1. Manuals
  2. Brands
  3. Trane Manuals
  4. Air Conditioner Accessories
  5. AFDR
  6. Installation instructions manual

Trane AFDR Installation Instructions Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Installation Instructions
AFDR Retrofit Air-cooled Adaptive
Frequency Drive™
For Use with RTHD Chillers
Models
AFDR
Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of
heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training.
Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury.
When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are
attached to the equipment.
June 2020
SAFETY WARNING
AFDR-SVN001D-EN

Advertisement

Table of Contents
loading

Related Manuals for Trane AFDR

Summary of Contents for Trane AFDR

  • Page 1 Installation Instructions AFDR Retrofit Air-cooled Adaptive Frequency Drive™ For Use with RTHD Chillers Models AFDR SAFETY WARNING 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.
  • Page 2 (Global Harmonized System of Classification and compounds have the same potential impact to the Labeling of Chemicals) guidelines for information on environment. Trane advocates the responsible handling of allowable personal exposure levels, proper all refrigerants-including industry replacements for CFCs respiratory protection and handling instructions.
  • Page 3 Copyright This document and the information in it are the property of WARNING Trane, and may not be used or reproduced in whole or in Conform to All Applicable National, State, part without written permission. Trane reserves the right to revise this publication at any time, and to make changes...

  • Page 4: General Information

    CH530, it must be replaced with the Tracer AdaptiView™ RTHD rotary chiller display upgrade kit (RCDA; sold separately). The AFDR can be ordered as a close floor mount, remote floor mount, or remote wall mount. Voltage options include 460/480 volts, 380/400 volts, and 575/600 volts.

  • Page 5: Table Of Contents

    Installing an AFDR Retrofit ... . 4 ......37 Panel Component Installation (All Kits) .

  • Page 6: Model Number Descriptions

    Model Number Descriptions For service purposes, Trane model Digit 15 — AFD Type AFDR air-cooled drive upgrade NEMA 1 (IP21) NEMA 12 (IP54) (Special) packages are assigned a multiple character alphanumeric model Digit 16 — Mounting Type number that precisely identifies each Close Mount—Conduit and...

  • Page 7: Environmental Conditions

    Environmental Conditions Important: The location of the AFDR is important if proper performance and normal operating life is to be expected. Therefore, unless designed for special environments, the controller should be installed in an area where the following conditions exist.

  • Page 8: Nameplates

    Nameplates AFDR Controls A nameplate is included for each AFDR air-cooled drive unit. Always provide the model number and serial number that is printed on this nameplate when making warranty If there is an existing CH530 controller, the Tracer inquiries, ordering parts, or ordering literature for the unit.

  • Page 9: Dimensions

    Dimensions Unit Submittal Drawings Figure 2. D1 drive, 2 conduit, 460 and 575V, below 185 amps — standard drive orientation AFDR-SVN001D-EN...
  • Page 10 Dimensions Figure 3. D1 drive, 2 conduit, 460 and 575V, below 185 amps — rotated drive orientation AFDR-SVN001D-EN...
  • Page 11 Dimensions Figure 4. D1 drive, 4 conduit, 460V, 185 to 334 amps — standard drive orientation AFDR-SVN001D-EN...
  • Page 12 Dimensions Figure 5. D1 drive, 4 conduit, 460V, 185 to 334 amps — rotated drive orientation AFDR-SVN001D-EN...
  • Page 13 Dimensions Figure 6. D2 drive, 4 conduit, 460 and 575V, 186 to 336 amps— standard drive orientation AFDR-SVN001D-EN...
  • Page 14 Dimensions Figure 7. D2 drive, 4 conduit, 460 and 575V, 186 to 336 amps — rotated drive orientation AFDR-SVN001D-EN...

  • Page 15: Drive Dimensions

    Drive Dimensions Figure 8. D1 drive dimensions - sheet 1 of 2 35.2 33.2 33.4 26.1 12.8 14.5 12.0 GLAND PLATE Figure 9. D1 drive dimensions - sheet 2 of 2 MOTOR MAINS TERMINALS TERMINALS 7.55 GROUND 3.14 3.14 GROUND AFDR-SVN001D-EN...
  • Page 16 Figure 10. D2 drive dimensions - sheet 1 of 2 2.76 11.02 43.28 41.36 41.42 34.25 16.54 2.94 10.67 14.51 15.7 GLAND PLATE Figure 11. D2 drive dimensions - sheet 2 of 2 MOTOR MAINS TERMINALS TERMINALS 13.00 GROUND 7.00 7.00 GROUND GROUND 6.00 6.00 GROUND AFDR-SVN001D-EN...

  • Page 17: Pedestal Drawings

    Dimensions Pedestal Drawings Figure 12. Pedestal drawing - D1 drive SHOWN WITHOUT COVER PLATES INSTALLED 15.7 12.8 14.6 11.2 Figure 13. Pedestal drawing - D2 drive SHOWN WITHOUT COVER PLATES INSTALLED 15.7 16.5 14.6 14.9 12.5 AFDR-SVN001D-EN...

  • Page 18: Pre-Installation

    Global harness Male to Amp connector 78.74in CAB01150 X19051623020 Extension Harness - 78.74inch X39002507010 Label, Warning (AFD) 507117810001 Label, Nameplate AFDR-SVN001*-EN KIT IOM (supplied by Trane) 507117830001 Schematics Printed on mylar BAS-SVX54*-EN Drive IOM 507118200001 AFD Label X39003759010 Label, Technical support...
  • Page 19 AFD DRIVE, 460V, IP21, 250KW, 134X2758, 127500150001 X13171807005 TR-200N250T4E21H2TGC7XXSXXXXAXBXCXXXXDX AFD DRIVE, 460V, IP21, 315KW, 134X2759, 127500160001 X13171807006 TR-200N315T4E21H2TGC7XXSXXXXAXBXCXXXXDX CONTROLS (one only) NONE - UC800 Only for customers with existing UC800 controls 18800260100 UC800/TD7 upgrade Kit with arm 18800270100 UC800/TD7 upgrade Kit without arm AFDR-SVN001D-EN...
  • Page 20 RAL01142 X13260722010 Relay Socket, 4PDT, Din rail mount 127500050001 X13500224207 Din rail 4inch X13491363010 Din Rail End Stop AFDR-SVN001*- KIT IOM (supplied by Trane) 507117830001 Schematics Printed on mylar BAS-SVX54*-EN Drive IOM 507118200001 AFD Label 507118300001 Motor Terminal Shield X39003759010...
  • Page 21 Global harness Male to Amp connector 78.74in CAB01150 X19051623020 Extension Harness - 78.74inch X39002507010 Label, Warning (AFD) 507117810001 Label, Nameplate AFDR-SVN001*- KIT IOM (supplied by Trane) 507117830001 Schematics Printed on mylar BAS-SVX54*-EN Drive IOM 507118200001 AFD Label X39003759010 Label, Technical support...
  • Page 22 X13260722010 Relay Socket, 4PDT, Din rail mount 127500090001 X13500224207 Din rail 4inch X13491363010 Din Rail End Stop AFDR-SVN001A- KIT IOM (supplied by Trane) 507117830001 Schematics Printed on mylar BAS-SVX54*-EN Drive IOM 507118200001 AFD Label 507118300001 Motor Terminal Shield VFD DRIVE (one only)

  • Page 23: Global Connector Harnesses

    4-PIN, FEMALE, TO EXTENSION SOLIDIFIED END, CAB01149 OR CAB01150 TO AFD Figure 16. CAB01149 (39”) /CAB01150 (78”) global connector harness CONNECTOR, DELPHI GT 150, CONNECTOR, DELPHI GT 150, 4-PIN, MALE, TO CAB01155 OR 4-PIN, FEMALE, TO CAB01151 CAB01534 OR CAB01153 AFDR-SVN001D-EN...

  • Page 24: Required Parts-Not Supplied

    • Modbus™ cable (for remote or wall mount) Because the distance varies with each application, For RTHD units manufactured prior to 2012, Trane Modbus™ connectors are not provided for remote and recommends completing non-mandatory gas pump wall mount kits. The Modbus™ connection requires a...
  • Page 25 Pre-Installation Figure 17. Select reports Figure 18. KestrelView screenshot—accessing Chiller Service report Figure 19. Chiller service report (example) AFDR-SVN001D-EN...

  • Page 26: Preparing Tracer Tu On The Service Computer

    Run the application to select specific chiller products required to re-program the chiller’s UC800. As of this and install the correct software versions for that printing, this version of Tracer TU is available for product. download at: Figure 20. AFDR-SVN001D-EN...
  • Page 27 Figure 22. product firmware. 4. The product firmware required for the AFDR is RTHD: 3.03 (full software build part number: 6200 0624- 3.xx) or later. Version 3.03 is the first version of the RTHD firmware that supports Modbus™...

  • Page 28: Oil And Refrigerant Removal

    (three plugs total) and drain the oil. Figure 25. Oil Plugs in Oil Plugs in Bearing Housing Motor Housing 11. Pull the plugs under the motor housing on the compressor (one or two plugs total) and drain the oil. AFDR-SVN001D-EN...
  • Page 29 (a) Unit configuration digits 1, 2 = compressor code (also shown in unit model number digits 6, 7); digits 3, 4 = evaporator code (unit model number digits 14, 15); digits 5, 6 = condenser code (unit model number digits 21, 22). AFDR-SVN001D-EN...
  • Page 30 Pre-Installation Figure 26. Component locations AFDR-SVN001D-EN...

  • Page 31: Installation

    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.

  • Page 32: Rthd Tracer Adaptiview Uc800 Controls Up- Grade

    RCDA-SVN001*-EN (Installation separator discharge lines as shown in figure below. Instructions: Tracer AdaptiView™ RTHD Rotary Chiller Display Upgrade Kit) before installing the AFDR drive. • Install on the “candy cane” line between the oil separator and the condenser.

  • Page 33: Panel Component Removal

    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.
  • Page 34 4 amps (460 volts). 10. Remove starter module 1A3. Note: The liquid level red power wire (64A) is connected to J3 Pin 1 of the starter module. This will be connected to the power supply 1A2. Refer to “Panel Control Wiring,” p. AFDR-SVN001D-EN...

  • Page 35: Solid State Starter Panel

    3. Remove and discard 1F1/2/3 line side harness. 4. Remove relay 1K11. 5. Remove and discard current transformers: 1T2-1, 1T2-2, and 1T-31. 6. Remove and discard (if applicable) under/over voltage transformers: T3-1, 1T3-2, and 1T3-1. 7. Remove and discard terminals 1X3. AFDR-SVN001D-EN...

  • Page 36: Panel Preparation-Close Mount

    Before drilling, make sure conduit to the AFD. and fittings will not interfere with evaporator or panel Notes: door. Figure 36. Conduit hole locations 2X Holes Drilled Panel Front 2X Ø 2.5 Panel Bottom Note: See “Dimensions,” p. 9 for conduit location dimensions. AFDR-SVN001D-EN...

  • Page 37: Panel Preparation-Close Mount (Kit 2 - 4 Conduit)

    Figure 37. Power conduit hole locations 2-4X Holes Drilled Panel Front 2-4X Ø 2.5 Panel Bottom Note: See “Dimensions,” p. 9 for conduit location dimensions. AFDR-SVN001D-EN...

  • Page 38: Panel Component Installation (All Kits)

    RELAY, 4PDT, 8A (relays 1K14 and 1K15) Dual Relay Output 1A8 FUSE HOLDER, 1F4-1F6 – REUSE (6–10 amp) DIN RAIL, 7.5 IN, REUSE Note: Items 3, 10, and 11 already exist and are re-used. Figure 38. Panel component installation locations AFDR-SVN001D-EN...
  • Page 39 Use backup wrench when installing and removing wire or buss bars from motor terminals and inspect terminals to ensure that they are not damaged. Motor terminals are ceramic and, if cracked, could create an electrical hazard when power is restored. AFDR-SVN001D-EN...

  • Page 40: Conduit Support And Conduit Installation (Kit 1 And Kit 2)

    Note: Make sure the position of the strut channel does 3. Cut four 16 AWG wires to the appropriate lengths and not interfere with panel door opening. Strut route through the 3/4-inch conduit. channel may need to be cut to height (anchor bolts and impact drill for concrete). AFDR-SVN001D-EN...
  • Page 41 3/4-inch conduit connectors and 3/8-inch grommet; refer to Figure Figure 48. Pedestal Drive Pedestal 1.25-in. 0.375 in. Grommet Grommet 2-in. Conduit Connector Pedestal Adapter Plate 5. Install power wire conduit into conduit connectors, and secure conduit to strut channel with provided clamps. AFDR-SVN001D-EN...
  • Page 42 Figure 49. Modbus™ cable and control power Figure 51. Adaptor plate assembly mounting Figure 50. Conduit connector assembly 7. Install the power wire conduits to the strut channel using supplied brackets. Figure 52. Power wire conduit mounting 6. Install pedestal adaptor plate to the pedestal. AFDR-SVN001D-EN...

  • Page 43: Drive Installation-Pedestal Mount (All Kits)

    2. Temporarily route power wire conduit to desired drive pedestal location to check for any routing issues. Figure 53. Figure 55. 3. Mark the locations for the anchor bolts using the bottom slots of the pedestal for a template. Figure 56. AFDR-SVN001D-EN...

  • Page 44: Recommended Rigging And Lifting Procedures For Afdr Drive Units

    An AFDR cabinet assembly is an AFDR drive unit to position it for installation, a top heavy. Test lift unit approximately 24 inches to spreader bar should be used to allow adjusting the verify proper center of gravity lift point.

  • Page 45: Line Voltage

    443 Maximum 535 Maximum Weight (lb) Heat Rejection (BTU/hr) 7708 9286 12370 12161 15566 19477 Table 10. AFDR unit weights and heat rejection (575V/600V) 575V/600V Catalog Max 109 Catalog/ 129 Catalog/ 160 Catalog/ 202 Catalog/ 242 Catalog/ 287 Catalog/ 333 Catalog/...

  • Page 46: Panel Power Wiring

    Figure 42, p. 39 to confirm phase designations. 6. Output wire from the drive to the motor terminals needs to be routed through the center of the provided cores. Install power wire at the motor terminals according to the provided schematics. AFDR-SVN001D-EN...
  • Page 47 Figure 64. Wire tap supplied 8. Install ground terminals in the control panel and on all options connect all ground wires. Drill as needed and use tapping screws and star washers provided. See Table 67, p. 48 for location. AFDR-SVN001D-EN...

  • Page 48: Panel Control Wiring

    H1 and H2; refer to Figure Figure 67. Terminals 1X5-1/11 Approximate Control location 1F4, Power of round 1F5, 1K15 Transformer 1F1, 1F2 1K14 Wires 20A, 21A 2. Strip insulation from Line 1 and Line 2 and install wire taps; refer to Figure AFDR-SVN001D-EN...
  • Page 49 4. Install wire tap case; refer to Figure tap and route wire to the 1F1 and 1F2 fuse; refer to Figure 70. Wire tap case install Figure Note: The following connections will be connected to some Terminal 1X5. Terminals 1X5-4 through AFDR-SVN001D-EN...
  • Page 50 7. Using 16 AWG wire, make the following connections 1X5-1 Heaters listed in Table (4E1, 4E2) Oil Loss Liquid Level Sensor Connections 5. Reconnect the oil loss liquid level sensor 24V supply to power supply 1A2 connector J5, Pin 1; this is a red wire AFDR-SVN001D-EN...
  • Page 51 From Pins 12 and 37 (Safe Stop) Figure 75. AFD—Pin location safe stop and running relay • The red wire on the Modbus™ cable is NOT connected to the AFD. Pins 4 and 5 (Running Relay2) Pins 12 and 37 (Safe Stop) AFDR-SVN001D-EN...

  • Page 52: Uc800 Software Installation And Configuration

    Installation Figure 76. AFD pin location—Modbus™ computer. If no shortcut exists, the program can be found in Programs > Trane > Tracer TU. Figure 77. Pins 61, 68, 69 (Modbus™) 1K14 Relay Connections 9. Using 16 AWG, make the following connections to...
  • Page 53 If the UC800 target controller has an application already installed, Tracer TU’s Unit Summary tab appears; refer to Figure 80. Skip to “Existing UC800 with Software Already Installed,” p. 4. A confirmation dialog box appears. Click OK to continue. AFDR-SVN001D-EN...
  • Page 54 5. The download’s progress is indicated by a bar at the bottom of the Application Software Download dialog box. Figure 83. Important: Trane recommends configuring the unit manually rather than browsing to an existing Chiller Service Report electronically. 8. Because the new AFD is being retrofit with Modbus™...
  • Page 55 For Starter Type (located in the UC800 section or c. For Compressor Rated Load Amps, enter the in the Starter section, depending on actual value noted as the Trane Motor Controller software version used), select TR200 Modbus™ nameplate's Output Current; refer to Figure 89 AFD;...
  • Page 56 10. Tracer TU automatically displays its Binding tab. At this time, all new LLIDs must be bound. If there is a mix of existing and new LLIDs, Trane recommends that all existing LLIDs be unbound; then, rebind existing LLIDs and bind new LLIDs.
  • Page 57 Installation Note: Because the AFDR does not use the IPC link, it Figure 95. will not appear on the binding list. Instead, the AFDR uses the new Modbus™ Master Communication port (labeled IMC on the UC800). Drive parameters must be set independently and manually.

  • Page 58: Existing Uc800 With Software Already Installed

    Select Reports > Chiller Service to open the Chiller Service Report dialog box, and save the report 1. If an AFDR retrofit is installed on an RTHD chiller with both as XML and PDF (check Convert Report to PDF).
  • Page 59 Figure 99. install it into Tracer TU on the service computer. Refer to “Preparing Tracer TU on the Service Computer,” p. Figure 100. 5. A confirmation dialog box appears. Click OK to continue. Figure 101. AFDR-SVN001D-EN...

  • Page 60: Drive Settings

    6. The download’s progress is indicated by a bar at the bottom of the Application Software Download dialog box. Important: Any AFDR drive module menu parameter numbers not listed in this manual are non- Figure 102. Trane specific program parameters. All...

  • Page 61: Retrofit Air-Cooled Rthd Adaptive Frequency Drive Model Afdr (Tr200)

    Table 17 for a list of items that are programmed in the drive at the factory for use with Trane chillers. In the event that the drive needs to be reset, these parameters need to be reprogrammed into the drive.
  • Page 62 Function at Mains Imbalance [3] Derate 14-21 Automatic Restart Time 14-50 RFI Filter [0] Off 14-51 DC Link Compensation [1] On 14-60 Function at Over Temperature [1] Derate 14-61 Function at Inverter Overload [1] Derate 14-62 Inv. Overload Derate Current AFDR-SVN001D-EN...

  • Page 63: Startup Test Log

    Return Maximum Reset Outdoor Reset Ratio Outdoor Start Reset Outdoor Maximum Reset Mode Overrides Evap Water Pump Cond Water Pump Expansion Valve Control Slide Valve Control Service Pumpdown Display Settings Date Format Date Time Format Time of Day Keypad/Display Lockout AFDR-SVN001D-EN...
  • Page 64 Cond Head Pressure Ctrl Command (%) Compressor Compressor Starts Compressor Run Time System Rfgt Diff Pressure (psid) Oil Pressure (psia) Compressor rfgt Discharge Temp (F) Discharge Superheat (F) % RLA L1 L2 L3 (%) Amps L1 L2 L3 (Amps) Volts AB BC CA AFDR-SVN001D-EN...

  • Page 65: Troubleshooting

    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.

  • Page 66: Recommended Periodic Maintenance And Inspection

    Frequency Drives for centrifugal chillers equipped with for signs of heat or failure (look for swelled or leaking AFDR starters, all UC800 chillers will be equipped with the capacitors, discolored reactors or inductors, broken LCP as standard on the drive power module. This is for pre-charge resistors, smoke or arc trails on MOVs and service only and NEVER for machine operation.

  • Page 67: Wiring Information

    30 VAC MAX LOW VOLTAGE SECTION AREA MOTOR TERMINALS CONTROL SECTION UC800 CLASS I 132 VAC MAX CONTROL VOLTAGE AREA EVAPORATOR (a) See Table 14, p. 51 for connections. See tables in section “Parts,” p. 18 for harness part numbers. AFDR-SVN001D-EN...

  • Page 68: Wire Harness Details

    PWR - 2L-1, 2L-2, 2L3 1 AWG 50711805 FLEXIBLE CONDUIT 2.5 INCH 59.25 PWR - 1T-1, 1T-2, 1T-3 50711806 1 AWG FLEXIBLE CONDUIT 2.5 INCH 69.25 PWR - 2T-1, 2T-2, 2T-3 50711807 1 AWG FLEXIBLE CONDUIT 2.5 INCH 74.5 AFDR-SVN001D-EN...
  • Page 72 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.

Table of Contents