Trane CVHE Installation Instructions Manual
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Trane CVHE Installation Instructions Manual

E-frame retrofit adaptive frequency drive
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Installation Instructions
AFDH E-Frame Retrofit Adaptive
Frequency Drive
For UCP2, Tracer CH531, and Tracer
AdaptiView Centrifugal Chiller Controllers
Models:
CVHE, CVHF, AFDH
Design Sequence:
B0
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.
May 2020
SAFETY WARNING
AFDH-SVN02D-EN

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Summary of Contents for Trane CVHE

  • Page 1 Frequency Drive For UCP2, Tracer CH531, and Tracer AdaptiView Centrifugal Chiller Controllers Models: CVHE, CVHF, AFDH Design Sequence: 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 Stand-Mounted AFDH Supported by inadvertently energized. For variable frequency drives or Equipment Room Floor! other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s literature Trane assumes no responsibility for equipment damage for allowable waiting periods for discharge of caused by the installation of an AFDH drive version that capacitors.
  • Page 4 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.

  • Page 5: Table Of Contents

    Table of Contents Model Number Descriptions Mounted Starter ..... . .30 ....6 Unit Model Number .

  • Page 6: Model Number Descriptions

    Model Number Descriptions Unit Model Number Digit 15 — VFD Frame Size 460 V/480 V 540 Maximum RLA For service purposes, Trane® Model 590 Maximum RLA AFDH Air-Cooled drive upgrade 678 Maximum RLA packages are assigned a multiple 730 Maximum RLA...

  • Page 7: General Information

    AFDH Retrofit Air-Cooled Adaptive Frequency™ Drive ® Other Literature Required Before package in place of an existing starter on a Trane CVHE or CVHF model centrifugal chiller. This only applies to chillers Ordering or Installing an AFDH having either a UCP2™ or UCP2 FastPak™ Controller, a Tracer™...

  • Page 8: Nameplates

    Nameplates A nameplate is installed on each AFDH Air-Cooled Drive unit. Always provide the model number and serial number that is printed on this nameplate when making warranty inquiries, ordering parts, or ordering literature for the unit. Figure 1. AFDH nameplate example AFDH-SVN02D-EN...

  • Page 9: Pre-Installation

    Pre-Installation Confirming the AFDH Package can Figure 2. Example of a direct-mount chiller starter be Properly Installed panel This chapter details potential interference fit problems, mechanical incompatibility situations, electrical code stipulations, and electrical conduit and wiring issues that can prevent the successful installation and/or operation of an AFDH retrofit drive package.

  • Page 10: Installation Considerations For Stand-Mounted Afdh

    Equipment Room Floor! Specifications,” p. 16 for the dimensions and Trane assumes no responsibility for equipment damage weights of all models of AFDH drives. caused by the installation of an AFDH drive version that is specified as being incorrect for the application. A stand-mounted version of an AFDH drive is designed to be rigidly supported by the equipment room floor.

  • Page 11: Installation Considerations For Remote Floor-Mounted Afdh

    The Drive and Compressor Motor! cable connections between the drive and the motor Trane assumes no responsibility for equipment damage terminals will be shrouded by an extended sheet-metal caused by use of improper cable lengths. The variable transition cover.

  • Page 12: Confirm Chiller Controller System Compatibility With Afdh Drive

    Pre-Installation UCP2 Compatibility with AFDH Drives Important: • Other factors that affect the space required to UCP2 chiller controller system history successfully install a remote floor-mounted AFDH drive include the clearance distances specified by the • Prior to July 1994, UCP2 and UCP2 FastPak controls did local electrical codes.

  • Page 13: Equipment Room Ambient Temperature Con

    These systems are found on conditions, the potential exists to trigger a drive shut down ® all Trane chillers built since 1985. from an over temperature fault—effectively disabling the chiller until the drive temperature drops to the factory set,...

  • Page 14: Requirements For Installation Technicians

    • Loctite 554 thread sealant for refrigerant already have the majority of the normal tools needed for applications (Trane part number SEL00528). this job. – Used in applications where a pressure In addition to the normally carried service tools and transducer needs to be installed.

  • Page 15: Unit Lifting Points

    Pre-Installation Unit Lifting Points Preferred Lifting Method • The preferred method for lifting an AFDH drive unit to Figure 5. Unit lifting points and center of gravity position it for installation, is to use an identical individual hoisting device at each lift point. Figure 6.

  • Page 16: Afdh Drive Package Specifications

    AFDH Drive Package Specifications E-Frame Drive Unit Dimensions Figure 8. Top, front, and side view of E-Frame AFDH cabinet with dimensions UCP2, or CH531 / Tracer AdaptiView control box Z-bracket mounting studs (each stud = 3/8-16 x 1.75 in.) Two-piece access door cover on top of the 7 in. x 14 in. incoming power wire cutout. Electrical disconnect switch Lower mounting bracket AFDH-SVN02D-EN...
  • Page 17 AFDH Drive Package Specifications Figure 9. Rear view of E-Frame AFDH cabinet with dimension Motor terminal access cover. Size of cutout is 8 in. x 17.5 in. Centerline of Z-bracket mounting studs UCP2 or CH531 / Tracer AdaptiView control box 0.88 in.

  • Page 18: Drive Unit Weights And Heat Rejection

    AFDH Drive Package Specifications Drive Unit Weights and Heat Rejection Table 4. AFDH E-Frame unit weights (460 V/480 V) 550 Catalog/ 632 Catalog/ 681 Catalog/ 460 V/V480 V E-Frame AFDH Catalog/Maximum Amps 590 Maximum 678 Maximum 730 Maximum Unit Weight 1231 lb 1280 lb 1381 lb...

  • Page 19: E-Frame Drive Unit Components

    AFDH Drive Package Specifications E-Frame Drive Unit Components Figure 10. (continued) Mounting location of D and E- Frame custom enclosure parts Drive Unit Component Parts Housed within the Custom Enclosure Figure 10. Mounting location of E-Frame custom enclosure parts Right-hand cabinet section houses the TR200 drive module for the unit.
  • Page 20 AFDH Drive Package Specifications Table 6. Custom enclosure parts; E-Frame 540 amp model drives (460 V/480 V) UCP2 020600520100 020600520200 020600520300 Trane Assembly Part Numbers for all Optional Model Versions CH531/Tracer of 460 V/480 V E-Frame 540 Amp AFDH 020600590100 020600590200 020600590300 AdaptiView...
  • Page 21 TRR00713 Table 9. Custom enclosure parts; E-Frame 730 amp model drives (460 V/480 V) UCP2 020600550100 020600550200 020600550300 Trane Assembly Part Numbers for all Optional Model Versions of 460 V/480 V E-Frame 730 Amp AFDH CH531/Tracer 020600620100 020600620200 020600620300 AdaptiView...
  • Page 22 AFDH Drive Package Specifications Table 10. Custom enclosure parts; E-Frame 450 amp model drives (575 V/600 V) UCP2 020600670100 020600670200 Trane Assembly Part Numbers for all Optional Model Versions CH531/Tracer of 575 V/600 V E-Frame 450 Amp AFDH 020600750100 020600750200...
  • Page 23 X13590079010 TRR00713 Table 13. Custom enclosure parts; E-Frame 630 amp model drives (575 V/600 V) UCP2 020600700100 020600700200 Trane Assembly Part Numbers for all Optional Model Versions of 575 V/600 V E-Frame 630 Amp AFDH CH531/Tracer 020600780100 020600780200 AdaptiView Figure 10...
  • Page 24 11. Fuse holder (for fuse 2F22 or 2F4) 12. Fuse (2F4) 30 amp Table 14. UCP2 control box component part numbers Figure 11 Callout Part Description Quantity Trane X-Code Part # Mnemonic # (if available) UCP2 Starter module 2U1 X13650453220 MOD01232 Start relay (2K1) 120 Vac X13260647010...
  • Page 25 Additional Hardware Shipped with All UCP2 AFDH Packages Table 15. UCP2 miscellaneous hardware package contents UCP2 Miscellaneous Hardware Kit Part # 506898920100 Component Parts List Trane X-Code Part Part Description Quantity Mnemonic # Pressure transducer -15 PSI to +35 PSI...
  • Page 26 13. Fuse (2F22) 2 amp Table 16. CH531/Tracer AdaptiView control box component part numbers Figure 13 Callout Part Description Quantity Trane X-Code Part # Mnemonic # (if available) Dual analog I/O board (2A11) X13650731050 BRD02945 Dual low voltage binary input board (2A10)
  • Page 27 AFDH Drive Package Specifications Additional Hardware Shipped with CH531/ Tracer AdaptiView AFDH Packages Table 17. CH531/Tracer AdaptiView miscellaneous hardware package contents CH531/Tracer AdaptiView Miscellaneous Hardware Kit Part # 506898930100 Component Parts List Trane X-Code Part Description Quantity Mnemonic # Part # Low pressure transducer;...
  • Page 28 E-Frame model AFDH drive will be considered an unsupported field modification to the drive unit design. Trane assumes no responsibility for the equipment damage caused by a stress or fatigue failure of the floor stand kit due to any use outside of its intended application.

  • Page 29: Installation

    Heavy Objects! inadvertently energized. For variable frequency drives or Failure to follow instructions below or properly lift unit other energy storing components provided by Trane or could result in unit dropping and possibly crushing others, refer to the appropriate manufacturer’s literature...

  • Page 30: Mechanical Removal Of The Existing Remote

    These welds can break if not lifted 4. Remove the bolts securing the bottom of the starter to straight up. To ensure a safe lift, Trane recommends the brackets on the evaporator. drilling a hole and bolting the tabs to the enclosure to 5.
  • Page 31 Installation lower mounting bracket. The front edge of the Table 19. Removal of Z-bracket weldment nuts evaporator brackets may need to be ground down to allow for more adjustment. b. Secure the lower mounting bracket to the evaporator brackets with the bolts previously used to secure the old starter panel to them.

  • Page 32: Mechanical Installation Of A Remote Floor-Mounted Afdh

    Installation 2. Prepare lifting equipment and rigging. Table 20. Leveling the AFDH drive cabinet against the Z- a. Depending upon the model type, a unit-mounted bracket AFDH can weigh up to 1400 pounds. Confirm the weight of the AFDH unit to be installed. Refer to Table 7, p.

  • Page 33: Electrical Installation (All Afdh Models)

    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: Install Shorting Buss Bars

    Installation Figure 18. Buss bar installation on compressor motor NOTICE terminal board Keep Dirt, Debris, or Metal Filings From Entering the Drive Cabinet! Failure to observe the appropriate precautions could result in damage to the electrical components when they are energized for the first time. Take all precautions necessary to prevent any dirt, debris, or metal filings from entering into the drive cabinet during the installation process.

  • Page 35: Grounding Afdh Cabinet

    Installation a. Install the appropriate conduit hubs before Figure 20. Factory installed input disconnect circuit reinstalling the access door pieces on top of the breaker cabinet. 2. Route the input wire leads into the cabinet and connect them to circuit breaker terminals L1, L2, and L3. a.

  • Page 36: Output Wiring From The Afdh To The Ctv Motor

    Installation Figure 21. Location of AFDH cabinet ground terminal Figure 22. Output wiring from AFDH to CTV motor Cabinet ground connection terminal Output Wiring from the AFDH to the CTV Motor 1. Remove the cover plate from the motor terminal access cutout on the back of the drive cabinet.

  • Page 37: Control Wiring Connections

    Installation Control Wiring Connections Figure 23. Factory provided conduit holes in AFDH (UCP2 Model AFDH Only) control box Figure 24. UCP2 wiring connections to 2X1 terminal strip in AFDH control box Hinged side of AFDH control box enclosure 1.13-inch cutout for 0.75-inch conduit 0.88-inch cutout for 0.50-inch conduit Factory installed wiring Field installed wiring...

  • Page 38: Afdh Only)

    Clear Language Display of a UCP2 control and how to access and set the menu parameters required for proper chiller operation with the AFDH drive, Figure 25. CH531 wiring connections to 2X1 terminal please refer to the CVHE-M-7, Water-Cooled strip in AFDH control box ® Hermetic CenTraVac...
  • Page 39 Intercept: The BPC Y-Intercept value is used to categories, such as impeller size, contact determine the location of the BPC in the control Trane Global Parts Technical Services. To algorithm. This front panel value is unique because it contact them, send a message to can be changed externally by the user, or internally by ATechnicalService@trane.com.

  • Page 40: Required Reprogramming Of Ch531 Controls

    Not Applicable Wye-Delta Non-Comm AFD Impeller Diameter (CPIM) 210–335 Enter CPIM from Unit Nameplate Compressor1: Number of stages CVHE = 3, CVHF = 2 Enter from Unit Nameplate Condenser Pressure Sensor Installed, Not Installed Not Installed Installed TechView Configuration View...

  • Page 41: Required Reprogramming Of Tracer Adaptiview Controls

    (i.e. motor data and compressor impeller data). If the unit nameplate is missing, unreadable, or of a vintage that did not include all of the required data categories, contact Trane Global Parts Technical Services. To contact them, send a message to ATechnicalService@trane.com. Provide the chiller serial number and request a copy of the shipped-with bill of materials for this unit.

  • Page 42: Reprogramming Factory Installed Tracer Adaptiview Controls (Ctv Firmware)

    Range Default Setting Recommended Setting Impeller Diameter (CPIM) 210–335 Enter CPIM from Unit Nameplate Number of Stages CVHE = 3, CVHF = 2 Enter from Unit Nameplate Tracer TU Configuration View: Starter Range Default Setting Recommended Setting Stop Delay Time (Contactor Interrupt 1–30 Seconds...
  • Page 43 Range Default Setting Recommended Setting Enter Chiller Model from Unit Nameplate Unit Type (MODL) CVHE, CVHF, CVHG, CVGF CVHE (Note: only CVHE or CVHF apply) Tracer TU Configuration View: UC800 Range Default Setting Recommended Setting Starter Type Not Applicable Unit Mount Wye-Delta...

  • Page 44: Afdh Startup Procedure

    Global Parts Technical Service Department. Complete all items on the commissioning checklist and The correct values are listed on the unit in the startup procedures for the CVHE and CVHF as nameplate shipped with each unit. defined in the operation maintenance manual or other applicable manual.
  • Page 45 Table 27, p. 45 for a list of items that are After the drive is reset, reprogram the items listed in ® programmed in the drive at the factory for use with Trane Table 27, p. Table 27. Trane default settings Group...

  • Page 46: 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 47: Startup Test Log

    Setting Manufacture AFD Control Auto Type Re-Optimization Sensitivity Vender ID Model Number UC800 Starter Type: Unit Mount AFD Trane Setting Tracer TU: Configuration View: Starter Default Volts and Hz Amps Restart Inhibit Stop to Start Time Motor Data: Surge Protection...

  • Page 48: Recommended Periodic Maintenance And Inspection

    For variable frequency drives or these tasks. other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s literature 1. Verify the drive cabinet cooling fans are operating.

  • Page 49: Wiring Diagram Matrix

    Wiring Diagram Matrix Table 28. Wiring Diagram Number Description 2309-7643 CenTraVac UCP2 Wiring Diagram with Danfoss Adaptive Frequency Drive 2309-7644 CenTraVac CH531 Wiring Diagram with Danfoss Adaptive Frequency Drive Note: Wiring diagrams are available via e-Library. AFDH-SVN02D-EN...
  • Page 52 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.

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