Trane Tracer CH530 Installation, Operation And Maintenance Manual Download | Manualshive

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Figure 5.

Power module component locations IO and control panel removed: Frame 4 units

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Drive and Cabinet

AFDK-SVU01C-EN

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(a) Material courtesy of Rockwell.

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Summary of Contents for Tracer CH530

Page 1: ...ipment The installation starting up and servicing of heating ventilating and air conditioning equipment can be hazardous and requires 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 a...

Page 2: ... 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 des...

Page 3: ... 3 Trademarks All trademarks referenced in this document are the trademarks of their respective owners Revision History AFDK SVU01C EN 14 Apr 2014 Remote Mounted Adaptive Frequency Drive references added to Wiring Schematics p 59 ...

Page 4: ...igerant Cooled 24 Remote Mounted Water Cooled 24 Plumbing 26 Water to Water Heat Exchanger 28 Water to Air Heat Exchanger 31 Corrosion 33 Maintenance 33 Input Power and Control Wiring 34 AFD Operation 40 Adaptive Frequency Drive Control 40 Service Interface 43 AFD Operator Interface 43 CH530 CH531 Operator Interface 43 Tracer AdaptiView Operator Interface 45 AFDK Pre startup Checks 48 Motor Checks...

Page 5: ...2 3496 2 and D2 3518 1 or the most recent revisions Cabinet Servicing For information regarding the servicing of drive components please refer to the appropriate Rockwell literature Service Information This equipment should be installed adjusted and serviced by qualified electrical maintenance personnel who are familiar with the construction and operation of the equipment and the hazards involved ...

Page 6: ...DK control within the chiller s UC800 or DynaView control The controls can control the inlet vanes and they can also modulate impeller speed from 38 to 60 hertz The IGBTs control the speed in response to the UC800 or DynaView compressor control signal Circuit breakers surge capacitors and ground fault protection are standard on all AFDK units Some of the basic features of the drive are Less than o...

Page 7: ...0 Hz 3 Phase Digit 10 11 Design Sequence A0 Digit 12 Cooling Type A Refrigerant cooled B Water to Water cooled C Water to Air cooled Digit 13 Agency Listing 1 UL and C UL Listed Digit 14 AFD Frame Size A 405 B 600 C 900 D 1200 Digit 15 Hose and Fittings 0 None 1 30 ft Hose and Fitting 2 60 ft Hose and Fitting 3 120 ft Hose and Fitting Digit 16 Reserved for Future Use 0 Blank Digit 17 Reserved for ...

Page 8: ...age is 460 or 480 volts variation must be within 10 percent Verify that the drive location will meet the environmental conditions specified in Table 1 Identifying Trane AFDK Cabinet Components The Trane AFDK cabinets have the following main components Ref er to Figure 1 p 9 and Figure 2 p 11 for Frame 3 and Figure 3 p 12 Figure 4 p 13 and Figure 5 p 15 for Frame 4 Drive Cabinet Component Locations...

Page 9: ...ons Frame 3 units a 1 2 11 9 14 15 16 17 6 7 25 8 23 24 22 18 19 21 5 13 12 26 4 10 20 3 28 27 29 Grounding Connection Input Power Wiring Connection 41 75 in 37 13 in Drive and Cabinet AFDK SVU01C EN 9 a Material courtesy of Rockwell ...

Page 10: ... Harness Assembly Power Supply Upper Gate 8 Inverter Power Interface Assembly 9 Wire Harness Assembly Power Supply Lower Gate 10 Insulation Sheet 11 DPI Communications Interface 12 Rectifier Power Interface Assembly 13 Wire Harness Assembly Gate Driver 14 Wire Harness Assembly Current Feedback Device 15 Wire Harness Assembly Line Sync 16 Wire Harness Assembly DC Bus Bleeder Resistors 17 Cable Asse...

Page 11: ...Figure 2 Power module component locations door open Frame 3 units a Drive and Cabinet AFDK SVU01C EN 11 a Material courtesy of Rockwell 15 16 13 2 14 12 8 10 4 4 10 3 7 7 1 1 9 9 11 6 5 6 5 7 25 ...

Page 12: ...Figure 3 Power module component locations door closed Frame 3 units a 22 21 23 20 11 19 17 18 24 20 25 Drive and Cabinet 12 AFDK SVU01C EN a Material courtesy of Rockwell ...

Page 13: ...ac Inductor 4 9 Transformer 3 kVA 10 Fan 115 Vac Contactor 11 Resistors 100k Ohms 50 W 12 Pre charge Resistors 13 Relay Pump and Control Power Terminals 14 Fuse Class RK 5 600 V 10 A 2 15 Fuse Class CC 600 V 25 A 1 16 Fuse Class CC 600 V 10 A 1 17 Fuse Class T 600 V 300 A 3 18 Fuse Class CC 600 V 20 A 3 19 Fuse Class CC 600 V 1 A 3 20 Ground Lug 2 600 MCM 21 Nameplate Power Module 22 Door Inter lo...

Page 14: ...l Fan 24 Vdc 5 Wire Harness Assembly Internal Fan 6 Wire Harness Assembly dc Power 7 Wire Harness Assembly dc Bus Resistors under top cover 8 Current Feedback Device 2000 A 9 Wire Harness Assembly Current Feedback Device Rectifier Side 10 Wire Harness Assembly Current Feedback Device Inverter Side 11 Wire Harness Assembly RTD Recitifier Side 12 Wire Harness Assembly RTD Inverter Side 13 Cable Asse...

Page 15: ...Figure 5 Power module component locations IO and control panel removed Frame 4 units a 5 3 1 2 9 11 8 12 4 10 6X 9 6 2X 7 Drive and Cabinet AFDK SVU01C EN 15 a Material courtesy of Rockwell ...

Page 16: ...Figure 6 Power module component locations front panel removed Frame 4 units a 18 13 16 17 14 15 2X Drive and Cabinet 16 AFDK SVU01C EN a Material courtesy of Rockwell ...

Page 17: ...y of Rockwell 2 380 18 000 30 250 17 750 4 625 6 000 30 250 17 750 6 000 6 0000 62 000 14 124 27 445 60 000 71 500 3 500 50 896 3 500 24 125 4 750 PANEL INPUT WIRING 17 208 11 875 17 208 OUTPUT WIRING PANEL 16 181 35 500 1 911 15 104 4 SPACES 3 000 12 000 1 125 LCD OIM COOLANT OUTPUT 3 4 NPT COOLANT INPUT 3 4 NPT DRIVE TUBE C CUSTOME 6 1 2 1 INPUT WIRING PANEL 10 6 X 15 3 OPENING WITH COVER REMOVE...

Page 18: ...FDK SVU01C EN a Material courtesy of Rockwell 71 500 375 WIDE X 3 250 LONG VENTS DRIVE TUBE CONNECTION ACCESS PLATE FLOOR MOUNTING KIT 3 PLACES SITE INSTALLED SHIPPED INSIDE CABINET CUSTOMER SUPPLIED 6 1 2 13 X 1 500 BOLT 10 1 2 FLAT WASHERS 6 1 2 LOCK WASHER 4 1 2 13 NUT WALL CLEARANCE Back View ...

Page 19: ... 2 75 97 79 0 98 4 75 70 36 10 45 50 00 61 46 FLOOR MOUNTING RAILS 5X BRACKETS SHIPPED LOOSE INSIDE CABINET 1 38 LIFTING HOLES AIR FILTER NOT VISIBLE FROM FRONT HARDWARE FOR MNTG RAILS SUPPLIED BY CUSTOMER 1 2 13 HHCS X 1 50 LG 10X 1 2 FENDER WASHER 20X 1 2 SPLIT LOCK WASHER 10X 1 2 13 HEX NUT 10X DRIVE CABINET ASSEMBLY OUTLINE SHOWN AS FIELD INSTALLED Top View Front View 4 40 16 50 5 25 REF 1 000...

Page 20: ... Cabinet 20 AFDK SVU01C EN a Material courtesy of Rockwell 23 68 3 50 3 33 23 11 15 08 35 13 REF 25 00 19 70 REF COOLING WATER RETURN 3 4 14 FPT COOLING WATER INLET 3 4 14 FPT 1 125 KO S EQ SPACED 4 3 00 6 00 MINIMUM WALL CLEARANCE Side View B C D DRIVE PIPING ACCESS Back View ...

Page 21: ...ng 1 Shorting buss bar kit contains 3 bars and 12 x 0 75 16 in hex jam nuts 1 Shorting buss bar kit contains 3 bars and 12 x 0 75 16 in hex jam nuts 1 Shorting buss bar kit contains 3 bars and 12 x 0 75 16 in hex jam nuts 1 Shorting buss bar kit contains 3 bars and 12 x 1 12 12 in hex jam nuts 1 Strainer 3 4 NPTI x 3 4 NPTI w drain 1 Valve Ball 3 4 copper to copper 2 Bushing 1 NPTE x 3 4 NPTI 2 Ad...

Page 22: ...r refer to Remote Mounted Water Cooled p 24 not required on unit mounted starters Loctite 515 sealant not required on remote mounted starters Lifting Procedure The maximum weight of the drive and the enclosure is 1520 lb 689 kg for Frame 3 and 2800 lb 1270 kg for Frame 4 WARNING Heavy Objects Do not use cables chains or slings except as shown Each of the cables chains or slings used to lift the un...

Page 23: ...Figure 11 Lift point locations for LiquiFlow 2 0 drives Frame 3 Frame 4 Drive and Cabinet AFDK SVU01C EN 23 Lift Points Lift Points Lift Points ...

Page 24: ...on the drive so that the flanges are straight and parallel Place the proper washers and nuts over the studs and snug them up by hand Be careful to maintain the parallel alignment of the flanges 9 Use a socket and torque wrench to further tighten the flange bolts to their proper torques Tighten the flange bolts in small equal steps to ensure an equal draw down of the flange onto the gasket Flange B...

Page 25: ...ve into place Do not bump or jolt the drive while lifting Refer to Lifting Procedure p 22 7 Secure the floor mounting rails to the floor using lag screws and washers 8 Install and connect one of the cooling systems described in Plumbing p 26 9 Connect power ground and control wiring connections Refer to Input Power and Control Wiring p 34 ...

Page 26: ... calculated for each installation Table 5 contains the available head pressure for each heat exchanger assembly and Table 6 contains the pressure information associated with commonly used parts for constructing the cooling loops To calculate the maximum piping distance for the primary loop complete the following steps 1 Select the available pump head fromTable 5 p 26 2 Use Table 6 to locate the pr...

Page 27: ...rop at minimum flow due to each foot of tubing that is planned to be used in the secondary loop Divide the value obtained in Step 2 by this number The result of this calculation is the maximum length of tubing that may be used in the secondary loop Note The maximum length of tube includes both the supply tube and return tube The distance between the chiller and heat exchanger should be half the ma...

Page 28: ...iping diagram of the heat exchanger assembly Figure 14 p 29 shows the dimensions of the heat exchanger assembly as well as the locations of piping and electrical connections Figure 13 Water to water heat exchanger piping diagram a a Material courtesy of DIMPLEX Thermal Solutions ...

Page 29: ...y 3 8 x 3 in Lag Screw 4 3 8 in Fender Washer 4 3 8 in Anchor 4 2 Connect process fluid lines to the proper fittings Make sure that the flow of fluid to and from the unit cannot be shut off or blocked while the system is in operation 3 Table 9 p 30 details the connections Some of the necessary fittings may be included in the accessory kits shipped separately from the drive refer to Additional Comp...

Page 30: ...power requirements on the assembly nameplate in accordance with local codes refer to Table 10 Table 10 Heat exchanger power requirements Heat Exchanger FLA Volts Phase Hz 020600880100 10 A 115 1 60 020600890100 10 A 115 1 60 5 Wire the customer remote contact connection to the pump control relay in the drive enclosure This connection gives the drive control of the cooling assembly refer to Standar...

Page 31: ...iping diagram of the heat exchanger assembly Figure 16 p 32 shows the dimensions of the heat exchanger assembly as well as the locations of piping and electrical connections Figure 15 Water to air heat exchanger piping diagram a a Material courtesy of DIMPLEX Thermal Solutions ...

Page 32: ... the flow of fluid to and from the unit cannot be shut off or blocked while the system is in operation 3 Table 12 details the connections Some of the necessary fittings may be included in the accessory kits shipped separately from the drive refer to Additional Components p 21 Note For NPTE fittings use Teflon paste recommended or Teflon tape If using tape wrapthreadsoffittingwithtwocompletewraps o...

Page 33: ...h as hydrogen sulfide ammonia and compounds with chlorides must be avoided at all costs in the cooling loops Water containing hydrazine is very good for prevention of corrosion of iron and copper Note Ammonia cannot be used in cooling tower water for this application Recommended concentration limits for impurities in water to prevent micro galvanic corrosion of unalloyed or galvanized iron is incl...

Page 34: ...cling and reduces somewhat when there is cold flow in the conducting metals Re torquing will re establish the surface pressure which is essential to keeping a low resistance drop between the two conducting surfaces and avoiding eventual failure NOTICE Equipment Damage When tightening connections at the drive terminals take care not stress the IGBTs The IGBTs are connected to the other end of the t...

Page 35: ...round connection point The grounding lug is capable of accepting up to 2 600 MCM wire Tighten the ground connections to 375 in lb 42 4 N m WARNING Proper Field Wiring and Grounding Required 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...

Page 36: ... SVU01C EN Installing Unit Mounted Output Conductors Unit mounted drives are connected to the motor by Flexibar conductors 1 Verify shorting bus bars are installed on motor terminals as described in Installing Shorting Busbars p 35 2 Verify Flexibar conductors are routed through the provided magnetic choke 3 The Flexibar connections to the motor terminals should be torqued to 27ft lb 36 6N m refer...

Page 37: ... tag the input power to the drive 2 Remove the output wiring access panel from the top right of the drive enclosure Refer to Figure 7 p 17 Figure 8 p 18 Figure 9 p 19 and Figure 10 p 20 for the exact location and dimensions of the output wiring access panels NOTICE Equipment Failure Do not cut holes in Adaptive Frequency Drive enclosure Debris falling inside of Adaptive Frequency Drive could cause...

Page 38: ...r and the starter AFD Starter to Control Panel Control Wiring Starter Panel Terminations Control Panel Terminations a a Termination numbers may differ if the controls are CH531 or a Tracer AdaptiView controls upgrade Comment AFD 120 volts ac Power Supply hot 2X1 1 1X1 1 AFD 120 volts ac Power Supply neutral 2X1 15 1X1 12 Ground 2X1 11 1X1 18 or gnd Panel ground Oil Pump Interlock 2K11 2X1 7 2X1 8 ...

Page 39: ...ection locations In remote mount applications the AFDK must also be wired to control the drive cooling assembly 2X1 23 and 2X1 24 provide a normally open contact When drive cooling is required the contact will close and begin the cooling system operation The accurate pressure readings required by the chiller controls to enable the most efficient operation of the chiller with the retrofitted AFDK d...

Page 40: ...stable operating conditions and adjusts the control boundary to avoid surge in the future Chiller and AFD Sequence of Operation The chiller AFD sequence of operation is identical to a standard fixed speed chiller Chiller capacity control safeties and limits work in the same manner regardless of whether an AFD is present The speed control algorithm will simultaneously set Inlet Guide Vane IGV posit...

Page 41: ...algorithm will periodically readjust this boundary This re optimization will occur when any of three different criteria are met 1 After startup stabilization the control will re optimize unless the surge is detected in that time period 2 Every 30 minutes the control will compare the current IGV position with the IGV position at the end of the last re optimization time and if greater than the user ...

Page 42: ...se when the AFD energizes the motor Note Unlike locked rotor amps associated with electromechanical starters the phase currents are not expected to rise above 85 percent RLA prior to 1 6 seconds following the sending of the speed signal after which they then remain above 85 percent RLA until the compressor motor has come up to speed An Up to Speed signal must occur before the Maximum Acceleration ...

Page 43: ...tiView upgrade and the AFDK when making your request CH530 CH531 Operator Interface The chiller s DynaView is the operator interface for the Adjustable Frequency Drive AFD For the operator s day to day operational information DynaView displays up to seven lines of data English or SI units simultaneously on the 1 4 VGA touch sensitive screen Logically organized groups of information chiller modes o...

Page 44: ...ontrol algorithm The BPC Y intercept is adjustable from 0 01 to 2 0 in increments of 0 01 3 AF Boundary PC Y Intercept Maximum The Boundary Pressure Coefficient BPC Y intercept is never allowed to exceed a maximum value This value is a manual way to control the aggressiveness of the efficiency optimizing procedure For example as this value is lowered the probability of encountering a surge decreas...

Page 45: ...atus can be viewed from the Tracer AdaptiView MOTOR target area on the home page Refer to CTV SVU01 EN Operations Guide Tracer AdaptiView Display for CenTraVac Water cooled Chillers for more information on the Tracer AdaptiView display Tracer TU Service Tool Laptop Computer Tracer TU is software installed on a portable laptop computer and used by the service technician or advanced operator to inte...

Page 46: ...Auto Fixed Auto N A Re Optimization Sensitivity 0 100 20 Percent Note Use only drive parameter sheet settings other settings may affect chiller reliability Note AF Re optimization Sensitivity Every 30 minutes the optimizing algorithm compares the current value of the inlet guide vane position to the value that was stored after the last re optimization If the difference is greater than the AF Re op...

Page 47: ...tor NP FLA TVA 0 1200 a Amps Nameplate Data Motor NP RLA 1 2000 a Amps Nameplate Data Motor NP Power 0 1000 a KW Nameplate Data Motor NP Hertz 5 250 a Hz Nameplate Data Motor NP RPM 60 24000 a RPM Nameplate Data Stator Resistance 0 10 000 000 a micro ohms Nameplate Data Flux Current Ref 0 1200 a Amps Nameplate Data Acceleration Time 1 99 30 Seconds Deceleration Time 1 99 30 Seconds Starter Current...

Page 48: ...ved allow at least 10 minutes for dc units to discharge after power is disconnected before servicing Use extreme caution when applying power Equipment terminals and other internal parts of the controller are at line voltagewhenacpowerisconnectedtothecontroller All ungrounded conductors of the ac power line must be disconnected from the controller before it is safe to touch any internal parts of th...

Page 49: ...Power and Control Wiring p 34 NOTICE Perform Visual Inspection Before powering up this drive for the first time conduct a visual inspection for the following Shipping damage Signs of moisture Signs of debris or dust from storage Signs of corrosion on components and or enclosure These conditions could cause equipment damage Do not power up equipment if you have concerns regarding equipment conditio...

Page 50: ...D follow the procedure below a The drive s main DC bus must be charged in order for the drive LLID to be recognized or bound Close the drive enclosure doors and reapply line power to the drive For CH530 531 only If the disconnect is open and you are using an external 115 V control power source to energize the unit controls reinstall fuse 2F1 and 2F2 to back feed power to the drive and energize the...

Page 51: ...orm any remaining startup items 6 When ready start the drive from the Tracer AdaptiView display or from the DynaView operator interface of the CH530 531 panel 7 Check the AFDK chiller drive response to the UC800 or DynaView Initially the drive will go to 38 hertz and stay there until the CenTraVac chiller vanes open based on load The drive will change the speed from there based on load demand 8 Do...

Page 52: ...P FLA TVA RLA Motor NP RLA KW Motor NP Power Volts Hz Motor NP Hertz Prestart Checks Date Checked Motor NP PRM Drive Grounded Stator Resistance Motor Rotation Flux Current Ref Drive Chassis Grounded Acceleration Time 30 Control Wiring Tight Deceleration Time 30 Drive Connections are Tight Starter Current Limit Verified Settings Current Limit Gain 10 Power Loss Mode Decel Comments Power Loss Time 0...

Page 53: ...Motor NP Volts 460 Drawing Motor NP FLA TVA 0 Serial Number Motor NP RLA 1 Nameplate Data Motor NP Power 0 RLA Motor NP Hertz 60 KW Motor NP PRM TRPM 3600 Volts Hz Stator Resistance SRES 0 Prestart Checks Date Checked Flux Current Ref FAMP 0 Motor Grounded Acceleration Time 30 Motor Rotation Deceleration Time 30 Drive Chassis Grounded Current Limit 1 Control Wiring Tight Current Limit Gain 10 Driv...

Page 54: ... Annunciation When an active diagnostic is present an Alarms key will be added to the persistent display area This key will serve two purposes The first purpose will be to alert the operator that a diagnostic exists The second purpose is to provide navigation to a diagnostic display screen The diagnostic screen is accessible by touching the Alarms enunciator A message description will be provided ...

Page 55: ...face Module OIM b Check ALL wiring tightness ribbon cables fully seated proper phasing etc c Refer to the Rockwell manuals for further troubleshooting information manuals D2 3518 1 and D2 3496 2 or the most recent revisions d If possible use the Rockwell OIM and provide the following drive parameter information LiquiFlo 2 0 inverter Parameters 49 50 209 210 224 225 226 227 228 229 230 243 244 245 ...

Page 56: ...e Overtemp 218 Rctfr IGBT Temp Phase Loss 37 Motor I Imbalance Drive Overcurrent 219 Rctfr IT Overld Motor Short 38 Phase U to Grnd Drive Overcurrent 220 Rctfr 12T Overld Motor Short 39 Phase V to Grnd Power Loss 221 Ride Thru Abort Motor Short 40 Phase W to Grnd High Bus 222 High AC Line Motor Short 41 Phase UV Short Power Loss 223 Low DC Bus Motor Short 42 Phase VW Short High Bus 224 Rctfr Over ...

Page 57: ...wer Other fans cycle with drive operation 2 Check historic fault codes using OIM connected to the AFD 3 Check configuration settings and confirm all proper settings are still present in the controls 4 Review the diagnostic history 5 Make Chiller Service report to document all setpoints 6 Check the UC800 or DynaView alarm histories for any indications of operational problems Do this every 1 12 mont...

Page 58: ...oled CenTraVac Chillers for Tracer AdaptiView display information Important Please note that the Tracer AdaptiView displayed voltage is line side input voltage whereas current and power factor are load side data Therefore these are not used together to calculate kW Tracer AdaptiView kW is communicated from the drive to the chiller panel and represents input power to the drive ...

Page 59: ...nted Adaptive Frequency Drive 900 1210 A LiquiFlo 2 Frame 4 2311 0454 Field Connection Diagram Simplex Trane Supplied Adaptive Frequency Drive 2311 0565 Remote Mounted Adaptive Frequency Drive 405 608 A LiquiFlo 2 Frame 3 2309 7647 Remote Mounted Adaptive Frequency Drive 900 1210 A LiquiFlo 2 Frame 4 2309 7646 Note Wiring diagrams are available via e Library ...

Page 60: ... are committed to using environmentally conscious print practices 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 AFDK SVU01C EN 11 May 2020 Supersedes AFDK SVU01B EN Apr 2014 ...

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