Trane AFDH Installation Manual Download Page 1

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March 20, 2009

AFDH-SVN01A-EN

Installation

AFDH Retrofit Air-Cooled
Adaptive Frequency™ Drive

For UCP2™, Tracer™ CH531, and Tracer
AdaptiView™ Centrifugal Chiller Controllers

Models: CVHE, CVHF, AFDH

Summary of Contents for AFDH

Page 1: ...March 20 2009 AFDH SVN01A EN Installation AFDH Retrofit Air Cooled Adaptive Frequency Drive For UCP2 Tracer CH531 and Tracer AdaptiView Centrifugal Chiller Controllers Models CVHE CVHF AFDH...

Page 2: ...onsible refrigerant practices are important to the environment our customers and the air conditioning industry All technicians who handle refrigerants must be certified The Federal Clean Air Act Secti...

Page 3: ...ed to lift the unit must be capable of supporting the entire weight of the unit Lifting cables chains or slings may not be of the same length Adjust as necessary for even unit lift Other lifting arran...

Page 4: ...or The variable frequency drive industry recommends that the length of the electrical cables connecting a drive unit to a motor should be kept to less than 50 feet to protect the motor from reflected...

Page 5: ...me of writing of this manual edition March 2009 only the D Frame version of the AFDH drive packages had been officially released for sale Note The AFDH series of retrofit air cooled Adaptive Frequency...

Page 6: ...ambient temperature considerations 17 Chiller upgrades 17 Electrical cable size specifications for AFDH drives 18 Table 2 Input output power wire cable sizes AFDH D Frame drives 18 Table 3 Input outp...

Page 7: ...AdaptiView miscellaneous hardware package contents 35 Figure 16 Buss bars specifications CH531 AdaptiView hardware packages 35 Other AFDH drive package accessories 36 Figure 17 Floor stand kit parts...

Page 8: ...able 18 Trane specific AFDH program parameters and settings 57 Required reprogramming of UCP2 controls 58 Table 19 UCP2 menu parameters for proper chiller operation with AFDH 58 Figure 33 AF PC Consta...

Page 9: ...Amps Digit 9 Voltage F 460 Volts 60 Hz 3 Phase G 480 Volts 60 Hz 3 Phase Digit 10 11 Design Sequence A0 Initial Design Digit 12 Enclosure Type C Retrofit Standard Enclosure Digit 13 Agency Listing 1...

Page 10: ...installed on each AFDH Air Cooled Drive unit Always provide the model number and serial number that is printed on this nameplate when making warranty inquiries ordering parts or ordering literature f...

Page 11: ...AFDH SVN01A EN 11 Nameplates Note This page has been intentionally left blank...

Page 12: ...minal board is flush with the back of the starter panel box Refer to Figure 2 A direct mount starter also lacks the Z brackets and transition cover that are an integral part of the standard unit mount...

Page 13: ...hat electrical disconnect switches can be no higher than 72 inches above the surface of the operator area floor or platform Check the potential mounted height of the AFDH disconnect switch especially...

Page 14: ...AFDH cabinet anywhere other than through the specified location on the cabinet roof will be considered an unsupported field modification to the cabinet design Important Other factors that affect the...

Page 15: ...n will be required to reconfigure the conduit and wiring Routing the incoming power conduit into the AFDH cabinet anywhere other than through the specified location on the cabinet roof will be conside...

Page 16: ...as low as 42 Hz In June 1998 the second version UCP2 software release allowed speed reduction down to 38 Hz which resulted in slightly improved energy savings AFDH compatible UCP2 hardware and softwar...

Page 17: ...r until the drive temperature drops to the factory set non adjustable safe temperature level that will allow the drive to be restarted If the ambient temperatures routinely exceeds either of these con...

Page 18: ...ire Lugs 250KCMIL 500KCMIL OUTPUT POWER TO COMPRESSOR MOTOR Number of Wire Cables Per Phase Size of Factory Installed Wires Two 3 0 Wires Two 4 0 Wires Two 250KCMIL Wires E Frame AFDH 540 Amp Drive 59...

Page 19: ...the correct software tools for the chiller controller involved in the application TechView or KestrelView service software version 11 0 with service pack SP 3 or newer Tracer TU service software vers...

Page 20: ...mproper Unit Lift An AFDH cabinet assembly is top heavy Test lift unit to an approximate height of no greater than 24 inches to verify proper center of gravity lift point To avoid dropping the unit re...

Page 21: ...ing method using two identical individual hoists Alternative lifting method If it is only possible to use a single hoisting device to lift an AFDH drive unit to position it for installation a spreader...

Page 22: ...s Figure 8 Top front and side view of D Frame AFDH cabinet with dimensions 1 UCP2 or CH531 AdaptiView control box 2 Z bracket mounting studs each stud 3 8 16 x 1 75 in 3 2 piece access door cover on t...

Page 23: ...x 17 5 in 2 Centerline of Z bracket mounting studs 3 UCP2 or CH531 AdaptiView control box 4 0 88 in diameter cutout for 0 50 in electrical conduit 5 1 13 in diameter cutout for 0 75 in electrical cond...

Page 24: ...Figure 10 Top front and side view of E Frame AFDH cabinet with dimensions 1 UCP2 or CH531 AdaptiView control box 2 Z bracket mounting studs each stud 3 8 16 x 1 75 in 3 2 piece access door cover on t...

Page 25: ...1 13 in diameter cutout for 0 75 in electrical conduit 6 Center to center spacing of the mounting notches for the angle iron bracket clips that will be removed from the unit mounted starter being rep...

Page 26: ...del size refer to the tables listed below a D Frame 302 amp drive see Table 6 b D Frame 361 amp drive see Table 7 c D Frame 443 amp drive see Table 8 d E Frame 540 amp drive see Table 9 e E Frame 590...

Page 27: ...b D Frame 361 amp drive see Table 7 c D Frame 443 amp drive see Table 8 d E Frame 540 amp drive see Table 9 e E Frame 590 amp drive see Table 10 f E Frame 678 amp drive see Table 11 g E Frame 730 amp...

Page 28: ...use Holder 3 Pole X13110658070 HLD00219 1 1 1 14 Fuse 15 amps X13110430220 FUS00897 2 2 2 15 Fuse 2 amps X13110430110 FUS01017 1 1 1 16 Potential Transformer X13590079010 TRR00713 3 3 3 Trane Assembly...

Page 29: ...Circuit breaker handle X32070764010 1 1 1 5 Circuit breaker cable X19070649010 1 1 1 6 Circuit breaker mechanism X14080863010 1 1 1 7 Circuit breaker X13050837010 1 1 1 8 Ground lug X19150083010 LUG0...

Page 30: ...Current transformer 468 667 amps X13580269070 TRR01255 3 13 Fuse Holder 3 Pole X13110658070 HLD00219 1 1 1 14 Fuse 20 amps 656412821000 FUS01895 2 2 2 15 Fuse 2 amps X13110430110 FUS01017 1 1 1 16 Po...

Page 31: ...20 amps 656412821000 FUS01895 2 2 15 Fuse 2 amps X13110430110 FUS01017 1 1 16 Potential Transformer X13590079010 TRR00713 3 3 Trane Assembly Part Numbers for all Optional Model Versions of E Frame 730...

Page 32: ...e 2F22 or 2F4 12 Fuse 2F4 30 amp Figure 13 Callout Part Description Quantity Trane X Code Part Mnemonic if available 1 UCP2 Starter module 2U1 1 X13650453220 MOD01232 2 Start relay 2K1 120 VAC 1 X1326...

Page 33: ...tor plug 1 X19220085040 CON00432 Transducer cable 480 inches long 1 X19060306020 CAB00203 Executive Beige Paint 10oz aerosol can 1 X35020476020 PAI00297 TR1 Series VFD Variable Frequency Drive Install...

Page 34: ...for fuse 2F22 13 Fuse 2F22 2 amp Figure 15 Callout Part Description Quantity Trane X Code Part Mnemonic if available 1 Dual analog I O board 2A11 1 X13650731050 BRD02945 2 Dual low voltage binary inpu...

Page 35: ...anching cable Male to two Female 39 37 inches long 1 X19051622020 CAB01147 Extension cable Male to Female 39 37 inches long 1 X19051623010 CAB01149 Executive Beige Paint 10oz aerosol can 1 X3502047602...

Page 36: ...eighs 1193 pounds Any attempt to adapt the 50689890010 Floor Stand Kit to an E Frame model AFDH drive will be considered an unsupported field modification to the drive unit design Trane assumes no res...

Page 37: ...out at the back of a unit mounted or stand mounted AFDH drive and connect to the compressor motor terminal board Table 17 Part numbers for motor panel transition covers Figure 18 D and E Frame floor m...

Page 38: ...ending upon the starter type proceed to verify that no electrical power exists at either the starter breaker or starter disconnect switch or starter terminal block and other starter components before...

Page 39: ...ended lifting device and rigging has the capacity to safely handle the load before hooking up to the designated lifting points on the starter unit 2 Using safe lifting practices slowly begin taking up...

Page 40: ...f any one particular type of remote starter For each facility that has a remote mounted starter to remove it is the responsibility of the technicians assigned to perform this task to determine the too...

Page 41: ...safe lifting practices carefully lift the cabinet and position it over the brackets on the evaporator a Bolt the angle iron clips removed from the old starter to the slots on the bottom of the drive...

Page 42: ...2 Bolt an angle iron clip that was removed from the old unit mount starter to each slot in the cabinet base 3 Lower drive unit until clips come in contact with bracket surface Figure 21 Leveling the...

Page 43: ...y the installation of an AFDH drive version that is specified as being incorrect for the application NOTICE Incorrect application Adapting a floor stand kit to an E Frame AFDH When properly installed...

Page 44: ...ng safe lifting practices carefully lift the cabinet only as high as is necessary to provide enough clearance to allow placing the assembled floor stand in position underneath a Secure the floor stand...

Page 45: ...AFDH SVN01A EN 45 Installation Figure 23 Attach assembled floor stand to drive unit 1 Attach assembled floor stand to the base of the drive unit with the remaining hardware from the stand kit...

Page 46: ...the two factory provided lifting points on top of the cabinet assembly c Use the appropriate rigging techniques to ensure that the cabinet assembly will be balanced about its center of gravity during...

Page 47: ...port kit parts mounted position of corner bracket on AFDH cabinet base 2 Hex head cap screws 0 50 13 UNC x 1 50 inches 3 Flat washer 0 531 in ID 4 Helical spring lock washer 0 531 in ID 5 Hex nut 0 50...

Page 48: ...to all applicable national state and local electrical codes during the electrical installation of this product Failure to observe this precaution could result in damage to or destruction of the equipm...

Page 49: ...re lengths Some existing starters may have this done already 1 Remove the motor terminal lug from all six terminals on the compressor motor terminal board 2 Install the three buss bars provided one ea...

Page 50: ...e required wire routing holes for the input wire leads a NOTE These wire routing holes are the only entry points that should be used for bringing input power wiring into the drive cabinet b NOTE In so...

Page 51: ...Factory installed input disconnect circuit breaker 1 Input disconnect circuit breaker 2 Nameplate location of breaker interrupting rating of 65 000 amps at 480 VAC 3 Inputpowerterminals Terminalconne...

Page 52: ...to do so could cause damage to the equipment 1 Run a suitable unbroken grounding conductor from the drive cabinet s ground connection terminal to the motor s ground terminal and then on to earth groun...

Page 53: ...h the CT s to the motor terminal access cutout 2 Motor leads routed through cabinet motor terminal access cutout 3 Transition cover removed and Z bracket blanked out of photo for clarity 4 Factory ins...

Page 54: ...hiller controls and the AFDH control box must be routed through the factory provided conduit holes at the hinged side of the AFDH control box enclosure Figure 30 Factory provided conduit holes in AFDH...

Page 55: ...l panel 5 Neutral feed to chiller control panel 6 Normally Closed terminal 2 on HPC High Pressure Cutout switch 3S1 7 115 VAC feed from breaker 1CB1 in the chiller control panel 8 From 1TB1 7 oil pump...

Page 56: ...utral feed to chiller control panel 6 115 VAC feed from breaker 1Q1 in the chiller control panel 7 Normally Closed terminal 2 on HPC High Pressure Cutout switch 2S1 8 From 1A7 J2 4 oil pump LLID 9 Fro...

Page 57: ...Readout 2 5 Motor Current A 6 Power KW 010 Small Readout 3 7 Power HP 27 Heat Sink Temp 012 Hand Start on LCP Hand start button 1 Enable 0 Disable 013 Off Stop on LCP Stop button 1 Enable 0 Disable 10...

Page 58: ...chiller and this option must be enabled within the UCP2 control for proper chiller operation with an AFDH drive 3 AF Adaptive Speed Control Algorithm For the AFDB control algorithm to work this parame...

Page 59: ...ped with bill of materials for this unit Figure 33 AF PC Constant formula and sample calculation 6 AF Re Optimization Factor This factor is a magnitude based parameter for clearing the Surge Flag It i...

Page 60: ...obability of encountering surge decreases but so does the potential efficiency improvement at a given operating condition b The maximum boundary pressure setpoint is adjustable from 0 01 to 2 0 in 0 0...

Page 61: ...pe Not Applicable Wye Delta Non Comm AFD Impeller Diameter CPIM 210 335 275 Enter CPIM from Unit Nameplate Compressor1 Number of stages CVHE 3 CVHF 2 2 Enter from Unit Nameplate Condenser Pressure Sen...

Page 62: ...the support person with the chiller serial number and request a copy of the shipped with bill of materials for this unit Important Make sure your laptop is loaded with the most current version of Trac...

Page 63: ...m Unit Nameplate Tracer TU Configuration View Starter Range Default Setting Recommended Setting Stop Delay Time Contactor Interrupt Failure 1 30 Seconds 3 30 Unit Voltage 180 15000 Volts 460 Enter fro...

Page 64: ...er TU Configuration View UC800 Range Default Setting Recommended Setting Starter Type Not Applicable Unit Mount Wye Delta Remote Mount Non Comm AFD Impeller Diameter CPIM 210 335 275 Enter CPIM from U...

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Page 68: ...Order Number AFDH SVN01A EN Date March 2009 Supersedes New Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without noti...

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