Trane AFDR Installation Instructions Manual

Page 1

Installation Instructions

AFDR Retrofit Air-cooled Adaptive Frequency Drive™

For Use with RTHD Chillers

Models

Only qualified personnel should install and service the equipment. 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 attached to the equipment.

June 2020

AFDR

SAFETY WARNING

AFDR-SVN001D-EN

Page 2

Introduction

Read this manual thoroughly before operating or servicing this unit.

Warnings, Cautions, and Notices

Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

The three types of advisories are defined as follows:

WARNING

CAUTIONs

NOTICE

Important Environmental Concerns

Scientific research has shown that certain man-made chemicals can affect the earth’s naturally occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all refrigerants containing these compounds have the same potential impact to the environment. Trane advocates the responsible handli ng of all refrigerants-including industry replacements for CFCs and HCFCs such as saturated or unsaturated HFCs and HCFCs.

Important Responsible Refrigerant Practices

Trane believes that responsible refrigerant practices are important to the environment, our customers, and the air conditioning industry. All technicians who handle refrigerants must be certified according to local rules. For the USA, the Federal Clean Air Act (Section 608) sets forth the requirements for handling, reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these service procedures. In addition, some states or municipalities may have additional requirements that must also be adhered to for responsible management of refrigerants. Know the applicable laws and follow them.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It could also be used to alert against unsafe practices.

Indicates a situation that could result in equipment or property-damage only accidents.

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 described in NEC and your local/state electrical codes.

WARNING

Personal Protective Equipment (PPE) Required!

Failure to wear proper PPE for the job being undertaken could result in death or serious injury. Technicians, in order to protect themselves from potential electrical, mechanical, and chemical hazards, MUST follow precautions in this manual and on the tags, stickers, and labels, as well as the instructions below:

• Before installing/servicing this unit, technicians MUST put on all PPE required for the work being undertaken (Examples; cut resistant gloves/sleeves, butyl gloves, safety glasses, hard hat/bump cap, fall protection, electrical PPE and arc flash clothing). ALWAYS refer to appropriate Safety Data Sheets (SDS) and OSHA guidelines for proper PPE.

• When working with or around hazardous chemicals, ALWAYS refer to the appropriate SDS and OSHA/GHS (Global Harmonized System of Classification and Labeling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection and handling instructions.

• If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other country-specific requirements for arc flash protection, PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASH CLOTHING. ENSURE ELECTRICAL METERS AND EQUIPMENT ARE PROPERLY RATED FOR INTENDED VOLTAGE.

Page 3

Introduction

WARNING

Follow EHS Policies!

Failure to follow instructions below could result in death or serious injury.

• All Trane personnel must follow the company’s Environmental, Health and Safety (EHS) policies when performing work such as hot work, electrical, fall protection, lockout/tagout, refrigerant handling, etc. Where local regulations are more stringent than these policies, those regulations supersede these policies.

• Non-Trane personnel should always follow local regulations.

WARNING

Conform to All Applicable National, State, and Local Electrical Codes!

Failure to follow all applicable codes could result in an arc flash event, electrocution, explosion, or fire, which could result in death or serious injury. Users MUST conform to all applicable national, state, and local electrical codes during the electrical installation and servicing of this product.

NOTICE

Excessive Cable Lengths Between AFDR Drive and Compressor Motor!

Trane assumes no responsibility for equipment damage caused by use of improper cable lengths. 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 250 feet to protect the motor from reflected voltage waves that can cause the motor to fail. Cable lengths that exceed 250 feet between the drive and the motor create the potential for damage to occur to the motor windings and/or insulation.

This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part without written permission. Trane reserves the right to revise this publication at any time, and to make changes to its content without obligation to notify any person of such revision or change.

Trademarks

All trademarks referenced in this document are the trademarks of their respective owners.

WARNING

Refrigerant under High Pressure!

Failure to follow instructions below could result in an explosion which could result in death or serious injury or equipment damage. System contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use nonapproved refrigerants, refrigerant substitutes, or refrigerant additives.

WARNING

Hazardous Voltage w/Capacitors!

Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury. Disconnect all electric power, including remote disconnects and discharge all motor start/run capacitors before servicing. Follow proper lockout/ tagout procedures to ensure the power cannot be inadvertently energized. For variable frequency drives or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s literature for allowable waiting periods for discharge of capacitors. Verify with an appropriate voltmeter that all capacitors have discharged.

For additional information regarding the safe discharge of capacitors, see PROD-SVB06*-EN.

Revision History

Added Vibration Mitigation - Line Weights Kit for Oil Separator Discharge Lines section to Installation chapter.

AFDR-SVN001D-EN 3

Page 4

General Information

The step-by-step instructions outlined in this manual describe the procedures required to successfully install an AFDR retrofit air-cooled Adaptive Frequency Drive™ package in place of an existing starter on a Trane RTHD helical rotary liquid chillers. This only applies to chillers having a Tracer AdaptiView™ controller. If the RTHD chiller has a CH530, it must be replaced with the Tracer AdaptiView™ RTHD rotary chiller display upgrade kit (RCDA; sold separately).

The AFDR can be ordered as a close floor mount, remote floor mount, or remote wall mount. Voltage options include 460/480 volts, 380/400 volts, and 575/600 volts. D-Frame size AFDH drive packages can be ordered in a unit-mounted, stand-mounted, or remote floor-mounted cabinet configuration. The AFDR units can be equipped with a drive having a maximum rating of 190 amps, 240 amps, 302 amps, 361 amps, 443 amps, or 535 amps for 460V/480V, and 131 amps, 155 amps, 193 amps, 242 amps, 344 amps, or 400 amps for 575V/600V.

Other Literature Required Before Ordering or Installing an AFDR Retrofit

This manual must be used in conjunction with the following publications:

• RTHD-SVX01*-EN (

Maintenance: Optimus™ Water-Cooled Chillers Model RTHD

• BAS-SVP04*-EN (

• BAS-SVX54*-EN (

D-Frame, 110–400kW

• RCDA-SVN001*-EN (

AdaptiView™ RTHD Rotary Chiller Display Upgrade

)

Kit

Note: Instructions provided in RCDA-SVN001*-EN

directly impact AFDR installation; review literature carefully!

Installation, Operation, and

)

Programming Guide: TR200)

Operating Instructions: TR200 New

)

Installation Instructions: Tracer

4 AFDR-SVN001D-EN

Page 5

Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . . 4

Other Literature Required Before Ordering or

Installing an AFDR Retrofit . . . . . . . . . . . . 4

Model Number Descriptions . . . . . . . . . . . . . . 6

Environmental Conditions . . . . . . . . . . . . . . . . 7

Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Output Current . . . . . . . . . . . . . . . . . . . . . . . . 8

AFDR Controls . . . . . . . . . . . . . . . . . . . . . . . . 8

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Unit Submittal Drawings . . . . . . . . . . . . . . . 9

Drive Dimensions . . . . . . . . . . . . . . . . . . . . . 15

Pedestal Drawings . . . . . . . . . . . . . . . . . . . . 17

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . 18

Required Tools . . . . . . . . . . . . . . . . . . . . . . . 18

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Global Connector Harnesses . . . . . . . . . . . 23

Required Parts—NOT Supplied . . . . . . . . . 24

Gas Pump Replacement in Older RTHD Units (Optional)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Preparation in DynaView™ . . . . . . . . . . . . 24

Check the Configuration and Set-Points in the

DynaView™ Display . . . . . . . . . . . . . . . . . 24

Export the DynaView™ Configuration and

Set-Points . . . . . . . . . . . . . . . . . . . . . . . . . 24

Preparing Tracer TU on the Service Computer

Oil and Refrigerant Removal . . . . . . . . . . . 28

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Shut Down Power . . . . . . . . . . . . . . . . . . . . 31

Vibration Mitigation - Line Weights Kit for Oil

Separator Discharge Lines . . . . . . . . . . . . . 31

RTHD ADF Line Weight Kit . . . . . . . . . . . 31

Installation Instructions . . . . . . . . . . . . . . 31

RTHD Tracer AdaptiView UC800 Controls Upgrade

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

AFDR Kit Identification . . . . . . . . . . . . . . . . 32

Panel Component Removal . . . . . . . . . . . . 33

Wye-Delta Panel . . . . . . . . . . . . . . . . . . . . 33

Solid State Starter Panel . . . . . . . . . . . . . 35

Panel Preparation—Close Mount (Kit 1 — 2

conduit)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Panel Preparation—Close Mount (Kit 2 — 4

conduit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Panel Component Installation (All Kits) . . .38

Conduit Support and Conduit Installation

(Kit 1 and Kit 2) . . . . . . . . . . . . . . . . . . . . . . . .40

Drive Installation—Pedestal Mount (All Kits)

Recommended Rigging and Lifting Procedures for AFDR Drive Units

Unit Lifting Points—Preferred Lifting Method 44

Unit Lifting Points—Alternative Lifting Meth-

od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

. . . . . . . . . . . . .44

Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . .45

AFD Mounting—Pedestal Installation

(All Kits) . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Panel Power Wiring . . . . . . . . . . . . . . . . . .46

Panel Control Wiring . . . . . . . . . . . . . . . . . . .48

UC800 Software Installation and Configura-

tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Existing UC800 with Software Already In-

stalled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Drive Settings . . . . . . . . . . . . . . . . . . . . . . . . .60

Retrofit Air-Cooled RTHD Adaptive Frequency Drive Model AFDR (TR200)

Installation and Startup . . . . . . . . . . . . . . .61

. . . . . . . . . . . . .61

Startup Test Log . . . . . . . . . . . . . . . . . . . . . . . . .63

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .65

Recommended Periodic Maintenance and In-

spection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Visual Inspection—Power Removed . . . . . .66

Operational Inspection—Power Applied . .66

Wiring Information . . . . . . . . . . . . . . . . . . . . . . 67

Wiring Diagram Matrix . . . . . . . . . . . . . . . . . 67

Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . .67

Wire Harness Details . . . . . . . . . . . . . . . . . . .68

AFDR-SVN001D-EN 5

Page 6

Model Number Descriptions

For service purposes, Trane model AFDR air-cooled drive upgrade packages are assigned a multiple character alphanumeric model number that precisely identifies each unit.

An explanation of the identification code that appears on the unit nameplate is shown below. Use of the service model number will enable the owner/operator, installing contractors, and service technicians to define the operation, components, and options for any specific unit.

Refer to the model number printed on the nameplate when ordering replacement parts or requesting service.

Digit 1, 2, 3 — Unit Function

A= Adaptive F = Frequency D= Drive

Digit 4 — Development Sequence

R = Development Sequence (Air

Cooled)

Digit 5, 6, 7, 8 — Unit Performance RLA

0312= 312 Rated Load Amps

Digit 9 — Chiller Voltage

F = 460 Volts 60 Hz 3 Phase G = 480 Volts 60 Hz 3 Phase H = 575 Volts 60 Hz 3 Phase J = 600 Volts 60 Hz 3 Phase R = 380 Volts 50 Hz 3 Phase (Special) T = 400 Volts 50 Hz 3 Phase (Special)

Digit 10, 11 — Design Sequence

AA = Next Generation D-Frame

Digit 12, 13 — Maximum Drive Output Current

575 V/600 V

1B = 131 Maximum (60 Hz) 1C = 155 Maximum (60 Hz) 2B = 192 Maximum (60 Hz) 0L = 242 Maximum (60 Hz) 0M = 290 Maximum (60 Hz) 0N = 344 Maximum (60 Hz) 0P = 400 Maximum (60 Hz)

460 V/480 V

0A = 190 Maximum (60 Hz) 0B = 240 Maximum (60 Hz) 0C = 302 Maximum (60 Hz) 0D = 361 Maximum (60 Hz) 0E = 443 Maximum (60 Hz) 1A = 535 Maximum (60 Hz)

Digit 14 — Chiller Control Type

1 = Tracer AdaptiView Controls 2 = CH531/Tracer AdaptiView

Controls

Digit 15 — AFD Type

1=NEMA 1 (IP21) 2 = NEMA 12 (IP54) (Special)

Digit 16 — Mounting Type

A = Close Mount—Conduit and

Power Wire Provided

B = Remote Floor Mount—Field

Provided Power Wiring

C = Remote Wall Mount—Field

Provided Power Wiring

Digit 17, 18 — Design Specials

00 = None AA = Yes

6 AFDR-SVN001D-EN

Page 7

Environmental Conditions

Important: The location of the AFDR is important if

proper performance and normal operating life is to be expected. Therefore, unless designed for special environments, the controller should be installed in an area where the following conditions exist.

• Verify that NEMA 1 enclosure is installed where it can be kept clean and dry, away from oil, coolants, or other airborne contaminants. The enclosure must be installed in a non-corrosive location.

• The area chosen should allow the space required for proper air flow. Adequate clearance for air circulation around the enclosure is a 6 in. (15.25 cm) minimum clearance required wherever vents are located in the cabinet.

• The area chosen should allow for service clearance in front of the enclosure. Three feet (0.91 m) is recommended for door swing and working space; more space may be required by local building codes or for service equipment, such as hoists used for drive replacement. Because codes and equipment may vary, determine the amount of space required for each specific installation.

• Do not install the drive over 3300 ft (1000 m) above sea level without derating output power. For every 300 ft (91.4 m) over 3300 ft (1000 m) above sea level, derate the output current 1 percent.

• Line frequency is 60 Hz.

• Line voltage options are 460, 480, 575 or 600 volts; variation must be within +

• Verify that the drive location will meet the environmental conditions specified in

10 percent.

Table 1.

Table 1. Environmental conditions

Con dit ion Sp e cif i ca tion

Opera t in g Tem p er at ure ( in sid e NEMA 1 en closu r e)

Am bient Temp er atur e ( ou t si de NEMA 1 enc lo su re)

St or ag e Temp er atu r e ( Am bien t ) - 40 °F t o 14 9° F ( -40 °C t o 65° C)

Hum id it y 5% t o 95 % ( non - con densin g)

AFDR-SVN001D-EN 7

32 ° to 13 1 ° F ( 0° C t o 5 5° C)

32 ° F t o 10 4°F ( 0 ° C to 40 °C)

Page 8

Nameplates

MOTOR CONTROLLER

Manufactured by Danfoss Drives For TRANE LaCrosse, WI 54601-759

TRANE P/O: TRANE Model No. : AFDR_____________________ Serial No.: Sch. Dwg.: Chiller Serial No.: Input Power:___VAC ___Amps, Phase, Hertz Output Current: ___Amps COMPRESSOR REQUIRES TRANE OIL: OIL00315 GROUNDING REQUIRED

See information packet for installation instructions

A nameplate is included for each AFDR 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 for the unit.

Figure 1. AFDR nameplate example

The AFDR nameplate label (Trane Motor Controller Nameplate) is customized for each AFDR order and is specific to each RTHD unit. The Trane Motor Controller Nameplate and must be installed on the Trane TR200 drive. Remove the adhesive backing and locate the label on the TR200 drive next to the AFD nameplate. The existing nameplate located on the RTHD chiller panel must also remain in place. When programming the current limit value into Tracer™ TU, always use the Trane Motor Controller Nameplate that is place on the TR200 drive.

AFDR Controls

If there is an existing CH530 controller, the Tracer AdaptiView™ RTHD rotary chiller display upgrade kit (RCDA) must be installed. Follow the installation

instructions in RCDA-SVN001*-EN (

Instructions: Tracer AdaptiView™ RTHD Rotary Chiller Display Upgrade Kit

) before installing the AFDR drive.

If the RTHD to be retrofitted to AFD already has a UC800 Tracer AdaptiView controller, that can be reused.

Important: Regardless if it is new or existing, the UC800

must have a software upgrade to support the AFDR. For more information, refer to

“UC800 Software Installation and Configuration,” p. 52

Installation

Output Current

The output current listed on the Trane motor controller nameplate on the AFD (see current that the drive will be required to provide when the compressor motor is operated at a frequency that results in reduced motor voltage. The output current is used by the RTHD chiller controller for correctly limiting chiller capacity under these conditions. The output current listed on the Trane motor controller nameplate on the AFD should NOT be confused with the chiller nameplate Rated Load Amps (RLA), which are unchanged by the retrofit. The RLA is now to be considered the input current to the chiller.

8 AFDR-SVN001D-EN

Figure 1) is the maximum

Page 9

Dimensions

17 . 7 6

50 . 6 7

12 . 8 0

1. 6 7

14 . 6 2

4. 6 0

13 . 5 7

5. 0 0

11 . 8 8

22 . 1 3

10 . 1 6

3. 1 9

3. 4 4

Unit Submittal Drawings

Figure 2. D1 drive, 2 conduit, 460 and 575V, below 185 amps — standard drive orientation

AFDR-SVN001D-EN 9

Page 10

Dimensions

8.79

50.67

1.67

20.94

14.62

12.80

4.60

10.16

3.19

3.44

11.88

22.13

5.00

Figure 3. D1 drive, 2 conduit, 460 and 575V, below 185 amps — rotated drive orientation

10 AFDR-SVN001D-EN

Page 11

Figure 4. D1 drive, 4 conduit, 460V, 185 to 334 amps — standard drive orientation

17.76

50.65

12.80

14.62

1.67

13.57

10.25

3.44

3.19

10.16

13.50

20.50

5.00

3.08

23.75

Dimensions

AFDR-SVN001D-EN 11

Page 12

Dimensions

8. 7 9

1. 6 7

14 . 6 2

12 . 8 0

20 . 9 4

50 . 6 7

3. 1 0

10 . 2 5

13 . 5 0

20 . 5 0

5. 0 0

3. 4 4

23 . 7 5

10 . 1 6

3. 1 9

Figure 5. D1 drive, 4 conduit, 460V, 185 to 334 amps — rotated drive orientation

12 AFDR-SVN001D-EN

Page 13

Figure 6. D2 drive, 4 conduit, 460 and 575V, 186 to 336 amps— standard drive orientation

17 . 7 6

1. 6 7

58 . 8 0

16 . 5 4

16 . 2 4

13 . 5 7

14 . 0 9

10 . 2 5

13 . 5 0

20 . 5 0

23 . 7 5

3. 1 9

3. 4 4

5. 0 0

3. 0 8

Dimensions

AFDR-SVN001D-EN 13

Page 14

Dimensions

8.79

1.67

58.80

24.68

16.54

14.62

10.25

13.50

20.50

23.75

3.44

5.00

3.19

14.09

3.08

Figure 7. D2 drive, 4 conduit, 460 and 575V, 186 to 336 amps — rotated drive orientation

14 AFDR-SVN001D-EN

Page 15

Drive Dimensions

33 . 2

7. 12. 9

2. 5 7. 9

14 . 5

12 . 8

33 . 4

35 . 2

26 . 1

12 . 0

6. 6

GLAND PLATE

Figure 8. D1 drive dimensions - sheet 1 of 2

Dimensions

Figure 9. D1 drive dimensions - sheet 2 of 2

MAI NS TERMIN ALS

GROUND 3. 1 4

4. 0

7. 5 5

MOTOR

TERMIN ALS

GROUND3. 1 4

1. 2 8 T 5 .5 3

S 3 .9 9

R 2 .44

U 7 .2 7

GROUND 6. 4 0

11 .5 2

V 8 .8 1

W 10 .3 5

4. 78

AFDR-SVN001D-EN 15

Page 16

Dimensions

16 . 5 4

43 . 2 8

41 . 4 2

34 . 2 5

14 . 5 1

2. 7 6 11 . 0 2

10 . 6 72. 9 4

41 . 3 6

.9 4

4X .4 3

15 . 7

6. 9 GLAND PLATE

Figure 10. D2 drive dimensions - sheet 1 of 2

Figure 11. D2 drive dimensions - sheet 2 of 2

MAI NS TERMIN ALS

3. 51

13 . 00

GROUND 7. 0 0

GROUND 6. 0 0

MOTOR

TERMIN ALS

2. 0 0 T 7 .0 0

S 5 .0 0

R 3 .00

V 1 2. 00

U 1 0. 00

GROUND7. 0 0

GROUND6. 0 0

15 .0

W 14 .0 0

4. 51

16 AFDR-SVN001D-EN

Page 17

Pedestal Drawings

11 . 2

8. 5

9. 4

12 . 8

15 . 7

14 . 6

5. 3

9. 8

SHOWN WI THOUT

COVER PLATES

I NSTALLED

14 . 6

16 . 5

15 . 7

14 . 9

12 . 5

9. 4

5. 3

9. 8

SHOWN WI THOUT

COVER PLATES

I NSTALLED

Figure 12. Pedestal drawing - D1 drive

Dimensions

Figure 13. Pedestal drawing - D2 drive

AFDR-SVN001D-EN 17

Page 18

Pre-Installation

Required Tools

Normal service tools are required to perform the majority of the work. A service technician with a well stocked tool chest should have the right tools to perform the job. In addition to the normal service tools and hardware, the following is a partial list of specific field supplied hardware/software components and special tools that are also required to perform the display retrofit:

• RS-232 male DB9 to female DB9 pin to pin serial cable to connect the DynaView™ to a PC or laptop computer

Note:

– The cable must NOT be a “null-modem” cable.

– The cable must be less than 50 feet in length.

• Type A to Type B USB cable to connect the Tracer™ UC800 controller to a PC or laptop computer

• A PC or laptop computer equipped with the following:

– KestrelView™ service software, version 14.0 or

newer

– Tracer TU service software, version 9.0.322 or

newer

– RTHD UC800 firmware build 3.03 or later (refer to

“Preparing Tracer TU on the Service Computer,” p. 26

)

• South pole magnet screwdriver (TOL01343)

• Electronics vacuum

•Drill

• 3/16-in. drill bit

• 3/8-in. drill bit for display arm

• 2.5-in hole saw (close mount kit only)

• Phillips screwdriver

• Wrench for fastening the bolts for the panel

• Wire cutter for large and small gage wire

•Vacuum pump

• Oil pump

• Impact drill for concrete

Parts

Table 2. Components — close mount 460 volts

Kit Pa rt N u m be r M n e m on ic Pa r t N u m be r Descrip t ion QT Y

Clo se Mou nt Com po n e n t s

RNG02 3 1 8 X136 4 0 734 0 1 0 Choke Cor e M- 1 1 6 5

53 1 4 051 1 0 100 Cor e Su ppo r t Brack et 1

53 1 4 054 7 0 100 Buss Bar, For m ed ( for m ot or conn ect io n) 2

53 1 4 054 8 0 100 Buss Bar, St ra ig h t ( for m o t or conne ct ion ) 1

BRD0 294 4 X13 6 507 3 3 060 Dua l Rela y ou t put Ref 1A8 ( lat est re visi on ) 1

HLD0 0 5 79 X13 2 607 2 1 020 Relay, 4PDT, 1 2 0 VAC, 8 am ps 2

RAL01 1 42 X132 6 0 722 0 1 0 Relay Socket , 4PDT, Din r ai l m ount 2

X135 0 0 224 0 7 0 Din r ai l 4 in ch 1

X134 9 1 363 0 1 0 Din Rail End St op 4

12 7 5 000 1 0 001 50 7 1 179 1 0 001 St r u t Chann el, 1.6 2 5 " x 1 . 6 2 5"x 5 f t ( black color ) 1

50 7 1 179 2 0 001 St r ut Ch ann el Base, 4" X6” ( bl ack co lo r ) 1

50 7 1 179 3 0 001 St r ut Ch ann el L Bra ck et 1

50 7 1 179 6 0 001 .75 in co ndu it con nect or 90 d eg r ee 1

50 7 1 179 7 0 001 .75 I N COND UI T CONNECTOR STRAI GHT 1

X190 8 0 029 0 4 0 0.7 5 in cond u it - AFD/ r elay signa l w ires 20 ft

X190 1 0 309 4 7 0 sing le con duct or cabl e - 1 6aw g UL 1 2 3 0 b lk 12 5 ft

CAB01 5 3 4 X190 5 1 6250 3 0 Globa l h ar n ess Fem ale t o Am p co n nect o r 7 8 . 7 4in 1

CAB01 1 5 3 X190 5 1 6240 3 0 Globa l h ar n ess Male t o Am p co nne ct or 7 8 . 74i n 1

CAB01 1 5 0 X190 5 1 623 0 2 0 Ext ension H ar n ess - 7 8 . 7 4in ch 1

X390 0 2 507 0 1 0 Label, Warni ng ( AFD) 1

50 7 1 178 1 0 001 Lab el, Nam eplat e 1

AFDR-SVN001 * - EN KI T I OM ( supp lied by Trane ) 1

50 7 1 178 3 0 001 Sch em ati cs Pri nt ed on m y la r 1

BAS- SVX54* - EN Dr iv e I OM 1

50 7 1 182 0 0 001 AFD Lab el 1

X39 0 0 3759 0 1 0 Label, Techn ical sup p or t 1

50 7 1 183 0 0 001 Mot or Term inal Shield 1

18 AFDR-SVN001D-EN

Page 19

Pre-Installation

Table 2. Components — close mount 460 volts (continued)

Kit Pa rt N u m be r M n e m on ic Pa r t N u m be r Descrip t ion QT Y

Con d u i t Ki t s

X190 3 8 200 0 0 0 Conne ct or, 2in con dui t 4

X191 2 0 032 0 6 0 2 inch co ndu it Sleev e 4

12 7 5 000 2 0 001 2 Con d u it Kit

12 7 5 000 3 0 001 4 Con du it Kit ( sm all ba se)

12 7 5 000 4 0 001 4 Con du it Kit ( la r ge ba se)

12 7 5 001 1 0 001 X131 7 1 807 0 0 1

12 7 5 001 2 0 001 X131 7 1 807 0 0 2

12 7 5 001 3 0 001 X131 7 1 807 0 0 3

12 7 5 001 4 0 001 X131 7 1 807 0 0 4

12 7 5 001 5 0 001 X131 7 1 807 0 0 5

12 7 5 001 6 0 001 X131 7 1 807 0 0 6

50 7 1 180 1 0 001 PWR WI RE ASSEMBLY D1 - B 1

50 7 1 180 3 0 001 PWR WI RE ASSEMBLY D1 - D 1

50 7 1 180 8 0 001 Mod ifi ed pede st al plat e ( Dwg p rov ide d) 1

50 7 1 179 9 0 001 AFD Dr ive Pedest al D 1H 1

X190 3 8 200 0 0 0 Conne ct or, 2in con dui t 8

X191 2 0 032 0 6 0 2 inch co ndu it Sleev e 8

50 7 1 180 0 0 001 PWR WI RE ASSEMBLY D1 - A 1

50 7 1 180 1 0 001 PWR WI RE ASSEMBLY D1 - B 1

50 7 1 180 2 0 001 PWR WI RE ASSEMBLY D1 - C 1

50 7 1 180 3 0 001 PWR WI RE ASSEMBLY D1 - D 1

50 7 1 181 1 0 001 Mod ifi ed pede st al plat e ( Dwg p rov ide d) 1

50 7 1 179 9 0 001 AFD Dr ive Pedest al D 1H 1

X190 3 8 200 0 0 0 Conne ct or, 2in con dui t 8

X191 2 0 032 0 6 0 2 inch co ndu it Sleev e 8

50 7 1 180 4 0 001 PWR WI RE ASSEMBLY D2 - A 1

50 7 1 180 5 0 001 PWR WI RE ASSEMBLY D2 - B 1

50 7 1 180 6 0 001 PWR WI RE ASSEMBLY D2 - C 1

50 7 1 180 7 0 001 PWR WI RE ASSEMBLY D2 - D 1

50 7 1 181 1 0 001 Mod ifi ed pede st al plat e ( Dwg p rov ide d) 1

50 7 1 181 8 0 001 AFD Dr ive Pedest al D 2 H 1

VF D DRI V E ( on e on ly)

AFD DRI VE, 460 V, I P21, 110 KW,1 3 4 X275 4 , TR-2 00N11 0 T4 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 460 V, I P21, 132 KW, 1 34X27 5 5 , TR-2 00N13 2 T4 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 460 V, I P21, 160 KW, 1 34X27 5 6 , TR-2 00N16 0 T4 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 460 V, I P21, 200 KW, 1 34X27 5 7 , TR-2 00N20 0 T4 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 460 V, I P21, 250 KW, 1 34X27 5 8 , TR-2 00N25 0 T4 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 460 V, I P21, 315 KW, 1 34X27 5 9 , TR-2 00N31 5 T4 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

CON TRO LS ( on e only )

NONE - UC80 0 Onl y fo r cust om ers w it h e xist ing UC80 0 con t r ol s

18 8 0 026 0 1 00 UC80 0 / TD7 upg rad e Kit wit h ar m

18 8 0 027 0 1 00 UC80 0 / TD7 upg rad e Kit wit h ou t arm

AFDR-SVN001D-EN 19

Page 20

Pre-Installation

Table 3. Components — remote mount 460 volts

Kit Pa rt N u m ber Mn e m onic P a r t Num b e r De scr ipt ion QT Y Pa c k a g e La be l

Re m ot e M o u n t Com po n e n t s

RNG02 3 18 X1 3 6 407 3 4 0 10 Ch ok e Co re 5

53 1 4 051 1 0 100 Cor e Su pp ort Bra ck et 1

53 1 4 054 7 0 100 Buss Bar, For m ed ( for m ot or conn ect io n) 2

53 1 4 054 8 0 100 Buss Bar, Stra ig h t ( f or m o t or con ne ct i on ) 1

X13 6 5 0 733 0 6 0 Du al Rel ay ou t p ut Ref 1 A8 (lat est re v isi on ) 1

BRD0 294 4 X1 9 220 0 8 5 030 HOUSI NG; 4 CKT TERM ( Phoe n ix conn ect or ) for 1 A8 2

HLD0 0 579 X1 3 2 607 2 1 020 Relay, 4PDT, 1 2 0 VAC, 8 am ps 2 1K14 , 1K15 Relay s

12 7 5 000 5 0 001

12 7 5 001 1 0 001 X13 1 7 1 807 0 0 1

12 7 5 001 2 0 001 X13 1 7 1 807 0 0 2

12 7 5 001 3 0 001 X13 1 7 1 807 0 0 3

12 7 5 001 4 0 001 X13 1 7 1 807 0 0 4

12 7 5 001 5 0 001 X13 1 7 1 807 0 0 5

12 7 5 001 6 0 001 X13 1 7 1 807 0 0 6

RAL01 1 42 X132 6 0 722 010 Relay So ck et , 4 PDT, Din r ail m oun t 2

X13 5 0 0224 2 0 7 Din r ai l 4in ch 2

X13 4 9 1363 0 1 0 Din Rail End St op 4

AFDR-SVN00 1 * EN

50 7 1 178 3 0 001 Schem ati cs Pri nt ed on m y la r 1

BAS- SVX54 * - EN Dr iv e I OM 1

50 7 1 182 0 0 001 AFD Label 1

50 7 1 183 0 0 001 Mot o r Ter m ina l Sh ie ld 1

X39 0 0 3759 0 1 0 Label, Techn i cal supp or t 1

NONE - UC80 0 Only fo r cust om ers w ith ex ist in g UC80 0 con t r ols

18 8 0 026 0 1 00 UC8 0 0/ TD7 up g rad e Kit w ith ar m

18 8 0 027 0 1 00 UC8 0 0/ TD7 up g rade Kit w ith out ar m

50 7 1 179 9 0 001 Opt iona l AFD Driv e Pedest al D1 H Below 334 Am ps 1

50 7 1 181 8 0 001

KI T I OM (supp li ed by Tran e) 1

VF D DRI V E ( on e on l y )

AFD DRI VE, 46 0 V, I P21 , 11 0 KW,1 3 4X275 4 , TR-2 00N11 0 T4 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 46 0 V, I P21 , 13 2 KW, 134 X2 7 5 5, TR-2 00N13 2 T4 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 46 0 V, I P21 , 16 0 KW, 134 X2 7 5 6, TR-2 00N16 0 T4 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 46 0 V, I P21 , 20 0 KW, 134 X2 7 5 7, TR-2 00N20 0 T4 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 46 0 V, I P21 , 25 0 KW, 134 X2 7 5 8, TR-2 00N25 0 T4 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 46 0 V, I P21 , 31 5 KW, 134 X2 7 5 9, TR-2 00N31 5 T4 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

CON TROLS ( on e only )

OP TI ON AL P ED ESTA L

Opt iona l AFD Driv e Pedest al D2 H 3 35 Am ps - 45 5 Am p s

Dr iv e Mo unt ha rdw are - ( la be l nu t s and scr ew s on ly )

Dr iv e Mo unt ha rdw are - ( la be l

nu t s and scr ew s on ly )

Se r v i ce able Com po n e n t

20 AFDR-SVN001D-EN

Page 21

Pre-Installation

Table 4. Components — close mount 575 volts

Kit Pa rt N u m be r Mn e mo n i c P a r t Nu m ber D e s cr i p t i o n QT Y

Clo se Mo u n t Com pone n t s

RNG02 3 1 8 X1 364 0 7 340 1 0 Chok e Cor e M- 116 5

53 1 4 051 1 0 100 Core Su p por t Br ack et 1

53 1 4 054 7 0 100 Buss Bar, Form ed ( for m o t or conne ct ion ) 2

53 1 4 054 8 0 100 Buss Bar, St r aigh t ( f or m ot or con n ect ion) 1

BRD0 294 4 X136 5 0 733 0 6 0 Du al Relay out put Ref 1A8 ( lat est re v isi on ) 1

HLD0 0 5 79 X132 6 0 721 0 2 0 Rela y, 4 PDT, 1 20VAC, 8am ps 2

RAL01 1 42 X13 2 6 0722 0 1 0 Relay So ck et , 4 PDT, Di n r ai l m oun t 2

X13 5 0 0 224 0 7 0 Di n r ail 4 inch 1

X13 4 9 1363 0 1 0 Di n Rail End St op 4

50 7 1 179 1 0 001 Str u t Channe l, 1 .62 5 " x 1.6 2 5 " x 5f t (bl ack color) 1

50 7 1 179 2 0 001 Str u t Cha nne l Base, 4"X6” ( black colo r ) 1

50 7 1 179 3 0 001 Str u t Cha nne l L Br ack et 1

50 7 1 179 6 0 001 .75i n con du i t con n ect or 9 0 d eg r ee 1

12 7 5 000 6 0 001

CAB01 5 3 4 X1 9 0 516 2 5 030 Gl ob al ha r ness Fem ale t o Am p co nne ct or 7 8 . 74i n 1

CAB01 1 5 3 X1 9 0 516 2 4 030 Gl ob al har ness Ma le t o Am p con nect or 78 .74 in 1

CAB01 1 5 0 X1 9 0 516 2 3 020 Ex t ension Ha rne ss - 7 8.7 4 inch 1

12 7 5 000 7 0 001 2 Con d u it Kit

12 7 5 000 8 0 001 4 Con du it Kit ( la r ge ba se)

12 7 5 001 7 0 001 X13 1 7 1 808 0 0 1

12 7 5 001 8 0 001 X13 1 7 1 808 0 0 2

12 7 5 001 9 0 001 X13 1 7 1 808 0 0 3

12 7 5 002 0 0 001 X13 1 7 1 808 0 0 4

12 7 5 002 1 0 001 X13 1 7 1 808 0 0 5

12 7 5 002 2 0 001 X13 1 7 1 808 0 0 6

50 7 1 179 7 0 001 .75 I N CONDUI T CONNECTOR STRAI GHT 1

X19 0 8 0029 0 4 0 0.7 5 in co ndu it - AFD/ relay sig n al w ires 20 ft

X19 0 1 0 309 4 7 0 sing le con d uct or cable - 16 aw g UL 1 230 blk 12 5 ft

X39 0 0 2507 0 1 0 Lab el , Wa r nin g ( AFD) 1

50 7 1 178 1 0 001 Label, Nam eplat e 1

AFDR-SVN00 1 * EN

50 7 1 178 3 0 001 Schem at ics Prin t ed on m y lar 1

BAS- SVX5 4 * - EN Dr iv e I OM 1

50 7 1 182 0 0 001 AFD Lab el 1

X39 0 0 3759 0 1 0 Lab el , Techni cal su pp ort 1

50 7 1 183 0 0 001 Mot or Term inal Shield 1

X19 0 3 8 200 0 0 0 Con nect o r, 2 in con d ui t 4

X19 1 2 0 032 0 6 0 2 i nch con du i t Sle ev e 4

50 7 1 180 1 0 001 PWR W I RE ASSEMBLY D1- B 1

50 7 1 180 3 0 001 PWR W I RE ASSEMBLY D1- D 1

50 7 1 180 8 0 001 Modi fied pedest al p lat e ( Dwg pr o vid ed ) 1

50 7 1 179 9 0 001 AFD Dri v e Pedest al D1 H 1

X19 0 3 8 200 0 0 0 Con nect o r, 2 in con d ui t 8

X19 1 2 0 032 0 6 0 2 i nch con du i t Sle ev e 8

50 7 1 180 4 0 001 PWR W I RE ASSEMBLY D2- A 1

50 7 1 180 5 0 001 PWR W I RE ASSEMBLY D2 - B 1

50 7 1 180 6 0 001 PWR W I RE ASSEMBLY D2 - C 1

50 7 1 180 7 0 001 PWR W I RE ASSEMBLY D2 - D 1

50 7 1 181 1 0 001 Modi fied pedest al p lat e ( Dwg pr o vid ed ) 1

50 7 1 181 8 0 001 AFD Dri v e Pedest al D2 H 1

KI T I OM (supp li ed by Tran e) 1

Con d u i t Ki t s

VF D DRI V E ( on e on ly)

AFD DRI VE, 60 0 V, I P21 , 110 KW, 1 3 4X276 0 , TR-2 00N11 0 T7 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 60 0 V, I P21 , 132 KW, 1 3 4X276 1 , TR-2 00N13 2 T7 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 60 0 V, I P21 , 160 KW, 1 3 4X276 2 , TR-2 00N16 0 T7 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 60 0 V, I P21 , 200 KW, 1 3 4X276 3 , TR-2 00N20 0 T7 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 60 0 V, I P21 , 250 KW, 1 3 4X276 4 , TR-2 00N25 0 T7 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFD DRI VE, 60 0 V, I P21 , 315 KW, 1 3 4X276 5 , TR-2 00N31 5 T7 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

AFDR-SVN001D-EN 21

Page 22

Pre-Installation

Table 4. Components — close mount 575 volts (continued)

Kit Pa rt N u m be r Mn e mo n i c P a r t Nu m ber D e s cr i p t i o n QT Y

12 7 5 002 3 0 001 X13 1 7 1 818 0 0 7

NONE - UC80 0 Onl y f or cust om er s w ith exist ing UC8 0 0 con t r ol s

18 8 0 026 0 1 00 UC8 00/ TD 7 u p gr ade Kit wi t h a r m

18 8 0 027 0 1 00 UC8 00/ TD7 u p gra de Kit wi t h ou t arm

Table 5. Components — remote mount 575 volts

Kit Pa rt N u m ber M ne m onic Pa rt N u m be r D e scri p t i o n QT Y Pa ck a g e La be l

RNG02 3 1 8 X1 3 6 407 3 4 010 Ch ok e Cor e 5

53 1 4 051 1 0 100 Core Supp or t Bra ck et 1

53 1 4 054 7 0 100 Buss Bar, For m ed ( for m otor conn ect io n) 2

53 1 4 054 8 0 100 Buss Bar, St raig ht ( for m ot or conn ect io n ) 1

BRD0 294 4 X1 365 0 7 3 306 0 Du al Relay o utpu t Ref 1 A8 ( lat est rev ision) 1

HLD0 0 5 79 X1 9220 0 8 503 0 HOUSI NG; 4 CKT TERM ( Phoe nix con n ect or ) for 1 A8 2

RAL01 1 42 X1 3 2 607 2 1 020 Relay, 4PDT, 1 2 0 VAC, 8 am ps 2 1K1 4 , 1K15 Relay s

12 7 5 000 9 0 001

12 7 5 001 7 0 001 X1 3 1 718 0 8 001

12 7 5 001 8 0 001 X1 3 1 718 0 8 002

12 7 5 001 9 0 001 X1 3 1 718 0 8 003

12 7 5 002 0 0 001 X1 3 1 718 0 8 004

12 7 5 002 1 0 001 X1 3 1 718 0 8 005

12 7 5 002 2 0 001 X1 3 1 718 0 8 006

12 7 5 002 3 0 001 X1 3 1 718 1 8 007

X13 2 6 0722 0 10 Relay Socket , 4PDT, D in rail m oun t 2

X13 5 0 0 224 2 0 7 Din r ail 4in ch 2

X13 4 9 136 3 0 10 Din Rail End St op 4

AFDR-SVN0 0 1AEN

50 7 1 178 3 0 001 Schem atics Print ed on m yla r 1

BAS- SVX54 * - EN Dr i ve I OM 1

50 7 1 182 0 0 001 AFD La bel 1

50 7 1 183 0 0 001 Mot or Term in a l Sh ie ld 1

NONE - UC80 0 On ly f or cu st om ers w ith ex ist in g UC80 0 con t r o ls

18 8 0 026 0 1 00 UC80 0 / TD7 upg r ad e Ki t w it h arm

18 8 0 027 0 1 00 UC80 0 / TD7 upg r ad e Ki t wit hout a r m

50 7 1 179 9 0 001 Opt iona l AFD Driv e Pedest al D1 H Below 186 Am ps 1

50 71 181 80 001 Opt ion al AFD Dri ve Pedest al D2H 18 6 Am ps - 366 Am ps 1

KI T I OM (supp li ed by Tran e) 1

AFD DRI VE, 60 0 V, I P21 , 110 KW, 1 34X276 0 , TR20 0 N1 1 0T7E2 1H2 TGC7XXSXXXXAXBXCXXXXD X

AFD DRI VE, 60 0 V, I P21 , 132 KW, 1 34X276 1 , TR20 0 N1 3 2T7E2 1H2 TGC7XXSXXXXAXBXCXXXXD X

AFD DRI VE, 60 0 V, I P21 , 160 KW, 1 34X276 2 , TR20 0 N1 6 0T7E2 1H2 TGC7XXSXXXXAXBXCXXXXD X

AFD DRI VE, 60 0 V, I P21 , 200 KW, 1 34X276 3 , TR20 0 N2 0 0T7E2 1H2 TGC7XXSXXXXAXBXCXXXXD X

AFD DRI VE, 60 0 V, I P21 , 250 KW, 1 34X276 4 , TR20 0 N2 5 0T7E2 1H2 TGC7XXSXXXXAXBXCXXXXD X

AFD DRI VE, 60 0 V, I P21 , 315 KW, 1 34X276 5 , TR20 0 N3 1 5T7E2 1H2 TGC7XXSXXXXAXBXCXXXXD X

AFD DRI VE, 60 0 V, I P21 , 400 KW, 1 34X276 6 , TR20 0 N3 1 5T7E2 1H2 TGC7XXSXXXXAXBXCXXXXD X

AFD DRI VE, 60 0 V, I P21 , 400 KW, 1 3 4X276 6 , TR-2 00N31 5 T7 E21 H2 TGC7XXSXXXXAXBXCXXXXDX

CON TRO LS ( on e o n ly )

Se r v i ce able Com po n e n t

Re m ot e M o u n t Com po n e n t s

VF D DRI V E ( on e on l y )

CON TROLS ( on e only )

OP TI ON AL P ED ESTA L

Dr iv e Mo u nt hardw are - ( labe l nu t s an d scr ew s on ly )

22 AFDR-SVN001D-EN

Page 23

Global Connector Harnesses

CONNECTOR, DELPHI GT150, 4- PIN, MALE, TO CAB01149 OR CAB0 1 1 5 0

CONNECTOR,

AMP,FEMALE,

TO UC80 0

CONNECTOR, DELPHI GT 150, 4- PIN, FEMALE, TO CAB0 1 1 51 OR CAB0 1 1 5 3

CONNECTOR, DELPHI GT 150, 4- PIN, MALE, TO CAB01155 OR

CAB01534

Figure 14. CAB01151 (39”) /CAB01153 (78”) global connector harness

Figure 15. CAB01155 (39”) /CAB01534 (78”) global connector harness

Pre-Installation

CONNECTOR, DELPHI GT1 5 0 , 4- PI N, FEMALE, TO EXTENSI ON CAB01149 OR CAB01150

Figure 16. CAB01149 (39”) /CAB01150 (78”) global connector harness

ULTRASONI C

SOLI DI FIED END,

TO AFD

AFDR-SVN001D-EN 23

Page 24

Pre-Installation

Required Parts—NOT Supplied

• Modbus™ cable (for remote or wall mount)

Because the distance varies with each application, Modbus™ connectors are not provided for remote and wall mount kits. The Modbus™ connection requires a unique connection type for the UC800 and a unique connection type for the AFD (listed above). The Global Connector Extension is used for spanning the rest of the wire distance between the panel and the AFD. Maximum length 250 feet.

NOTICE

Excessive Cable Lengths Between AFDR Drive and Compressor Motor!

• Global Connector Harness without Conduit

– CAB01151 (39 inches) or CAB01153 (78 inches)

for UC800 connection (See

– CAB01155 (39 inches)

for AFD connection (See

– CAB01149 (39 inches)

inches) Global Connector Extension for variable distance between the control panel and AFD (See Figure 16, p. 23.)

• Global Connector Harness with Conduit

Note: If conduit is required for Modbus™ wire, a

shielded 16 gage wire pair can be used in lieu of global connectors. Use end connections from CAB01151 and CAB01149.

“AFD Control Wire Connections,” p. 51

See

Table 14.

• OIL00315/317

• Oil filter (FLR01683)

• Cold filter (FLR01682)

• 3/8 inch anchor bolts

• Refrigerant

• Control wire and conduit for control power wiring

• 2-1/2 hole saw or punch

Figure 14, p. 23.)

or CAB01534 (78 inches)

Figure 16, p. 23.)

and/or CAB01150 (78

Gas Pump Replacement in Older RTHD Units (Optional)

For RTHD units manufactured prior to 2012, Trane recommends completing non-mandatory gas pump replacement per RTHD-SVN01*-EN (

Instructions: Gas Pump Replacement - RTHD/RTHC

Installation

Preparation in DynaView™

Check the Configuration and Set-Points in the DynaView™ Display

1. Check the current configuration of the DynaView™ and confirm that all settings are correct. Make any necessary changes.

2. Check all of the current chiller setpoints programmed into the DynaView™ and confirm that they are all correct for the unit. Make any necessary changes.

Export the DynaView™ Configuration and Set-Points

Configuration and setpoint values must be saved from the DynaView™ control in order to successfully configure the upgraded UC800 controller. Using KestrelView™ on a PC or laptop computer:

1. Generate a Chiller Service Report from the DynaView™ with Level 4 active. To do this, click on Reports Menu and select Chiller Service Report.

2. Select all reports to ensure a complete report and convert the report to PDF. The PDF will be required to manually copy configuration and setpoint values with

Tracer UC800 are installed.

3. Verify that the PDF was printed. The PDF will be used when configuring the upgraded UC800 controller within Tracer

After the configurations and settings from the CH530 DynaView™ controller have been saved to a file on your service computer, the controller change-out can proceed.

TU after the Tracer AdaptiView™ display and

TU.

24 AFDR-SVN001D-EN

Page 25

Figure 17. Select reports

Figure 18. KestrelView screenshot—accessing Chiller Service report

Pre-Installation

Figure 19. Chiller service report (example)

AFDR-SVN001D-EN 25

Page 26

Pre-Installation

Preparing Tracer TU on the Service Computer

After this retrofit, the UC800 controller will communicate with the TR200 drive via a dedicated Modbus™ Master connection (independent of the IPC bus). A software upgrade is required to support this. The following steps detail how to obtain and install the necessary software onto the service laptop computer.

1. Tracer™ TU service tool version 9.0.322 or newer is required to re-program the chiller’s UC800. As of this printing, this version of Tracer TU is available for download at:

Figure 20.

https://home.ingerrand.com/sites/ softwaredownloads/SitePages/TU.aspx

2. If it is not already present, install this version of Tracer TU on the service computer.

3. After the correct version of Tracer TU is installed on the service computer, return to the same page (see link provided in Firmware link. In the screen that appears, click the Latest Version : Download link to download an EXE file. Run the application to select specific chiller products and install the correct software versions for that product.

Step 1, p. 26), and click the UC800

26 AFDR-SVN001D-EN

Page 27

Pre-Installation

Figure 21.

Figure 22.

Figure 23.

Important: Although it is possible to download all of

the products and all of their versions, this is not advisable due to the size of the resulting download.

Note: In general, the latest versions of the various

products will already be embedded and present in recent Tracer TU releases. This method is only required to obtain very recent releases for specific product firmware.

4. The product firmware required for the AFDR is RTHD:

3.03 (full software build part number: 6200 0624-

3.xx) or later. Version 3.03 is the first version of the

RTHD firmware that supports Modbus™ Master communications between the UC800 and the TR200 AFD. Check the box for RTHD: 3.03 and click Next.

Figure 24.

5. Accept the default destination folder for proper installation into Tracer TU, and click Install. The selected code will now be placed into Tracer TU and can be downloaded into the UC800 controller of the RTHD AFDR when convenient.

AFDR-SVN001D-EN 27

Page 28

Pre-Installation

Oi l P l u g s i n Mot o r H o u sing

Oi l Pl u g s i n Be a ri n g H o u sin g

Oil and Refrigerant Removal

WARNING

Refrigerant under High Pressure!

RTHD units with an AFD require a lower viscosity oil to operate. With an AFD installed on an RTHD chiller, a

minimum nominal oil viscosity of 110 cSt must be attained. The existing oil (OIL00048) must be removed

from the RTHD unit and replaced with the new oil (OIL00315/317) (not included) before operating with an AFD.

To attain the minimum nominal viscosity, at least 90 percent of the existing oil must be removed from the chiller; refer to chiller nameplate for original chiller oil charge. Both the oil filter (FLR01683) and cold

filter (FLR01682) must be replaced and are not included with this upgrade. It is acceptable to change the oil to the new oil and still run the RTHD unit without the AFD installed, if it is more convenient to change to the new oil and operate the RTHD unit for a period of time before the AFD can be installed.

See

Figure 26, p. 30 in the following steps to reference

valves locations by number.

Notes:

• Follow all manufacturer's recommendations for

recovery equipment usage.

• Keep all oil removed to measure the total amount of oil removed from the unit.

• The replacement oil (OIL00315/317) and oil filters are NOT supplied with this upgrade and must be purchased separately.

1. Connect hoses from recovery unit to chiller, configured to recover liquid refrigerant (Push-Pull/Mechanical Pump). Use 5/8” access value on the evaporator or condenser (number 25 or number 19).

2. Open valves on chiller and start recovery machine. Complete the transfer of the liquid from the unit to the cylinder(s).

3. Once all of the liquid has been recovered, reconfigure the recovery unit for vapor by moving hose from liquid port to a vapor port to separate the refrigerant from the Solest 68 (OIL00048).

4. Recover vapor down to 0 psi.

5. Weigh and record the total amount of refrigerant removed from chiller.

6. Pressurize the evaporator to 2 psi nitrogen at the valve (number 30).

7. Pressurize the condenser to 2 psi nitrogen at the valve (number 13).

8. Drain the oil at the oil sump valve (number 7).

9. Energize the oil solenoid valve (number 40).

10. Pull the plugs under the gear housing on the compressor (three plugs total) and drain the oil.

Figure 25.

11. Pull the plugs under the motor housing on the compressor (one or two plugs total) and drain the oil.

28 AFDR-SVN001D-EN

Page 29

Pre-Installation

Note: C-, D-, and E-frame compressors have two

plugs; B-frame compressors have one plug.

12. De-energize the oil solenoid valve.

13. Change the oil filter (number 38; not insulated). Change the cold oil filter (number 48; insulation will need to be removed).

14. Perform pressure test.

15. Evacuate the unit to a minimum of 500 microns and perform a rise test.

16. Add the total oil charge according to

Table 6. Adding an

AFD to the RTHD chiller requires more oil than the original factory configuration.

a. Add enough Solest 120 (OIL00315/317) to the oil

filter (number 7) to fill the filter.

b. Add remaining total Solest 120 (OIL00315/317)

charge at the oil sump (number 7).

Important: Be sure to either run the evaporator and

condenser pumps when adding refrigerant to prevent freezing or verify that the water has been drained to prevent freezing tubes.

17. Compare amount of refrigerant removed in previous step to the nameplate charge. Charge appropriately at evaporator (number 25) according to the table for units with an AFD. Add refrigerant as needed to ensure the unit is fully charged.

Important: Oil charges shown in Table 6 are for new

RTHD chillers with AFD; when retrofitting existing RTHD chillers with AFD, increase oil charge shown in Table 6 proportionately based on how much oil was extracted during oil removal process.

18. At the oil sump, apply provided oil label sticker listing the new oil, OIL00315.

Table 6. Oil type and oil charge for RTHD chillers with AFD

Un it Co n f igur a t i o n ( a) B1 B1 B1 B 1 C1D1 B2 B 2 B2 B2 C2 D2 C1 D5 E4 C1 D 6E5 C1 E1 F1 C2 D3 E3

Oil Typ e So le st 1 20 ( OI L0031 5 / 317)

Oil Charge, gal 7.57.57.57.5101011 10

Oil Ch ar g e, L 28 . 5 2 8 . 5 2 8 . 5 2 8 .5 38 38 42 38

Un it Co n f igur a t i o n ( a) C2 D4 E4 C2 F2 F3 D 1 D1 E1 D 1 F1 F2 D 1 G1 G1 D1 G2 G2 D2 D 2 E2 D2 F2 F3

Oil Typ e So le st 1 20 ( OI L0031 5 / 317)

Oil Ch ar g e, gal 10 12 9. 5 11 1 3.5 13.5 9. 5 11

Oil Charge, L 3845.536 425151 3642

Un it Co n f igur a t i o n

Oil Typ e So le st 1 20 ( OI L0031 5 / 317)

Oil Ch ar g e, gal 13 . 5 1 3 . 5 9.5 11 13 . 5 9.5 11 1 3 .5

Oil Charge, L 51 5136 4251 364251

( a) Unit con f ig urat ion d igit s 1, 2 = com pre sso r cod e ( al so sh own in u nit mod el n um be r d ig it s 6, 7) ; d ig it s 3, 4 = ev apor ator code

( un it m od el n u m ber dig it s 14 , 1 5 ) ; digit s 5, 6 = con de nse r code ( un it m od el nu m ber digit s 2 1, 22) .

( a)

D2 G2 G1 D2 G3 G3 D 3 D2 E2 D 3F2 F3 D3 G2 G1 E3 D 2 E2 E3 F2F3 E3 G2 G1

AFDR-SVN001D-EN 29

Page 30

Pre-Installation

condenser

oil sump

epa

tor

epa

evaporator

compressor

gas pump

TRV

RTHD Valve Location

EXV

vent line

ole

components in box only

on applications requiring

an oil cooler

dual discharge lines only on C, D & E frame compressors

dual discharge lines

only on C, D & E frame

compressors

Figure 26. Component locations

30 AFDR-SVN001D-EN

Page 31

Installation

WARNING

Hazardous Voltage w/Capacitors!

For additional information regarding the safe discharge of capacitors, see PROD-SVB06*-EN.

Shut Down Power

1. Using lockout/tagout safety procedures, shut down the chiller’s main power.

2. Open all starter and control panel disconnect switches and secure them in the open position.

3. Confirm that the power is off to the control panel of the chiller.

Each line weight is comprised of two individual clamps.

Figure 27. Individual clamp (two required for each line

weight)

Installation Instructions

Chillers with B-Frame Compressor Size

• Number of oil separator discharge lines: 1

• Number of kits required: 1

Install 2 weights (4 clamps) on the single oil separator discharge line as shown in figure below.

• Install on the “candy cane” line between the oil separator and the condenser.

• Mount just below the weld or on any smooth surface in that area.

Vibration Mitigation - Line Weights Kit for Oil Separator Discharge Lines

The addition of an Adjustable Frequency Drive (AFD) on RTHD chillers may result in vibration resonance at low frequencies on the oil separator discharge line(s). Line weights are added to mitigate this vibration.

RTHD ADF Line Weight Kit

Table 7. Line weight kit 017500010100

Com po n e n t

Clam p CMP014 3 0

Scr ew SCR02 6 8 7

Mn u e m on ic

N u m be r D e csr ipt ion Qu a nt i t y

Clam p, Line

We ig h t

M6 X 3 0 MM, SCH

CAP

Figure 28. Line weight installation location – B-frame

compressors

AFDR-SVN001D-EN 31

Page 32

Installation

Figure 29. Line weight installed – B-frame compressors

Figure 31. Line weight installed on C, D, or

E-frame compressors

RTHD Tracer AdaptiView UC800

Chillers with C, D, or E-Frame Compressor Size

• Number of oil separator discharge lines: 2

• Number of kits required: 2

Install 2 weights (4 clamps) on EACH of the two oil separator discharge lines as shown in figure below.

• Install on the “candy cane” line between the oil separator and the condenser.

• Mount just below the weld or on any smooth surface in that area.

Figure 30. Line weight installation location – C, D, or

E-frame compressors

Controls Upgrade

If there is an existing CH530 controller, the Tracer AdaptiView™ RTHD rotary chiller display upgrade kit (RCDA) must be installed. Follow the installation

instructions in RCDA-SVN001*-EN (

Instructions: Tracer AdaptiView™ RTHD Rotary Chiller Display Upgrade Kit

If the RTHD to be retrofitted to AFD already has a UC800 Tracer AdaptiView controller, that can be reused.

Important: Regardless if it is new or existing, the UC800

) before installing the AFDR drive.

must have a software upgrade to support the AFDR. For more information, refer to

“UC800 Software Installation and Configuration,” p. 52

Installation

AFDR Kit Identification

• Close Mount Kit 1 has two power wire harnesses

• Close Mount Kit 2 has four power wire harnesses

• Remote Mount Kit 3 has NO power wire harnesses or Modbus™ cables

Note: The Modbus™ wiring for the remote mount

option must be purchased separately; refer to

“Required Parts—NOT Supplied,” p. 24 for part

numbers to determine the lengths needed. Purchase appropriate lengths for the distance required to wire to the AFD.

32 AFDR-SVN001D-EN

Page 33

Panel Component Removal

1 K4

1 K1

1 K3

1 K2

1 R 1 1R2 1R3

1 A3

1 T 3 -1 1 T 3 -2 1 T 3 -3

1 F1 / 2 / 3 Fu se

Lin e- Sid e Ha r ne ss 1 F1 / 2 / 3

High- Fa u l t Br a cin g

1 T 2 -1 1 T 2 -2 1 T 2 -3

WARNING

Hazardous Voltage w/Capacitors!

For additional information regarding the safe discharge of capacitors, see PROD-SVB06*-EN.

Wye-Delta Panel

Note: For solid state starter panels, see “Solid State

Starter Panel,” p. 35

Figure 32. Wye-delta component locations

Installation

AFDR-SVN001D-EN 33

Page 34

Installation

St a rt e r Modu le

Te rm ina ls 1 X 3

Fu se 1 F1 / 2 / 3

1. Remove and discard high-fault bracing.

WARNING

Backup Wrench Required!

Failure to follow instructions below could result in death or serious injury. Use backup wrench to prevent twisting/stress on motor terminals when installing and removing wire or buss bars from terminals and inspect terminals to ensure that they are not damaged. Motor terminals are ceramic and, if cracked, could create an electrical hazard when power is restored.

2. Remove and discard power wire from breaker/ terminal, contactors, and motor terminals.

Note: Be sure to save motor terminal nuts for

installation.

Figure 33. Use backup wrench when removing wire or

buss bars from motor terminals

Figure 34. Starter module location

3. Remove and discard 1F1/2/3 line side harness.

4. Remove and discard contactors: 1K1, 1K2, 1K3, and 1K4.

5. Remove and discard resistors: 1R1, 1R2, and 1R3.

6. Remove and discard current transformers: 1T2-1, 1T2-2, and 1T-31.

7. Remove and discard (if applicable) under/over voltage transformers: T3-1, 1T3-2, and 1T3-1.

8. Remove and discard terminals 1X3.

9. Remove and save Fuse 1F1/2/3 for later use; refer to

Figure 34 and Figure 38.

Note: This fuse will be rated at 5 amps (380–415 volts)

10. Remove starter module 1A3.

and 4 amps (460 volts).

Note: The liquid level red power wire (64A) is

connected to J3 Pin 1 of the starter module. This will be connected to the power supply 1A2. Refer to “Panel Control Wiring,” p. 48.

34 AFDR-SVN001D-EN

Page 35

Solid State Starter Panel

Figure 35. Solid state starter component locations

Installation

1T2- 1 1T2- 2 1T2- 3

High Fault Bracing

1. Remove and discard high-fault bracing.

WARNING

Backup Wrench Required!

Solid St at e St ar ter

1K11

1A3

1T3- 1 1T3- 2 1T3- 3

Lin e- Side Harness 1 F1/ 2/ 3

8. Remove and save Fuse 1F1/2/3 for later use.

Note: This fuse will be rated at 5 amps (380–415 volts)

and 4 amps (460 volts).

9. Remove starter module 1A3.

Note: The liquid level red power wire (64A) is

connected to J3 Pin 1 of the starter module. This will be connected to the power supply 1A2. Refer to “Panel Control Wiring,” p. 48.

10. Remove solid state starter module. See Figure 34, .

p. 34

1F1/ 2/ 3 Fuse

2. Remove and discard power wire from breaker/ terminal, contactors, and motor terminals. See

Figure 33, p. 34 for use of backup wrench.

Note: Be sure to save motor terminal nuts for

installation.

3. Remove and discard 1F1/2/3 line side harness.

4. Remove relay 1K11.

5. Remove and discard current transformers: 1T2-1, 1T2-2, and 1T-31.

6. Remove and discard (if applicable) under/over voltage transformers: T3-1, 1T3-2, and 1T3-1.

7. Remove and discard terminals 1X3.

AFDR-SVN001D-EN 35

Page 36

Installation

2 X H o l e s D ri lle d

Pa ne l Fr o n t

Pa ne l Bo t t om

2 X Ø 2 . 5

Panel Preparation—Close Mount (Kit 1 — 2 conduit)

If using a remote mount or wall mount option with fieldprovided power wire and conduit, skip to

Component Installation (All Kits),” p. 38

Refer to

1. Drill two 2.5-inch diameter holes at Location 2 and

Notes:

Figure 36. Conduit hole locations

Figure 36 during the following procedure.

Location 4, as shown in used to route the power wire which connects the unit to the AFD.

Figure 36. These holes will be

“Panel

• Test-fit the 2.5-inch conduit fittings at the locations to

ensure the conduit and or fitting will not interfere with the unit evaporator and or panel before drilling holes.

• Depending on the unit’s evaporator size the holes may

be located further inward than specified without interference between conduit and evaporator. Locating the holes further inward will aid in harness installation later. Before drilling, make sure conduit and fittings will not interfere with evaporator or panel door.

Note: See

36 AFDR-SVN001D-EN

“Dimensions,” p. 9 for conduit location

dimensions.

Page 37

Panel Preparation—Close Mount (Kit 2 — 4 conduit)

2 - 4X H ole s D rill e d

Pa ne l Fr o n t

Pa ne l Bo t t om

2 - 4X Ø 2 .5

Installation

Refer to

2. Drill four 2.5-inch diameter holes at Locations 1–4, as

Notes:

• Test-fit the 2.5-inch conduit fittings at the locations to

Figure 37. Power conduit hole locations

Figure 37 during the following procedure.

shown in the power wire which connects the unit to the AFD.

ensure the conduit and or fitting will not interfere with the unit evaporator and or panel before drilling holes.

Figure 37. These holes will be used to route

• Depending on the unit’s evaporator size the holes may

Note: See

AFDR-SVN001D-EN 37

“Dimensions,” p. 9 for conduit location

dimensions.

Page 38

Installation

1 0

1 1

Panel Component Installation (All Kits)

Install the following components listed in approximate locations as shown in

Table 8 at the

Figure 38.

Table 8. AFD panel component installation

I nd e x D e scr ipt ion Qt y

1 SUPPORT, CHOKE CORE 1

2 D I N RAI L, 4I N 1

3 FUSE HOLDER, 1 F1- 1F3 – REUSE ( 4–5 am p) 1

4 D I N RAI L END- STOP 4

5 BUSS BAR, STRAI GHT 1

6 BUSS BAR, FORMED 2

7 RELAY SOCKET, 4 PDT ( f or r elay s 1K14 an d 1 K1 5) 2

8 RELAY, 4PDT, 8 A ( r elay s 1K14 an d 1K15 ) 2

9 D ual Relay Outpu t 1 A8 1

10 FUSE HOLD ER, 1F4- 1 F6 – REUSE ( 6 –10 am p) 1

11 DIN RAI L, 7 . 5 I N, REUSE 1

Note: It ems 3, 10, an d 1 1 a lr ea dy exist an d ar e re- used.

Figure 38. Panel component installation locations

38 AFDR-SVN001D-EN

Page 39

Installation

1. Install choke core support bracket (1) using 6 mm thread rolling screws (13) so that is centered between the motor terminals.

Figure 39. Choke core support bracket

2. Install 4-inch din rail (2) using 6 mm thread rolling screws (13).

3. Locate the 1F-1F3 fuse (3) (refer to

Figure 38), and install on 4-inch din rail (2).

4. Install din rail end-stops (4) on din rail (2).

Figure 40. Din rail/1F1-1F3 fuse install

Figure 34 and

5. Install motor terminal buss bars (5/6). Torque to 40 ft·lb.

Note: Motor terminal buss bars must be flush on

motor terminal connection points; refer to

Figure 41.

Figure 41. Correct and incorrect motor terminal buss

bar installation

WARNING

Backup Wrench Required!

Failure to follow instructions below could result in death or serious injury. Use backup wrench when installing and removing wire or buss bars from motor terminals and inspect terminals to ensure that they are not damaged. Motor terminals are ceramic and, if cracked, could create an electrical hazard when power is restored.

Figure 42. Installed motor terminal buss bars; inset

shows buss bars over original terminals

AFDR-SVN001D-EN 39

Page 40

Installation

L- Bra ck et

St r ut Cha n n e l

St r ut Cha n n e l Ba se

6. Install 1K1 and 1K2 relay sockets and relays (8/9) on existing 7.5-inch din rail (10) where Fuse 1F1/2/3 was removed.

7. Install din rail end-stops (4) on din-rail (10).

Figure 43. 1K1, 1K2 relay socket

8. If not already installed, install dual relay output 1A8 (12).

Figure 44. Dual relay 1A8 install

Figure 45. Strut channel assembly

9. Remove all metal chips and shavings from inside the panel, and remove any loose debris, wires, or parts.

Conduit Support and Conduit Installation (Kit 1 and Kit 2)

1. Assemble and install the supplied strut channel; refer

Figure 45 and Figure 46.

Note: Make sure the position of the strut channel does

not interfere with panel door opening. Strut channel may need to be cut to height (anchor bolts and impact drill for concrete).

Figure 46. Strut channel installed

2. Route control wire and Modbus™ cable along the bottom side of panel and secure with provided loopclamps; refer to see

Note: Be sure to leave enough wire length to route

wire inside the control panel and the AFD and reach the termination points.

3. Cut four 16 AWG wires to the appropriate lengths and route through the 3/4-inch conduit.

Figure 47.

40 AFDR-SVN001D-EN

Page 41

Figure 47. Control cable

Con tr ol Po w er Con du it

M odbu s™ Ca b le

Loop Cl a m p

Con du it Con ne ct o r

Cab le Bu sh in g

Dr ive Pe de st a l

0 . 3 75 in. Gr o m me t

1 . 2 5- i n . Gr o m me t

2 - in. Co n d u it Con ne ct o r

Pe de st a l Ad a p te r Pla te

4. Remove pedestal adapter plate and install 2-inch and 3/4-inch conduit connectors and 3/8-inch grommet; refer to

Figure 48.

Figure 48. Pedestal

Installation

5. Install power wire conduit into conduit connectors, and secure conduit to strut channel with provided clamps.

AFDR-SVN001D-EN 41

Page 42

Installation

Figure 49. Modbus™ cable and control power

mounting

Figure 51. Adaptor plate assembly

Figure 50. Conduit connector assembly

6. Install pedestal adaptor plate to the pedestal.

7. Install the power wire conduits to the strut channel using supplied brackets.

Figure 52. Power wire conduit mounting

42 AFDR-SVN001D-EN

Page 43

Installation

Drive Installation—Pedestal Mount (All Kits)

Important:

• For wall mount option, follow instructions for remote

wall in BAS-SVX54*-EN (Operating Instructions: TR200 New D-Frame, 110–400kW).

• See

1. Determine the desired location for the drive and

2. Temporarily route power wire conduit to desired drive

Figure 53.

“Drive Dimensions,” p. 15 and “Pedestal

Drawings,” p. 17

Figure 8, p. 15 or Figure 10, p. 16 for wall mount

dimensions.

position the pedestal in place.

pedestal location to check for any routing issues.

or drive mounting dimensions.

4. Drill the four required holes for the anchor bolts and install the 3/8-inch anchor bolts.

Figure 54.

Figure 55.

3. Mark the locations for the anchor bolts using the bottom slots of the pedestal for a template.

AFDR-SVN001D-EN 43

Figure 56.

Page 44

Installation

Recommended Rigging and Lifting Procedures for AFDR Drive Units

WARNING

Heavy Objects!

Failure to follow instructions below or properly lift unit could result in unit dropping and possibly crushing operator/technician which could result in death or serious injury, and equipment or property-only damage. Ensure that all the lifting equipment used is properly rated for the weight of the unit being lifted. Each of the cables (chains or slings), hooks, and shackles used 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.

WARNING

Improper Unit Lift!

Failure to properly lift unit could result in unit dropping and possibly crushing operator/technician which could result in death or serious injury, and equipment or property-only damage. An AFDR cabinet assembly is top heavy. Test lift unit approximately 24 inches to verify proper center of gravity lift point. To avoid dropping of unit, reposition lifting point if unit is not level.

Unit Lifting Points—Preferred Lifting Method

• The preferred method for lifting an AFDR drive unit to position it for installation is to use an identical individual hoisting device at each lift point.

Figure 57. Preferred lifting method using two identical

individual hoists

Unit Lifting Points—Alternative Lifting Method

• If it is only possible to use a single hoisting device to lift an AFDR drive unit to position it for installation, a spreader bar should be used to allow adjusting the rigging as necessary to balance the unit around its center-of-gravity to ensure full control of the unit during lifting.

Figure 58. Alternative lifting method using a single

hoist and spreader bar

44 AFDR-SVN001D-EN

Page 45

Table 9. AFDR unit weights and heat rejection (460V/480V)

Installation

4 6 0V/ 4 8 0V Ca ta log Ma x Am ps

Weig h t ( lb ) 13 5 1 3 5 1 35 275 27 5 2 7 5

Heat Rej ect ion ( BTU/ hr) 77 0 8 928 6 12 3 7 0 121 6 1 1556 6 19 477

1 5 8 Ca t alo g /

1 9 0 M a xim um

2 0 0 Ca t alog /

2 4 0 M a xim um

2 5 2 Ca t alog /

3 0 2 M a xim um

3 0 1 Ca t alo g /

3 6 1 M a xim um

3 6 9 Ca t alo g /

4 4 3 M a xim um

4 4 6 Ca t alo g /

5 3 5 M a xim um

Table 10. AFDR unit weights and heat rejection (575V/600V)

5 7 5V/ 6 0 0V Cat a log M a x Am ps

Weig h t ( lb ) 135 1 3 5 13 5 2 75 27 5 2 75 27 5

Heat Reject i on ( BTU/ hr)

Line Voltage

Hazardous Voltage w/Capacitors!

1 0 9 Ca ta log/

1 3 1 M a xim um

59 3 9 7 168 9 0 3 7 1 0 4 88 12 7 0 1 15 2 3 2 17 1 5 4

1 2 9 Ca ta log/

1 5 5 M a xim um

1 6 0 Ca ta log/

1 9 2 M a xim um

2 0 2 Ca t alog /

2 4 2 M a xim um

2 4 2 Ca t alog /

2 9 0 M a xim um

2 8 7 Ca t alo g /

3 4 4 M a xim um

2. After lowering the drive onto the pedestal, securely fasten the drive to the base at all connection points at

WARNING

the front and back of the base.

Figure 60.

3 3 3 Ca t alog /

4 0 0 M a xim um

For additional information regarding the safe discharge of capacitors, see PROD-SVB06*-EN.

AFD Mounting—Pedestal Installation (All Kits)

1. Remove the front cover of the pedestal base for easy access to power wires Using safe lifting practices and keeping the wires inside the drive enclosure, carefully lower the drive onto the pedestal base.

Figure 59.

AFDR-SVN001D-EN 45

3. Connect all power wire and dedicated ground wire to the drive according to the supplied schematics. AFD termination location allows 2 wires per phase.

Page 46

Installation

Figure 61.

4. Replace the front panel of the pedestal base.

Figure 62.

Panel Power Wiring

NOTICE

Compressor Damage!

Before connecting power wire to the motor terminals, with the motor terminal jumpers removed, verify proper phasing between the drive and motor terminals with an Ohmmeter for all connections. Improper phasing occurs between the drive and motor terminals can cause compressor damage.

After verifying proper phasing between the drive and motor terminals with an Ohmmeter

at the breaker/terminal according to the provided schematics. Refer to designations.

6. Output wire from the drive to the motor terminals needs to be routed through the center of the provided cores. Install power wire at the motor terminals according to the provided schematics.

46 AFDR-SVN001D-EN

Figure 42, p. 39 to confirm phase

, install power wire

Page 47

Installation

W ir e t a p supplie d

on a ll o p t ions

Figure 63.

7. Use provided tie wraps to secure the cores to the core bracket and use tie wraps to keep the power wire positioned in the center of the cores.

Figure 64.

Figure 65.

9. Align cover over motor terminals and drill four holes for mounting. Install cover over motor terminals using four screws (provided); refer to

Figure 66.

Figure 66. Cover installation

8. Install ground terminals in the control panel and connect all ground wires. Drill as needed and use tapping screws and star washers provided. See

Table 67, p. 48 for location.

AFDR-SVN001D-EN 47

Page 48

Installation

Te rm ina ls 1 X 5 -1 / 1 1

1 A2

1 A 8

1 K1 5

1 K1 4

1 F1 , 1 F2

W ir e s 2 0 A, 2 1A

1 F4 , 1 F5 , 1 F6

Con tr ol Po w er Tr an sform er

Ap pr oxim at e

of ro u n d

ug s

lo ca tio n

Panel Control Wiring

Refer to schematic 5071-1783 for the following connections.

1. Using the provided 12 AWG, route wires 20A, and 21A from the 1F1 and 1F2 fuse to the control power wire transformer, terminals H1 and H2; refer to

Figure 67.

2. Strip insulation from Line 1 and Line 2 and install wire taps; refer to

Figure 68.

48 AFDR-SVN001D-EN

Page 49

Installation

Figure 68. Wire tap installation

Figure 69. 12 AWG wire connections

3. Connect one 12 AWG to the opposite side of each wire tap and route wire to the 1F1 and 1F2 fuse; refer to

Figure 69.

AFDR-SVN001D-EN 49

4. Install wire tap case; refer to

Figure 70. Wire tap case install

Note: The following connections will be connected to

some Terminal 1X5. Terminals 1X5-4 through

Figure 70.

Page 50

Installation

1 X 5 Te rm ina l

1 2 3 4 5 6 7 8 9 1 0 1 1

1 X 5 - 2 Ma st e r Oi l Sol ( 4Y 3 ) / Dual Re l a y ( 1A 8 )

1 X 5 -3 HP Cut out ( 48 29 )

Ti e d 1 X5 -4 t h r o ugh - 7 Ele ct r ica lly Tie d ( 11 5 V = “ H ot ” )

1 X 5 -8 t hr o ug h - 1 1 Ele ctr i ca l ly Ti e d ( 1 1 5 V - Com )

1 X 5 -1 Hea t e r s ( 4E1 , 4 E2 )

1X5-7 are electrically tied together and are connected to terminal X1 of the control power transformer (115V “hot”). Terminals 1X5-8 through 1X5-11 are electrically tied together and connect to terminal X2 of the control power transformer, (115V com); refer to

Figure 71.

Figure 71. 1X5 Terminal location

(64A) and was previously connected to the starter module J3 Pin 1.

Note: J3 or J4 Pin 1 on power supply 1A2 may also be

used for oil loss liquid level sensor connection.

Table 11. Pin-out, oil loss liquid level sensor (4B2)

W ire D e scr i p t i on

64 A ( Red ) Se nsor 2 4v+ in

Ma t i n g Con n e cti on De scr ipt ion

J5, Pin 1, Power Su ppl y ( 1A2)

24 V+ ou t

Figure 73. Oil loss liquid level sensor connection

1K15 Relay Connections

6. Using 16 AWG wire, make the following connections listed in

Table 12.

Table 12. Pin-out, relay 1K15

Figure 72. Terminals 1X5-1 through -11

Te r mi n a l — Re l a y 1 K1 5 D e scr i p t i on

10 N/ C con t a ct 1 X5 - 4 t hru 7 11 5 V “ h ot ”

11 N/ O co ntact 1X5 - 4 t h ru 7 115 V “ h ot”

2 N/ C con t act 1X5-1

7 N/ O cont act 1 X5 - 2

A2 Coil - com 1X5- 8 t hru 1 1 115 V “ comm on”

A1 Coil - “ h ot ” Pin 5 - AFD D r iv e Runni ng Rela y

Dual Relay Output 1A8 Connections

7. Using 16 AWG wire, make the following connections listed in

Table 13.

Ma t i n g Con n ect i o n De scr ipt ion

Heat er s - 4 E1, 4E2 , W ires: 2 8A an d 2 8 B

Mast er Oil Solen oi d 4 Y3 - Wir e: 29 B

Oil Loss Liquid Level Sensor Connections

5. Reconnect the oil loss liquid level sensor 24V supply to power supply 1A2 connector J5, Pin 1; this is a red wire

50 AFDR-SVN001D-EN

Page 51

Installation

Re move W hi t e W ir e Fr om Pi ns 1 2 a nd 3 7 ( Safe St o p )

Pi n s 4 a n d 5 ( Running R e l a y 2 )

Pi n s 1 2 an d 3 7 ( Safe St op)

Table 13. Pin-out, dual relay output (1A8)

Te r m ina ls— 1 A8 Descrip t ion

J11 Pin s 1 –4 PWR/Com WB2

J2 Pin 6 Rel ay 115 V in 1 X5 - 4 / 7 To 11 5 V “ h ot ”

J2 Pin 4 Rela y N/ O 1 X5 -2

Ma t i n g Con nect i o n De scr ipt ion

LLI D com mu n ica t ion / power bu s

To M a st er Oi l Solen oi d 4 Y3 - Wir e: ( 29B)

AFD Control Wire Connections

8. Using 16 AWG wire make the following connections to the AFD listed in

Important:

• Remove and discard white wire connecting Pin 12 and

Pin 37 on the AFD drive.

• The red wire needs to be removed from the connector on the UC800 end.

Table 14.

Table 14. Pin-out, AFD

Te r min a l— AFD De s cr i p t i on

Pin 61

Pin 68

Pin 69

Pin 4 Runni ng Relay 1X5 - 4 / 7 115V “ hot ”

Pin 5 Runni ng Relay 1K1 5 , p in A1 Coil – “ h ot ”

Pin 37 Saf e St o p 1 K1 4 , pi n 9 N/ O con t act

Pin 12 2 4 V ou t 1K14 , pin 5 N/O con t act

Mod bu s™ ( RS48 5 ) Com ( BK)

Mod bu s™ ( RS48 5 ) + ( BLU)

Mod bu s™ ( RS48 5 ) – ( GY)

Ma t i n g Con n ect ion De scr ipt ion

PIN 2 ( I MC) UC80 0 1A1

PIN 3 ( I MC) UC80 0 1A1

PIN 4 ( I MC) UC80 0 1A1

Mod bu s™ ( RS48 5 ) Com ( BK)

Mod bu s™ ( RS48 5 ) + ( BLU)

Mod bu s™ ( RS48 5 ) – ( GY)

Figure 74. AFD—Remove white wire (safe stop)

Figure 75. AFD—Pin location safe stop and running

relay

• The red wire on the Modbus™ cable is NOT connected to the AFD.

AFDR-SVN001D-EN 51

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Installation

Pi n s 6 1, 6 8 , 6 9 ( Mo d b u s™)

Figure 76. AFD pin location—Modbus™

1K14 Relay Connections

9. Using 16 AWG, make the following connections to relay 1K14 listed in

Table 15. Pin-out, relay 1K14

Te r m ina l— Re l a y 1 K14 D e scr i p t i on

A1 Coil, 1 1 5V “ hot ” 1 X5 - 3

A2 Coil, 1 1 5V com 1 X5 - 8 t h r u 1 1

9 N/ O con t act Pin 37 AFD Dr i ve Safe St op

5 N/ O con t act Pin 12 AFD Dr i ve 24 V ou t

Table 15.

Ma t i n g Con n e cti on D e scri p t i o n

To H i g h Pr e s s u r e Cut o ut , N C ( RED Wir e )

To 115 V com mo n

computer. If no shortcut exists, the program can be found in Programs > Trane > Tracer TU.

Figure 77.

NOTICE

Compressor Damage!

Before connecting power wire to the motor terminals, with the motor terminal jumpers removed, verify proper phasing between the drive and motor terminals with an ohmmeter for all connections. Improper phasing occurs between the drive and motor terminals can cause compressor damage.

2. After Tracer TU is launched, the Startup Task Panel dialog box appears; refer to

Figure 78. Select Direct

Connection and then click Connect button.

Important: Tracer TU version 9.0.322 is required. If that

version or newer is not already installed, refer to

“Pre-Installation,” p. 18 for details

on how to obtain and upgrade Tracer TU.

UC800 Software Installation and Configuration

Note: The software upgrade process requires that the

UC800 ether have no application code already installed, or if an application is existing, that the controller be in the Stop mode and that the compressor and the pumps have been shut off. TU will enforce this requirement with pop-up messages at the appropriate step in the process, but it is best to Stop the chiller before the software upgrade process begins.

1. Connect the service laptop computer to the target RTHD UC800 using an A/B type USB cable. Launch Tracer TU service tool software in the service

52 AFDR-SVN001D-EN

Page 53

Installation

Figure 78.

a. If the UC800 target controller has no application

already installed

appears; refer to

Step 3, p. 53.

Figure 79.

, the Tracer TU Connect dialog box

Figure 79. Click OK and proceed to

Figure 80.

3. The Application Software Download dialog box

appears, allowing selection of chiller products. For

Product Name, select RTHD, and for Version, select

3.03 (or newer). Then click Upgrade Device.

If the UC800 target controller has an application

already installed

appears; refer to

with Software Already Installed,” p. 58

, Tracer TU’s Unit Summary tab

Figure 80. Skip to “Existing UC800

Figure 81.

4. A confirmation dialog box appears. Click OK to

continue.

AFDR-SVN001D-EN 53

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Installation

Figure 82.

5. The download’s progress is indicated by a bar at the bottom of the Application Software Download dialog box.

Figure 83.

7. Tracer TU’s Configuration tab appears; refer to

Figure 86.

6. After the download is complete, two confirmation dialog boxes appear. Click OK in each dialog box.

Figure 84.

Figure 85.

Important: Trane recommends configuring the unit

manually rather than browsing to an existing Chiller Service Report electronically.

8. Because the new AFD is being retrofit with Modbus™ Master communications, reference the Chiller Service Report in PDF or XML to configure the unit for best results.

54 AFDR-SVN001D-EN

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Installation

MOTOR CONTROLLER

Manufactured by Danfoss Drives For TRANE LaCrosse, WI 54601-759

See information packet for installation instructions

a. For Starter Type (located in the UC800 section or

in the Starter section, depending on actual software version used), select TR200 Modbus™ AFD; refer to Figure 87.

Figure 87.

c. For Compressor Rated Load Amps, enter the

value noted as the Trane Motor Controller nameplate's Output Current; refer to and

Figure 90.

Figure 89

Notes:

• The Compressor Rated Load Amps need to be

increased over the previously set RLA current as this value now refers to the currents occurring between the drive and the motor, which are slightly higher (at full load rating point) than for a Wye Delta Starter Type.

• The new Compressor Rated Load Amps are used to “calibrate” the UC800 controller so it can provide a current limit function at the correct current level. Motor protection becomes a function of the AFD and its settings.

• Current flowing into the unit (into the drive) remains at or below the previous RLA stamped on the original shipped RTHD nameplate; thus, there is no need to increase the upstream branch wiring or circuit protection.

Figure 89.

b. For Line Voltage Sensing, select Not Installed;

refer to

Figure 88.

AFDR-SVN001D-EN 55

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Installation

Figure 90.

Important: Nameplate values, including Product

Model Number, Product Serial Number,

and Product Sales Order must be set for the unit as well; refer to

Figure 91.

9. Verify all configuration settings and then click the Save. Tracer TU downloads the configuration settings to the target UC800 controller. A progress dialog box appears, followed by a resetting target dialog box. After the configuration has been stored successfully, click OK to close the dialog box.

Figure 92.

10. Tracer TU automatically displays its Binding tab. At this time, all new LLIDs must be bound. If there is a mix of existing and new LLIDs, Trane recommends that all existing LLIDs be unbound; then, rebind existing LLIDs and bind new LLIDs.

Important: For more information about binding LLIDs,

refer to RCDA-SVN001*-EN (

Instructions: Tracer AdaptiView™ RTHD Rotary Chiller Display Upgrade Kit

original RTHD chiller

Operation, and Maintenance

Figure 93.

Installation

) or the

Installation,

manual.

Figure 91.

56 AFDR-SVN001D-EN

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Installation

Note: Because the AFDR does not use the IPC link, it

will not appear on the binding list. Instead, the AFDR uses the new Modbus™ Master Communication port (labeled IMC on the UC800). Drive parameters must be set independently and manually. For more information about AFDR TR200 setup, refer to

“Drive Settings,” p. 60.

11. After all LLIDs have been properly bound (refer to

Figure 94), navigate to Tracer TU’s Setpoints tab to

check and adjust settings accordingly. Refer to the existing Chiller Service Report for customer settings such as Low Refrigerant Temperature Cutout,

Low Water Temperature Cutout, Chilled Water Setpoints, etc.

Figure 94.

Figure 95.

12. Navigate to Tracer TU’s Field Startup tab and verify

the following settings for the Modbus™ AFD:

a. For firmware versions 3.03 and newer, use the

following settings:

• Current Limit Proportional Gain = 8.0

• Current Limit Integral Time = 60 sec

• RLA State Feedback for Water Control = 4.0

b. For earlier firmware versions, use the following

settings:

• Current Limit Proportional Gain = 2.0

• Current Limit Integral Time = 6 sec

• RLA State Feedback for Water Control = 1.0

Figure 96.

AFDR-SVN001D-EN 57

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Installation

Existing UC800 with Software Already Installed

1. If an AFDR retrofit is installed on an RTHD chiller with an existing UC800 controller/Tracer AdaptiView™ display, the software installation will be slightly different than in

Configuration,” p. 52

code and configurations installed, when Tracer™ TU is launched on the service laptop with a direct USB connection to the controller, Tracer TU displays its Unit Summary tab; refer to

Figure 97.

“UC800 Software Installation and

. Because the UC800 already has

Figure 97.

2. If a Chiller Service Report has not already been generated, Trane recommends creating one at this time. Select Reports > Chiller Service to open the Chiller Service Report dialog box, and save the report both as XML and PDF (check Convert Report to PDF). Be sure to note the location where the files will be stored, or use Browse to specify a different location. Click Save.

Figure 98.

58 AFDR-SVN001D-EN

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Installation

3. Navigate to the Configuration tab (Utilities > Equipment > Configuration, or double-click the

“wrench” icon on the right-hand side of Tracer TU and then click the Configuration tab). Click the Upgrade Controller button.

Figure 99.

4. The Application Software Download dialog box

appears, allowing selection of chiller products. For

Product Name, select RTHD, and for Version, select

3.03 (or newer). Then click Upgrade Device.

Note: If version 3.03 (or newer) does not appear for

selection, obtain that or a newer version and install it into Tracer TU on the service computer. Refer to

Computer,” p. 26

Figure 100.

“Preparing Tracer TU on the Service

5. A confirmation dialog box appears. Click OK to

continue.

Figure 101.

AFDR-SVN001D-EN 59

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Installation

6. The download’s progress is indicated by a bar at the bottom of the Application Software Download dialog box.

Figure 102.

The remainder of the software installation process is very similar to the procedure included in

Installation and Configuration,” p. 52

the configuration and settings are carried through in this application. Proceed with procedure

Configuration,” p. 52

“UC800 Software Installation and

Step 8, p. 54 (included in the

“UC800 Software

, except that most of

Drive Settings

Important: Any AFDR drive module menu parameter

numbers not listed in this manual are nonTrane specific program parameters. All non-Trane specific program parameter values have been set by the manufacturer before shipment, to provide optimum drive performance. Under no circumstances should any of the pre-set values in these menu parameters be changed unless specifically directed to do so by a factory engineer or a factory technical support person.

Note: Please refer to BAS-SVP04*-EN, or the most recent

version ( program parameter details and descriptions, and the instructions necessary to operate the Local Control Panel (LCP) and program the necessary drive parameters.

Refer to Table 16, p. 61 for a list of items that need to be set in the frequency drive at startup. For additional information, refer to the programming manual that is shipped with the drive. The programming manual includes a detailed section that discusses accessing the parameters in the drive.

This process is summarized briefly below:

1. To access the parameters, press the Main Menu key.

2. If required, enter the password (999).

3. To select a parameter group, use the up/down arrow keys to highlight the parameter group, and then press the Enter key to access that group.

4. Use the up/down arrow keys to access the parameter number, and then press the OK key.

5. Use the up/down arrow keys to change the parameter, and then press the OK key to change the setting.

Programming Guide: TR200),for full

60 AFDR-SVN001D-EN

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Installation

Retrofit Air-Cooled RTHD Adaptive Frequency Drive Model AFDR (TR200)

Installation and Startup

Most of the drive parameters are already set up when the drive is shipped except for a short list of unit specific parameters obtained from the unit and motor nameplates that need to be field programmed.

NOTICE:

Compressor Damage!

Improper drive parameter settings could cause compressor damage or failure. Verify drive parameters

Important: When confirming these parameters it

is important that [0-03 Regional settings] be left in the “North American” category. Do NOT change this

default setting.

are set correctly prior to unit operation.

Table 16. Compressor specific parameters (motor frame/voltage/Hertz)

B1 / B2 C1 / C2 D1 / D 2 / D 3

I D De scrip t ion

1- 21 Mot o r Pow er 23 3 HP 2 3 3HP 33 4 HP 3 3 4HP 441 HP 4 4 1HP

1- 22 Mot o r Volt a ge 4 60V 57 5 V 4 60V 5 7 5 V 460 V 5 7 5 V

1- 23 Motor Frequ en cy 6 0H z 6 0 Hz 60 Hz 60Hz 6 0 Hz 60 Hz

1- 24 Mot or Cur ren t Ou tput Am ps v a lue f r o m new AFD R n a m ep la t e st icker ; r e f e r to Fi gure 8 8, p. 5 5.

1- 25 Mot o r Nom Speed 351 2 RPM 3512 RPM 35 31RPM 35 3 1RPM 3 5 3 5RPM 353 5 RPM

1- 30 Sta t or Resi st ance 0.0 3 0 3 Ω 0.04 3 0 Ω 0 .02 0 1 Ω 0.03 0 8 Ω 0. 012 2 Ω 0. 019 7 Ω

1- 31 Roto r Resist a nce 0. 0257 Ω 0. 0 365 Ω 0. 0 146 Ω 0. 0 227 Ω 0.0 0 9 1 Ω 0.0 1 4 4 Ω

1- 35 Mai n React ance 5 . 3 684 Ω 8. 0 570 Ω 3. 0 050 Ω 4. 8 8 57 Ω 2. 8 8 82 Ω 4. 8 5 5 3 Ω

1- 36 Fe Lo ss Resist an ce 1 88. 3 8 8 Ω 28 0.7 3 0 Ω 1 5 2 .61 2 Ω 24 3 . 610 Ω 12 5 . 5 49 Ω 193. 8 5 0 Ω

3- 03 Ma x Referen ce 60Hz 6 0Hz 6 0 Hz 60Hz 6 0 Hz 60 Hz

4- 14 Mt r Spd Hig h Lim . 60Hz 6 0 Hz 60 Hz 6 0Hz 60 Hz 60 Hz

14 - 1 1 Volt at Main s Fault 39 1 V 4 8 9V 39 1 V 4 89V 3 9 1 V 489 V

4 6 0V / 6 0 Hz 57 5V/ 6 0 H z 4 60 V / 6 0 H z 5 7 5V / 6 0 Hz 4 6 0V/ 6 0 Hz 5 7 5V/ 6 0H z

Refer to Table 17 for a list of items that are programmed in the drive at the factory for use with Trane chillers. In the event that the drive needs to be reset, these parameters need to be reprogrammed into the drive.

To reset the drive to the Danfoss defaults, perform the following procedure.

1. Disconnect power to the drive, and wait for the display to shut down.

2. While powering up the drive, press and hold the following keys: Status, Main, and OK.

3. After 5 seconds, release the keys.

After the drive is reset, reprogram the items listed in

Table 17.

Important: These parameters are supposed to have

been set at the factory to the Trane-specific values shown here in

Table 17. Always

confirm before actual drive start up that this is so and correct any one of the parameter settings as necessary.

AFDR-SVN001D-EN 61

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Installation

Table 17. Non-compressor specific parameters

I D De scri p t i o n V a l u e s

0- 03 Reg io n Set t i ngs [ 1 ] North Am eri can

0- 20 Disp lay Li ne 1.1 Sm all [ 1 6 12] Mot or Volt ag e

0- 24 Displ ay Lin e 3 Lar g e [1 6 1 7] Speed [ RPM]

0- 40 [ Han d on] Key on LCP [ 0] Di sab led

0- 41 [ Of f ] Key on LCP [ 0] Di sab led

0- 60 Mai n Menu Passw ord 99 9

0- 61 Access t o Main Men u w /o Passw ord [ 1] LCP: Read Only

1- 03 Tor qu e Ch ar act er ist ics [ 0 ] Com presso r Torqu e

1- 71 St ar t Del ay 2s

1- 73 Fly in g St ar t [ 0 ] Di sab led

1- 78 Com pre ssor St art Max Spe ed [ Hz] 20H z

1- 79 Com pre sso r St ar t Max Ti m e t o Trip 10s

1- 87 Trip Spe ed Low [ Hz] 25Hz

3- 02 Min Ref er ence 30Hz

3- 13 Refer en ce Sit e [ 1] Rem o t e

3- 15 Ref er en ce 1 Sour ce [ 0 ] No Fun ct ion

3- 41 Ram p 1 Ram p Up Tim e 10 s

3- 42 Ram p 1 Ram p D ow n Tim e 10 s

4- 10 Motor Speed Di r ect ion [0] Clo ck w ise

4- 12 Mot or Speed Low Lim it [ Hz] 30 Hz

4- 18 Curren t Lim it 107%

8- 01 Con t r ol Sit e [ 2] Cont r olwor d o nly

8- 03 Cont rol Ti m e ou t Tim e 15 s

8- 04 Cont r ol Tim eout Funct io n [ 2] St op

8- 30 Prot ocol [ 2 ] Mod bus RTU

8- 31 Addr ess 3

8- 82 Ba ud Rat e [ 7] 11 5 200 Baud

14 - 00 Swit ch ing Patt ern [ 1] SFAVM

14 - 03 Ov erm odu lat ion [ 0 ] Off

14 - 10 Mains Fail ur e [ 4] Kin et ic Back- up

14 - 1 2 Funct io n a t Mai ns I mb alance [ 3] Derat e

14 - 21 Au t om atic Rest art Tim e 8 s

14 - 5 0 RFI Filt er [ 0 ] Off

14 - 5 1 DC Link Com pensat ion [ 1] On

14 - 60 Funct io n at Ove r Tem p er atur e [ 1] Der at e

14 - 61 Function at I nve r t er Ov er l oad [ 1] Dera t e

14 - 6 2 I nv. Ov er l oa d Der at e Cur r ent 75%

62 AFDR-SVN001D-EN

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Startup Test Log

Settings Tab

Front Panel Chilled Water Setpt (F)

Front Panel Current Limit Setpt (RLA)

Differential to Start (F)

Differential to Stop (F)

Setpoint Source

Chilled Water Reset

Return Reset Ratio

Return Start Reset

Ret urn Maxi mum Reset

Outdoor Reset Ratio

Outdoor Start Reset

Outdoor Maximum Reset

Evap Water Pump

Cond Water Pump

Expansion Valve Control

Slide Valve Control

Service Pumpdown

Date Format

Date

Ti me Format

Time of Day

Keypad/Display Lockout

Display Settings

Settings

Chiller

Feature Settings

Mode Overrides

Note: For startup procedure, see RTHD-SVX01*-EN

(Installation, Operation, and Maintenance, Optimus™ Water-Cooled Chillers, Model RTHD).

Chiller Settings

AFDR-SVN001D-EN 63

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Startup Test Log

Main Tab 15 min 30 min 1 hr

Chiller Mode

Evap Ent/Lvg Water Temp

Cond Ent/Lvg Water Temp

Active Chilled Water Setpoint (F)

Average Line Current (%RLA)

Active Current Limit Setpoint (%RLA)

Software Type

Software Version

Reports Tab

Evap Entering Water Temperature (F)

Evap Leaving Water Temperature (F)

Evap Sat Rfgt Temp (F)

Evap Rfgt Pressure (psia)

Evap Approach Temp (F)

Evap Water Flow Switch Status

Expansion Valve Position (%)

Expansion Valve Position Steps

Evap Rfgt Liquid Level (in)

Cond Entering Water Temperature (F)

Cond Leaving Water Temperature (F)

Cond Sat Rfgt Temp (F)

Cond Rfgt Pressure (psia)

Cond Approach Temp (F)

Cond Water Flow Switch Status

Cond Head Pressure Ctrl Command (%)

Compressor Starts

Compressor Run Time

System Rfgt Diff Pressure (psid)

Oil Pressure (psia)

Compressor rfgt Discharge Temp (F)

Discharge Superheat (F)

% RLA L1 L2 L3 (%)

Amps L1 L2 L3 (Amps)

Volts AB BC CA

Compressor

Run Time

Chiller Log

Evaporator

Condenser

Operator Log

64 AFDR-SVN001D-EN

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Troubleshooting

The drive displays three types of faults:

• Warning

A warning or alarm is signaled by the LEDs on the front of the AFD by a code on the LCP.

A warning indicates a condition that may require attention or a trend that may eventually require attention, and will remain active until the cause is no longer present. Under some circumstances, motor operation may continue.

•Trip

A trip is the action when an alarm has appeared. The trip removes power to the motor and, after the condition has been cleared, can be reset by pressing the Reset button. The event that caused an alarm cannot damage the AFD or cause a dangerous condition.

After its cause has been rectified, an alarm must be reset to restart operation.

•Trip Lock

A trip lock is an action when an alarm occurs that may cause damage to the AFD or equipment. Power is removed from the motor, and a trip lock can only be reset after the condition is cleared by cycling power.

Once the problem has been rectified, only the alarm continues flashing until the AFD is reset.

d. In the Binding view of the Tracer TU service tool,

verify there is a green face indicating that the Starter LLID is bound.

e. Record any drive diagnostics found.

2. Collect Chiller Information.

a. Note the following chiller information:

• Operating mode and any sub-mode (i.e., 100%

or 75% load etc.)

• Number of chiller starts, and hours of operation.

• Time since last diagnostic shutdown (<1 minute,

<1 hour, >1 hour, etc.)

b. What was the chiller state at the time of the failure?

(Chiller starting? Running low load? Running full load? etc.)

c. Record the chiller’s sales order and serial numbers,

and the drive’s serial and model numbers.

3. Troubleshooting

a. Measure and record the DC bus (via the Local

Control Panel [LCP]).

b. Check ALL wiring (tightness, ribbon cables fully

seated, proper phasing, etc.)

c. Refer to the Danfoss manuals for further

troubleshooting information.

WARNING

Hazardous Voltage w/Capacitors!

For additional information regarding the safe discharge of capacitors, see PROD-SVB06*-EN.

1. CH531/Tracer AdaptiView only: Collect alarm and

parameter information.

a. DO NOT cycle unit power or reset the controls.

Leave the AFD and the UC800 in their present states.

b. Record all UC800 active and historic alarms. Make

a full chiller service report.

c. Document and check all applicable parameter

settings. This information can be verified off of the chiller nameplate, and by referring to this manual.

AFDR-SVN001D-EN 65

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Recommended Periodic Maintenance and Inspection

Visual Inspection—Power Removed

WARNING

Hazardous Voltage with Capacitors!

For additional information regarding the safe discharge of capacitors, see PROD-SVB06*-EN.

1. Ensure the door interlocks are present and working.

2. Verify the safety ground connections to the door panels are securely connected.

3. Inspect power wire cables and devices to assure no abrasion is occurring from vibrations against chassis of cabinets, or other edges.

4. Ensure the drive interior and exterior is clear of any dust or debris. Fans, circuit boards, vents, etc. must be clean. Only use a vacuum for cleaning. Do NOT use compressed air.

5. Inspect the interior of the drive for any signs of moisture entry or leakage.

6. Visually inspect all drive components and wiring. Look for signs of heat or failure (look for swelled or leaking capacitors, discolored reactors or inductors, broken pre-charge resistors, smoke or arc trails on MOVs and capacitors, etc.)

7. Closely inspect the motor terminal board for any signs of leakage, arcing, etc.

8. Check ALL cable/lug/terminal connections inside the drive enclosure. Ensure all are clean and tight, and not rubbing against each other anywhere.

Operational Inspection—Power Applied

WARNING

Live Electrical Components!

During installation, testing, servicing and troubleshooting of this product, it may be necessary to work with live electrical components. Have a qualified licensed electrician or other individual who has been properly trained in handling live electrical components perform these tasks. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.

1. Verify the drive cabinet cooling fans are operati ng. This should be done from outside the enclosure, by looking into the cabinet at door and cabinet vents, to avoid electrical hazards.

Note: The power module fan comes on with power.

Other fans cycle with drive operation.

2. Check historic fault codes using LCP 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 alarm histories for any indications of

operational problems.

Do this every 1–12 months depending on operating environment.

To properly diagnose service issues for Adaptive Frequency Drives for centrifugal chillers equipped with AFDR starters, all UC800 chillers will be equipped with the LCP as standard on the drive power module. This is for service only and NEVER for machine operation.

66 AFDR-SVN001D-EN

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Wiring Information

DASHED LINES I NDI CATE FIELD WIRI NG BY OTHERS. PHANTOM LI NES IN DICATE ALTERNATE CIRCUITRY OR AVAILABLE S ALES OPTIONS. CHECK SALES ORD ER TO D ETERMINE I F WIRI NG I S REQUIRED FOR SPECIFIC OPTIONS.

NOTES:

LOW VOLTAGE

AREA

MAX CONTROL

VOLTAGE AREA

CONTROL SECTI ON

LIN E VOLTAGE AND POWER

SECTION

LIN E VOLTAGE

(SEE N AMEPLATE)

EVAPORATOR

30 VAC MAX

132 VAC

ALL FI ELD WI RING MUS T BE I N ACCORDANCE WI TH THE N ATIONAL ELECTRIC

COMPLY WITH LOCAL APPLICABLE COD ES.

POWER WI RE - LI NE VOLTAGE AFD TO MOTOR.

CONTROL WI RE - 30 VA C MAX, 2 S INGLE CONDU CTOR CABLES, 16 AWG UL 123 0.

POWER WI RE - LI NE VOLTAGE I N TO AFD.

CONTROL WI RE - MODBUS, GLOBAL HARNESS - 4 CONDUCTOR 1 8 AWG TWISTED PAIR

CODE AND STATE AND LOCAL REQUIREMENTS. EXPORT UNIT WIRI NG MUST

CONTROL WI RE - 132 VAC MAX, 2 S INGLE CONDU CTOR CABLES, 16 AWG UL 123 0.

CLASS I I

CLASS I

AFD

MOTOR TERMI NALS

UC800

Wiring Diagram Matrix

Table 18.

W irin g D i a g r a m N u mb e r D e scr i p t i on

50 7 1 - 1 783 RTHD AFD, RETROFIT SCHEMATI C

Note: Wir in g di ag r am s ar e av ai lab le v ia e - Libr ary.

Field Wiring

Figure 102. Field wiring connections

(a)

( a) See

Tabl e 14, p. 51 f or con nect ion s. See t able s in sect io n “ Pa r t s, ” p. 18 f or ha r ness p ar t num ber s.

AFDR-SVN001D-EN 67

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Wiring Information

Wire Harness Details

Figure 103. Wire harness details

HARNESS P/ N I NDEX WI RE NO. / DESCRI PTION GAUGE / SI ZE LENGTH ( I N)

50 7 11 800

50 7 11 801

50 7 11 802

50 7 11 803

50 7 11 804

50 7 11 805

50 7 11 806

50 7 11 807

1 PWR - 1- L1, 1-L2 , 1 - L3 4 / O 1 0 0 2 GND 1 AWG 94 3 FLEXIBLE CONDUI T 2.5 I NCH 5 4 .7 5 14/O

PWR - 2L- 1, 2 L2, 2 L3 10 8 2 GND 1 AWG 3 FLEXIBLE CONDUI T 2.5 I NCH 14/O

PWR - 1T- 1, 1T-2 , 1 T- 3 1 24 2 GND 1 AWG 3 FLEXIBLE CONDUI T 2.5 I NCH 14/O

PWR - 2T- 1, 2T-2 , 2 T- 3 1 30 2 GND 1 AWG 3 FLEXIBLE CONDUI T 2.5 I NCH 14/O

PWR - 1L- 1, 1 L- 2 , 1L-3 105 2 GND 1 AWG 3 FLEXIBLE CONDUI T 2.5 I NCH 14/O

PWR - 2L- 1, 2 L- 2 , 2L3 113 2 GND 1 AWG 3 FLEXIBLE CONDUI T 2.5 I NCH 14/O

PWR - 1T- 1, 1T-2 , 1 T- 3 1 29 2 GND 1 AWG 3 FLEXIBLE CONDUI T 2.5 I NCH 14/O

PWR - 2T- 1, 2T-2 , 2 T- 3 1 35 2 GND 1 AWG 3 FLEXIBLE CONDUI T 2.5 I NCH

10 3

59 . 25

11 7

69 . 25

12 4

74 . 5

54 . 75

10 8

59 . 25

12 2

69 . 25

12 9

74 . 5

68 AFDR-SVN001D-EN

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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.

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.

AFDR-SVN001D-EN 01 June 2020

Supersedes AFDR-SVN001C-EN (Feb 2018)

Trane AFDR Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual