Trane CH530 Installation, Operation And Maintenance Manual
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Trane CH530 Installation, Operation And Maintenance Manual

Liquid-cooled adaptive frequency drive with tracer adaptiview
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Installation, Operation, and Maintenance
Liquid-Cooled Adaptive Frequency™
Drive
With Tracer AdaptiView™ or CH530/CH531
Control
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
AFDK-SVU01C-EN

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  • Page 1 Installation, Operation, and Maintenance Liquid-Cooled Adaptive Frequency™ Drive With Tracer AdaptiView™ or CH530/CH531 Control 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: Introduction

    This document and the information in it are the property of refrigerants. Know the applicable laws and follow them. 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 3 Introduction Trademarks All trademarks referenced in this document are the trademarks of their respective owners. Revision History AFDK-SVU01C-EN (14 Apr 2014) • Remote Mounted Adaptive Frequency Drive references added to “Wiring Schematics,” p. 59 AFDK-SVU01C-EN...

  • Page 4: Table Of Contents

    Chiller Operator Display Content ..58 Identifying Trane AFDK Cabinet Components Wiring Schematics ..... . .59 Drive Cabinet Component Locations .

  • Page 5: General Information

    Parts Ordering Information Refer to the model number printed on the Trane Adaptive Frequency™ Drive nameplate when ordering replacement parts or service for the drive. When ordering parts, contact the local Trane Parts Office in your area. For service, contact a qualified service organization.

  • Page 6: Overview

    This manual covers the features and specifications that are unique to the Adaptive Frequency Drives being produced for Trane. Only product information is covered here that supplements that presented in the standard Liqui-Flo instruction manuals that ship with the unit.

  • Page 7: Model Number Descriptions

    Model Number Descriptions Model Number Description Digit 1, 2, 3 — Adaptive Frequency™ Drive Digit 4 — Aftermarket LF2 Digit 5, 6, 7, 8 — Nameplate RLA Digit 9 — Voltage 460 Volt, 60 Hz, 3 Phase 480 Volt, 60 Hz, 3 Phase Digit 10, 11 —...

  • Page 8: Drive And Cabinet

    -40°C to 65°C (40°F to 149°F) 28. Metal Oxide Varistor (m.o.v.) Humidity 5% to 95% (non-condensing) 29. Magnetic Choke Identifying Trane AFDK Cabinet Components The Trane AFDK cabinets have the following main components. Ref er to Figure 1, p. 9 Figure 2, p. 11 AFDK-SVU01C-EN...
  • Page 9 Drive and Cabinet Figure 1. Drive components locations: Frame 3 units Grounding Connection Input Power  Wiring Connection 41.75 in. 37.13 in. (a) Material courtesy of Rockwell. AFDK-SVU01C-EN...

  • Page 10: Power Module Component Locations

    Drive and Cabinet Power Module Component Locations Frame 3 Units (405, 600 A) The main power module components for a Frame 3 unit are listed below. Each numbered item corresponds to a number in Figure 2 Figure 1. Wire Harness Assembly, Power Supply, Logic 2.
  • Page 11 Drive and Cabinet Figure 2. Power module component locations door open: Frame 3 units (a) Material courtesy of Rockwell. AFDK-SVU01C-EN...
  • Page 12 Drive and Cabinet Figure 3. Power module component locations door closed: Frame 3 units (a) Material courtesy of Rockwell. AFDK-SVU01C-EN...

  • Page 13: Drive Cabinet Component Locations

    Drive and Cabinet 9. Transformer, 3 kVA Drive Cabinet Component 10. Fan, 115 Vac, Contactor Locations 11. Resistors, 100k Ohms, 50 W Frame 4 Units (900, 1200 A) 12. Pre-charge Resistors 13. Relay, Pump, and Control Power Terminals The main drive components for a Frame 4 unit are listed below.

  • Page 14: Power Module Component Locations

    Drive and Cabinet Power Module Component Locations Frame 4 Units (900, 1200 A) The main power module components for a Frame 4 unit are listed below. Each numbered item corresponds to a number in Figure 5, p. 15 Figure 6, p. 1.
  • Page 15 Drive and Cabinet Figure 5. Power module component locations IO and control panel removed: Frame 4 units (a) Material courtesy of Rockwell. AFDK-SVU01C-EN...
  • Page 16 Drive and Cabinet Figure 6. Power module component locations front panel removed: Frame 4 units (a) Material courtesy of Rockwell. AFDK-SVU01C-EN...

  • Page 17: About The Cabinet

    Drive and Cabinet Figure 7, p. 17 Figure 8, p. 18 show overall About the Cabinet dimensions for Frame 3 units; Figure 9, p. 19 Figure 10, p. 20 show overall dimensions for Frame 4 This section provides cabinet dimension information and units.
  • Page 18 Drive and Cabinet Figure 8. Drive cabinet dimensions: Frame 3 (dimensions shown in inches [mm]) WALL .375 WIDE X 3.250 LONG VENTS CLEARANCE Back View 71.500 DRIVE TUBE CONNECTION FLOOR MOUNTING KIT (3 PLACES) ACCESS PLATE SITE INSTALLED SHIPPED INSIDE CABINET (CUSTOMER SUPPLIED) (6) 1/2-13 X 1.500 BOLT (10) 1/2 FLAT WASHERS...
  • Page 19 Drive and Cabinet Figure 9. Drive cabinet dimensions: Frame 4 (dimensions in inches) 2.75 15.00 15.00 2.75 INPUT WIRING OUTPUT WIRING ACCESS ACCESS 3.03 3.05 19.25 Top View 19.25 INPUT WIRING OUTPUT WIRING ACCESS ACCESS 1.38 LIFTING HOLES 8.02 67.77 4.75 61.46 81.11...
  • Page 20 Drive and Cabinet Figure 10. Drive cabinet dimensions: Frame 4 (dimensions in inches) 6.00 MINIMUM WALL CLEARANCE COOLING WATER RETURN 3/4-14 FPT Side View COOLING WATER INLET 1.125 KO'S 3/4-14 FPT EQ SPACED 4 @3.00" 3.50 19.70 23.68 15.08 3.33 23.11 25.00 35.13 REF...
  • Page 21 Adapter; 3/4Female JIC Flare X 3/4 ID Hose 8 selected and the existing equipment. A list of additional Elbow; 3/4NPTE X 3/4 Male JIC Flare, 90° components available from Trane is provided in Table Clamp; Hose—1.00 ID Some of these components may be added to an order Adapter;...

  • Page 22: Lifting Procedure

    Drive and Cabinet speed drives. Table 3, p. 22 provides the part numbers necessary for motor brush installation. WARNING Heavy Objects! Table 3. Motor brush installation part numbers Do not use cables (chains or slings) except as shown. Motor Compressor Frame Manufacturing Inspection...
  • Page 23 Drive and Cabinet Figure 11. Lift point locations for LiquiFlow 2.0 drives Lift Points Lift Points Lift Points Frame 3 Frame 4 AFDK-SVU01C-EN...

  • Page 24: Mounting

    Mounting bolts in small equal steps to ensure an equal draw- Unit-Mounted (Refrigerant- down of the flange onto the gasket. Cooled) Flange Bolt Torques: 1/2-in. bolts = 90 ft·lb (122.1 N·m) 1. If present, disconnect existing power wiring and ground connection. 5/16-in.
  • Page 25 Mounting 4. Attach floor mounting rails to the bottom of the enclosure. 5. Install anchors in floor. 6. Carefully lift the drive into place. Do not bump or jolt the drive while lifting. Refer to “Lifting Procedure,” 7. Secure the floor mounting rails to the floor using lag screws and washers.

  • Page 26: Plumbing

    Drive Frame Water-to-Water Water-to-Air operation. Table 4 lists the Trane part numbers for the Frame 3 Drives (405, 600 A) 020600880100 020600900100 correct heat exchanger. These assemblies include both Frame 4 Drives (900, 1200 A)
  • Page 27 Plumbing Table 6. Pressure drops for primary loop components at Table 7. Pressure drops for secondary loop components minimum flow (ft of water) at minimum flow (ft of water) Frame 3 Frame 4 Frame 3 Frame 4 900 A and 405 A 600 A 900 A...

  • Page 28: Water-To-Water Heat Exchanger

    Plumbing heat exchanger assembly as well as the locations of piping Water-to-Water Heat Exchanger and electrical connections. Figure 13 shows the piping diagram of the heat-exchanger assembly. Figure 14, p. 29 shows the dimensions of the Figure 13. Water-to-water heat exchanger piping diagram (a) Material courtesy of DIMPLEX Thermal Solutions.
  • Page 29 Plumbing Figure 14. Heat exchanger layout diagram (dimensions in inches) (a) Material courtesy of DIMPLEX Thermal Solutions. 2. Connect process fluid lines to the proper fittings. Make Installation sure that the flow of fluid to and from the unit cannot 1.
  • Page 30 Plumbing Table 9. Water-to-water heat exchanger connections Attachment Point Fitting(s) Required Pump outlet • 90° elbow, 3/4 NPTE x 3/4 male JIC AFD panel outlet • 90° elbow, 3/4 NPTE x 3/4 male JIC AFD panel inlet • 90° elbow, 3/4 NPTE x 3/4 male JIC Heat exchanger inlet •...

  • Page 31: Water-To-Air Heat Exchanger

    Plumbing heat exchanger assembly as well as the locations of piping Water-to-Air Heat Exchanger and electrical connections. Figure 15 shows the piping diagram of the heat-exchanger assembly. Figure 16, p. 32 shows the dimensions of the Figure 15. Water-to-air heat exchanger piping diagram (a) Material courtesy of DIMPLEX Thermal Solutions.
  • Page 32 Plumbing Figure 16. Heat exchanger layout diagram (dimensions in inches) (a) Material courtesy of DIMPLEX Thermal Solutions. Table 12 details the connections. Some of the Installation necessary fittings may be included in the accessory 1. Ensure the unit is placed on a flat, level, hard surface in kits shipped separately from the drive (refer to a location that allows adequate room for servicing per “Additional Components,”...

  • Page 33: Corrosion

    Plumbing should match power requirements on the assembly Recommended concentration limits for impurities in nameplate in accordance with local codes (refer to water to prevent micro-galvanic corrosion of unalloyed or Table 13). galvanized iron is included in Table. Note: These values are only recommended values and Table 13.

  • Page 34: Input Power And Control Wiring

    For variable frequency drives Use a torque wrench to tighten power connections. A or other energy storing components provided by Trane torque wrench eliminates the human element and or others, refer to the appropriate manufacturer’s provides proper hardware tightening.
  • Page 35 Input Power and Control Wiring 3. Once removed, drill the wire routing holes in the panel. An input disconnect circuit breaker is factory-installed in These wire routing holes are the only entry points for the cabinet. Verify that the available fault current is less input power wiring into the cabinet.
  • Page 36 Input Power and Control Wiring Figure 17. Busbar installation on compressor motor Figure 18. Motor connection assembly terminal board 1. Compressor motor terminal board 2. Remove motor terminal lugs (from all 6 terminals). 3. Install shorting busbars across the motor terminal  pairs as shown.
  • Page 37 Failure to follow this precaution could result in inadvertently energized. For variable frequency drives damaged equipment. or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s 3. Once removed, drill the wire routing holes in the panel.
  • Page 38 Input Power and Control Wiring Table 18 indicates the typical control wiring for AFDK Table 17. Drive terminal specifications installation. Four knockouts have been provided on the left side of the AFDK enclosure for control and communication Wire Binding  wires.
  • Page 39 Input Power and Control Wiring Figure 20. Expanded view of terminal block 1. Din Rail 2. Relay Socket 3. Relay 4. End Barrier 5. Ground Terminal Block 6. Terminal Block 7. Tab 8. Tab 9. Jumper (a) Material courtesy of Rockwell. Communications wires should be terminated at the Hardware kit for AFDK (020600790100).

  • Page 40: Afd Operation

    When the total pressure (static + dynamic) schedule at whenever practical. For assistance with leaving the compressor is less than the condenser optimizing tower relief, contact Trane controls personnel. pressure, refrigerant will start to flow backwards from the Surge Boundary condenser.
  • Page 41 AFD Operation and inlet guide vane position to achieve the desired chiller 3. When the re-optimization timer expires. capacity and pressure coefficient. At the heart of the The control is re-optimized by increasing the AF Surge control is a match model that describes the relationship Boundary Offset Coefficient every minute until surge between control parameters and actuators.
  • Page 42 AFD Operation AFD faults are sent over the M-bus to the UC800 or Figure 24. Motor current signature representing surge DynaView™ controls for communication on the chiller display. Rectified Present Sampled Motor High Pressure Cutout—The inverter accepts a NC HPC Previous Value Current...

  • Page 43: Service Interface

    TechView™ is a portable laptop computer control panel interface for the service technician or advanced operator. When you need more detailed information about a Trane chiller, connect your laptop computer (with the TechView software installed in it) to the DynaView™ plug-in port.
  • Page 44 AF Re-Optimization Time Remaining Hrs/Mins AFD DC Bus Voltage AFD Last Diagnostic Code (decimal) number Table 21. TechView™: Setpoint View: Starter Tab (for CH530 Main Processor Control Algorithm settings) Description Factory Default Units AFD Re-Optimization Timer Hours AFD Re-Optimization Sensitivity...

  • Page 45: Tracer Adaptiview Operator Interface

    (a) These items must be set to the values given on the drive parameter sheet for proper operation. To request a drive parameter sheet, send a message to ATechnicalService@trane.com. Please provide the serial numbers for the chiller, control panel (if CH531), and the AFDK when making this request.
  • Page 46 Service Interface Table 24. Tracer™ TU: Unit Status view: Motor Expanding section Motor Winding Temp #1 Motor Winding Temp #2 Motor Winding Temp #3 Table 25. Tracer™ TU: Unit Status view: AF Expanding section AFD DC Bus Voltage AFD Last Diagnostic Code (decimal) number AFD Output Power AFD Transistor Temp...
  • Page 47 Note: These items must be set to the values given on the drive parameter sheet for proper operation. To request a drive parameter sheet, send a message to ATechnicalService@trane.com. Please provide the serial numbers for the chiller, control panel (if Tracer AdaptiView™ upgrade), and the AFDK when making this request.

  • Page 48: Afdk Pre-Startup Checks

    NEC and your local/state electrical codes. Failure to by Trane or others, refer to the appropriate follow code could result in death or serious injury. manufacturer’s literature for allowable waiting periods for discharge of capacitors.

  • Page 49: Afdk Checks

    AFDK Pre-startup Checks 6. Check to ensure that incoming power to the drive is phased A, B, C. AFDK Checks NOTICE Perform Visual Inspection! Before powering up this drive for the first time conduct a visual inspection for the following: •...

  • Page 50: Afdk Startup Procedure

    Follow the procedure below when starting the water the drive. chiller and drive. For CH530/531 only: If the disconnect is open and 1. The UC800 or DynaView™ is the primary controller for you are using an external 115 V control power the CenTraVac™...
  • Page 51 6. When ready, start the drive from the Tracer AdaptiView™ display, or from the DynaView operator interface of the CH530/531 panel. 7. Check the AFDK chiller drive response to the UC800 or DynaView. Initially, the drive will go to 38 hertz and stay there until the CenTraVac chiller vanes open based on load.

  • Page 52: Startup Test Log

    Comments: Power Loss Time Flying Start Disable Flying Start Gain 2000 Use Trane Defaults (for all other AFD parameters not accessible via Tracer TU) RTD Type *Must be set per sales order variable. Test Log Date: Log 1 Log 2...
  • Page 53 Verified Settings Power Loss Time Flying Start Enable disable Comments: Flying Start Gain 2000 Use Trane Defaults (for all other AFD parameters not accessible via TechView) Test Log Date: TechView Status View: Motor Log 1 Log 2 % RLA Average...

  • Page 54: Troubleshooting

    Alarms enunciator. A message description will be DynaView™ messages. provided. The Trane service tool, TechView™, can be utilized to view A scrollable list of the last (up to 10) active diagnostics will the last AFD diagnostic code from with in the Motor be presented.

  • Page 55: Troubleshooting

    If possible, use the Rockwell OIM and provide the inadvertently energized. For variable frequency drives following drive parameter information: or other energy storing components provided by Trane • LiquiFlo 2.0 (inverter) Parameters 49, 50, 209, or others, refer to the appropriate manufacturer’s...

  • Page 56: Alarm Messages And Fault Codes

    Alarm Messages and Fault Codes Tracer AdaptiView™ note: The “AFD Last Diagnostic located under the Unit Status tab, in the Motor expanding Code” value is available using Tracer™ TU. This value is box. Table 30. Alarm messages and fault codes Tracer AdaptiView Tracer TU or Tracer AdaptiView...

  • Page 57: Recommended Periodic Maintenance And Inspection

    Applied 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 WARNING or others, refer to the appropriate manufacturer’s Live Electrical Components! literature for allowable waiting periods for discharge of capacitors.

  • Page 58: Chiller Operator Display Content

    Recommended Periodic Maintenance and Inspection Chiller Operator Display Content Refer to CTV-SVU01*-EN (Operations Guide: Tracer AdaptiView™ Display for Water-cooled CenTraVac™ Chillers) for Tracer AdaptiView™ display information. Important: Please note that the Tracer AdaptiView displayed voltage is line side input voltage, whereas current and power factor are load side data.

  • Page 59: Wiring Schematics

    2311-0453 LiquiFlo 2, Frame 3 Unit Mounted Adaptive Frequency Drive 900–1210 A  2311-0454 LiquiFlo 2, Frame 4 Field Connection Diagram - Simplex - Trane Supplied 2311-0565 Adaptive Frequency Drive Remote Mounted Adaptive Frequency Drive 405–608 A  2309-7647 LiquiFlo 2, Frame 3 Remote Mounted Adaptive Frequency Drive 900–1210 A ...
  • Page 60 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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