap over the top of the connector to gain access to the connector conductors.) 6. Refer to Table 7 which lists the normal resistance range for each exten- sion of current transformer. Check the measured resistance against the value listed per ...

30 RLC-SVD03A-EN Current Transformer Table 8 Compressor Phase Current vs. AC Input Voltage at MCSP ACTUAL COMPRESSOR PHASE AMPS THRU CT TERMINALVOLTAGE (V RMS) % OF CT RATING EXT-01 EXT-02 EXT-03 EXT-04 EXT-05 EXT-09 EXT-10 0 0 0 0 0 0 0 0.00 0 5 8 10 14 20 2.5 3.75 1.19 5 10 15 20 28 40 5 7.5 1.37 ...

RLC-SVD03A-EN 31 Current Transformer Table 9 Overload Dip Switch Setting vs. Internal Software Gain CPRSR RATED RLAAS A % OF CT RATING OVERLOAD DPSWITCH SETTING DECIMALSETTING SOFTWAREGAIN 66 00000 00 1.500000 67 00001 01 1.483870 68 00010 02 1.467743 69 00011 03 1.451613 70 00100 04 1.435483 71 001...

32 RLC-SVD03A-EN Under-Over Voltage Transformer The hardware required for the Under/Over voltage sensing function of the UCM is standard on the 70-125 Ton RTAA chiller. This feature must be Enabled in the Service Settings Menu for it to be active. A custom designed transformer whose primary is conne...

RLC-SVD03A-EN 34 Compressor Capacity The 35 to 60 ton helical rotary screw compressors are loaded and unloaded by means of an internal slide valve and a female unloader valve. In simple terms, these valves can regulate the amount of “bite” of the compressor rotors as they turn at relatively constant...

RLC-SVD03A-EN 35 Compressor Capacity Checkout Procedure for MCSP Load/Unload Outputs WARNING Live Electrical Components! During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed electrician or ...

36 RLC-SVD03A-EN Compressor Capacity prevent a compressor from loading even if the chilled water setpoint is not satisfied. Refer to the RTAA-IOM-4 for discussion on condenser, evaporator, and current limiting functions and setpoints. Refer to the Mode display under the Chiller Report on the CLD for...

RLC-SVD03A-EN 37 Compressor Capacity NOTE: Enabling the “Compressor Test” only affects which compressor will be cycled on next and is not an override mode. The chiller will continue to operate normally (not withstanding circuit lockout) and will stage compressors on and off, as well as attempt to mo...

38 RLC-SVD03A-EN Compressor Capacity Unload NOTE: The following assumes that the compressor's slide valve is already at some loaded position and %RLA is higher than the minimum noted in step 1. 1. Manually close the Unload toggle switch to continuously energize the Unload Solenoid Valve. 2. If the %...

RLC-SVD03A-EN 39 Compressor Capacity pressure, then the Slide Valve is bound. 5. If cylinder cavity pressure does not decrease or is at suction pressure before the Unload toggle switch was closed, the problem lies with either the solenoid coil or valve. 6. Check coil 7. If coil checks out, change th...

RLC-SVD03A-EN 41 Module Power and Miscellaneous I/O This section will detail the normal voltage levels present on each of the modules inputs and outputs under various conditions or states. Typical operation of the I/O will be discussed in terms of chiller operation. This should help the serviceman d...

42 RLC-SVD03A-EN Module Power and Miscellaneous I/O Clear Language Display (CLD) 1U6 Keypad Overview Local operator interface with the system is accomplished using the 16 keys on the front of the Clear Language Display panel. The readout screen is a two line, 40 character liquid cr ystal display wit...

RLC-SVD03A-EN 43 Module Power and Miscellaneous I/O Select Report Group This group of four keys allows the operator to select and view the following reports: - Custom Report - Chiller Report - Refrigerant Report - Compressor Report The Custom Report is the only report of the four that is defined by ...

44 RLC-SVD03A-EN Module Power and Miscellaneous I/O When any of the four report keys are pressed, the first readout on the display will be the header. The header identifies the title of the report and summa-rizes the items in the report. The Next key and Previous key allow the operator to scroll up ...

RLC-SVD03A-EN 45 Module Power and Miscellaneous I/O Press Next to move down through the Chiller Report. As shown in the figures, the flowchart explains the conditions that the UCM looks at to determine which readout is to be displayed next. For example: Press Chiller Report to display the header Pre...

46 RLC-SVD03A-EN Module Power and Miscellaneous I/O When updating is successfully completed, the system will default to the first display after the Chiller Report header: MODE: OPERATING MODE] REQUESTED SETPOINT SOURCE: [SETPT SOURCE] and the backlight will be activated. LEDs There are four LEDs loc...

RLC-SVD03A-EN 47 Module Power and Miscellaneous I/O Test Points There are two test points associated with the CPM module. They are easily read with a DC voltmeter by probing the PC board solder pads found in the upper left hand corner of the module. The positive meter lead should be connected to the...

48 RLC-SVD03A-EN Module Power and Miscellaneous I/O I/O terminals For the checkout of the I/O, refer to the block diagram of the module in Figure 10 and the Chiller Wiring Diagrams for both high and low voltage circuits. All voltages are measured differentially between terminal pairs specified unles...

50 RLC-SVD03A-EN Module Power and Miscellaneous I/O Options Module (CSR) (1U2) WARNING Live Electrical Components! During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed electrician or other ...

RLC-SVD03A-EN 51 Module Power and Miscellaneous I/O 2. Has its negative terminal tied to chassis ground. If the intended source does not meet the above requirement, an isolation module must be used The 4-20mA/2-10VDC inputs may be tested in the following ways: 1. Enable External Chilled Water Setpoi...

52 RLC-SVD03A-EN Module Power and Miscellaneous I/O Setpoint Priority There are many ways in which the Chilled Water and Current Limit setpoints can be adjusted or reset when the Options Module is present in the Chiller control system. The following flow charts show how these methods are prior-itize...

RLC-SVD03A-EN 53 Module Power and Miscellaneous I/O “TRACER” implies Trane Integrated Comfort System remote device (ICS) using the digital communication link. “EXTERNAL” implies generic building automation system or process controller interface using a 4-20ma loop or a 2-10 VDC analog signal. Figure...

54 RLC-SVD03A-EN Module Power and Miscellaneous I/O “TRACER” implies Trane Integrated Comfort System remote device (ICS) using the digital communication link. “EXTERNAL” implies generic building automation system or process controller interface using a 420ma loop or a 2-10 VDC analog signal. Figure ...

RLC-SVD03A-EN 55 Module Power and Miscellaneous I/O ICS Communications ICS (Tracer) communication is handled the same as on previous products using the Trane proprietary Comm3 standard 1200 baud isolated serial communication link. The following are some things to check when experi-encing loss of ICS...

56 RLC-SVD03A-EN Module Power and Miscellaneous I/O Table 19 CSR Normal Terminal Voltages for Options Module 1U2 TerminalDesignation Descriptionof Circuit Normal Terminal Voltagesfor Various Conditions J1-4 to 3or J1-2 to 1 IPC Communications 19.2 kbaud serial data, 5 volt signal level. Refer to Int...

58 RLC-SVD03A-EN Module Power and Miscellaneous I/O Electronic Expansion Valve Module (EXV) (1U3) WARNING Live Electrical Components! During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed el...

RLC-SVD03A-EN 59 Module Power and Miscellaneous I/O A “FLAG” stop is located at either end of the threaded portion of the motor shaft. The stops interfere with the milled flag on the drive coupling, restricting rotation of the motor shaft and producing a clicking sound when the valve is driven fully...

60 RLC-SVD03A-EN Module Power and Miscellaneous I/O Electronic Expansion Valve Location The valve should be installed with the motor in a vertical position, or no greater than 45° from vertical, as shown in Figure 16 . This will prevent oil logging and the possibility of contamination reaching the m...

RLC-SVD03A-EN 61 Module Power and Miscellaneous I/O Test Points There is only one test point associated with the EXV module. It is easily read with a DC voltmeter by probing the PC board solder pad found in the upper left hand corner of the module. The positive meter lead should be connected to the ...

62 RLC-SVD03A-EN Module Power and Miscellaneous I/O diagnostic suggests that there is a problem with the valve or the valve wiring. To confirm this, it is necessary to continue the procedure. The Electrical Integrity test will be completed in about 2 seconds. Regardless of whether or not a diagnosti...

RLC-SVD03A-EN 63 Module Power and Miscellaneous I/O 3. Check the resistance from each of the three phase pins (J4-3, J4-2, and J4-1) to the board edge GND, with the connector unplugged. This resis-tance should be between 100K and 200K ohms. If the valve/wiring/connector combination fails the above t...

64 RLC-SVD03A-EN Module Power and Miscellaneous I/O used, it is important to direct the flame away from the valve body. See Figure 17 . A wet cloth should be wrapped around the body during soldering to provide extra protection. This will help prevent overheating and damage to the synthetic seals and...

RLC-SVD03A-EN 65 Module Power and Miscellaneous I/O 2. Disconnect all the line voltage to the power supply of this unit. 3. Refer to the exploded view in Figure 18 while performing the remaining instructions. CAUTION Prevent Injury! Refer to Figure 18 . The pushrod is under spring pressure and will ...

66 RLC-SVD03A-EN Module Power and Miscellaneous I/O to the valve body until the sealing surfaces make contact. Tighten the actuator approximately 1/8 turn to seal the knife edge joint. 12. The motor cap quad-ring may be replaced by removing the ferrule motor cap nut. Be sure that the motor cap does ...

RLC-SVD03A-EN 67 Module Power and Miscellaneous I/O SEHI Electronic Expansion Valve Servicing The procedures listed below are to. be followed for proper disassembly, inspection, cleaning and reassembly to the valve. The valve does not need to be removed from the refrigerant piping before servicing. ...

68 RLC-SVD03A-EN Module Power and Miscellaneous I/O Figure 19 SEHI Electronic Expansion Valve Exploded View -OTOR!DAPTOR!SSEMBLY 0ISTON!SSEMBLY "ODY!SSEMBLY 3IGHTGLASS

RLC-SVD03A-EN 69 Module Power and Miscellaneous I/O SEO Valve Module ° TP1 +5V J6-1 — 115VAC HOTJ6-2 — 115VAC HOTJ6-3 — KEY (N/C)J6-4 — NEUTRAL IPC (+) — J1-4 J6-5 — NEUTRAL IPC (-) — J1-3 IPC (+) — J1-2 IPC (-) — J1-1 MANUF. NO CONN. — J2-2 USE ONLY NO CONN. — J2-1 L H 0 LOW PRESSURE SIG.— J7-5 I W...

70 RLC-SVD03A-EN Module Power and Miscellaneous I/O I/0 terminals For the checkout of the I/O, refer to the block diagram of the EXV module in Table 21 and the Chiller Wiring Diagrams for both high and low voltage circuits. All voltages are measured differently between terminal pairs SEHI Valve Modu...

RLC-SVD03A-EN 71 Module Power and Miscellaneous I/O specified, unless other wise indicated. The first terminal in the pair is the positive (or hot) terminal. Voltages given are nominals and may vary by ±5%. Unregulated Voltages (unreg) or 115 VAC voltages may vary by ±15%. Table 21 EXV Module Normal...

72 RLC-SVD03A-EN Module Power and Miscellaneous I/O Compressor Module (MCSP) (1U4 AND 1U5) WARNING Live Electrical Components! During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed electrici...

RLC-SVD03A-EN 73 Module Power and Miscellaneous I/O Binary Inputs The binary inputs shown in Table 22 all use the same basic circuit. A pullup resistor to the 12V power supply is connected to the higher numbered input pin. The lower numbered pin is connected to ground. The voltage between the two pi...

74 RLC-SVD03A-EN Module Power and Miscellaneous I/O the currents are higher than actual and will show up as an error in the %RLA displayed by the CPM. The compressor will operate safely but may unload due to the current limit function. Refer to Current Transformers and Current Inputs for more detail...

76 RLC-SVD03A-EN Module Power and Miscellaneous I/O J7-8,9 Step Load Solenoid Normally open contact, closes to energize the Step Load Solenoid Valve. J7-1, E7 Slide Valve Open(Load Solenoid) Output Triac Output, Refer to Checkout Procedure for MCSP Load/Unload Outputs. J7-1, E8 Slide Valve Close(Unl...

78 RLC-SVD03A-EN Module Power and Miscellaneous I/O Interprocessor Communication Bridge Module (IPCB) (1U7) The IPCB provides an extension of the IPC link to the Remote Clear Language Display. See Figure 23 It prevents “crashes” of the IPC and UCM if the link to the RCLD is shorted or misapplied. Th...

RLC-SVD03A-EN 79 Module Power and Miscellaneous I/O LonTalk® Communications Interface - Chillers Module(LCI-C) (1U8) The Tracer LCI-C interface acts as a translator between Trane's IPC (Inter-Processor Communication) and Echelon's LonTalk® communications protocol (ANSI/EIA/CEA 709.1). This allows th...

80 RLC-SVD03A-EN Variable Speed Fan System The purpose of this troubleshooting guide is to help technicians determine if the variable speed fan inverter, the compressor module, the variable speed fan inverter contactor, the fan motor or the interconnecting wiring is faulty. WARNING Hazardous Voltage...

RLC-SVD03A-EN 83 Variable Speed Fan System .6 VDC. If there is no voltage at either of these two test points, check the incoming 115 VAC between pins J6-1 (hot) and J6-5 (neutral) and check fuse F1, mounted on the upper right-hand corner of the circuit board. If the fuse is OK and the voltage betwee...

RLC-SVD03A-EN 85 Other Service Features Service Pumpdown The UCM provides for a "onetime" Service Pumpdown mode, in which a service-technician can direct a particular compressor to start and run for one minute, to accomplish pumpdown of the low side of the refrigeration system (evaporator an...

86 RLC-SVD03A-EN Other Service Features WARNING Hazardous Voltage w/Capacitors! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy s...

RLC-SVD03A-EN 87 Other Service Features tioned (if not already controlling). Most often the stage-on will be accom-panied by a controlled stage-off of an already running compressor. Since normal operation is in effect, a constant load or setpoint change may be required to keep the compressor from st...