Trane CVHE Installation Manual
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Trane CVHE Installation Manual

Retrofit air-cooled adaptive frequency drive
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Installation
AFDH Retrofit Air-Cooled
Adaptive Frequency™ Drive
For UCP2™, Tracer™ CH531, and Tracer
AdaptiView™ Centrifugal Chiller Controllers
Models: CVHE, CVHF , AFDH
AFDH-SVN01A-EN
March 20, 2009

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Summary of Contents for Trane CVHE

  • Page 1 Installation AFDH Retrofit Air-Cooled Adaptive Frequency™ Drive For UCP2™, Tracer™ CH531, and Tracer AdaptiView™ Centrifugal Chiller Controllers Models: CVHE, CVHF , AFDH AFDH-SVN01A-EN March 20, 2009...

  • Page 2: Warnings, Cautions And Notices

    CFCs such as HCFCs and HFCs. 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. 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.
  • Page 3 Disconnect all electric power, including remote disconnects 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.

  • Page 4: Introduction

    AFDH Retrofit Air-Cooled Adaptive Frequency™ Drive package in place of an existing starter on a Trane® CVHE or CVHF model centrifugal chiller. This only applies to chillers having either a UCP2™ or UCP2 FastPak™ Controller, a Tracer™ CH531 Controller Retrofit, or a Tracer AdaptiView™...

  • Page 5: Other Literature Required Before Ordering Or Installing An Afdh Retrofit

    Heat-Recovery Direct-Drive CenTraVacs with UCP2 Control Panels, Operation and Maintenance manual. Trademarks Trane® and the Trane logo are trademarks of Trane in the United States and other countries. All trademarks referenced in this document are the trademarks of their respective owners. AFDH-SVN01A-EN...

  • Page 6: Table Of Contents

    Table of Contents Warnings, Cautions and Notices ......... 2 Introduction .
  • Page 7 ......25 Table 4. AFDH D-Frame unit weights ......25 Table 5.
  • Page 8 Figure 32. CH531 wiring connections to 2X1 terminal strip in AFDH control box AFDH drive program parameters used with all Trane controls ..57 ..57 Table 18.

  • Page 9: Unit Model Number

    5 = 12 Pulse Autotransformer Number Digit 15— VFD Frame Size C = 302 Maximum RLA For service purposes, Trane Model D = 361 Maximum RLA AFDH Air-Cooled drive upgrade packages are assigned a multiple E = 443 Maximum RLA...

  • Page 10: 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-SVN01A-EN...
  • Page 11 Nameplates Note: This page has been intentionally left blank. AFDH-SVN01A-EN...

  • Page 12: Pre-Installation

    Pre-Installation Confirming the AFDH package can be properly installed 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. Installation considerations for unit-mounted AFDH drives Unit-mounted AFDH drives are incompatible with direct-mount starters Certain chillers larger than 800 tons in size that were built after 2001, were equipped with direct-...
  • Page 13 Pre-Installation Evaluate space available for rigging/installing unit-mounted AFDH All models of the D-Frame and E-Frame AFDH unit-mounted retrofit drives are taller, wider, and deeper than the typical Wye Delta unit-mounted starter they are intended to replace. Accordingly any project should start with a careful evaluation on whether there is ample enough space to rig the AFDH into place and if any of the existing building piping and conduit will not interfere with its mounting.

  • Page 14: Installation Considerations For Stand-Mounted Afdh

    Therefore, a stand-mounted AFDH drive is not recommended for use with a chiller that is equipped with spring-type vibration or seismic isolators. Trane recommends using a remote floor-mounted AFDH drive in this application. Trane assumes no responsibility for equipment damage caused by the installation of an AFDH drive version that is specified as being incorrect for the application.

  • Page 15: Installation Considerations For Remote Floor-Mounted Afdh

    Cable lengths that exceed 50 feet between the drive and the motor create the potential for damage to occur to the motor windings and/or insulation. Trane assumes no responsibility for equipment damage caused by use of improper cable lengths.

  • Page 16: Confirm Chiller Controller System Compatibility With Afdh Drive

    Pre-Installation Confirm chiller controller system compatibility with AFDH drive Before starting the process of installing the AFDH, first confirm that the existing chiller controller system has the hardware and/or software components required to make it compatible with an AFDH retrofit. The controller systems that can accept an AFDH retrofit are: •...

  • Page 17: Equipment Room Ambient Temperature Considerations

    65°F . Important: Under such low condenser water conditions, use of an oil recovery system is recommended. These systems are found on all Trane chillers built since 1985. Refer to general service bulletins CTV-SB-26 and CTV-SB-68 for upgrade information.

  • Page 18: Electrical Cable Size Specifications For Afdh Drives

    Pre-Installation Electrical cable size specifications for AFDH drives Table 2. Input/output power wire cable sizes AFDH D-Frame drives D-Frame AFDH 302 Amp Drive 361 Amp Drive 443 Amp Drive INCOMING POWER TO DRIVE CIRCUIT Two Wire Lugs BREAKER: Two Wire Lugs Three Wire Lugs 250KCMIL - Number of Cable Lugs Per Phase &...

  • Page 19: Requirements For Installation Technicians

    • Self-adhesive cable tie mounting bases and cable ties. – Used to help “clean up” wiring runs during the installation process. • Loctite® 554 thread sealant for refrigerant applications (Trane part number SEL00528). – Used in applications where a pressure transducer needs to be installed.

  • Page 20: Recommended Rigging And Lifting Procedures For Afdh Drive Units

    Pre-Installation Recommended rigging and lifting procedures for AFDH drive units WARNING Heavy Objects! Only attach cables (chains or slings) to the designated lifting points. Each of the cables (chains or slings) used to lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or slings) may not be of the same length.

  • Page 21: Preferred Lifting Method

    Pre-Installation Preferred lifting method • The preferred method for lifting an AFDH drive unit to position it for installation, is to use an identical individual hoisting device at each lift point. Figure 6. Preferred lifting method using two identical individual hoists Alternative lifting method •...

  • Page 22: Afdh Drive Package Specifications

    AFDH Drive Package Specifications D-Frame drive unit dimensions Figure 8. Top, front, and side view of D-Frame AFDH cabinet with dimensions 1. UCP2, or CH531 / AdaptiView control box 2. Z-bracket mounting studs (each stud = 3/8-16 x 1.75 in.) 3.
  • Page 23 AFDH Drive Package Specifications Figure 9. Rear view of D-Frame AFDH cabinet with dimensions 1. Motor terminal access cover. Size of cutout is 8 in. x 17.5 in. 2. Centerline of Z-bracket mounting studs 3. UCP2 or CH531 / AdaptiView control box 4.

  • Page 24: E-Frame Drive Unit Dimensions

    AFDH Drive Package Specifications E-Frame drive unit dimensions Figure 10. Top, front, and side view of E-Frame AFDH cabinet with dimensions 1. UCP2, or CH531 / AdaptiView control box 2. Z-bracket mounting studs (each stud = 3/8-16 x 1.75 in.) 3.

  • Page 25: Drive Unit Weights

    AFDH Drive Package Specifications Figure 11. Rear view of E-Frame AFDH cabinet with dimension 1. Motor terminal access cover. Size of cutout is 8 in. x 17.5 in. 2. Centerline of Z-bracket mounting studs 3. UCP2 or CH531 / AdaptiView control box 4.

  • Page 26: D-Frame And E-Frame Drive Unit Components

    AFDH Drive Package Specifications D-Frame and E-Frame Drive unit components Drive unit component parts housed within the custom enclosure Figure 12. Mounting location of D and E-Frame custom enclosure parts 1.Right-hand cabinet section houses the TR1 drive module for the unit. For the part numbers of the components housed within the left-hand custom enclosure section of the unit by drive model size,...
  • Page 27 AFDH Drive Package Specifications Figure 12. (continued from previous page) 12.Custom enclosure components mounted on left interior wall of cabinet. For the component part numbers by drive model size refer to the tables listed below: a.D-Frame 302 amp drive see Table 6 b.D-Frame 361 amp drive see Table 7...
  • Page 28 AFDH Drive Package Specifications Table 6. Custom enclosure parts; D-Frame 302 amp model drives UCP2 020600290100 020600290200 020600290300 Trane Assembly Part Numbers for all Optional Model Versions of D-Frame 302 Amp AFDH CH531/ AdaptiView 020600360100 020600360200 020600360300 Figure 12 Trane X-Code...
  • Page 29 AFDH Drive Package Specifications Table 8. Custom enclosure parts; D-Frame 443 amp model drives UCP2 020600310100 020600310200 020600310300 Trane Assembly Part Numbers for all Optional Model Versions of D-Frame 443 Amp AFDH CH531/ AdaptiView 020600380100 020600380200 020600380300 Figure 12 Trane X-Code...
  • Page 30 AFDH Drive Package Specifications Table 9. Custom enclosure parts; E-Frame 540 amp model drives UCP2 020600320100 020600320200 020600320300 Trane Assembly Part Numbers for all Optional Model Versions of E-Frame 540 Amp AFDH CH531/ AdaptiView 020600390100 020600390200 020600390300 Figure 12 Trane X-Code...
  • Page 31 AFDH Drive Package Specifications Table 11. Custom enclosure parts; E-Frame 678 amp model drives UCP2 020600340100 020600340200 Trane Assembly Part Numbers for all Optional Model Versions of E-Frame 678 Amp AFDH CH531/ AdaptiView 020600410100 020600410200 Figure 12 Mnemonic # Callout...

  • Page 32: Control Box Components For Ucp2 Version Afdh

    11.Fuse holder (for fuse 2F22 or 2F4) 12.Fuse (2F4) 30 amp Table 13. UCP2 control box component part numbers Figure 13 Part Description Quantity Trane X-Code Part # Mnemonic # (if available) Callout UCP2 Starter module 2U1 X13650453220 MOD01232 Start relay (2K1) 120 VAC...

  • Page 33: Additional Hardware Shipped With All Ucp2 Afdh Packages

    AFDH Drive Package Specifications Additional hardware shipped with all UCP2 AFDH packages Table 14. UCP2 miscellaneous hardware package contents UCP2 Miscellaneous Hardware Kit Part # 506898920100 Component Parts List Trane X-Code Part Description Quantity Part # Mnemonic # Pressure transducer -15 PSI to +35 PSI...

  • Page 34: Control Box Components For Ch531/Adaptiview Version Afdh

    12.Fuse holder (for fuse 2F22) 13.Fuse (2F22) 2 amp Table 15. CH531/AdaptiView control box component part numbers Figure 15 Part Description Quantity Trane X-Code Part # Mnemonic # (if available) Callout Dual analog I/O board (2A11) X13650731050 BRD02945 Dual low voltage binary input board (2A10)

  • Page 35: Additional Hardware Shipped With Ch531/Adaptiview Afdh Packages

    AFDH Drive Package Specifications Additional hardware shipped with CH531/AdaptiView AFDH packages Table 16. CH531/AdaptiView miscellaneous hardware package contents CH531/AdaptiView Miscellaneous Hardware Kit Part # 506898930100 Component Parts List Trane X-Code Part Description Quantity Part # Mnemonic # Low pressure transducer; (PX) 0 - 50 PSIA, with integral male global connector...

  • Page 36: Other Afdh Drive Package Accessories

    50689890010 Floor Stand Kit to an 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 37 AFDH drive, and connect to the compressor motor terminal board. Table 17. Part numbers for motor panel transition covers Part Description Trane Part # Mnemonic # 6-inch motor panel transition cover assembly 506820000100...

  • Page 38: Installation

    Disconnect all electric power, including remote disconnects 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.

  • Page 39: Mechanical Removal Of The Existing Unit-Mounted Starter

    Installation Mechanical removal of the existing unit-mounted starter WARNING Heavy Objects! Only attach cables (chains or slings) to the designated lifting points. Each of the cables (chains or slings) used to lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or slings) may not be of the same length.

  • Page 40: Mechanical Removal Of The Existing Remote-Mounted Starter

    Installation Mechanical removal of the existing remote-mounted starter WARNING Heavy Objects! Only attach cables (chains or slings) to the designated lifting points. Each of the cables (chains or slings) used to lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or slings) may not be of the same length.
  • Page 41 Installation Figure 19. Removal of Z-bracket weldment nuts 1. Z-bracket 2. Weldment nuts (4 total on bracket, only 2 shown) drill out or grind off flush 1. Inspect the Z-bracket on the chiller motor flange. If the Z-bracket is equipped with weldment nuts, these nuts must either be ground off or drilled out to allow the 3/8-inch studs on the back of the new drive cabinet assembly to slide into the bracket at these locations.
  • Page 42 Installation Figure 20. Position cabinet base over evaporator brackets and install clips 1. Lining up slots in drive cabinet base with slots in evaporator brackets 2. Bolt an angle iron clip (that was removed from the old unit-mount starter) to each slot in the cabinet base 3.

  • Page 43: Mechanical Installation Of A Stand-Mounted D-Frame Afdh

    50689890010 Floor Stand Kit to an 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 44 Installation c. NOTE: The slots in the angle bracket feet can accommodate up to a 0.625 in. diameter concrete anchor bolt. 3. Prepare lifting equipment and rigging. a. Depending upon the model version, a stand-mounted D-Frame AFDH can weigh close to 900 pounds.
  • Page 45 Installation Figure 23. Attach assembled floor stand to drive unit. 1. Attach assembled floor stand to the base of the drive unit with the remaining hardware from the stand kit AFDH-SVN01A-EN...

  • Page 46: Mechanical Installation Of A Remote Floor-Mounted Afdh

    Installation Mechanical installation of a remote floor-mounted AFDH WARNING Heavy Objects! Only attach cables (chains or slings) to the designated lifting points. Each of the cables (chains or slings) used to lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or slings) may not be of the same length.
  • Page 47 Installation Figure 24. Assembly and installation of corner support kit components 1. Assembly of corner support kit parts; mounted position of corner bracket on AFDH cabinet base 2.Hex head cap screws; 0.50-13 UNC x 1.50 inches 3.Flat washer; 0.531 in. ID 4.Helical spring lock washer;...

  • Page 48: Electrical Installation (All Afdh Models)

    Disconnect all electric power, including remote disconnects 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.

  • Page 49: Install Shorting Buss Bars

    Installation Install shorting buss bars Note: Shorting buss bars must be installed since the AFDH is a three-lead device while the starter was a six-lead device. The wires must be connected (shorted) at both ends (at the AFDH and at the motor terminals) to ensure that there is no difference in potential between the two paired leads caused by different wire lengths.

  • Page 50: Input Power Wire Installation

    Installation Input power wire installation Note: The L1, L2, and L3 input power leads for this unit will be connected to a factory installed input disconnect circuit breaker inside of the drive cabinet. Verify that the available fault is less than the 65,000 amps at 480 VAC interrupting rating of this circuit breaker (this specification is listed on the circuit breaker nameplate) before installing the input power wiring.
  • Page 51 Installation Figure 27. Factory installed input disconnect circuit breaker Input disconnect circuit breaker 2. Nameplate - location of breaker interrupting rating of 65,000 amps at 480 VAC 3. Input power terminals. Terminal connections should be torqued to 23 foot-pounds AFDH-SVN01A-EN...

  • Page 52: Grounding Afdh Cabinet

    Installation Grounding AFDH cabinet WARNING Ground Wire! All field-installed wiring must be completed by qualified personnel. All field-installed wiring must comply with NEC and applicable local codes. Failure to follow this instruction could result in death or serious injuries. WARNING Grounding Required! Follow proper local and state electrical code on requirements for grounding.
  • Page 53 Installation Note: These power connections should be re-torqued to 44 foot-pounds after the first three to six months of operation and then on an annual basis thereafter. 4. Put the transition cover back in place and reseal it when finished. Figure 29.

  • Page 54: Routing Of Control Wiring To Afdh Cabinet (All Models)

    Installation Routing of control wiring to AFDH cabinet (all models) Important: All field installed wiring runs between the chiller controls and the AFDH control box must be routed through the factory provided conduit holes at the hinged side of the AFDH control box enclosure.

  • Page 55: Control Wiring Connections (Ucp2 Model Afdh Only)

    Installation Control wiring connections (UCP2 model AFDH only) Figure 31. UCP2 wiring connections to 2X1 terminal strip in AFDH control box 1. Factory installed wiring 2. Field installed wiring 3. Note: actual wire designators may vary depending upon the specific model/version of chiller control that the AFDH drive is being linked with.

  • Page 56: Control Wiring Connections (Ch531/Adaptiview Model Afdh Only)

    Installation Control wiring connections (CH531/AdaptiView model AFDH only) Figure 32. CH531 wiring connections to 2X1 terminal strip in AFDH control box 1. Factory installed wiring 2. Field installed wiring 3. Note: actual wire designators may vary depending upon the specific model/version of chiller control that the AFDH drive is being linked with.

  • Page 57: Afdh Drive Program Parameters Used With All Trane Controls

    • Please refer to the table below for the Trane specific menu parameters that must be reviewed and/or programmed into the AFDH drive module before doing the initial machine start-up. Table 18. Trane specific AFDH program parameters and settings...

  • Page 58: Required Reprogramming Of Ucp2 Controls

    Note: For detailed instructions on how to operate the 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, please refer to the CVHE-M-7 Water-Cooled Hermetic CenTraVac® Models CVHE and CVHF 50 and 60 Hz Cooling-Only and Heat-Recovery Direct-Drive CenTraVacs with UCP2 Control Panels, Operation and Maintenance manual.
  • Page 59 Trane Technical Services through the toll-free Trane automated phone support system at 877-788-7263 and using the menu code sequence of 4-2-7. Provide the support person with the chiller serial number and request a copy of the shipped- with bill of materials for this unit.
  • Page 60 Installation a. The re-optimization timer is adjustable from 1 to 255-hours, in 1-hour increments. Optimal chiller performance is most often achieved using the recommend setting value of 24 (which equals 24-hours). 8. AF Boundary Pressure Coefficient (BPC) Y -Intercept: The BPC Y-Intercept value is used to determine the location of the BPC in the control algorithm.

  • Page 61: Required Reprogramming Of Ch531 Controls

    CH531 menu parameters listed in the table below (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 Technical Services through the toll-free Trane automated phone support system at 877-788-7263 and use the menu code sequence of 4-2-7.

  • Page 62: Required Reprogramming Of Adaptiview Controls

    UC800 menu parameters listed in the table below (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 Technical Services through the toll-free Trane automated phone support system at 877-788-7263 and use the menu code sequence of 4-2-7.
  • Page 63 Default Setting Recommended Setting UC800 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: Range Default Setting Recommended Setting Starter Stop Delay Time (Contactor Interrupt Failure)

  • Page 64: Reprogramming Factory Installed Adaptiview Controls (Ctv Firmware)

    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...
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  • Page 68 Date March, 2009 Supersedes www.trane.com Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice. For more information, contact your local Trane office or e-mail us at comfort@trane.com...

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