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Ingersoll-Rand TRANE AFDJ, Installation, Operation And Maintenance Manual

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Ingersoll-Rand TRANE AFDJ Installation, Operation And Maintenance Manual Download Page 64

© 2014 Trane   All rights reserved

AFDJ-ADF001A-EN 10 Oct 2014

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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.

We are committed to using environmentally 

conscious print practices that reduce waste.

Summary of Contents for TRANE AFDJ

Page 1: ...roperly 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...

Page 2: ...lows WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTIONs Indicates a potentially hazardous situation which if not avoided could re...

Page 3: ...01D EN 31 Mar 2015 Revised specifications for conduit used with customer wiring in CE for MV Drives p 7 Updated Model Number p 15 WARNING Refrigerant May Be Under Positive Pressure Failure to recover...

Page 4: ...15 Model Number Digit Identification 15 Cabinet 16 A Frame and B Frame Notes 18 Pre Installation 27 Receipt Inspection 27 Scope 27 Receiving 27 Export Crating 27 Accessories 28 Rigging 29 General Han...

Page 5: ...Detection 48 UC800 Interface to Adaptive Frequency Drive 49 Pre Commissioning Start Up 50 Trane AFDJ MV Drive 50 Check List 50 Commissioning 50 Start up Commissioning Services 50 Drive Commissioning 5...

Page 6: ...proper lockout tagout procedures to ensure the power can not be inadvertently energized WARNING Hazardous Voltage w Capacitors Failure to disconnect power and discharge capacitors before servicing co...

Page 7: ...es Service personnel must use proper PPE for servicing and must also use proper lockout tagout procedures during servicing lock the drive disconnect handle before servicing to prevent accidental pulli...

Page 8: ...f moisture Signs of debris or dust from storage Signs of corrosion on components and or enclosure Do not power up equipment if you have concerns regarding equipment condition Upon initial power up rem...

Page 9: ...ted without the owner of the product signing a waiver Service personnel should never be in possession of their own duplicate keys Match the personal protective equipment PPE you use to the voltage lev...

Page 10: ...ockout is not feasible then tagout the circuit breaker to warn other people working in the same area not to turn the switch back on as it will re energize the control WARNING Hazardous Voltage w Capac...

Page 11: ...stream from the MV cabinet Identify sources of potential back feed power downstream from the MV cabinet Prevent back feed power by locking blocking or by other measures to positively control back feed...

Page 12: ...For information regarding the servicing of drive components please refer to the appropriate Rockwell literature that ships with the drive Service Information This equipment should be installed adjust...

Page 13: ...ion to drive and terminate X Line 3 phase voltage to drive be sure to do this before fan shroud installation A Frame only Fan 3 phase voltage to drive B Frame Drive to motor power wiring Control power...

Page 14: ...ered or an alarm on the drive the Tracer AdaptiView display will indicate alarm and an Alarm message Other Features Totally isolated low voltage and medium voltage compartments Mechanical and electric...

Page 15: ...ed Digit 5 6 7 8 Starter Size Use Rated Load Amps RLA value Digit 9 Unit Voltage K 2300V 60Hz 3Ph L 2400V 60Hz 3Ph N 4160V 60Hz 3Ph P 3300V 60Hz 3Ph X 6600V 60Hz 3Ph V 3300V 50Hz 3 Ph W 6000V 50Hz 3 P...

Page 16: ...p kW Max Heat Rejection Weight Btu h kW lb kg 94 3300 V 50 60 Hz 81 500 373 68000 19 9 6500 2948 94 3300 V 50 60 Hz 93 560 418 72000 21 1 6500 2948 94 3300 V 50 60 Hz 105 600 448 76000 22 3 6500 2948...

Page 17: ...120 6405 182 3300 V 50 60 Hz 215 1250 933 123000 36 0 14120 6405 182 3300 V 50 60 Hz 250 1500 1119 144000 42 2 14120 6405 182 4160 V 60 Hz 160 1250 933 110000 32 2 14120 6405 182 4160 V 60 Hz 185 1450...

Page 18: ...ble 7 p 38 6 Maximumline non shieldedcable size is 1 0 MCM one per phase for top entry or 1 0 MCM one per phase for bottom entry For AWG MCM equivalents in mm2 refer to Table 7 p 38 Maximum load non s...

Page 19: ...87 2 67 68 International Symbols Label for CE applications International Symbols Label for CE applications for non CE applications Figure 4 A Frame Bottom view in mm 4 00 X 4 00 102 X 102 3 79 96 34 7...

Page 20: ...Cabinet 20 AFDJ SVU01D EN Figure 5 A Frame Door swing requirements...

Page 21: ...t hand view in mm 27 50 699 10 00 254 9 55 243 15 86 403 18 50 470 17 72 450 3 63 92 30 00 762 34 00 864 35 00 889 80 05 2033 52 16 1325 2 67 68 2 67 68 2 35 60 2 35 60 1 35 34 10 83 264 13 17 335 10...

Page 22: ...Cabinet 22 AFDJ SVU01D EN Figure 7 A Frame Interior view major components in mm...

Page 23: ...634 733 900 840 182 in 181 67 176 76 28 90 32 84 28 82 39 37 37 01 mm 4614 4490 734 834 732 1000 940 190 in 189 54 184 63 28 90 40 72 28 84 47 24 44 88 mm 4814 4690 734 1034 732 1200 1140 197 in 197 4...

Page 24: ...00 25 11 00 279 13 67 347 54 50 1379 47 00 1194 31 00 787 8 00 203 19 00 483 26 00 660 2 67 68 91 25 2318 112 11 2848 2 00 51 5 00 127 International Symbols Label for CE applications for non CE applic...

Page 25: ...in mm 27 50 699 34 00 864 30 00 762 7 87 200 53 67 1363 46 17 1173 4 90 124 38 67 982 35 00 889 39 65 1007 31 54 1563 19 10 485 19 84 504 5 26 134 5 26 134 4 32 110 11 84 301 62 73 1593 15 00 381 3 63...

Page 26: ...Cabinet 26 AFDJ SVU01D EN Figure 13 B Frame Interior view major components...

Page 27: ...e shock indicator will show blue in the chevron shaped area if that shock level was attained during transit If the shock indicator is blue contact Rockwell Automation Product Support Group in Cambridg...

Page 28: ...ng fans and fan enclosures Accessories Accessory items may be shippedwith the drive During the post delivery inspection all accessories or loose items listed on the shipping documentation should be lo...

Page 29: ...e holes of the lifting angles Use only 1 5 in 38 mm diameter holes for shackles 2 The angle between the lifting cables is not to exceed 45 from vertical see Figure 21 p 30 3 A spreader bar may also be...

Page 30: ...has a freezing point higher than 4 F 20 C Check the freeze point of the coolant by reading the label on coolant drum and ensure that the storage temperature does not go below that point Relative humid...

Page 31: ...tral Resistor Assembly Note Valid only for A Frame configuration On top of the converter cabinet a sheet metal enclosure containing power resistors is to be installed 1 Locate the resistor assembly on...

Page 32: ...could be caused by the operation of the CMC by isolating the base of the CMC from the VFD Enclosure floor These black rubber strips are placed between the CMC and the floor of the CMC Cabinet Air Baff...

Page 33: ...behind the barrier Ensure reinstallation of this barrier after the CMC is installed Removing CMC Cabinet Access Plates Preparing the CMC Remove the four mounting bolts that secure the CMC to the wood...

Page 34: ...ee Figure 29 and Figure 30 p 34 on the floor of the CMC cabinet before the installation of the CMC Installing the CMC Ensure that the CMC is oriented correctly so the four side mounted electrical term...

Page 35: ...abinet Secure the mounting hardware see Figure 28 p 34 Figure 30 p 34 and Figure 39 p 37 Important Before servicing disconnect all power sources and allow at least 40 minutes for capacitors to dischar...

Page 36: ...laced on top of the baffles and affixed with taptite screws Note The rear baffle support must be removed before installing the CMC Figure 35 Ground cable termination Figure 36 Thermistor terminal bloc...

Page 37: ...r Lock Washer M12 Nut Flat Washer M12 Bolt Cable Termination Lug Pad Figure A Front Perspective Shown Above Figure B Left Perspective with Section Cut Shown Below Unexploded View Exploded View M12 Nut...

Page 38: ...opper and should be sized according to applicable codes to handle the drive s continuous rated input current Refer to submittals for power lug sizes and location along with control wiring specifics fo...

Page 39: ...Refer to controller and motor nameplates for electrical data Important Before servicing disconnect all power sources and allow at least 40 minutes for capacitors to discharge All electrical enclosure...

Page 40: ...nt Damage Failure to follow instructions below could result in damage to the equipment Do not route signal and control wiring with power wiring in the same conduit This can interfere with drive operat...

Page 41: ...agram a 1 Line power 2 Motor to drive power 3 Fan power B frame 4 Chiller control power 5 HPC Interlock 6 Oil pump interlock 7 Jumper required or remote stop switch 8 Chiller to drive communication li...

Page 42: ...figuration Motor to Drive CPTR power or 120V HPC oil pump interlock Trane IPC link B frame fan Line Vac Supply 3 phase Vac Fan Supply Figure 43 PowerFlex 7000 Scope of input voltages to from drive Lin...

Page 43: ...ction to the chiller motor terminals U to T1 V to T2 W to T3 3 B Frame MV drive only Main Cooling Fan three phase supply 208 or 408 as specified L1 to L1 L2 to L2 L3 to L3 Grd to Grd 4 Chiller Control...

Page 44: ...mmunication link Models CDHF CDHG CVHE CVHF and CVHG 1A1 J5 1 to 2A32 1 Red 1A1 J5 2 to 2A32 2 Black 1A1 J5 3 to 2A32 3 Blue 1A1 J5 4 to 2A32 4 Gray Shield Ground one end at the chiller control panel...

Page 45: ...e optimal operating condition is found the algorithm can avoid the surge in the future When surge is detected a surge recovery routine makes adjustments to move out of surge reestablish stabile operat...

Page 46: ...up and sets the AFD at a speed that will support the predicted pressure ratio across the compressor The UC800 makes this correction by converting condenser water temperature to a pressure and compari...

Page 47: ...sition with the IGV position at the end of the last re optimization time and if greater than the user adjustable sensitivity will re optimize 3 When the re optimization timer expires The control is re...

Page 48: ...tion Surge detection control logic monitors changes in compressor motor current A surge occurrence leaves a characteristic motor current signature as shown in Figure 47 This signature is formed becaus...

Page 49: ...sent to the drive The digital speed signal is set up such that the AFD operates over a 38 60 Hz frequency range AFD faults are sent over the M bus to the UC800 controls for communication on the Trace...

Page 50: ...working hours are available on a time and material basis Note Do not apply power to the drive prior to Rockwell site visit Damages resulting from improper wiring and power up will not be covered by wa...

Page 51: ...0 Confirm cabling of drive to motor isolation transformer and line feed 11 Collect test reports indicating megger hi pot test has been performed on line and motor cables 12 Control power checks to ver...

Page 52: ...r Loss Reset Time 60 Drawing Unit Line Voltage Serial Number Motor NP FLA TVA Nameplate Data Motor NP RLA RLA Motor NP Power KW Motor NP Hertz Volts Hz Motor NP PRM Prestart Checks Date Checked Stator...

Page 53: ...ued power connections will require tightening every year Due to the critical nature of the applications run on MV drives the key word is preventive Investing approximately 8 0 hours per year on these...

Page 54: ...s can close and seal in Verify all single phase cooling fans for operation This includes the cooling fans in the AC DC Power supplies and the DC DC converter Verify the proper voltage levels at the CP...

Page 55: ...service tool software directly to the UC800 controller to view the AFD last diagnostic code refer to Table 10 p 56 for detailed information on which AFD settings you can see using Tracer TU Troublesho...

Page 56: ...ur 96 Drive Overcurrent RNeut OvrCur 115 Drive Overtemp DCLinkOvrTmp 34 Drive Overtemp InvHSnkOvTmp 178 Drive Overtemp RecHSnkOvTmp 146 Drive Overtemp TxReacOvrTmp 33 Drive Overtemp when available Amb...

Page 57: ...meout Flashes green when firmware detects valid IPC3 messages but the communications loss timer has expired since the last message directed at the RECOMM TRANE Solid green after a message directed at...

Page 58: ......

Page 59: ...ARNING Personal Protective Equipment PPE Required Installing servicing this unit could result in exposure to electrical mechanical and chemical hazards Before installing servicing this unit technician...

Page 60: ...are complete initial each check box and provide the date It will be necessary to review this with the electrician or electrical contractor Photocopy the check list and fax the copy to the Medium Volt...

Page 61: ...____ Rockwell GMS Service Engineer Requested YES _____________________________________________________ Scheduled Commissioning Date a _________________________________________________________________...

Page 62: ...Contractor All 3 phase control wiring is with in specified levels and has been verified for proper rotation UVW All single phase control wiring is within specified levels and has grounded neutrals Pr...

Page 63: ...voltage and low voltage power is available for start up activities Strongly recommended that full load is available for full load testing at start up Drive Commissioning final setup requires full loa...

Page 64: ...e 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...

Page 65: ......

Page 66: ...ortable 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...

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