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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

Содержание AFDH

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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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