Trane Symbio CVRF Installation Instructions Manual

Installation Instructions

Symbio™ Chiller Controller  Retrofit Replacement Panel UCP2

Model Number:

Note: Distribution/use of this document is limited to the Trane sales and service organization in support of the Symbio™ control

panel upgrade and is not intended for independent third party use or for use apart from the Symbio™ control panel.

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.

August 2022

CVRF

SAFETY WARNING

CVRF-SVN005C-EN

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 handling 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/national 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 u 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,

WAYS refer to the appropriate SDS and OSHA/GHS

AL (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 elec 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.

nit, technicians

trical contact, arc, or

WARNING

Refrigerant May Be Under Positive Pressure!

Failure to follow instructions below could result in an explosion which could result in death or serious injury or equipment damage.  System contains refrigerant and may be under positive pr

essure; system may also contain oil. Recover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or non-approved refrigerant additives.

WARNING

Follow EHS Policies!

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

• All Trane personnel must follow the company’s

Env

ironmental, 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.

Introduction

• CTV-SVD005*-EN1, Diagnostics Manual - Diagnostic Descriptions, Troubleshooting Tables, and Control Component Overview for Water-Cooled CenTraVac™ Chillers with Tracer AdaptiView™ Control

• BAS-SVU047*-EN1, Getting Started Guide: To ol

• CVRF-SVP01*-EN, Programming Guide: Tracer

™ Panel Upgrade

Symbio

TU Service

Revision History

Minor updates to the document.

Copyright

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.

Other Required Manuals

This manual must be used with the following publications (or their most recent versions):

• CVHE-SVX005*-EN1, Installation, Operation, and Mainten CenTraVac™ Chillers With Symbio™ Control

• CTV-SVU004*-EN1, Operations Guide - Tracer® Adap Chillers with Symbio™

• CTV-SVP004*-EN1, Tracer TU Service Tool for WaterCoo

ance - CVHE, CVHF, and CVHG Water-Cooled

tiView™Display for CenTraVac™Water-Cooled

led CenTraVac Chillers with Symbio™ Control

CVRF-SVN005C-EN 3

Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . 5

About This Manual . . . . . . . . . . . . . . . . . . . . . . 5

Application Guidelines . . . . . . . . . . . . . . . . . . . 5

Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . 5

Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Symbio™ Panel Conversion Kit Contents . . . 6

Notes for Remote Starter and 

AFD Installations . . . . . . . . . . . . . . . . . . . . . . . 8

Note for Open Transition Starters . . . . . . . . . . 8

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . 8

Field-Provided Material . . . . . . . . . . . . . . . . . . 8

Model Number Descriptions . . . . . . . . . . . . . . . 10

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Control Panel Conversion . . . . . . . . . . . . . . . 12

Before You Begin . . . . . . . . . . . . . . . . . . . . . . 12

Removal of Existing Panel . . . . . . . . . . . . . . 13

Installation of New Control Panel . . . . . . . . . 13

Wiring Installation . . . . . . . . . . . . . . . . . . . . . . 13

Motor Temperature Devices . . . . . . . . . . . . . 14

Mount Display Arm and Display . . . . . . . . . . 14

Adjusting the Tracer® AdaptiView™ 

Display Arm . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Oil Pressure Transducer Installation . . . . . . 17

Sensor Installation and Wiring . . . . . . . . . . . 17

Mounting Sensors Externally . . . . . . . . . . . . 18

Temperature Sensor Cable

Mounting for Wells . . . . . . . . . . . . . . . . . . . . . 18

Option I/O Installation . . . . . . . . . . . . . . . . . . 18

Inlet Guide Vane Actuator Installation . . . . . 18

Running the IPC Bus . . . . . . . . . . . . . . . . . . . 19

Purge Control Installation . . . . . . . . . . . . . . . 21

PRGC Purifier Purge . . . . . . . . . . . . . . . . . 21

PRGD, PRGG and PRGF EarthWise Purge 21

LONTALK® Option Installation . . . . . . . . . . . 22

Communication Option Installation . . . . . . . . 22

Wi-Fi Installation . . . . . . . . . . . . . . . . . . . . . 22

Air-Fi Installation . . . . . . . . . . . . . . . . . . . . 23

LTE Modem Installation . . . . . . . . . . . . . . . 23

Communication Device Mounting . . . . . . . 24

Water Flow Measurement . . . . . . . . . . . . . . . .25

Standard Accuracy Option . . . . . . . . . . . . . .25

Mounting of Flow Measurement Assembly .25

High Accuracy, Customer Provided 

Meter Option . . . . . . . . . . . . . . . . . . . . . . . .26

Heat Recovery/Aux COND Option . . . . . . . .27

Energy Meter Option Installation . . . . . . . . . .28

480 Volts and Lower Installations . . . . . . . .29

Oil Pump Control . . . . . . . . . . . . . . . . . . . . .31

120 Vac Components Matrix . . . . . . . . . . . .31

120 Vac Oil Pump Starter Capacitor and Starter

Relay (Left) . . . . . . . . . . . . . . . . . . . . . . . . . 31

Line Voltage Pump Installation . . . . . . . . . .31

120 Vac Non Refrigerant Pump Style 

Oil Pump Installation . . . . . . . . . . . . . . . . . . 31

120 Vac Refrigerant Pump Style Oil 

Pump Installation . . . . . . . . . . . . . . . . . . . . .32

Installation of Oil Pump

Motor Wiring and Terminals . . . . . . . . . . . . . .32

Starter Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Starter Control Planning . . . . . . . . . . . . . . . . .33

Starter Sub-Box Installation . . . . . . . . . . . . . .33

Starter Sub-Panel . . . . . . . . . . . . . . . . . . . . . .34

Starter Sub-Panel Installation . . . . . . . . . . . . . 37

AFD Sub-Panel . . . . . . . . . . . . . . . . . . . . . . . . 39

Control Power Transformer . . . . . . . . . . . . . . .40

Current Transformers, CTs . . . . . . . . . . . . . . .40

CT Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Potential Transformers, Optional PTs . . . . . .44

Starter Wiring . . . . . . . . . . . . . . . . . . . . . . . . . .44

Wiring Diagram Matrix . . . . . . . . . . . . . . . . . . . . .46

4 CVRF-SVN005C-EN

General Information

MODEL NUMBER : CVRF21000AA1FFB1001001000C000100A1 SERIAL NUMBER : L22C01078 ORDER NUMBER : LARRYSP4 ORIG. SERIAL NUMBER; L22A00000

LITERATURE CVRF-SVN005*-EN CVHE-SVX005*-EN CTV-SVU004*-EN BAS-SVNU47*-EN CVRF-SVP001*-EN CTV-SVP004*-EN www.trane.com/Patent MADE IN USA

SYMBIO 800

UPGRADE CONTROL AND PANEL

FOR USE ON LIQUID CHILLERS

About This Manual

This manual is provided to support the factory-assembled CVRF complete control panel for former factory installed UCP2 control panels. It does not apply to model CVRA, CVRB, CVRC, CVRD, or CVRE retrofit controls. This work replaces the older control panel with the current Symbio™ Chiller Control system. The factory assembled portion is the control panel only. Some of the control items will be field-installed.

The step-by-step instructions outlined in this manual describe

e procedures required to successfully install Symbio™

th controls on CVHE, CVHF, or CVHG units with a UCP2-based control system.

Notice that the insta divided into the following general topic areas:

1. Control panel installation includes removal of existing control pa

llation instructions in this manual are

nel. It is followed by installation of new panel and

4. AFD planning for UCP2 starter module equipped AFDB, AFDC, AFDG and early AFDH AFDs.

5. Actuator mounting includes removal

of the old actuator and

installation instructions for the stepper IGV actuator.

6. Accessories and options installation includes information

n how to install and wire any optional LLIDs or

o components. LLIDs are individual control components that communicate with the main processor.

Note: Ne

w Symbio™ and older Trane® wiring diagrams are often referenced throughout this manual. Locate any drawings reflecting changes, upgrades, or BAS tie-ins that have been performed on the unit since original installation. A complete set of Symbio™ wiring diagrams are referenced in

p. 46

in this manual. You may find it helpful to obtain a

py of the machine or job specific drawings before

co

“Wiring Diagram Matrix,”

you attempt to perform the control system conversion.

mounting brackets, and wiring in the new control panel.

2. Sensor installation includes the

mounting of temperature

and pressure sensors and wiring instructions.

3. Starter Panel planning for wye-delta starter applications, as additional information for converting non-wye-

as well

Application Guidelines

This Symbio™ control package is specifically designed to upgrade the controls of CVHE, CVHF, and CHVG water cooled chillers with a UCP2 control panel electrical section.

delta starters.

Table 1. Retrofit panel types

Description Application

Single door pneumatic 1966 to 1976 Trane CenTraVac chillers with pneumatic controls and a single horizontal door control panel

Double door pneumatic 1976 to 1980 Trane CenTraVac chillers with pneumatic controls and a double horizontal door control panel

Classic 1980 to 1985 CVHE/CVHB CenTraVac chillers with

(b)

UCP1

(b) 1993 to 2001 CVHE/CVHF/CVHG CenTraVac chillers having factory installed Trane UCP2 digital controls

UCP2

(a) These are general guidelines. The dates are not exact. It is necessary to confirm exactly which control system your chiller has. (b) The UCP1 and UCP2 application is specific to those units originally shipped with those controls. It does NOT include retrofit UCP1, UCP2, and UCP2 FastPak™ controllers;

to upgrade chillers with retrofit UCP1, UCP2, and UCP2 FastPak™ controllers, please refer to the appropriate manual for the original unit controls.

1985 to 1993 CVHE/CVHB/CVHF CenTraVac chillers having factory installed Trane UCP1 digital controls

(a)

Trane electronic “Classic” type controls

Getting Started

Figure 1. Symbio™ nameplate example

To properly install a Tracer® AdaptiView™ retrofit, the technician must have a good knowledge of Symbio™ control systems. Training in Symbio™ controls is highly recommended before beginning this retrofit.

Nameplates

A Symbio™ nameplate is provided with the kit; the nameplate should be placed onto the panel after installation. Always provide the model number and serial number information from the nameplate when making inquiries, or ordering parts or literature for the Symbio™ retrofit system.

CVRF-SVN005C-EN 5

General Information

Remove the existing chiller nameplate on the unit and relocate to the outside of the new control panel. Important information is contained on this existing nameplate that must be retained for future unit servicing.  If nameplate cannot be removed and relocated, copy information from old nameplate onto new vinyl nameplate included in retrofit package.

installed, wired, bound, and tested, along with some device LLIDs shipped loose that require field installation and binding.

Before commencing the Symbio™ control retrofit, be sure to compare the data on the panel nameplate and ordering and shipping information to the data in the following tables to verify that the proper Symbio™ components were shipped. The tables are split into those components that are factory installed and those that are shipped loose and need to be field installed.

Symbio™ Panel Conversion Kit Contents

If an inspection of the conversion package reveals damage or material shortages, be sure to file these claims with the carrier

immediately. Specify the extent of the damage or material Each Symbio™ panel conversion kit includes a pre-assembled control panel with a number of standard features and options

Table 2. LLID legend and identification

LLID Name Description Part Number

Tracer® Adaptiview™ color display MOD03183

LON

DAIO Dual analog input and output BRD04875

DBI Dual low voltage binary input BRD04873

DHVBI Dual high voltage binary input BRD04874

DRO Dual relay output BRD04878

HPRO High power relay output MOD01401

IGV Inlet guide vane stepper actuator ACT00680

(a)

®

LonTalk Communications interface for chillers

shortages and be sure to notify the appropriate Trane

representative. Do not install a damaged component or panel.

KIT18458, KIT; ECHELON MODULE FIELD INSTALL KIT

Power supply 27 Vac to 24 Vdc for bus power supply BRD02102

Pressure sensor Low pressure range, 0 to 50 psia TDR00733

Pressure sensor High pressure range, 0 to 475 psia TDR00734

Pressure transducer

QRO Quad relay output BRD04879

Starter module Trane control board, starter module BRD04877

Starter module power supply 110 Vac/24 Vdc power supply PWR00147

Starter module on sub plate without power supply or LV PTs

Starter module on sub plate without power supply with LV P Ts

Starter module on sub plate with power supply without LV P Ts

Starter module on sub plate with power supply and LV PTs

AFD starter nodule on sub plate without power supply or LV PTs

AFD starter nodule on sub plate with power supply without LV PTs

Temp sensor Low range temperature sensor SEN02133

Triac Dual triac output BRD04876

TWTI Triple winding temperature input MOD02462

Danfoss pressure transducer, 475 PSI  7/16-20 NUF

Starter sub-panel for unit mount medium voltage

starters

Starter sub-panel for remote mount medium voltage

starters

Starter sub-panel for unit mount low voltage starters 018504220100

Starter sub-panel for remote mount low voltage

starters

Assembly for unit mount UCP2 AFDB, AFDC, and noncommunicating AFDH

Assembly for remote mount UCP2 AFDB, AFDC, and non-communicating AFDH

TDR00735

018504210100

018504330100

018504350100

018504340100

018504370100

Symbio™ controller MOD02979

6 CVRF-SVN005C-EN

General Information

Table 2. LLID legend and identification

(a)

(continued)

LLID Name Description Part Number

WIFI WiFi Mobile App MOD03122

AIRFI Air-Fi BACnet via Zigbee

LTE LTE 4G modem MOD03184

(a) All part number information in this table is subject to change at any time. Contact the Tran e Parts Center for assistance with identification of all parts involved with the Symbio™

system.

018504240100 MOD02971

Table 3. Factory installed LLIDs

DBI DHVBI HPRO QRO TWTI

Panel type—factory UCP2 1 2 1 3 1 2 1 1

Power Supply Symbio™ 800 Color Display

Table 4. Field installed LLIDs for various options

PS

475

DBI DHVBI DBO HPRO QRO DAIO LON IGV

Panel type factory UCP2

Starter module 3-phase

Actuator stepper

Oil protection full, low pressure, or high pressure

Heat recovery / aux con

denser

Hot gas bypass 1 1

Cold water reset 1

Enhanced

ection

prot

Chilled/tower water flow display, standard accuracy with Trane provided sensor/meter

Chilled/tower wa

ter flow display, high accuracy

Heat recovery / aux con

denser water flow display, standard accuracy

Heat recovery / aux con

denser water flow display, high accuracy

Extended opera

tion

1 2

1

2 1 1

PSI

1 or 2

4

2

Tem p

Sensor

7 1

3 1

PS

0 to 50

or 475

PSI

2

Starter

Module

1

Color

Display WiFi AirFi LT E

CVRF-SVN005C-EN 7

General Information

Table 4. Field installed LLIDs for various options (continued)

PS

475

Tem p

PSI

DBI DHVBI DBO HPRO QRO DAIO LON IGV

Free cooling 1 1

®

LONTALK

Generic BAS 2

WiFi Mobile App 1

Air-Fi BACnet via Zigbee

LTE 4G modem 1

Notes for Remote Starter and 

1

Note: Some field provided material will be required to

AFD Installations

For applications having remote starters or AFDs, the remote starter/AFD backplate will be provided with a 24 Vdc power supply. When this power supply is used, connect the existing starter module communications twisted pair to the communications terminals of one of the power supplies at the control panel.

• Type A to Type B USB cable

• Computer having Tracer® TU version 13.0 or newer

• Digital multi-meter, with phase detection capability

• 13-mm and 14-mm wrenches

• 6-mm Allen wrench

Sensor

perform the replacement. This is a partial list in addition to normal service tools and hardware.

PS

0 to 50

or 475

PSI

Starter

Module

Color

Display WiFi AirFi LTE

1

Do not connect 24 Vdc power between the panel power supplies and the starter backplate supply.

You can use CAB01163 to connect the starter module to the control panel if new communications cable is needed. This cable is not included in the standard package and can be ordered through Trane Parts Centers. It is a four conductor 150 foot cable that can be used for communication.

Note for Open Transition Starters

Field-Provided Material

Some field provided material will be required to perform the Symbio™ controls retrofit. A list of material is provided here to help the technician plan ahead and to avoid material shortages at the job site.

• Wire, Red #16 AWG - Control wire will be required to make the connections between LLIDs and existing components.

• Wire connectors (fork, ring, 1/4 and 3/16-inch female quick

For applications with open transition starters, the starter will have to be replaced with a closed transition style. Symbio™ controls will not function with an open transition starter.

connect), and crimping tool for these connectors. Wire markers will be required to identify field wiring. Wire nuts and splicers may be required if splicing wires in the control panel. Cable ties help to “clean up” wiring runs.

Tools Required

Common hand tools and hand-held power tools are required to perform the work. A trained service technician with a wellstocked tool chest should have all of the necessary tools to perform the job. The following list is a sampling of the tools that one could expect to find inside the technician’s tool chest:

• Box-end wrenches in sizes from 5/16 to 1.5-inch.

• 3/8 and 1/2-inch drive socket sets

• Electric drill with 1/2-inch. chuck

• Drill index with bit sizes ranging from 3/32 to 1/2-inch.

• Wire strippers and cutters

• A standard selection of Phillips-head and flat-bladed screwdrivers in various sizes and lengths

The following special tools are also required to perform the controls retrofit:

• A heat conductive adhesive will be required when mounting the bearing temperature sensors to the bearing oil return lines. Use “Loctite® 383 Output High Strength Adhesive”, or equal.

• An epoxy will be required when mounting plastic sensor sleeves on the machine for externally mounted sensors. Trane recommends Loctite® Quickset Epoxy.

• A can of Executive Beige spray paint (Trane part # PAI00061) or standard gray may be required for touch-up work.

• Field provided fuses will be required when installing the optional potential transformers. Refer to

Table 5, p. 9 for

proper fuse sizing.

• Field provided relays may be required in the starter (refer to

“Wiring Diagram Matrix,” p. 46).

• A control power transformer may be required if the existing transformer in the starter panel does not have a minimum capacity of 3 kVA.

8 CVRF-SVN005C-EN

General Information

• “Loctite 565 Liquid Thread Sealant” (Trane part number SLT00042) for installing pressure transducers. This sealant type does not require the use of heat to break the seal if a transducer needs to be replaced in the future.

• “Loctite 277 Thread Lock” (Trane part number SLT00037

ml tube) for the adapter fittings used to convert the flare connections previously required by the oil differential pressure switch (1S2) from the existing control system to allow installation of Symbio™ pressure transducers on the copper oil lines.

for a 10-ml tube, or Trane part number SLT00038 for a 50-

Table 5. Fusing added for 2F1, 2F2 and 2F3 (as needed) for optional PT transformers

Voltage (Vac) Fuse (A) Voltage (Vac) Fuse (A)

200 1 600 1

230 1 2400 1

380 1 4200 1

460 1 3300 1

575 1 6600 1

Replacing an existing UCP2 control system with one based on the Symbio™ control scheme requires a number of wiring and hardware changes. To ensure that the chiller control system retrofit procedure is performed properly, carefully review the instructions in this section, and, if necessary, contact a qualified service organization before beginning the work.

Important: R

ecord a detailed description of all electricalchanges made during the Symbio™ retrofit process. Be sure to add a copy of this report to the chiller record file for future reference.

CVRF-SVN005C-EN 9

Model Number Descriptions

For service purposes, Symbio™ 800 Panel Upgrade Kits 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 servicer will enable the owner/operator, installing contractors and service technicians to define the operation, components and options for any specific unit. Refer to the control panel model number printed on the nameplate when ordering replacement parts or requesting service.

Digit 1, 2, 3

CVR CenTraVac® liquid chiller retrofit

Digit 4 — Development Sequence

F = Tracer Symbio™800 chiller controller

Digit 5 — Panel Type

A = Single door pneumatic controls B = Double door pneumatic controls C = Classic black controls G = Generic 1 = UCP–1 2 = UCP–2

Digit 6 — Solid State Oil Relay Control

1 = No solid state relay A = Solid state relay only B = Solid state relay W/ELM01116 C = Solid state relay W/ELM08119

Digit 7, 8 — Chiller RLA (CTs)

00 = None, uses existing signal 0J = <600 V, 33–50 A, 2" hole, CTs (3) 0K = <600 V, 18–27 A, 2" hole, CTs (3) 0A = <600 V, 67–100 A, 2" hole, CTs (3) 0B = <600 V, 100–150 A, 2" hole, CTs (3) 0C = <600 V, 134–200 A, 2" hole, CTs (3) 0D = <600 V, 184–275 A, 2" hole, CTs (3) 0E = <600 V, 267–400 A, 2.5" hole, CTs (3) 0F = <600 V, 334–500 A, 2.5" hole, CTs (3) 0G = <600 V, 467–700 A, 2.5" hole, CTs (3) 0H = <600 V, 667–1000 A, 2.5" hole, CTs (3) 0L = <600 V, 936–1400 A, 3.5" hole, CTs (3) 0M = <600 V, 1260–1800 A, 4" hole CTs (3) 0N = Turn down transformer 5 A to 100 mA (3) 0P = >600 V, 8–18 A, 1.25" hole, CTs (3) 0R = >600 V, 18–27 A, 1.25" hole, CTs (3)

0T = >600 V, 24–144 A, 4" hole, CTs (3) 0U = >600 V, 120–252 A, 4" hole, CTs (3) 0V = >600 V, 480–1080 A, 4" hole, CTs (3) 0W = >600 V, 864–1800 A, 4" hole, CTs (3)

Digit 9 — Chiller Voltage Monitoring (Potential Transformers)

0 = None A = 480 Vac or less B = Greater than 600 Vac C = 2300/2400 Vac D = 3300 Vac E = 4200 Vac F = 6600 Vac/50 Hz

Digit 10, 11 — Design Sequence

A0 = 1st Design sequence

Digit 12 — Actuator

1 = Stepper actuator 2 = Pulse actuator (generic only)

Digit 13 — Oil Protection

F = Full protection for low pressure

units

H = Full protection for high pressure

units (generic only)

P = Oil pressure status for low

pressure units (generic only)

Digit 14 — Motor Protection and HPC

F = Full motor protection with 15 psig HPC switch H = High pressure option with 195 psig HPC switch (generic only)

Digit 15 — Symbio™ 800 Monitor

A = Without Symbio™ 800 monitor B = With Symbio™ 800 monitor

Digit 16 — Starter Box

0 = None 1 = Starter enclosure

Digit 17 — Free Cooling

0 = No 1 = Yes

Digit 18 — Heat Recovery/Auxiliary Condenser

0 = No 1 = Yes

Digit 19 — Hot Gas Bypass

1 = No 2 = Compressor discharge temp

sensor with LLID, bulb well 3 = 3 in. HGBP valve with sensor, LLID, bulbwell, conduit 4 = 4 in. HGBP valve w/sensor, LLID,

bulbwell, conduit 5 = 5 in. HGBP valve w/sensor, LLID,

bulbwell, conduit

Digit 20 — Tracer Interface Control

0 = None 2 = With generic BAS 5 = LonTalk

®

Digit 21 — Cold Water Reset (CWR)

0 = No 1 = Yes

Digit 22 — Enhanced Protection

0= No 1 = -15 to 35 psig (0 to 50 psia) low

pressure transducer

2 = 15 to 335 psig (0 to 350 psia)

high pressure transducer (generic only)

Digit 23 — Extended Operation

0 = No 1 = Yes

Digit 24 — Chilled/Tower Water Flow Display

0 = No 1 = Water flow display standard

accuracy, dual pressure sensor

2 = Water flow display high

accuracy, customer flow meter

Digit 25 — Design Special

0 = Standard unit offering

Digit 26 — Purge Upgrade

A = No purge option C = Interface for UCP2 purge E = ECOWISE purge

Digit 27 — AirFi Operation

0 = No 1 = Yes

Digit 28 — WiFi Operation

0 = No 1 = Yes

Digit 29 — LTE Operation

0 = No 1 = Yes

Digit 30 — Panel Enclosure

1 = Standard enclosure, NEMA 1

type

2 = NEMA 4 enclosure

Digit 31 — NEMA 4 Communication Box

0 = Without box 1 = Small box 2 = Large box

Digit 32 — Energy Meter Operation

0 = No A = Energy meter, 480V and low

10 CVRF-SVN005C-EN

Digit 33 — Starter Type

0 = No starter module 3 = Starter module current limit 3

phase A = Starter module with plate for low voltage unit starter B = Starter module with plate for low voltage remote starter C = Starter module with plate for

unit AFD D = Starter module with plate for

remote AFD E = Starter module with plate for medium voltage unit starter F = Starter module with plate for medium voltage remote starter

Digit 34 — Oil Pump Type

1 = 120 Vac standard type oil pump 2 = 120 Vac refrigerant type oil

pump 3 = Line voltage oil pump

Model Number Descriptions

CVRF-SVN005C-EN 11

Installation

Field Installed Nameplate

Control Panel Conversion

The control panel conversion will consist of removing, marking, and retaining selected wires in the existing control panel. The existing control panel will be removed.

The new control panel will be installed. The existing wires will be terminated panel along with any new wires required.

Make a note of run hours and starts o counter. Symbio™ controller will allow you to enter this information into its program.

Remove the nameplate from the exi original nameplate is a stick-on label, it may be necessary to cut out the metal section. This nameplate needs to be moved and attached to the new control panel near the new control panel nameplate. The old nameplate contains original unit information that will be useful in service and parts issues in the future.

A blank vinyl nameplate is included. Transfer information from

e old nameplate to the new one and install on new panel.

th

Figure 2. Recommended nameplate location on new

on the terminal block or LLIDs in the control

n the hour meter and start

sting panel. If the chiller

nel

pa

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 a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged.

WARNING

PPE for Arc/Flash Required!

Failure to wear appropriate PPE could result in death or serious injury.  On this unit, if the handle shield is cracked the circuit breaker could arc/flash when reset. To avoid being injured, technicians MUST put on all necessary Personal Protective Equipment (PPE), in accordance with NFPA70E for arc/flash protection, PRIOR to entering the starter panel cabinet.

Before You Begin

1. Identify all field modifications made to the existing chiller

control scheme; then label all field-installed wiring entering the control panel accordingly, if required. This may include things like the power supply for the purge and any BAS interface wiring.

2. Determine how each of the field-adapted control functions

just iden Symbio™ chiller control panel.

3. Capture all existing chiller control settings before powering

dow

4. Open all starter and control panel disconnect switches and

secure them in th

tified in

n chiller controls.

Step 1 will be assumed by the new

at position.

Note: T

5. Disconnect all field-installed wiri panel (i.e., identified in termina 1TB1-11 to -13.

6. Remove from the control panel terminal block all wiring that has been routed through conduit from the starter panel to the control panel. (Wires 3D, 4C and oil pump interlock between 1TB1-7 to -8 and 120 Vac power to control panel between 1TB1-1 to -2 are typical.)

o eliminate migration of refrigerant into the oil sump, temporarily connect a field supplied thermostat and an auxiliary 115 Vac power source to the oil heater. Refer to wire 42A on the IU2 module, terminal J20-I.

ng entering the control

Step 1) from the control panel

l strip. This is typically between 1TB1-10 to -12 and

12 CVRF-SVN005C-EN

Installation

Stepper Module (1U3)

Circuit Module (1U2)

Chiller Module (1U1)

Option Module (1U5) (Optional) Digit 6

Figure 3. Typical UCP2 before retrofit

Removal of Existing Panel

Remove the existing UCP2 panel. The existing brackets on the chiller will be reused to mount the new control panel.

Installation of New Control Panel

Install the new control panel using existing hardware to mount it to the UCP2 brackets.

Wiring Installation

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 pe

rsonnel. 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/national electrical codes.

Unless otherwise indicated, all 115 volt control circuits use, as a minimum, #16 AWG, 600 volt wire. Be sure to use existing conduit wherever possible and separate all 115V wiring from any low voltage circuits.

Most wiring will use the existing wires removed and marked

m the original panel and moved to the terminal block in the

fro new panel. Some wires may need to be connected directly on a LLID terminal.

Table 6, p. 13 

details the “before and after” of wires from the the new panel. Also refer to the connection and schematic diagrams listed in

“Wiring Diagram Matrix,” p. 46 for additional

detail.

original panel to

For 50 Hz applications, the control power transformer (1T1) is supplied as a 60 Hz application. To convert from 60 Hz to 50 Hz, the following step must be performed: move wire 2H from H3 on 1T1 to H2.

If you have wired a temporary thermostat and 115 Vac power

urce to the oil heater leads, wait to connect these wires until

so the Tracer® AdaptiView™ retrofit is complete to avoid too much cooling of the oil.

The information in

t exited the old control panel is to be rewired in the new

tha

Table 6, p. 13 describes where the wiring

factory panel. Also refer to the connection and schematic diagrams listed in

“Wiring Diagram Matrix,” p. 46.

Table 6. Field wiring cross reference, UCP2 to new

panel

To

Existing

Wire #

P5A 1U1 J3-1 1A13 J2-1 External Auto/Stop

P5A 1U1 J3-2 1A13 J2-2 External Auto/Stop

P5B 1U1 J5-3 1A13 J2-3 Emergency stop

P5B 1U1 J5-4 1A13 J2-4 Emergency stop

Black 1U2 J3-1 1A26 J2-1

White 1U2 J3-3 1A26 J2-2

Green 1U2 J3-5 1A26 J2-3

Red 1U2 J3-6 1A26 J2-4

42A 1U2 J20-1 1X1-22 Oil Heater 4HR1

2N 1TB1-4 1X1-8 Oil Heater 4HR1 Neutral

2M 4B3-2 1X1-7

9B/19A 1U2 J22-1 1X1-16 to 4K8 oil pump relay

From

(in Existing Panel)

1U1 J14-1 1A5 J2-1

5K2 Neutral Open neutral

1U1 J12-1 1A5 J2-4 Evap water pump relay

5K1 Neutral Open neutral

1TB1-10 1X1-4 to 5K1, 5S2 flow switches

1TB1-11 1X1-4 to 5K2, 5S3 flow switches

1TB1-12 1X1-19

1TB1-13 1X1-20

Starter Panel Ground 1X1-G

2TB1-1 (1TB1-1) 1X1-1

2TB1-2 (1TB1-2) 1X1-6

(in New

Panel)

Description or

Comments

Motor winding temp sensor

Condenser water pump

y 5K2 coil

rela

Condenser water pump relay 5K2 neutral

Evap water pump relay

tral

neu

Oil pump motor (4B3) neutral

from 5K1, 5S2 flow

s

switche

from 5K2, 5S3 flow

s

switche

Panel ground (from starter)

120 Vac power to control panel from starter 2TB11

120 Vac neutral to control pan

el from starter 2TB1-

2

CVRF-SVN005C-EN 13

Installation

Table 6. Field wiring cross reference, UCP2 to new

panel (continued)

To

Existing

Wire #

41B 1U2 J16-1 1X1-21

2X 1TB1-4 1X1-7

From

(in Existing Panel)

2TB1-9 (1TB1-8) 1X1-14 Oil pump interlock

2TB1-8 (1TB1-7) 1X1-15 Oil pump interlock

(in New

Panel)

Description or

Comments

Vent line solenoid valve 4L1

Vent line solenoid valve 4L1 neutral

Motor Temperature Devices

The new Symbio™ panel comes with the motor winding temperature input LLID (IA26). This is used for motors that have RTD-type sensors embedded in the motor windings. If the motor does not have RTD-type sensors, motor temperature protection can be accomplished a temperature sensor which installed in the bulb well of the motor, and connect to the IPC bus.

Mount Display Arm and Display

1. Secure the arm to the control panel using the 5/16 - 18 x

1-inch hex bolts, 5/16-inch lock washers, and 5/16 - 18 hex nuts provided. There are pre-drilled holes on the left and right sides of the control panel; select the side that’s most suitable for your specific application.

Note: Th

Figure 5. Production display arm bracket

ere is a production display arm bracket BRK04345

provided that where applicable can be mounted to the

existing control panel mounting arms. When used, the holes on the unused side should be plugged.

Figure 4. Bolting display arm to the panel

2. Securely fasten the Tracer® AdaptiView™ display to the mounting plate on the end of the display arm with the hardware provided.

14 CVRF-SVN005C-EN

Figure 6. Attaching the Tracer® AdaptiView™ display to arm

Installation

3. After the display is attached, recheck the arm tension. The arm tension should be set so that the display does not spring up or sag down out of the position it is moved to by the operator.

CAUTION

Tension in Display Support Arm!

Failure to follow instructions below could result in unexpected movement of the spring-loaded support arm which could result in minor to moderate injury. Ensure that the support arm position when removing the Tracer AdaptiView display from the support arm.

is in the full upright

CVRF-SVN005C-EN 15

Installation

1

3

4

2

Adjusting the Tracer® AdaptiView™  Display Arm

The Tracer® AdaptiView™ display arm may be too loose or too tight and in need of adjustment. To adjust the tension on the display arm:

1. There are three joints on the display arm that allow the

racer® AdaptiView™ display to be positioned at a variety

T of heights and angles (refer to items labeled 1, 2, and 3 in

Figure 7. Joint locations on the display arm

2. Joint 3 has a 6 mm hex screw controlling the tension on a gas spring, which allows the Tracer® AdaptiView™ display to tilt up and down.

3. Joints 1 and 2 are covered by a plastic cap. Remove the plastic cap to access wrench as necessary.

4. To adjust the swivel of the T (the spin right and left similar to the steering wheel on a car), you need to adjust the hex bolt located inside the display arm back plate. This adjustment needs to be done BEFORE attaching the display. Use a 9/16-inch or 14 mm wrench.

5. Use a 13 mm wrench to adjust the bolt (item labeled 4 in

Figure 7, p. 16) that allows the entire display arm to swivel

the left and right.

to

the hex bolt. Adjust using a 13 mm

racer® AdaptiView™ display

Figure 7, p. 16). At each joint in the display arm there is

ither a hex bolt (1 and 2) or hex screw (3). Turn the hex

e bolt or screw in the proper direction to increase or decrease tension.

Note: Each hex bolt or screw is labeled with ‘loosen’/

‘tighten’, or '+'/'–' indicators.

16 CVRF-SVN005C-EN

Oil Pressure Transducer Installation

Installation

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 a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged.

WARNING

PPE for Arc/Flash Required!

Failure to wear appropriate PPE could result in death or serious injury.  On this unit, if the handle shield is cracked the circuit breaker could arc/flash when reset. To avoid being injured, technicians MUST put on all necessary Personal Protective Equipment (PPE), in accordance with NFPA70E for arc/flash protection, PRIOR to entering the starter panel cabinet.

The two existing oil pressure transducers will be replaced with new

transducers.

1. Use Loctite 565 on pressure transducer so connection can be broke transducer is required. Note which line is oil pump discharge pressure and which is sump pressure. Quickly attach sensors to lines to avoid large quantities of air entering machine.

Adapter fittings are provided with the kit. The transducers can be moun and transducers mounted to minimize any potential stacking of liquid on top of the transducers.

2. Label pressure transducers using labels provided.

n without heat if future replacement of pressure

ted in any direction. Lines should be routed

Sensor Installation and Wiring

Existing UCP2 sensors cannot be used with a Symbio™ retrofit. It is recommended that existing bulb wells be used. Installing new wells would necessitate opening the chiller to atmosphere

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 refrigerant under high pressure. Re

cover refrigerant to relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use non-approved refrigerants, refrigerant substitutes, or refrigerant additives.

If installing new bulb wells (optional), use safe refrigerant p

ractices to evacuate the chiller. Install and wire each of the

temperature sensors listed below.

When the sensor is installed in a bulb well, be sure to:

• Add thermastic paste to each b sensor.

• Ensure that the sensor “bottoms ou well.

It is recommended that sensors “1” through “3” be mounted in

lls. The rest may be installed externally. Connect all

we Symbio™ temperature sensors to the main IPC bus using the provided pluggable cables.

ulb well before inserting the

t” at the base of the bulb

NOTICE

Equipment Damage!

Failure to follow instruction below could result in equipment damage. Never route low-voltage leads with other conductors carrying 30 or more volts.

The Symbio™ component identification is in parenthesis following each sensor name:

1. Oil tank temperature senso

2. Evaporator leaving water te

3. Evaporator saturated refri (4R10)

4. Condenser entering and leaving sensors (4R8 and 4R9)

5. Evaporator entering water temperature sensor (4R6)

6. Condenser saturated refrigeran (4R11)

Locate sensor at the bottom of the condenser or on the

ndenser liquid line upstream of any orifices or float

co valves.

Note: If u

nit has an EarthWise™ purge, PRGD (CH530 controls), the sensor bound as Condenser Saturated Refrigerant Temperature Sensor (used as Purge Liquid Temperature) cannot be used and will need to be unbound. Install the temperature sensor sent with the Tracer® AdaptiView™ components as described above.

r (4R5)

mperature sensor (4R7)

gerant temperature sensor

water temperature

t temperature sensor

CVRF-SVN005C-EN 17

Installation

7. Condenser discharge refrigerant temperature sensor 4R16 (optional). This sensor is only shipped if Hot gas bypass or Enhanced Protection packages were ordered and are to be installed.

8. Bearing temperature sensors: inboard-4R1, outboard-4R2 (optional). These sensors are only shipped if Enhanced Protection package was ordered and is to be installed.

Mounting Sensors Externally

1. Remove the paint and rust from the pipe or chiller surface; then use a wire wheel to expose bare metal.

2. Epoxy the supplied plastic sleeve to the pipe surface. Use

3. Install the sensor probe, with thermastic paste,

4. Wrap the sensor with Armaflex® insulation,

Figure 8. Epoxy application

®

Loctite

sleeve. Wire tie the sensor leads to the plastic sleeve tab.

Epoxy Quick Set, or equivalent,

Figure 8, p. 18.

into the

Figure 9, p. 18.

To install insert the threaded end screw this into the temperature well, be inserted through the hole in the strain relief.

Figure 10. Strain relief

Figure 10, p. 18. The temperature probe can

Option I/O Installation

Wire additional LLIDs as shown on schematics. Pay careful attention to which LLIDs require low voltage inputs and which are 115 Vac inputs.

Inlet Guide Vane Actuator Installation

WARNING

Hazardous Voltage w/Capacitors!

Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury.

Figure 9. Sensor mounting with Armaflex insulation

Temperature Sensor Cable Mounting for Wells

For a convenient way to mount Symbio™ temperature sensors into existing wells, order and strain relief CON00849 (10 per package).

18 CVRF-SVN005C-EN

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 a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged.

WARNING

PPE for Arc/Flash Required!

Failure to wear appropriate PPE could result in death or serious injury.  On this unit, if the handle shield is cracked the circuit b

reaker could arc/flash when reset. To avoid being injured, technicians MUST put on all necessary Personal Protective Equipment (PPE), in accordance with NFPA70E for arc/flash protection, PRIOR to entering the starter panel cabinet.

Inlet guide vane (IGV) stepper actuator mounting and wiring follows:

Installation

1. Installing Symbio™ stepper actuator.

a. Determine the inlet guide vane stroke by manually

closing and opening the vanes and accurately measuring the length of travel.

b. Record this value as it will be used when performing the

post conversion

2. Remove the existing IGV actuator and existing conduit and wire.

3. Install the new IGV actuator on the chiller.

a. Use the connecting hardware retained when the old

ctuator was removed.

a

b. Use the existing actuator mo

and mounting hardware to install the new electric actuator.

The motor can be rotated 180 degrees to accommodate

hardware. The actuator rod may be connected to

existing the mounting plate at the compressor housing or to the vane linkage.

checkout.

unting plate, piston yoke

NOTICE

Equipment Damage!

Failure to ensure that the 0 degree vane position corresponds with the actuator fully closed when mounting the actuator could result in severe damage to the machine.

Figure 11. Installed stepper IGV actuator

through your local Trane Parts Center. Refer to PART-SVB16*EN for identification of individual cables.

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 a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged.

WARNING

PPE for Arc/Flash Required!

Failure to wear appropriate PPE could result in death or serious injury.  On this unit, if the handle shield is cracked the circuit breaker could arc/flash when reset. To avoid being injured, technicians MUST put on all necessary Personal Protective Equipment (PPE), in accordance with NFPA70E for arc/flash protection, PRIOR to entering the starter panel cabinet.

4. The IGV ships in a mid-position. powered up, it will drive closed. This may mean travel as much as 1 inch. Disconnect the IGV actuator from the IGV linkage until fully retracted.

The first time the IGV is

Running the IPC Bus

There are several ways to string the IPC communication bus on the chiller. The Symbio™ retrofit kit includes a general wire kit that has several different types of wires. An example of a wiring layout can be seen in

vary depending on the options. You may have extra cables,

will or may be short needed cables. Extra cables can be ordered

CVRF-SVN005C-EN 19

Figure 12, p. 20. Each application

Installation

Control Panel

CAB01155 leads to female

CAB01149 short, male to female

CAB01146 short, male to 2 female

Transducer LLID

Figure 12. Sample of IPC cable routing

To connect the IPC bus to the control panel LLIDs, thread the bus into the control panel via a knockout or other entry. The CAB01155 connector has a female plug on one end and four stripped leads on the other end. Attach the four stripped leads to the power supply in the control panel.

Figure 13. Connecting the stripped leads to the power

supply

Notes:

• R. Red wire for 24 Volts direct current

• Bk. Black wire for ground

• Bl. Blue

• Gr

wire for IPC+ connection

. Gray wire for IPC- connection

Make sure all devices and LLIDs are connected together in some way. Use the correct cables so that you don’t have any open plugs when finished. Avoid placing wire ties directly over plug connectors. This may press on the locking mechanism and over time the plugs may release.

Table 7. Cables shipped for various options

Standard panel cables 5 5 5 10 9 1 2 2

Actuator-stepper 1

Oil protection—full, low pressure or high pressure

Heat recovery / aux

ndenser

co

Hot gas bypass—electric actuator

20 CVRF-SVN005C-EN

CAB01146

branch M

(a)

2F 500 mm

to

1 1

1 1 1

1 1

CAB01147 branch M to 2F 1000 mm

CAB01148

branch M to

3F 500 mm

CAB01149

extension M

to F 1000 mm

CAB01150

extension M

to F 2000 mm

CAB01152

extension M

to leads 1000

mm

CAB01154

extension M

to receptacle

1M

CAB01155

extension F to

leads 1000

mm

Table 7. Cables shipped for various options (continued)

Installation

CAB01146

branch M

2F 500 mm

Hot gas bypass—pulse actuator

Cold water reset 1 8

Enhanced protection 1 2 1 3

Chilled/tower water flow

, standard

display accuracy

Heat recovery / aux co

ndenser water flow display, standard accuracy

(a) The letters M and F represent male and female connectors.

CAB01147

(a)

branch M to

to

2F 1000 mm

1 1

2

1

CAB01148

branch M to

3F 500 mm

Purge Control Installation

Important: Be sure to retain all existing purge safety

controls!

The purge power line connections for the power to the unit

ld be wired per the purge wiring diagram. In general the

shou 115 Vac power for the purge originates from the unit control panel. In the new control panel a circuit breaker 1Q2 is provided to power the purge. A neutral connection can be found on the 1X1 terminal strip.

CAB01149

extension M

to F 1000 mm

5. Remove IPC bus cable from power supply LLID. (Ensure rema

6. It is optional to remove and discard the wires (303A, 304A, and 318A) from control power transformer to this power supply LLID (3A5).

7. Disconnect the cable from the DynaView to the power su

8. Remove the tilt bracket from the purge base. DynaView can remain attached to the tilt bracket panel.

9. Connect the IPC bus from the control panel to the IPC bus

PRGC Purifier Purge

The PRGC Purifier™ purge uses UCP2-based

for the purge using an IPC bus cable.

Figure 14. CABO1151 or CABO1153

communications and does not communicate with Tracer® AdaptiView™ controls. To convert the purge to a standalone purge, order KIT02586 from a Trane Parts Center and install it, making sure to install a jumper between terminals J1-5 and J16 on the 3UI module when doing the conversion. A PRGC requires a compressor running signal connected to J26, 1 and 2 on 3U1 in the purge to operate in the auto or adaptive modes. Use the Compressor Running contact closure from the quad relay LLID - 1A8, connected to 115 Vac purge source.

CAB01150

extension M

to F 2000 mm

CAB01152

extension M

to leads 1000

mm

CAB01154

extension M

to receptacle

1M

ining LLIDs are still connected to IPC bus).

pply LLID.

CAB01155

extension F to

leads 1000

mm

PRGD, PRGG and PRGF EarthWise Purge

If a stand-alone EarthWise purge (CH530 control) exists on the chiller, it will need some hardware changes to work with the Symbio™ retrofit controls. If the purge is a new installation with the Symbio™, then skip to

1. The compressor running LLID (3A6) will not be needed, nect and remove.

discon

2. The condenser saturated refri

(purge liquid temperature) will not be needed, disconnect and remove.

3. The existing 120-27 Vac transformer and DC power supply

in the purg

e is undersized and should be removed. The purge control will be powered by the Symbio™ panel power supply.

4. Remove and save purge power supply LLID.

CVRF-SVN005C-EN 21

Step 9.

gerant temperature LLID

Installation

1A22 SYMBIO800 UNIT CONTROLLER

ETHERNET

USB

LON

1K47

INTERFACE

TRACER

OPTIONAL

COMMUNICATIONS

LTE

4Y2

MODEM

OPTIONAL

1 2

1324

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 a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged.

WARNING

PPE for Arc/Flash Required!

Failure to wear appropriate PPE could result in death or serious injury.  On this unit, if the handle shield is cracked the circuit breaker could arc/flash when reset. To avoid being injured, technicians MUST put on all necessary Personal Protective Equipment (PPE), in accordance with NFPA70E for arc/flash protection, PRIOR to entering the starter panel cabinet.

Figure 15. LON module

Figure 16. LON wiring, ref. 50712738

LONTALK® Option Installation

Symbio™ 800 system uses a U60 LON module through the USB connection instead of the LCI-C LLID.

1. Install the U60 LON module (KIT18458, KIT; ECHELON MODUL put it at left side of Symbio™ 800.

2. Connect U60 LON module to Symbio™ 800 by USB cable which any one of the four USB ports under the Symbio™ 800 controller.

3. Connect U60 LON module to the BAS system using shie

22 CVRF-SVN005C-EN

E FIELD INSTALL KIT) on the DIN rail on the door,

is provided with the module Connect this cable to

lded cable.

Communication Option Installation

Symbio™ 800 system supports up to 3 wireless interfaces at same time, these are:

• Wi-Fi mobile APP for BAS interface

• Air-Fi BACnet via Zigbee for component interface

• LTE 4G modem interface for remote c

Wi-Fi Installation

Refer to BAS-SVN042*-EN for more information. Mounting and wiring of Wi-Fi module (MOD03122).

1. Drill a 1.36-inch holes on the top of polycarbonate box, curely fasten the Wi-Fi module by gasket and nut which

se provided by module.

2. Connect Wi-Fi module to Symbio™ 800 by USB cable

ich provide by module, plug USB MICRO-B side to

wh

ommunications.

Installation

+24

G

-

+

IMC

RED

BLK

GRN

WHT

RED

BLK

BLU

GRY

VDC

+24

G

-

+

MACHINEBUS

VDC

P3

-

+

BACKNET

P1

-

+

-

+

MODBUS

P2

G

IMC

B

IMC

A

1A22 SYMBIO800 UNIT CONTROLLER

SERVICE

ETHERNET 12

USB

1324

TOOL

WI-FI

4Y1

ANTENNA

OPTIONAL

WHT

GRN

BLK

LTE

4Y2

MODEM

OPTIONAL

bottom of Wi-Fi module and USB-A side to any one of the four USB ports under the Symbio™ 800 controller.

Figure 17. Wi-Fi wiring, ref. 50712738

Air-Fi Installation

Refer to BAS-SVX040*-EN for more information. Mounting and wiring of Air-Fi module (0185-0424-0100).

1. Drill a 0.87-inch holes on the top of polycarbonate box, gn this hole with thread hole on the module, and securely

ali fasten the Air-Fi module by M4 screw.

2. Connect Air-Fi module to Symbio™ 800 by Modbus 

cable.

3. Remove the cover of module, connect 4 wires cable into 4

wire conn side of cable into two 2 wire connectors and plug them into the Symbio™ 800 controller IMC terminal.

Figure 18. Connecting wiring harness

ector and plug in Air-Fi module, connect other

Figure 19. Wiring harness connection

Figure 20. Air-Fi wiring, ref. 50712738

RE

RED

BLU

BLK

IMC

A

1X3-1

1X3-2

1X3-3

BLK

WHT

GRN

G

+

-

P1

BACKNET

1A22 SYMBIO800 UNIT CONTROLLER

P2

MODBUS

USB

1324

-

+

-

MACHINEBUS

+

P3

BLK

GRY

RED

GRN

G

+24

-

VDC

ETHERNET 12

+

BLU

G

IMC

BLK

RED

IMC

B

+24

VDC

SERVICE

TOOL

OPTIONAL

4K48

AIR-FI

INTERFACE

LTE Modem Installation

Modem part is MOD03184, MODULE; CELLULARLE USB 2.9 METER CABLE. Refer to provided literature for setup and operation details.

1. Drill a 1.36-inch holes on the top of polycarbonate box, curely fasten the LTE modem by gasket and nut which

se provided by modem.

2. Connect LTE modem to Symbio™ 800 by USB cable which

provide by module, plug USB MICRO-B side to bottom of LTE modem and USB-A side to any one of the four USB ports under the Symbio™ 800 controller.

CVRF-SVN005C-EN 23

Installation

1A22 SYMBIO800 UNIT CONTROLLER

ETHERNET

USB

1324

LON

1K47

INTERFACE

TRACER

OPTIONAL

COMMUNICATIONS

LTE

4Y2

MODEM

OPTIONAL

12

LTE AirFi WiFi

Figure 21. LTE modem wiring, ref. 50712738

Communication Device Mounting

There devices are intended to be mounted on polycarbonate boxes. There are two installation approaches:

1. Each device is mounted independently on a small box (0185-0426-0100).

Figure 23. Boxes

2. Multiple devices are mounted on a large box (0185-0427-

100).

0

All devices connect Symbio™ 800 by standard USB or

bus cable. For installation standard application need to

Mod field drill a 1.09-inch hole on side of box for a snap bushing. This bush can be replaced as field straight connector and conduit (3/4-inch size) as NEMA 4 applications.

The boxes have magnets for flexible attachment to the

™ panel.

Symbio

Figure 22. Device mounting

The single box is 7-inch Long x 5-inch Wide x 5-inch height

Figure 24. Box mounting

The triple box is 15.5-inch Long x 6-inch Wide x 4-inch height.

24 CVRF-SVN005C-EN

Figure 25. Boxes

Pressure

transducer

Flow

sensor

Temperature

sensor

Installation

Water Flow Measurement

Standard Accuracy Option

Water flow is determined by measuring pressure drop across heat exchanger using water pressure transducer LLID’s. Standard flow measurement transducers can be ordered for condense, evaporator and auxiliary/heat recovery heat exchangers. The standard accuracy part is (0185-3475-0100), there are two transducer (0185-3475-0100) provided per heat exchanger. Field connect by male to 2 female 1000mm branch cable (CAB01147) which provided in package.

Figure 26. Standard accuracy option

Water Box Types

Figure 27. Fabricated Non-Marine - ¾ inch NPTI port

Figure 28. Fabricated Marine - ¾ inch NPTI port

Mounting of Flow Measurement Assembly

This guidance is for mounting transducers on a wide variety of water boxes including marine type, non-marine type, for both 150 and 300 PSI applications in both fabricated steel and castiron construction.

CVRF-SVN005C-EN 25

Installation

IPC BUS

LINE 269

-

Pg

+

SIG

4BP4

-

Pg

+

SIG

4BP5

-

Pg

+

SIG

4BP6

-

Pg

+

SIG

4BP7

WATER PRESSURE

EVAP ENTERING

OPTIONAL

TRANSDUCER

WATER PRESSURE

EVAP LEAVING

OPTIONAL

TRANSDUCER

WATER PRESSURE

COND ENTERING

OPTIONAL

TRANSDUCER

WATER PRESSURE

COND LEAVING

OPTIONAL

TRANSDUCER

Figure 29. Cast – ½ inch NPTI port

Preparation of Wells

Install the provided well using bushings as needed.

Water Box Valve Mounting

Figure 30. Standard accuracy flow meter wiring, ref.

50712746

High Accuracy, Customer Provided  Meter Option

The high accuracy customer provided meter option provides an analog input/output LLID to monitor a customer provided high accuracy meter 0-10 Vdc or 4 – 20 mA outputs. (Rosemont, etc.) This option allows monitoring of condenser, evaporator flow and auxiliary heat exchangers.

Install needed DAIO LLID(s) (BRD04873) in CVRF control

anel:

p

1. LLID (1A21) is needed for EVAP and COND water flow. nnect flow meter wires to 1A21-J2-1 and 1A21-J2-1 for

Co EVAP, 1A21-J2-4 and 1A21-J2-5 for COND.

2. LLID (1A28) is need for HR Aux/COND water flow. nnect flow meter wires 1A28-J2-1 and 1A28-J2-1 for HR

Co flow or Aux COND.

Mount transducers on the entering and leaving side water box locations with the strainer horizontal, the strainer clean out port pointing down and the transducer facing upwards and connect to unit control buss. After system is filled, loosen the transducer in its threaded fitting. Then crack the isolation valve until water starts dripping from threads. Close the valve and re-tighten the transducer, and then reopen the valve for use.

26 CVRF-SVN005C-EN

Figure 31. High accuracy customer meter wiring, ref. 50712746

4

RED

J11

1

J1

1

OPTIONAL WATER FLOW METER

CUSTOMER PROVIDE 4-20MA INPUT

1A21 DUAL ANALOG I/O

OPTIONAL

INPUT 1

OUTPUT 121

GND

INPUT 2

OUTPUT 2

GND

4

3

J2

5

6

COND FLOW METER

5B2 CUSTOMER PROVIDE

4-20mA

FLOW

METER

OUTPUT

EVAP FLOW METER

5B1 CUSTOMER PROVIDE

SIGNAL

24VDC

1A2 J5-1

0V

4-20mA

FLOW

METER

24VDC

1A1 J5-1

0V

1A2 J5-2

1A1 J5-2

OUTPUT

SIGNAL

Installation

Heat Recovery/Aux COND Option

When heat recovery/Aux COND option is selected, a DHVBI LLID (BRD04874) is required as 1A29, wires matrix show as following:

Wire # AWG From To

14B 16 1A29-J3-2 1X1-21

2K 16 1A29-J3-1 1X2-10

CVRF-SVN005C-EN 27

Installation

Figure 32. HR/Aux COND flow switch wiring, ref. 50712747

RED

REQUIRED OPTIONAL

1X1-3

5S11 5K3

P

d

1X2-G

1A29 DUAL HIGH VOLTAGE BINARY INPUT

4

OPTIONAL

HEAT RECOVERY

AUX CONDENSER

WATER FLOW SWITCH

1

RED

14B

2

J3

1

2

J2

1

J11

J1

Energy Meter Option Installation

The Trane energy meter provides instrument grade accuracy power, volts and amps monitoring of Symbio™ controls installations. It has 1% accuracy for measuring both real power and energy and reactive power and energy. All data measured by the meter is communicated via Modbus to Symbio™ control system. See BAS-SVN224*-EN for more information.

Figure 33. Energy meter

1X1-21

2K

1X2-10

HEAT RECOVERY AUX CONDENSER WATER FLOW SWITCH

The meter is connected to line voltage of up to 480 volts and should be mounted within the starter cabinet. It is provided with a mounting bracket that can either be mounted on DIN rail or directly to the starter cabinet wall using the provided bracket.

Figure 34. Mounting bracket

28 CVRF-SVN005C-EN

Installation

+

Shielded Wire

120 terminators on the first/last devices of daisy

chain

Ω

The meter is connected to Modbus communications and is self-powered by the unit voltage potential inputs. Review meter literature for setup and operation details.

Modbus communications is by shielded 14 – 26 AWG cable from meter to Symbio™ module. Please install 120 OHM resistors at first and last modules on Modbus daisy chain.

Figure 35. Modbus communication

–

S

The communications wiring will be

terminated at the Modbus distribution terminal (1X3) beside Symbio™ 800 using the 3 poles connector which provide in energy meter kits.

Figure 36. Distribution terminal

Figure 37. Modbus wiring, ref. 50712738

OPTIONAL

ENERGY METER

LINE 52

OPTIONAL

4Y1

WI-FI

ANTENNA

OPTIONAL

RED

BLK

BLU

IMC

A

1A22 SYMBIO800 UNIT CON

1X3-2

1X3-3

+

-

P1

BACKNET

1X3-1

+

-

G

MODBUS

GRN

-

P2

WHT

480 Volts and Lower Installations

POTENTIAL INPUT – Install provided fused inputs to line voltage per schematic.

CURRENT INPUT – Install provided Rogowski CTs per

ematic.

sch

Figure 38. Rogowski CTs

BLK

+

CVRF-SVN005C-EN 29

Installation

2T50

2T51

2T52

LINE 99

TO 1X3

WHT

BLK

WHT

BLK

WH

T

BLK

RED

BLK

BLU

YEL

ORG

BRN

WHT

2F54

2F52

2F53

0.5A

DETAIL A

ENERGY METER OPTION

NOT US

ED

WB22

X1 X2 X1 X2 X1 X2 +-G

MODBUS

VOLT INPUTS

L1 L2 L3 N

2F1 LINE SIDE

2F2 LINE SIDE

2F3 LINE SIDE

2P25

ENERGY METER

(E23)

CT INPUTS

L1 L2 L3

T

Figure 39. Energy meter wiring, 480V and low application, ref. 50712756

30 CVRF-SVN005C-EN

Installation

OIL PUMP MOTOR

1X1-6

LINE 143

TO 1X2-8

12C

1X1-14

21C

2M

23B

24B

123

124

23A

24A

22A

(6-1/4 A)

LT

RT

1K8

2

3

2

1

1X1-15

1X1-16

1F9

1F8

LT RT

1C1

34

1K8

Oil Pump Control

The Symbio™ control panel allows control UCP2:

• Line voltage oil pumps directly with th

e LLID relay output

• 120 Vac non refrigerant pump oil pumps using a standard

city relay and capacitor

capa

• 120 Vac refrigerant pump style oil pumps using a high

city relay and capacitor

capa

120 Vac Components Matrix

120 Vac

oil pump

Non-refrigerant pump RLY03888 CPT01766

Refrigerant pump RLY03555 CPT01767

Figure 41. Line voltage oil pump wiring, ref 50712732

Starter

relay

Starter

capacitor Fuses

FUS01510 (6 ¼ Amp)

FUS00938 (15 Amp)

120 Vac Oil Pump Starter Capacitor and Starter Relay (Left)

Figure 40. Oil pump starter capacitor and starter relay

Line Voltage Pump Installation

1. Remove start relay, start capacitor and related wiring from Symbio™ panel and discard. These items will not be used in this application.

2. Wire oil pump contactor coil between terminals 1X1-14 and 1X1-6 as per schematic.

12C

1X1-14

120 Vac Non Refrigerant Pump Style  Oil Pump Installation

1. Remove start capacitor from oil pump motor junction box and discard. This item will not be used in this application.

Figure 42. Non-refrigerant oil pump wiring, ref. 50712737

TO 1X2-8 LINE 143

OIL PUMP MOTOR

1X1-6

2. Install new wire of same gauge as existing from control panel to oil pump.

3. Wire oil pump terminal box from terminals 1X1-15, 1X1-16 and 1X1-6 per schematic.

CVRF-SVN005C-EN 31

Installation

120 Vac Refrigerant Pump Style Oil  Pump Installation

1. Remove start capacitor from oil pump motor junction box and discard. This will not be used in this application.

2. Install new wire of same gauge as existing from control

el to oil pump.

pan

Figure 43. Refrigerant oil pu

mp wiring, ref. 50712738

Installation of Oil Pump Motor Wiring and Terminals

The CVRF installation will relocate the oil pump relay to the control panel. Follow the below steps for installation.

1. Disconnect conduit from terminal box and disconnect Seal-Tite® fitting from conduit.

2. Use fish tape to thread wire through conduit for the new

y location in the control panel.

rela

3. Remove starter relay star the Symbio™ panel and discard. Replace these items with the larger capacity relay, capacitor and fuse provided with the kit.

4. Wire oil pump terminal box from terminals 1X1-15, 1X1-16

nd 1X1-6 per schematic.

a

t capacitor and oil pump fuse from

5. Attach Term-Lok adapters (KIT07955 included with kit)) and wire per schematic.

3. Remove and discard existing relay from oil pump junction box.

4. Remove the backing to expose the adhesive on the insulator (GKT04571 included with kit), and then install the insulator over the Fusite pins.

32 CVRF-SVN005C-EN

Starter Work

WARNING

Electrical Fault!

Failure to follow instructions below could result in death or serious injury from burns or electric shocks. Tracer® AdaptiView™ wye-delta starter timing is different from UCP2 wye-delta starter timing. Symbio™800 uses contactor auxiliary switches to prevent simultaneous closure of run and shorting contactors. Starter wiring changes MUST be made per drawings listed in pr

event an electric fault condition.

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 pe

rsonnel. 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/national electrical codes.

Important: Symb

Starter Control Planning

Electrical Fault!

Failure to follow instructions below could result in severe injury and equipment damage. Tracer® Adaptiview™ requires the use of contactor auxiliary switches to prevent simultaneous closure of run and shorting contactors. Existing mechanical interlocks will wear out and fail if not used in combination with contactor auxiliary and result in the contactors exploding. Starter wiring documented in

Diagram Matrix,” p. 46

electrical fault condition.

The starter work required varies significantly from one application to the next. These instructions are somewhat generic. Detailed plans have to be worked out using these instructions as a guide along with your specific starter wiring and hardware information. Use the existing starter wiring and the Symbio™ ship with starter wiring diagrams for determining your exact wiring.

The 3-phase starter module can control the starter using one

methods:

of two

– Direct control of each starter contactor

“Wiring Diagram Matrix,” p. 46 to

WARNING

io™800 requires a closed transition starter. If the existing starter is an open transition style, it must be replaced.

WARNING

, MUST be made to

“Wiring

prevent an

– Pilot relay interface to the existing contactors

Both methods result in similar operation of the starter. When

module is wired for direct control all functions of the dry run

the test can be performed. The pilot relay method must be used when the contactor coils are voltages other than 115 Vac. If both direct control or pilot relay control can be used on your application, select the method that best suits your needs.

The wiring diagrams for direct control are referenced in

Diagram Matrix,” p. 46 p. 46

for pilot relay diagrams, sometimes referred to as

stomer supplied starter wiring. Pilot relays are field provided.

cu

Retain any special options and determin into the new method of control. Keep a detailed record of your revisions to help with future troubleshooting.

Starter panel conversion varies starter control voltage. For reference,

p. 46

lists the electrical schematics for typical Symbio™ wiring for wye-delta, across-the-line, primary reactor, auto transformer, and solid-state starters.

Important: T

The instructions that follow detail the rework of delta starter for direct control by Symbio™ and the starter module LLID.

While this conversion procedure specifically applies to wye-

elta starters, it can be adapted to successfully modify other

d types of starters for operation with a Symbio™ starter module.

. Also use “Wiring Diagram Matrix,”

e how they might fit

with existing starter type and

“Wiring Diagram Matrix,”

o ensure that the starter panel retrofit procedure is performed properly, carefully review the instructions in this section. Record a detailed description of all electrical changes made during the starter retrofit process. Be sure to add a copy of this report to the chiller record file for future reference.

“Wiring

a typical wye-

Starter Sub-Box Installation

The starter sub-box is intended for remote mount starter installations where due to their custom nature there isn’t room for mounting the sub-panel in the starter enclosure and/or such an installation inside the enclosure would be inconvenient or un-safe.

As the Symbio™ starter sub-panel provides a direct

lacement for a UCP2 starter module it is expected that the

rep sub-box will be rarely required, however a description of its installation is provided in case it is needed.

1. Installing the Starter Panel sub-box

2. Mounting of the optional starter sub-box:

a. Remove door from box. Door can be hinged on either

of cabinet.

side

b. Mount starter sub-box on starter panel as shown in

Figure 45, p. 35 using hardware provided. When

drilling holes in starter cabinet, take care to avoid getting metal shavings into starter cabinet.

CVRF-SVN005C-EN 33

Starter Work

c. Drill 3/4-inch or 1-inch hole through panel and starter

cabinet, near top of cabinet, to accommodate wires from sub-box to starter. Add grommet to hole.

3. Mounting and pre-wiring of components on back panel.

a. Mount starter sub-panel on the back panel.

b. Label components using labels provided.

c. Attach starter module LLID to IPC bus.

Figure 44. Starter sub-panel with PTs, CTs and power

pply

su

Starter Sub-Panel

The Symbio™ starter module is provided on an assembled sub-panel that is a direct replacement for the UCP2 starter module mounted in conventional starters and AFD applications. The sub panel has three significant options:

– It has the option of a 24 Vdc power supply to be used

remote mount starters and drives.

on

– It has the option of pre-installe

transformers

– It comes in a starter and AFD configuration. The AFD

configuration includes the needed LLIDS for UCP2 AFD control.

Each subpanel It is also provided as standard with a mounting

racket that allows mounting of factory installed AFD LLIDs or

b field installed secondary current transformers or pilot relays when needed.

A description of the sub-panel’s types and uses is below:

d 600 V or less current

Table 8. Sub-panel types

Model # Digit 33 Application Part Number Description

Starter module with plate for

E

medium voltage unit starter

Starter module with plate for low

A

F

B

C

D

age unit starter

volt

Starter module with plate for

dium voltage remote starter

me

Starter module with plate for low voltage remote starter

Starter module with plate for unit AFD

Starter module with plate for re

mote AFD

0185-0421-0100

0185-0433-0100

0185-0422-0100

0185-0435-0100

0185-0434-0100

0185-0437-0100

Starter module on sub plate W/O power supplier, W/O PT

Starter module on sub plate W/O power supplier, W/ PT

Starter module on sub plate W/ power supplier, W/O PT

Starter module on sub plate W/ power supplier, W/ PT

AFD Starter module on sub plate W/O power supplier, W/O PT

AFD Starter module on sub plate W/ power supplier, W/O PT

Starter

Mount Type

Unit mount MV starter

Unit mount LV Starter

Remote mount

Unit mount

Remote mount

PTs

Configuration Selection FACT/FCOD

MV starter

LV Starter

AFD starter already has LV PTs

STYP/STUN; TPOT=NONE

STYP/STUN; TPOT=CPTA,CPTB,CPTC, CPTD,CPTE,CPTF

STYP/STRE; TPOT=NONE

STYP/STRE; TPOT=CPTA,CPTB,CPTC, CPTD,CPTE,CPTF

STYP/AFUN; TPOT=NONE,CPTB,CPTC

,CPTD,CPTE,CPTF

STYP/AFRE; TPOT=NONE,CPTB,CPTC ,CPTD,CPTE,CPTF

34 CVRF-SVN005C-EN

Starter Work

Figure 45. Mounting starter sub-box

Starter control and power wires are connected to the terminal block on the right side of the sub-panel. CTs and starter module communications and power wires are connected directly to starter module on the left side.

Figure 46. Starter sub-panel

Figure 47. Low voltage potential transformer

connections

IMPORTANT NOTE FOR WYE DELTA AND AUTO TRANSFORMER STARTER APPLICATIONS

Per the schematics, Wye Delta and Auto Transformer starter require normally closed contactor interlock signals for proper operation. In the case that the starters do not have available auxiliary contacts, pilot relays can be substituted per the schematic notes below. If space is available, the relay(s) can be mounted on the sub-panel bracket.

Medium voltage potential transformer outputs are directly wired to starter module current inputs L1, L2, and L3 per the schematic drawing. Low voltage L1, L2, and L3 potential signals are connected to the potential transformer white and black leads on the sub-panel in the order below.

Note: If repla

cing a UCP2 starter module, you can remove and discard the 27 VAC UCP2 starter module transformer as it is not required for the CH530 type starter module operation.

Figure 48. Pilot relay terminal locations

CVRF-SVN005C-EN 35

Starter Work

Figure 49. Pilot relay switching configuration

Figure 50. Wye delta interlock and pilot relay wiring

36 CVRF-SVN005C-EN

Figure 51. Autotransformer interlock and pilot relay wiring

Starter Work

Starter Sub-Panel Installation

Virtually all Symbio™ UCP2 panel upgrades will have the starter sub panel installed as a direct replacement of the existing UCP2 starter module.

The starter module LLID, and CTs and any turn-down

nsformers can be mounted on the sub- panel.

tra

The starter control conversion will provide a direct replacement

existing UCP2 starter module. For UCP2 installations it

of the is recommended that the existing CTs and PTs will be reused and mounted on the Symbio™ starter sub-panel.

Installation steps are as follows:

1. Remove existing UCP2 module keeping potential nsformers and secondary current transformers if

tra needed for reuse.

CVRF-SVN005C-EN 37

2. Install existing potential transformers on lower panel if required and secondary current transformers if needed on the bracket.

3. Power and communications.

a. For unit mount starters, use global connector to provide

wer and communications to starter module.

po

b. For remote mount starters

i. Starter module power will be supplied by sub-panel

ower supply.

p

ii. Use existing communications cable to connect

mbio™ communications bus to starter module.

Sy

4. Wire Starter control interface per schematic. Remove the

xisting UCP2 wires between terminal 2TB1-6 and UCP2

e starter module J10-3, J12-3, and J14-3. See UCP2 existing starter module schematic drawing below of existing UCP2 wires to be discarded.

Starter Work

Figure 52. Existing UCP2 wires to be discarded

Figure 53. Starter sub panel customer connections 5071-0496

Notes:

• Be sure to refer to the wiring diagrams listed in

Diagram Matrix,” p. 46

as you review the following

“Wiring

instructions. The wire numbers and component

designations indicated in these steps appear in these figures. Actual existing numbers may vary for your unit. Service literature that includes sample original unit wiring can be found in CVHE-M-7 or CVHE-IN-8.

38 CVRF-SVN005C-EN

Starter Work

• To simplify future chiller trouble analysis, Trane recommends removing all existing, non-essential components from the starter panel enclosure.

AFD Sub-Panel

The Symbio™ starter module is provided on an assembled sub-panel that is a direct replacement for a UCP2 starter module mounted on an AFD. The panel contains the analog output, binary input and timer required to run the AFD as a noncommunicating Symbio™ drive.

Installation steps are as follows:

1. Remove existing UCP2 module keeping medium voltage

AFD potential transformers and CTs for reuse.

and

2. Install new sub-panel in place of existing UCP2 starter

e and existing potential transformers on the bracket.

modul

3. Wire AFD control interface per schematic.

Figure 54. AFD sub panel customer connections 5071-1536

4. Power and communications.

a. For unit mount AFDs

i. Wire per schematic

ii. Use global connector to provide power and

nications to starter module.

commu

b. For remote mount AFDs

i. Wire per schematic, starter module will be powered

b-panel power supply.

by su

ii. Use existing communications cable to connect

mbio™ communications bus to starter module.

Sy

5. Shunt trip output (Optional) shunt trip function is not documented by the Symbio™ AFD schematic. It is not used on UCP2 AFDH and is not required for a Symbio™ upgrade.

The UCP2 starter module

If keeping shunt trip control is desired, a Symbio™ programmable binary output can be setup to transition upon starter fault. Wire the output normally open contact with 115 Vac to the AFD circuit breaker in order to initiate shunt trip.

Notes:

• Be sure to

Diagram Matrix,” p. 46 as you review the following

CVRF-SVN005C-EN 39

refer to the wiring diagrams listed in

“Wiring

instructions. The wire numbers and component designations indicated in these steps appear in these figures. Actual existing numbers may vary for your unit. Service literature that includes sample original unit wiring can be found in CVHE-M-7 or CVHE-IN-8.

Starter Work

• To simplify future chiller trouble analysis, Trane recommends removing all existing, non-essential components from the starter panel enclosure.

Control Power Transformer

If the existing starter does not have 115 Vac 3 kVA of additional control power, install a transformer (fieldsupplied) that will provide 115 Vac to the Symbio™ control panel. (As just described, transformer requirements are: line voltage primary/ 115 Vac secondary, minimum capacity 3 kVA.)

Current Transformers, CTs

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 a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged.

WARNING

PPE for Arc/Flash Required!

Failure to wear appropriate PPE could result in death or serious injury. On this unit, if the handle shield is cracked the circuit breaker could arc/flash when reset. To avoid being injured, technicians MUST put on all necessary Personal Protective Equipment (PPE), in accordance with NFPA70E for arc/flash protection, PRIOR to entering the starter panel cabinet.

Three new current transformers CTs (“donut” shape) are optio

nal to re-work the starter. If used, install these three new

CTs as shown on wiring diagram. Pay careful attention to the

Table 9. CT specifications for single transformer per phase

polarity dot and its orientation. The polarity dot should face incoming power, in other words, towards the disconnect.

Figure 55. Current transformer, single turn-down

DIM “B”

DIM “A”

Schematic

Polarity Dot

1/4 in. male quick connect 2 places

Wire the leads from the CT male quick connects to the starter

ule as shown on the wiring diagram. Use female insulated

mod quick connect terminals.

The application of Symbio™ chiller controls to a medium voltage chiller recommends specific use of the dual current transformer (CT) application, rather than a single CT which is a common option on low voltage applications (600 Vac or less). Refer to CVRD-SVN11*-EN for wiring of medium voltage CT applications.

The dual CT installation uses a primary CT

that reduces the amperage to less than 5 amps. A second CT is then used to reduce the current input to the starter module to a nominal 100 mA value. Use dual CT data tables in the startup and programming manual CVRE-SVP01A-EN, or the latest version.

It is recommended that you confirm the correct CT has been

rovided before starting installation. Before wiring the starter

p module and CT be sure to confirm incoming power phasing. If Phase A, B, and C are wired in the wrong order the controls will not allow the motor to start. Use the phase meter on the low voltage side of the potential transformer. Do NOT use the meter on the primary side where there is medium voltage because it probably exceeds the safe operating voltage range of most service meters.

Actual Motor

RLA (A) CT Part Number CT Ratio (A:A) CT Rating (A)

67-100 TRR02028 40:00.1 100 2 3.35 1 100

100-150 TRR00715 30:00.1 150 2 3.35 1 150

134-200 TRR02029 20:00.1 200 2 3.35 1 200

184-275 TRR02030 35:00.1 275 2 3.35 1 275

267-400 TRR02031 40:00.1 400 2.5 3.95 1 400

334-500 TRR01142 20:00.1 500 2.5 3.95 1 500

467-700 TRR01255 40:00.1 700 2.5 3.95 1 700

40 CVRF-SVN005C-EN

Diameter

(a)

(inches)

Primary

Tur ns

CT Meter

ScaleInside A Inside B

Table 9. CT specifications for single transformer per phase (continued)

Starter Work

Actual Motor

RLA (A) CT Part Number CT Ratio (A:A) CT Rating (A)

667-1000 TRR01405 40:00.1 1000 2.5 3.95 1 1000

964-1400 TRR01597 20:00.1 1400 3.5 5.25 1 1400

1200-1800 TRR01580 00:00.1 1800 4 6.5 1 1800

(a) Refer to

Figure 55, p. 40 for location of diameter A and B.

CT Work

Diameter

The existing CTs can be reused for UCP2. applications with a single CT or two CTs per phase. The output

(a)

(inches)

Primary

Tur ns

This is true for

of both CT applications is in the 100 mA range that the

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 a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged.

Symbio™ starter module requires.

When reusing CTs it may be necessary to confirm all the

olarity of existing wiring is correct per these instructions.

p

In some cases starters shipped with ammeters. can remain if they have their own CTs.

When using existing CTs having a nominal chiller current to 5

mp ratio (i.e., 200:5), it is necessary to install or have ordered

a secondary CTs. In this case, two CTs are used per phase to either achieve the necessary turn-down or for metering convenience. The first stage consists of either the X13580271010 (TRR01287), X13580272010 (TRR01288), X13580048010 (TRR00448) and X13580048020 (TRR00449) (each of these CTs have a 5 amp secondary). The second stage consists of small CT transformers that reduce the nominal 3.6 amp signal to the 100 mA value used by the starter

WARNING

PPE for Arc/Flash Required!

Failure to wear appropriate PPE could result in death or serious injury. On this unit, if the handle shield is

module. The existing 5 amp CTs cannot be used if they do not match the required ratio in

Table 9, p. 40.

The part number on the secondary CT is X13580266-01, Trane

art number TRR00975, three required per starter.

p

cracked the circuit breaker could arc/flash when reset. To avoid being injured, technicians MUST put on all necessary Personal Protective Equipment (PPE), in accordance with NFPA70E for arc/flash protection, PRIOR to entering the starter panel cabinet.

Table 10. CT specifications for two transformers per phase

CT Meter

ScaleInside A Inside B

The meters

Actual Motor

RLA (A)

8.0-12.0 TRR01288 TRR00975 50:05:00 50 1.25 3 12

12.0-18.0 TRR01288 TRR00975 50:05:00 50 1.25 2 18

18.0-27.0 TRR01289 TRR00975 75:05:00 75 1.25 2 27

24.0-36.0 TRR01288 TRR00975 50:05:00 50 1.25 1 36

36.0-54.0 TRR01289 TRR00975 75:05:00 75 1.25 1 54

48.0-72.0 TRR01287 TRR00975 100:05:00 100 1.75 1 72

24.0-36.0 TRR00448 TRR00975 150:05:00 150 2.5 3 36

28.8-43.2 TRR00448 TRR00975 180:05:00 180 2.5 3 43.2

36.0-54.0 TRR00448 TRR00975 150:05:00 150 2.5 2 54

43.2-64.8 TRR00448 TRR00975 180:05:00 180 2.5 2 64.8

48.0-72.0 TRR00448 TRR00975 200:05:00 200 2.5 2 72

60.0-90.0 TRR00449 TRR00975 250:05:00 250 2.5 2 90

CVRF-SVN005C-EN 41

Primary CT

Number

Second CT

Number CT Ratio (A:A) CT Rating (A)

Inside Dia.

(inches) Primary Turns CT Meter Scale

Starter Work

Front View / Primary

RED BRN

Front View / Secondary

BLK WHT

Bottom View

BLKWHT

RED BRN

Primary Leads

Secondary Leads

Schematic

RED

BROWN

BLACK

WHITE

Primary

Secondary

Table 10. CT specifications for two transformers per phase (continued)

Actual Motor

RLA (A)

72.0-108.0 TRR00448 TRR00975 150:05:00 150 2.5 1 108

86.4-129.6 TRR00448 TRR00975 180:05:00 180 2.5 1 129.6

96.0-144.0 TRR00448 TRR00975 200:05:00 200 2.5 1 144

120-180 TRR00449 TRR00975 250:05:00 250 2.5 1 180

144-216 TRR00449 TRR00975 300:05:00 300 2.5 1 216

168-252 TRR00449 TRR00975 350:05:00 350 2.5 1 252

192-288 TRR00450 TRR00975 400:05:00 400 2.5 1 288

240-360 TRR00450 TRR00975 500:05:00 500 2.5 1 360

288-432 TRR00450 TRR00975 600:05:00 600 2.5 1 432

336-504 TRR00451 TRR00975 700:05:00 700 2.5 1 504

384-576 TRR00451 TRR00975 800:05:00 800 2.5 1 576

480-720 TRR00451 TRR00975 1000:05:00 1000 2.5 1 720

480-720 TRR00655 TRR00975 1000:05:00 1000 4 1 720

576-864 TRR00499 TRR00975 1200:05:00 1200 2.5 1 864

576-864 TRR00655 TRR00975 1200:05:00 1200 4 1 864

720-1080

720-1080 TRR00655 TRR00975 1500:05:00 1500 4 1 1080

864-1296 TRR00453 TRR00975 1800:5, X1-X2 1800 4 1 126

1008-1512 TRR00453 TRR00975 2100:5, X1-X3 2100 4 1 1512

1200-1800 TRR00453 TRR00975 2500:5, X1-X4 2500 4 1 1800

Primary CT

Number

TRR00499 TRR00975 1500:05:00 1500 2.5 1 1080

Second CT

Number CT Ratio (A:A) CT Rating (A)

Inside Dia.

(inches) Primary Turns CT Meter Scale

The secondary CT used in the two transformer per phase is shown in

Figure 56, p. 42. For a typical wiring diagram used for

wiring low voltage applications using dual CTs, two transformers per phase, see

Figure 57, p. 43.

Figure 56. Secondary CT used with 5 amp primary CT, X13580266-01, TRR00975

42 CVRF-SVN005C-EN

Figure 57. Dual CT wiring example

Starter Work

CVRF-SVN005C-EN 43

Starter Work

Schematic

Secondary Leads, 0.187 in. terminals

Top View

Primary Leads, 0.250 in. terminals

Polarity Dots

Secondary

Primary

Polarity Dots

Potential Transformers, Optional PTs

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 a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged.

Figure 58. Potential transformer, X13590079-01, TRR00713

WARNING

PPE for Arc/Flash Required!

Failure to wear appropriate PPE could result in death or serious injury. On this unit, if the handle shield is cracked the circuit breaker could arc/flash when reset. To avoid being injured, technicians MUST put on all necessary Personal Protective Equipment (PPE), in accordance with NFPA70E for arc/flash protection, PRIOR to entering the starter panel cabinet.

Install the optional potential transformers (PTs). The potential transformers are used to measure line voltage. The wiring must have the correct polarity for them to work correctly.

For applications greater than 600 Vac, a large medium voltage

is used to step from line voltage to 115 Vac and a second

PT PT steps the voltage to less than 30 Vac. The large PT is a three phase type except for the 6600 Vac where three single phase PTs are used. Refer to CVRD-SVN11*-EN, for detailed wiring instructions.

For applications less than 600 Vac a single PT per phase like

at shown in

th to a voltage less than 30 Vac for input into the starter module. The black leads are connected to the line from phases A-B, BC and C-A. The green ground wire is connected to chassis ground. Field provided wires connect the Starter module to the terminals on the PTs.

The part number on the less than 600 volt PT is X13590079-

Trane part number TRR00713, three required per starter.

01,

Note: Fu

44 CVRF-SVN005C-EN

Figure 58, p. 44 is used to step the signal down

ses (2F1, 2F2 and 2F3) must be installed with the

optional potential transformers (see

“Wiring Diagram

Matrix,” p. 46 for a list of the appropriate wiring diagram

examples). Use

Ta bl e 5, p. 9 to size the fuses.

Starter Wiring

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/national electrical codes.

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 a CAT III or IV voltmeter rated per NFPA 70E that all capacitors have discharged.

WARNING

PPE for Arc/Flash Required!

Failure to wear appropriate PPE could result in death or serious injury. On this unit, if the handle shield is cracked the circuit breaker could arc/flash when reset. To avoid being injured, technicians MUST put on all necessary Personal Protective Equipment (PPE), in accordance with NFPA70E for arc/flash protection, PRIOR to entering the starter panel cabinet.

NOTICE

Module Damage!

Failure to follow the following instruction could result in equipment damage. Do NOT connect the secondaries of the line-to-120 Vac potential transformer to the starter module!

Starter Work

Table 11. Starter wiring (continued)

Wi r e # F r om Te r mina l To Te rmin a l

507 2U1 J8-2 2K11 coil +

510 2U1 J8-1 2A1 J8-1

512 2U1 J10-3 2A1 J6-3

516 2U1 J10-1 2K3 AUX NC

518 2U1 J12-3 2A1 J4-3

521 2U1 J12-1 2K4 AUX NC

523 2U1 J14-3 2A1 J2-3

524 2U1 J14-1 2A1 J2-1

Additional wires

Wire # From Terminal To Te r min a l

508 2K11 coil - 2TB1-2

506 2K11 NO 2K1 AUX NO

505 2A1 J10-1 2K11 NO

514 2A1 J6-1 2K11 NO

515 2K11 NO 2K3 AUX NC

519 2A1 J4-1 2K4 AUX NC

IPC cable connected to either J1 or J3 1-4.

Remove

2T4 and all wires connected to it.

Comm Link wires connected to 2U1 J1-1,2.

Table 11. Starter wiring

Wire # From Terminal To Ter m inal

236A 2U1 J3-3 2A1 J5-1

237A 2U1 J3-4 2A1 J5-2

238A 2U1 J3-5 2A1 J5-3

239A 2U1 J3-6 2A1 J5-4

240A 2U1 J3-7 2A1 J5-5

241A 2U1 J3-8 2A1 J5-6

101A 2U1 J5-1 2A1 J7-1

102A 2U1 J5-2 2A1 J7-2

103A 2U1 J5-3 2A1 J7-3

104A 2U1 J5-4 2A1 J7-4

105A 2U1 J5-5 2A1 J7-5

106A 2U1 J5-6 2A1 J7-6

503 2U1 J4-2 2A1 J12-2

504 2U1 J4-1 2A1 J12-1

4B 2U1 J6-3 2A1 J10-3

CVRF-SVN005C-EN 45

Wiring Diagram Matrix

Table 12. Wiring diagrams matrix

TYPE NUMBER

CONTROL

Unit Controls 50712738

Unit and Option 50712745

Option 50712746

Option 50712747

Legend 50712748

Field Connection Dia 50712755

Comm Panel Dia 50712779

STARTERS

Wye-Delta TS 50710492

X-Line TS 50710493

Primary Reactor TS 50710494

Auto X-Former TS 50710495

Solid State TS 50710528

Wye-Delta CS 50710523

X-Line CS 50710524

Primary Reactor CS 50710525

Auto X-Former CS 50710527

Starter Subpanel VFD 50711536

Energy Meter Option, 480V and Low 50712756

Energy Meter Option, 575 and 600V 50712757

Energy Meter Option, MV With Single

Energy Meter Option, MV With Double

Note: Wiring diagrams, including those for chillers equipped with drives, are

age PT

St

age PT

available via e-Library. Also refer to the drive Installation, Operation, and Maintenance manual for the appropriate diagrams. If the existing chiller has an AFDB or AFDC drive, contact Trane Global Parts Technical Service for specific instructions.

50712758

50712759

46 CVRF-SVN005C-EN

Notes

CVRF-SVN005C-EN 47

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.

CVRF-SVN005C-EN 05 Aug 2022

Supersedes CVRF-SVN005B-EN (May 2022)

Trane Symbio CVRF Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual