Trane Voyager III, IntelliPak II, IntelliPak I Installation Manual

Installation

Variable Frequency Drive
Conversion TR1 to TR200

IntelliPak™ I and II and Voyager™ III only

Models: Only Clarksville built units with factory installed VFDs. This includes the following Voyager III
commercial units with the VAV option and IntelliPak I and II units with the VAV and/or Statitrac™
option built prior to Trane TR200 drive unit installation.

S*HF 20 to 75 ton (IntelliPak I) TC, YC and TE 27½ to 50 ton (VIII)
S*HG 90 to 130 ton (IntelliPak I)
S*HJ 90 to 150 ton (IntelliPak II)

July 2009

PART-SVN121A-EN

Warnings, Cautions and Notices

Warnings, Cautions and Notices. Note that warnings, cautions and notices appear at

appropriate intervals throughout this manual. Warnings are provided to alert installing contractors
to potential hazards that could result in personal injury or death. Cautions are designed to alert
personnel to hazardous situations that could result in personal injury, while notices indicate a
situation that could result in equipment or property-damage-only accidents.

Your personal safety and the proper operation of this machine depend upon the strict observance
of these precautions.

ATTENTION: Warnings, Cautions and Notices appear at appropriate sections throughout this

literature. Read these carefully.

 WARNIN G: Indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury.

 CAUTION: 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.

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

Note: This document is customer property and must be retained by the unit's owner for use by

maintenance personnel.

WARNING

Personal Protective Equipment (PPE) Required!

Installing/servicing this unit could result in exposure to electrical, mechanical and chemical
hazards.

• Before installing/servicing this unit, technicians MUST put on all Personal Protective
Equipment (PPE) recommended for the work being undertaken. ALWAYS refer to appropriate
MSDS sheets and OSHA guidelines for proper PPE.

• When working with or around hazardous chemicals, ALWAYS refer to the appropriate MSDS
sheets and OSHA guidelines for information on allowable personal exposure levels, proper
respiratory protection and handling recommendations.

• If there is a risk of arc or flash, technicians MUST put on all necessary Personal Protective
Equipment (PPE) in accordance with NFPA70E for arc/flash protection PRIOR to servicing the
unit.

Failure to follow recommendations could result in death or serious injury.Introduction

This manual describes the installation procedures required to retrofit TR1 Variable Frequency
Drives (VFD).

Trademarks

Trane, the Trane logo, IntelliPak, Statitrac, and Voyager are trademarks of Trane in the United States
and other countries. All trademarks referenced in this document are the trademarks of their
respective owners.

© 2009 Trane All rights reserved PART-SVN121A-EN

Table of Contents

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

About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Removing the Existing VFD and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation of TR200 VFD and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

VFD and Back Panel Assembly for TR200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

TR200 VFD Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

VFD Programming Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

VFD Removal from Back Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Power Supply Wiring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Control Wiring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

TR1 Keypad Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

TR200 Drive Installation instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Power Supply Wiring to TR200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Control Wiring to TR200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Keypad and Cable Adapter Assembly Installation for TR200 . . . . . . . . . 16

Wiring Diagram Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

PART-SVN121A-EN 3

General Information

About This Manual

The step-by-step instructions outlined in this manual describe the procedures required to
successfully retrofit a TR1 on 20 ton to 150 ton IntelliPak™ I and II rooftop air conditioning and 27½
to 50 ton Voyager™ III rooftop air conditioning units to a Trane TR200 VFD drive. For help selecting
the proper parts for this work, refer to general service bulletin PART-SVB24A-EN or the most current
version of that same literature.

The installation instructions in this manual are divided into three general topic areas:

• Removal of existing TR1 VFD and components.

• Installation of replacement TR200 VFD and components.

• TR200 programming of parameters.

Follow start-up and trouble shooting procedures outlined in the service manuals of the unit and/
or the literature that is included with this TR200 control.

Tools Required

Very few tools are required to perform this installation. A service technician with a well-stocked tool
chest should have the right tools to perform the job; However, a large-frame VFD will require a
crimping tool for ring lugs and a drill with a #21 (4mm) drill bit sized to allow a #10-32 screw to
thread into sheet metal.

4 PART-SVN121A-EN

Removing the Existing VFD and Components

SUPPLY FAN VFDSUPPLY FAN VFD

VARIABLE FREQUENCY DRIVEVARIABLE FREQUENCY DRIVE
ENCLOSUREENCLOSURE

EXHAUSTEXHAUST

FANFAN
VFDVFD

RETURN & EXHAUST SECTIONRETURN & EXHAUST SECTION

FILTER

SECTION

EVAP COIL

SUPPLY FAN SECTIONSUPPLY FAN SECTION

CONDENSER FANSCONDENSER FANS

COMPRESSOR SECTIONCOMPRESSOR SECTION

HEAT SECTIONHEAT SECTION

HTG ACCESS

PANEL

HEAT SECTION

ELEC CONTROL

ELEC CONTROL

PANELPANEL

SUPPLY FAN SECTION

EVAP COIL

EVAP COIL

FILTER

SECTION

O/A DAMPERSR/A DAMPERS

RETURN & EXHAUST

EXHAUSTEXHAUST

FAN

FAN

VFDVFD

VARIABLE FREQUENCY DRIVEVARIABLE FREQUENCY DRIVE
ENCLOSUREENCLOSURE

SUPPLY FAN VFDSUPPLY FAN VFD

CONDENSER FANS

COMPRESSOR SECTION

The section that follows will give the procedure to remove a TR1 VFD from its panel assembly and
remove the remote keypad in the IntelliPak I, IntelliPak II, and Voyager III main control panels.

Programming parameters are supplied with the VFD and a minimum of five must be set based on
unit specifications, see Table 4, p. 17.

VFD Removal from Back Panel Assembly

Locate the existing TR1 VFD unit enclosure near the return and exhaust section as shown in

Figure 1 and Figure 2, p. 5 for IntelliPak I units, adjacent to the supply/exhaust sections of IntelliPak

II Figure 3, p. 6 and opposite supply fans on the Voyager III units as shown in Figure 4, p. 6.

Identify the correct VFD for replacement. The IntelliPak I and II rooftops can have both supply and
exhaust/return VFDs. The IntelliPak I supply VFD is located on the back panel of the unit enclosure
and the exhaust/return VFD is located on the inner door of the unit enclosure which must be turned
to the open position for the VFD to be removed. The IntelliPak II supply VFD is adjacent to the supply
fan section, and the exhaust/return VFD is adjacent to the exhaust/return fan section. Voyager III
units only have supply VFDs and are located by the supply fan on the opposite side of the unit from
the control panel.

Figure 1. Typical IntelliPak I 20 to 75 ton configuration

Figure 2. Typical IntelliPak I 90 to 130 ton configuration

PART-SVN121A-EN 5

Removing the Existing VFD and Components

Return/

Exhaust

Fan

Fresh Air
Dampers

Supply Fan

Condenser

Fans

Compressor

Section

Heating
Section

Exhaust Damper

Hood

Evap Coil

Evap Coil

Controls

Variable

Frequency

Drive (VFD)

Filter Section

Reheat Coil Option

Fresh Air
Dampers

Return Air Dampers

Variable

Frquency

Drive (VFD)

Variable

Frequency

Drive

Baysens set
2-Pc connection

tubings

Variable

Frequency

Drive

VFD ACCESS

Figure 3. Typical IntelliPak II 90 to 150 ton configuration

Figure 4. Typical Voyager III 27.5 to 50 ton configuration

6 PART-SVN121A-EN

 WARNING

Hazardous Voltage!

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

Note: For additional information regarding the safe discharge of capacitors, see

PROD-SVB06A-EN or PROD-SVB06A-FR

Disconnect the following power supply and control wires from each VFD.

Power Supply Wiring Removal

The following instructions relate to either the IntelliPak I, II or Voyager III.

VFD with bypass

– Disconnect power supply wires 1A, 2A, 3A from VFD connection points 91, 92, 93 (L1, L2, L3

respectively) and wires 10A, 11A, 12A, 13A from VFD connection points 96, 97, 98, 95 (T1, T2,
T3, GND respectively).

VFD without bypass

– Disconnect power supply wire 1A, 2A, 3A from VFD connection points 91, 92, 93 (L1, L2, L3

respectively) and wires T1, T2, T3, 13A from VFD connection points 96, 97, 98, 95 (T1, T2, T3,
GND respectively).

Removing the Existing VFD and Components

PART-SVN121A-EN 7

Removing the Existing VFD and Components

Control Wiring Removal

Disconnect all control wires from the TR1 VFD itself and note the connection point numbers. The
TR1 and TR200 have the same connection point numbers. See Tab l e 1, p. 8 for common control
wires and their connection point numbers. See Tab l e 2 , p. 8 for VFD keypad cables listed according
to product line and function.

Table 1. Listed are typical control wires to remove from the TR1 and reinstall on the TR200. This

applies to IntelliPak I, IntelliPak II, and Voyager III drives except as noted. Extra spaces
are included in the table so that any other control wires may be recorded

Control Wire

18B 12

28A 27

30A 53

31A 55

32A 18

34A*** 05

Jumper wire*** 39 and 04

VFD keypad cable*

45A** 02*

46A** 01*

Notes

1. * See Table 2, p. 8 for cable names.

2. ** IntelliPak I 90-130 ton units only.

3. ***VFD with bypass only.

VFD Connection
Point

Sub D Connector (front
of VFD)

Table 2. Listed are VFD keypad cables according to product line and VFD function

Product/Function Keypad Cable

IntelliPak I/ Supply Fan CBL3U72-6

IntelliPak I/ Exh/Rtn Fan CBL3U74-6

IntelliPak I/ Supply Fan #1* CBL3U72-6

IntelliPakI/ Supply Fan #2* CBL3U73-6

IntelliPak II/ Supply Fan CBL5U16-6

IntelliPak II/ Exh/Rtn Fan CBL8U17-6

Voyager III/ Supply Fan CBLVFD-6

Note: * IntelliPak I 90-130 ton units only.

8 PART-SVN121A-EN