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RTAA-SB-18
Service Literature
Refrigeration
Rotary Liquid Chillers
RTAA
General Service Bulletin
18
July 1998
SV-RF-RLC-RTAA-SB-18-0798

Supersedes
Literature Change History:
Original Service Bulletin: RTAA-SB-18

Subject: RTAA 100 Ton Compressor Lip Seal Failures

Introduction:
We have experienced infant failures of the lip seal on the 100 ton compressors built after U97A****.
The failure does not affect the reliability of the compressor but it will affect the compressors ability to
unload properly. This problem can be masked by high head pressure diagnostics, low oil flow diagnostics
or frequent cycling of the compressor.

Discussion:
The 70 to 100 ton compressors are unloaded via internal porting in the compressor. The lip seal is used to
isolate a cavity behind the bearings that is ported to suction. This creates a path from the unload solenoid
to suction which relieves the pressure from behind the piston. If the lip seal develops a leak, internal porting is not large enough to vent the additional discharge gas back to suction. As the bearing cavity
increases in pressure, the piston can no longer unload.
The lip seal can not be replaced in the field but the porting of the unload solenoid can be routed externally
with out any adverse affect on the compressor. Do not re-route the porting of the unload solenoid until all
other components used in unloading the compressor have been verified as operational. To determine if
the lip seal is leaking, follow the steps under Corrective Action , prior to re-routing the unload solenoid.

Units Affected:
The infant failures of the lip seal could affect any 100 ton compressor on the RTAA 130-400 units built
after U97A****.

Since the Trane Company has a policy of continuous product improvement, it reserves the right to change specifications
and designs without notice. The installation and servicing equipment referred to into this booklet should be done by qualified experienced technicians.

Corrective Action:

shrader valve must be added to the top of the

compressor.
8. To add the schrader valve, isolate the compressor by closing the suction service valve, discharge service valve and the oil line angle valve.
Manually energize the master solenoid. Relieve
the pressure from the backseat port of the suction
service valve.
9. Remove the plug from the on top of the compressor, adjacent to the unload solenoid. Refer to
Figure 2.

Read through all of the steps prior to starting the

procedure. Additional information from other bulletins is necessary.
I)
Check-out Procedures
Below are the steps to determine the cause of the
unloading problem. These steps must be completed
before attempting a solenoid re-route.
NOTE: The re-route will NOT resolve all unloading
problems. It is only intended to be used when a leaking lip seal exists.

NOTE: At times, it is difficult to determine the

exact cause of the loading problems. The only way
to verify that the problem is NOT associated with
the solenoids is to insert block-offs (shim stock)
under both the unload solenoid and the load solenoid
and verify the pressure in the piston cavity. The
shims can be added under the solenoids while the
compressor is isolated. If the shims are added, the
compressor will need to be manually loaded and
unloaded with a gauge set for the remainder of the
test.

1. Cycle the unit off line.

WARNING
Some procedures must be
completed with power applied. Be
certain to follow proper electrical
practices to avoid shock or
electrocution.

10. Perform and log the results of RTAA-SB-4

including the additional bearing cavity readings
for each step. Compare the results to Table 1 to
help determine what has failed.

2. Attach an amp meter to the one of the main leads

to the compressor.
3. Monitor and record the actual RLA at start-up.
4. Determine if the compressor is starting loaded.

NOTE: As the bearing cavity pressure rises above

piston pressure, the compressor will begin to load
when the unload solenoid is pulsed. If the lip seal
leak is severe enough, the unload solenoid will no
longer hold in reverse, causing the compressor to go
fully loaded continuously.

NOTE: The high head pressure from starting loaded

increases the pressure drop across the oil line which
could be enough to generate a low oil flow diagnostic. Starting loaded can also cause pressures to rise
quick enough to open relief valves and or trip the
unit on high pressure diagnostic.

11. If it is determined that the lip seal is leaking. Follow the Unload Solenoid Porting Re-route procedures.

5. If the compressor appears to have trouble

unloading, refer to RTAA-SB-4 to troubleshoot
the solenoids, microprocessor triacs and the piston.
6. Before logging the measurements in RTAA-SB4, one additional pressure must be read that is
not included in RTAA-SB-4. This is the bearing
cavity measurement.
7. To measure the bearing cavity pressure, a
RTAA-SB-18

Table 2: Possible Causes to Loading Problem

Possible Problem

Operating properly

Recorded
Measurement

Energize Load
Solenoid

Energize Unload
Solenoid

De-energize both load

and unload solenoids

Piston Pressure

increase

decrease

remain constant

Amp Draw

increase

decrease

remain constant

Bearing Cavity
Pressure

gradually increase
to no more than 30
psi above suction
pressure

gradually increase
to no more than 30
psi above suction
pressure

gradually increase to
no more than 30 psi
above suction pressure

Piston Pressure

increase

decrease

remain constant

Amp Draw

remain constant

remain constant

remain constant

Bearing Cavity
Pressure

gradually increase
to no more than 30
psi above suction
pressure

gradually increase
to no more than 30
psi above suction
pressure

gradually increase to
no more than 30 psi
above suction pressure

Piston Pressure

increase

increase

increase

Amp Draw

increase

increase

increase

NOTE: Leaking piston

can only be confirmed
by blocking off the solenoids and re-checking
the pressures.

Bearing Cavity
Pressure

gradually increase
to no more than 30
psi above suction
pressure

gradually decrease
to approx. 30 psi
above suction
pressure

gradually increase to
no more than 30 psi
above suction pressure

Leaking unload solenoid

Piston Pressure

remain constant or
decrease

decrease

decrease

Amp Draw

remain constant or
decrease

decrease

decrease

Bearing Cavity
Pressure

gradually increase
to no more than 30
psi above suction
pressure

gradually increase
to no more than 30
psi above suction
pressure

gradually increase to
no more than 30 psi
above suction pressure

Piston Pressure

may load properly if

<70% RLA

increase or
remain constant particularly at
>70% RLA

increase - particularly
at >70% RLA

Amp Draw

may increase correctly <70% RLA

increase or
remain constant particularly at
>70% RLA

increase - particularly
at >70% RLA

Bearing Cavity
Pressure

Gradually increase
to approx. discharge pressure

Gradually
increase to approx.
discharge pressure

Gradually increase to
approx. discharge pressure

Stuck piston

Leaking load solenoid or leaking piston

Leaking Lip Seal

RTAA-SB-18

II)
Unload Solenoid Porting Re-Route
When the lip seal develops a leak, the compressor is
no longer able to unload through the internal porting. To unload the compressor without any adverse
affects, follow the steps below:
1. Cycle the unit off line.
2. Disconnect all power.
3. Close the discharge service valve, oil line angle
valve and the suction service valve.
4. Manually energize the master solenoid.
5. Evacuate the compressor through the backseat
port on the suction service valve.
6. Remove the load and unload solenoids.
7. Replace the small brass pill filters if installed
under the solenoids on the compressor. The latest design of compressor will have one pill filter
under each solenoid.

11. Thread in the 1/4 FL x 1/8 NPT connector to

the side port on the block using a thin film of
Fel-Pro Tight #51604 or other appropriate thread
sealant. Refer to Figure 2.
12. Remove the 1/4 pipe plug from the bottom of
the rotor housing. Refer to Figure 2.
13. Route a 1/4 copper line from the block over to
the suction port on the bottom of the compressor.
Figure 2.Installed Re-route Block

Note: The pill filters are intended to filter out startup debris. All compressors will operate successfully
without the filters. If damage occurs to the filter,
remove it from the compressor entirely and proceed
with step 8.
8. Partially assembly the re-route block prior to
installing on the compressor. Lay the first pair of
gaskets over the ports on top of the re-route
block. Refer to Figure 1.
9. Mount the solenoids on top of the re-route block
using the M6x1-55 mm screws.

Note: To avoid line breakage, run the copper line as

close to the compressor as possible without securing
the line with brackets.

Parts Information:
One re-route kit, KIT 06282, is required for each
affected 100 ton compressor. Contact your local
Trane Parts Center to obtain the parts.
Unload

Production Changes

Load

Investigation of the problem is currently underway.

Figure 1. Top of Re-route Block

Note: Gaskets need to be installed on both sides of

the re-route block, between the solenoids and the
block and the block and the compressor.
10. Install the gaskets between the compressor and
the re-route block and secure by torquing the
M6X1-55 mm screws to 10 ft-lbs.
RTAA-SB-18