TRANE RTAE Stealth Model Chillers Field Replacement of GP4 Classic Compressor Instruction Manual

June 13, 2024
Trane

TRANE RTAE Stealth Model Chillers Field Replacement of GP4 Classic

Compressor

SAFETY WARNING

  • Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and require specific knowledge and training.
  • Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury.
  • When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment.

Introduction

  • Read this manual thoroughly before operating or servicing this unit.

Warnings, Cautions, and Notices

  • Safety advisories appear throughout this manual as required.
  • Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.
  • The three types of advisories are defined as follows:

WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It could also be used to alert against unsafe practices.
NOTICE Indicates a situation that could result in equipment or property damage only accidents.

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

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

WARNING

  • Proper Field Wiring and Grounding Required!
  • Failure to follow code could result in death or serious injury. All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state/national electrical codes.

WARNING

  • Personal Protective Equipment (PPE) Required!
  • Failure to wear proper PPE for the job being undertaken could result in death or serious injury. Technicians, in order to protect themselves from potential electrical, mechanical, and chemical hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well as the instructions below:
  • Before installing/servicing this unit, technicians MUST put on all PPE required for the work being undertaken (Examples; cut-resistant gloves/sleeves, butyl gloves, safety glasses, hard hat/bump cap, fall protection, electrical PPE and arc flash clothing). ALWAYS refer to the appropriate
  • Safety Data Sheets (SDS) and OSHA guidelines for proper PPE.
  • When working with or around hazardous chemicals, ALWAYS refer to the appropriate SDS and OSHA/GHS (Global Harmonized System of Classification and Labeling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection and handling instructions.
  • If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other country-specific requirements for arc flash protection, PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASH CLOTHING. ENSURE ELECTRICAL METERS AND EQUIPMENT ARE PROPERLY RATED FOR THE INTENDED VOLTAGE.

WARNING
Follow EHS Policies!

  • Failure to follow the instructions below could result in death or serious injury.
  • All Trane personnel must follow the company’s Environmental, Health and Safety (EHS) policies when performing work such as hot work, electrical, fall protection, lockout/tagout, refrigerant handling, etc. Where local regulations are more stringent than these policies, those regulations supersede these policies.
  • Non-race personnel should always follow local regulations.

Copyright

  • This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part without written permission. Trane reserves the right to revise this publication at any time, and to make changes to its content without obligation to notify any person of such revision or change.

Trademarks

  • All trademarks referenced in this document are the trademarks of their respective owners.

Revision History

  • Document updated to reflect Service Offering number.

General Information

Initial production RTAE chillers include 1st Gen GP4 Screw Compressors with legacy motors (Phase Motion), external inductors between the drive and compressor, and (on some units) smaller AFD3 frames compared to second generation chillers. While 2nd Gen GP4 Screw Compressors include an updated motor (Regal Beloit), no external inductors, and (on some units) larger AFD3 frames.

Table 1. GP4 classic compressor


Description

| 1 st Gen GP4 Classic Compressor| 2 nd Gen GP4 Classic Compressor
---|---|---
Motor| Phase Motion| Regal Beloit
External Inductor| Yes| No
AFD3 Frame Size| Smaller on some units| Larger on Some units

With the conversion to the GP4 Variable VI ratio (VarVI) compressor architecture, in the event of a compressor failure, it is not possible to replace 1st or 2nd Gen GP4 Classic Compressors with the new GP4 VarVi model. A service model GP4 VarVi Compressor was developed for replacement of
both 1st and 2nd-Gen GP4 Classic Compressors. This service model compressor performs similarly as a classic GP4 compressor due to the following adaptations:

  • Locked VI assembly to high VI configuration (same as GP4 Classic).
  • 2nd generation motor (Regal Beloit instead of Phase Motion).
  • Removal of external inductors (if installed).

Replacement of a 2nd Gen GP4 Classic Compressor requires replacement of the compressor motor terminal box but no other adaptations to unit electrical wiring or AFD3 programming. Replacement of the 1st Gen GP4 Classic Compressor requires extra steps to replicate similar unit operation. This document outlines extra retrofit conversion steps in the event of a failure of a 1st Gen GP4 Classic Compressor on an RTAE Chiller:

  • Replacement of 1st Gen GP4 Classic Compressor to GP4 Locked VarVI Service Compressor.
  • Removal of external inductors.
  • Re-programming of AFD3 (including special RLA values for some models).
  • Addition of common mode chokes.
  • Replacement of the compressor motor terminal box.

Note: Some units will lose a small portion of top-end operational capacity due to the difference in motor performance and the size of the originally installed AFD3 on the 1st Gen RTAE unit. The reduction of top-end capacity is small and noted later in this document.

TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-1

Installation

Compressor Replacement
If a 1st-Gen or 2nd-Gen GP4 Classic Compressor has failed on an RTAE Chiller, only the Locked VarVi Service Compressor can be used as a replacement. The Classic chassis has been discontinued. Motor information for a specific compressor can be obtained by checking the model number on the compressor nameplate. The motor number (MN) is stored in the 6th and 7th digits of the compressor model number.

Example: Compressor model CHHSRB1A1A0 indicates a B1 motor, which is a 100T Standard Lift 1st Gen GP4 Classic motor. Refer to the RTAE Service Guide (RTAE-SVG001*-EN) for more detailed instructions for the compressor replacement procedure.
Notes

  • Piping and fitting modifications may be required.
  • All units will require field-installed insulation. Install insulation before adding refrigerant for proper adhesion.

Table 2. GP4 compressor cross-list for RTAE chiller

__

GP4 Screw Compressors

| 1 st Gen GP4 Classic (Phase Motion Motor)| 2 nd Gen GP4 Classic (Regal Beloit Motor)| VarVi GP4 Service Model (Regal Beloit Motor)
---|---|---|---
Capacity| Lift| Voltage| MN| Service Number| MN| Service Number| MN| Service#
__

100T

| __

SL

| 440-528V| __

B1(a)

| __

COM11023

| BA| COM11539| BA| COM13092
360-439V| BB| COM11540| BB| COM13093
__

100T

| __

HL

| 440-528V| __

C1(a)

| __

COM11024

| CA| COM11541| CA| COM13094
360-439V| CB| COM11542| CB| COM13095
125T| SL| 440-528V| E3| COM11027| EA| COM11543| EA| COM13087
125/150T| SL| 360-439/440-528V| E2| COM11026| EB| COM11544| EB| COM13086
150T| SL| 360-439V| E1| COM11029| EC| COM11545| EC| COM13085
__

150T

| __

HL

| 440-528V| __

F2(a)

| __

COM11031

| FA| COM11546| FA| COM13088
360-439V| FB| COM11547| FB| COM13089

Covers both 360-439V and 440-528V voltage ranges. Voltage-specific replacement compressor for 360-439V or 440-528V depends on chiller-rated voltage. Refer to the chiller nameplate to identify the rated voltage. 360-439V motors are used on 380V/400V chillers. 440-528V motors are used on 200V/230V/460V/575V chillers.

Additional Parts Required

Note: Must be ordered separately.
Important: Only the compressor is delivered as standard.
Additional parts will be required and must be ordered separately.
Follow the steps below to identify additional parts required:

  1. Record the model number, digit 5 (R or S) from the RTAE nameplate located on the unit.
  2. Record the model number, digit 7 (number or letter) from the motor nameplate located on the compressor motor.
  3. Determine which circuit needs the replacement compressor (circuit #1 or #2).
  4. Determine which additional parts need to be ordered from the list below using the above information and purchase them for the GP4 Classic compressor replacement.

GP4 Model Number Description

  • Refer to the model number breakdown for the GP4 compressor family:

TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-2

GP4 Classic Compressor Parts List

Heater
A new cartridge heater will be required for all units. If the band heater is in good condition, it can be reused. Use the table below to order the heaters required for the GP4 classic compressor replacement from digit 5 of the unit model number (R or S).

Table 3. Compressor heaters

Heater Type| Compressor Frame Size| Service Part| Voltage| Power
---|---|---|---|---
Cartridge| R and S| HTR19149| 120V| 125 Watts
Band| R| HTR13547| 120V| 70 Watts
Band| S| HTR13548| 120V| 90 Watts

Terminal Box
A new terminal box is required. Determine which circuit (1 or 2) of the GP4 classic compressor is being replaced and order the terminal box using the table below.

Table 4. Compressor terminal box

Terminal Box Mnemonic
Circuit 1A Terminal Box BOX03969
Circuit 2A Terminal Box BOX03970

Sound Attenuator (Optional)

  • A new sound attenuation package may be required. If the unit in the field includes the sound attenuation option, then the appropriate kit must be ordered for the new GP4 VarVi frame size. Two parts are required for the specific compressor frame size (R or S).
  • Refer the below table to determine which sound attenuation package is required using digit 5 of the unit model number (R or S):

Table 5. Sound attenuation package

Frame Mnemonic Part Number Description


R

| ATT00536| 572448450001| ATTENUATOR; SOUND BOX, BOTTOM, R
ATT00538| 572448470001| ATTENUATOR; SOUND BOX, FRONT, R



S

| ATT00537| 572448460001| ATTENUATOR; SOUND BOX, BOTTOM, S
ATT00539| 572448480001| ATTENUATOR; SOUND BOX, FRONT, S

Suction and Discharge Gasket
A new suction and discharge gasket is required. Determine which gaskets to order from the table below using digit 5 of the unit model number (R or S):

Frame Suction Gasket Discharge Gasket
R GKT04723 GKT04722
S GKT04724 GKT04721

Common Mode Chokes
Common mode chokes are required for the replacement of phase motion motors. If the unit has load inductors installed then common mode choke (cores) are required. From the compressor nameplate model number determine the 7th digit. If digit 7 is a number then the cores will need to be ordered. If digit 7 is a letter, do not order the cores.

Example: CHHSRB1A1XX

Phase motion motors (Early GP4 classic) (Common Mode Choke (cores) will need to be ordered)

A1| (future use)
B1| 145- 010| Motor designations from Phase part numbers –
C1| 170- 011| The first 3 digits correspond to motor length (A – F in Trane model number)
C2| 170- 095| The last 3 digits correspond to winding characteristics. (Numeric digit in Trane model number)
D1| (future use)|
E1| 165- 010
E2| 165- 014
E3| 165- 016
F1| 190- 011
F2| 190- 014
GP4 Classic Regal Motors (Regal part number shown) (Common Mode Choke (cores) will not need to be ordered):
BA| 2520869-003| 100T| SL| 460V
BB| 2520869-004| 100T| SL| 380V
CA| 2520869-001| 100T| HL| 460V
CB| 2520869-002| 100T| HL| 380V
EA| 2520867-005| 125T| SL| 460V
EB| 2520867-006| 125T/150T| SL| 380V/460V
EC| 2520867-007| 150T| SL| 380V
FA| 2520867-001| 150T| HL| 460V
FB| 2520867-002| 150T| HL| 380V
FC| 2520867-003| 165T| HL| 460V
FD| 2520867-004| 165T| HL| 380V

Table 6. Common mode chokes

Description Quantity Mnemonic Part Number
Common Mode Core Assembly One per circuit COR00252 50711456
Individual Conductor Core Five per conductor COR00253 X13641390010

Note: These parts must be sourced locally.
Inline Connectors

  • With the removal of the output inductor, the power conductors will need to be spliced together.
  • Polaris Electrical Connectors are recommended (Catalog No.: IT-250). Six pieces are needed. There are two conductors per phase.

TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-3

Piping and Fitting Changes

  • Piping and fitting changes may be required. Source locally.

Insulation

  • All units require field-installed insulation. Install insulation before adding refrigerant for proper adhesion.

Heater Information

There are two heaters per compressor:

  1. One cartridge/rod style that is the same part number for both R and S frame compressors. This part number changed between GP4 classic and VVi. Heaters need to be ordered as separate service parts for the retrofit to work. See Table 3, p. 7 for the correct part numbers to order.
  2. The band style has not changed between GP4 Classic and VVi. The existing band-style heaters on the RTAE compressor can be reused.

Compressor Heaters

  • The compressor must be heated any time it is not running to prevent refrigerant from condensing in the compressor. The heaters are sized to maintain a minimum of 18°F or 20°F rise above the ambient temperature.
  • Two heaters are required: a cartridge type in the suction end of the rotor housing and a band type on the muffler. See Table 3, p. 7 for heater details.

Removal of Output Inductors (1st Gen GP4 Classic Compressor Only)

Physically remove the output inductor from each circuit. Remove thermal cutout limit switch connections 1B3 (circuit 1) or 1B4 (circuit 2); connect wires 431D to wire 433A (circuit 1); or connect wires 424D to wire 425A (circuit 2). Bypass or cap off coolant lines that pass through the inductor. Reconnect the power conductors together with the recommended POLARIS insulated in-line splice connector (See Step ).

TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-4TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-5 TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-6 TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-7

Adding Common Mode Chokes (1st Gen GP4 Classic Compressor Only)

Common mode chokes are necessary to maintain protection against bearing currents causing premature failure of the compressor bearings. With the removal of the output inductor, common mode chokes are necessary. The choke assembly encircles all current-carrying conductors between the drive and compressor. Do not include ground conductors. Individual cores must also be installed on the power conductors. Refer to the schematic and image below. With the removal of the output inductor, the power conductors will need to be spliced together. Polaris electrical connectors are recommended (Catalog No.: IT-250). Six pieces are needed. There are two conductors per phase.

Table 7. Common mode chokes

Description Quantity Mnemonic
Common Mode Core Assembly One (1) per circuit COR00252
Individual Conductor Core Five (5) per conductor COR00253

TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-8 TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-9

Reprogramming AFD3

Re-programming the AFD3 is necessary after replacing either the 1st or 2nd Gen GP4 Classic compressor with the GP4 VarVi Service Model on an RTAE unit. Re- program the parameters shown in Table 8, p. 13 via the Config and Binding view in TU software.

TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-10

High-level view process

  1. Navigate to the binding process.
  2. Unbind the appropriate circuit AFD3 drive in the binding view.
  3. In TU, navigate to the appropriate Config screen.
  4. Change required parameters.
  5. Navigate to the binding process.
  6. Rebind AFD3.

For reference, see the AFD3 Service Guide (AFD-SVG01-EN) and RTAE Installation, Operation, and Maintenance (IOM) manual (RTAE-SVX001-EN).

Parameter Update Required for 1st Generation Only

Table 8. Programming values for AFD3 drive

AFD3 Parameter Name (FCAT)| GP4 Gen Replacing| GP4 VarVi Service Model Number (a)
---|---|---
| | FA| EA| EB (b)| CA| BA| EB (b)| FC| FB| EC| FD| CB| BB
Motor Type (MTPx)| | Internal Permanent Magnet
Transformer Input Ratio (ITRx)| | 1
Total System Inertia (TSIx)| | 0.36 kg-m^2
Motor NP Volts (MVTx)| | 400 V| 400 V| 400 V| 400 V| 400 V| 330 V| 400 V| 340 V| 340 V| 340 V| 340 V| 330 V
Motor NP RLA Current (MRAx)(c)| 1st Gen| 274 A| 214 A| 225 A| 188 A| 158 A| 225 A| 304 A| 304 A| 304 A| 365 A| 225 A| 204 A
2nd Gen| 298 A| 214 A| 249 A| 188 A| 158 A| 250 A| 304 A| 338 A| 304 A| 397 A| 232 A| 204 A
Motor NP Power (MRPx)| | 168 kW| 125 kW| 153 kW| 123 kW| 103 kW| 128 kW| 194 kW| 178 kW| 151 kW| 196 kW| 123 kW| 103 kW
Motor NP Number of Poles (MNPx)| | 6 poles
Motor NP RPM (MRSx)| | 4805

RPM

| 4004

RPM

| 4805

RPM

| 5800

RPM

| 5800

RPM

| 4004

RPM

| 5250

RPM

| 4805

RPM

| 4805

RPM

| 5250

RPM

| 5800

RPM

| 5800

RPM

Motor NP magnet flux (MMFx)| | 167

mWb

| 207

mWb

| 174

mWb

| 140

mWb

| 141

mWb

| 174

mWb

| 162

mWb

| 152

mWb

| 149

mWb

| 133

mWb

| 115 mWb| 120

mWb

AFD3 Parameter Name (FCAT)| GP4 Gen Replacing| GP4 VarVi Service Model Number (a)
---|---|---
| | FA| EA| EB (b)| CA| BA| EB (b)| FC| FB| EC| FD| CB| BB
Motor NP D-Axis Inductance (MDIx)| | 308 µH| 475 µH| 332 µH| 317 µH| 378 µH| 332 µH| 250 µH| 219 µH| 244 µH| 170 µH| 212 µH| 270 µH
Motor NP Q-Axis Inductance (MQIx)| | 308 µH| 475 µH| 332 µH| 317 µH| 378 µH| 332 µH| 250 µH| 219 µH| 244 µH| 170 µH| 212 µH| 270 µH
Stator Resistance (MSRx)| | 2106 µΩ| 2780 µΩ| 1960 µΩ| 2240 µΩ| 2840 µΩ| 1960 µΩ| 1380 µΩ| 1220 µΩ| 1440 µΩ| 940 µΩ| 1500 µΩ| 2040 µΩ
Active Harmonic Damping (AHDx)| | Disable
Reset to Defaults (RDFx)| | No
Input Choke Impedance (IMPx)| | 3%
Rectifier Type (RCTx)| | 6 Pulse
Leakage Signals (MLIx)| | 200 µH| 280 µH| 230 µH| 230 µH| 300 µH| 270 µH| 190 µH| 180 µH| 185 µH| 135 µH| 175 µH| 215 µH

  • Motor information is stored in the 6th and 7th digits of the model number. For example, the digits in bold of this model number correspond to the information in the tables above CHHSRB1A1A0.
  • Motor model EB is unique in that it has dual ratings at both 460V and 380V. For 200V/230V/460V/575V chillers use the leftmost EB column. For 380V/400V chillers use the right most EB column.
  • For certain models, a lesser RLA is used since the installed AFD3 drive is smaller on chillers with 1st Generation GP4 Classic Compressors. Refer to Table 2, p. 6 to decipher the generation of the failed compressor being replaced. Program the appropriate RLA per the 1st-Gen or 2nd-Gen row in the table.

Installation Procedure

TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-11 TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-12 TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-13 TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-14 TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-15 TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-16 TRANE-RTAE-Stealth-Model-Chillers-Field-Replacement-of-GP4-Classic-
Compressor-FIG-17

Trane – by Trane Technologies (NYSE: TT), a global climate innovator – creates comfortable, energy efficient indoor environments for commercial and residential applications. For more information, please visit trane.com or tranetechnologies.com.

Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.

SO-SVN019A-EN 31 Aug 2023 Supersedes PART-SVN237B-EN (Apr 2022)

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