Trane AFDH Installation Instructions Manual
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Trane AFDH Installation Instructions Manual

D-frame upgrade adaptive frequency drive for tracer adaptiview centrifugal chiller
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Installation Instructions
AFDH D-Frame Upgrade Adaptive
Frequency Drive™
For Tracer AdaptiView™ Centrifugal Chiller
Controllers
Direct Mount
Models:
CVHE, CVHF, CVHG
Design Sequence:
F0
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.
July 2020
Transition Mount
SAFETY WARNING
AFDH-SVN005B-EN
Remote Mount

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Summary of Contents for Trane AFDH

  • Page 1 Installation Instructions AFDH D-Frame Upgrade Adaptive Frequency Drive™ For Tracer AdaptiView™ Centrifugal Chiller Controllers Remote Mount Direct Mount Transition Mount Models: CVHE, CVHF, CVHG 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 Equipment Room Floor! 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. A stand-mounted version of an AFDH drive is designed to be rigidly supported by the equipment room floor.
  • Page 4 If the starter that is being replaced by the AFDH drive has the incoming power conduit routed horizontally across the top of the starter, or connected to the side or to the bottom of the starter cabinet, an electrician will be required to reconfigure the conduit and wiring.

  • Page 5: Table Of Contents

    Installation Considerations for Unit-Mounted D-Frame AFDH ......44 AFDH Drives ..... . . 11...
  • Page 6 Air Filter ......58 Wiring Diagram Matrix ....59 AFDH-SVN005B-EN...

  • Page 7: Model Number Description

    990 Maximum RLA 50 Hz (380/400V) 1B = 190 Maximum RLA - 60 Hz (460/480V) Digit 15 — Chiller Control Type For service purposes, Trane Model 1C = 240 Maximum RLA - 60 Hz AdaptiView Controls Only AFDH Air-Cooled drive upgrade (460/480V) packages are assigned a multiple Digit 16 —...
  • Page 8 1M = Advanced Filter -208 Amp free standing harmonic filter 1N = Advanced Filter -208 Amp free standing harmonic filter 1P = Advanced Filter -208 Amp free standing harmonic filter 1Q = Advanced Filter -208 Amp free standing harmonic filter AFDH-SVN005B-EN...

  • Page 9: General Information

    Ordering or Installing an AFDH AFDH Upgrade Air-Cooled Adaptive Frequency™ Drive (AFD) package in place of an existing starter on a Trane Upgrade CVHE, CVHF or CVHG model centrifugal chiller. This only applies to chillers having a Tracer®...

  • 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...

  • Page 11: Pre-Installation

    Motor terminal access in left-center quadrant of cabinet. Motor terminal access in an AFDH drive cabinet is located to the left in Upgrading direct mount starter with direct the upper third portion of the cabinet.

  • Page 12: Installation Considerations For Remote Floor-Mounted Afdh

    Typical code regulations require However, be advised that all models of the AFDH air- an average of 36 inches of clearance from the panel to cooled drives are not suitable for installation into...

  • Page 13: Chiller Upgrades

    Condition Specification recommended. These systems are found on Humidity 5% to 95% (non-condensing) all Trane® chillers built since 1985. Chiller Upgrades Electrical Cable Size • The chiller condenser loop setpoint should be set to 72°F to fully exploit the energy savings possible with a Specifications for AFDH Drives retrofit AFDH drive.
  • Page 14 Pre-Installation AFDH D-Frame drives (380V/400V) (continued) Table 2. Input/output power wire cable sizes 100K Short Circuit Withstand Rating Amps Phase wire between drive and CB: Number of Wire Cable Per Phase and Size of 1/0 DLO 1/0 DLO 3/0 DLO...
  • Page 15 2/0-600 KCMIL 2/0-600 KCMIL 2/0-600 KCMIL 2/0-600 KCMIL Sizes Lugs will Accepts (Remote Mount) AFDH D-Frame drives (575 V/600 V) Table 4. Input/output power wire cable sizes 35K Short Circuit Withstand Rating Amps Incoming power to drive One wire lugs...
  • Page 16 Pre-Installation AFDH D-Frame drives (575 V/600 V) (continued) Table 4. Input/output power wire cable sizes 35K Short Circuit Withstand Rating Amps Output power to fuse blocks: Number of Wire Cable Per Phase and Size of Factory 1/0 DLO 1/0 DLO...

  • Page 17: Requirements For Installation Technicians

    Note: The most current CTV and CVR microprocessor (MP) firmware files are included with the program An AFDH cabinet assembly may be top heavy. Test lift unit approximately 24 inches to verify proper center of files for the Tracer® TU service software tools.

  • Page 18: Unit Lifting Points

    Pre-Installation Unit Lifting Points Figure 3. Unit lifting points and center of gravity (direct mount) 6.50 CENTER CENTER CENTER GRAVITY GRAVITY GRAVITY 25.01 ORIGINAL CENTER 20.78 25.01 6.56 GRAVITY AFDH-SVN005B-EN...
  • Page 19 Pre-Installation Figure 4. Unit lifting points and center of gravity (transition mount) 6.82 CENTER CENTER CENTER GRAVITY GRAVITY GRAVITY 28.20 ORIGINAL CENTER 21.95 28.20 6.72 GRAVITY AFDH-SVN005B-EN...
  • Page 20 Pre-Installation Figure 5. Unit lifting points and center of gravity (remote mount) 6.82 CENTER CENTER GRAVITY GRAVITY CENTER 42.33 GRAVITY ORIGINAL CENTER 15.45 42.33 7.60 GRAVITY AFDH-SVN005B-EN...

  • Page 21: Preferred Lifting Method

    Pre-Installation Preferred Lifting Method Alternative Lifting Method The preferred method for lifting an AFDH drive unit to Lift is only possible to use a single hoisting device to lift an position it for installation, is to use an identical individual AFDH drive unit to position it for installation, a spreader hoisting device at each lift point.

  • Page 22: Afdh Drive Package Specifications

    AFDH Drive Package Specifications AFDH D-Frame Dimensions Figure 8. Top, front, and side view of D-Frame AFDH cabinet with dimensions (direct mount) 16.98 16.98 11.48 11.48 TOP ACCESS PANEL 62.66 DOOR SWING 62.02 60.00 16.50 49.00 19.55 1. Two-piece access door cover on top of the 10 in. x 15.5 in. incoming power wire cutout.
  • Page 23 AFDH Drive Package Specifications Figure 9. Top, front, and side view of D-Frame AFDH cabinet with dimensions (transition mount) 15.50 TOP ACCESS PANEL 8.50 50.43 DOOR SWING 18.91 62.02 60.00 15.00 15.90 18.24 1. Z-bracket mounting studs (each stud = 3/8-16 x 1.75 in.).
  • Page 24 AFDH Drive Package Specifications Figure 10. Top, front, and side view of D-Frame AFDH cabinet with dimensions (remote mount) 16.25 12.75 47.85 TOP ACCESS PANEL DOOR SWING 86.02 84.00 41.35 18.47 32.00 21.52 1. Two-piece access door cover on top of the 11 in. x 14.5 in. incoming power wire cutout.
  • Page 25 AFDH Drive Package Specifications Figure 11. Rear view of D-Frame AFDH cabinet with dimensions (direct mount) 23.56 12.10 1. Motor terminal access cover. Size of cutout is 12.1 in. x 23.56 in. Figure 12. Rear view of D-Frame AFDH cabinet with dimensions (transition mount) 16.50...

  • Page 26: Drive Unit Weights And Heat Rejection

    AFDH Drive Package Specifications Drive Unit Weights and Heat Rejection Table 5. AFDH D-Frame unit weights (380 V/400 V) 380 V/400 V D-Frame AFDH Maximum Amps Enclosure Type Direct Transitional Remote Direct Transitional Remote Direct Transitional Remote Unit Weight 725 Lb...

  • Page 27: D-Frame Drive Unit Components

    D-Frame Drive Unit Components Drive Unit Component Parts Housed within the Custom Enclosure Figure 13. Mounting location of D and E-Frame custom Figure 14. D-Frame AFDH UC800/Tracer AdaptiView enclosure parts ancillary control components Right-hand houses the TR200 drive module for the unit. For the...
  • Page 28 AFDH Drive Package Specifications Table 8. Custom enclosure parts: D-Frame 212 amps model drives (380V/400V) Trane Assembly Part Numbers for all Optional Model Versions of 380V/400V D-Frame 212 Amp AFDH Figure 13 Trane X-Code Part Quantity Callout Part Description Number...
  • Page 29 AFDH Drive Package Specifications Table 11. Custom enclosure parts: D-Frame 395 amps model drives (380V/400V) Trane Assembly Part Numbers for all Optional Model Versions of 380V/400V D-Frame 395 Amp AFDH Figure 13 Trane X-Code Part Quantity Callout Part Description Number...
  • Page 30 AFDH Drive Package Specifications Table 14. Custom enclosure parts: D-Frame 190 amp model drives(460V/480V) Trane Assembly Part Numbers for all Optional Model Versions of 460V/480V D-Frame 190 Amp AFDH Figure 13 Trane X-Code Part Quantity Callout Part Description Number Supplier Part Number...
  • Page 31 AFDH Drive Package Specifications Table 17. Custom enclosure parts: D-Frame 361 amp model drives(460V/480V) Trane Assembly Part Numbers for all Optional Model Versions of 460V/480V D-Frame 361 Amp AFDH Figure 13 Trane X-Code Part Quantity Callout Part Description Number Supplier Part Number...
  • Page 32 AFDH Drive Package Specifications Table 20. Custom enclosure parts: D-Frame 131 amp model drives(575V/600V) Trane Assembly Part Numbers for all Optional Model Versions of 575V/600V D-Frame 131 Amp AFDH Figure 13 Trane X-Code Part Quantity Callout Part Description Number Supplier Part Number...
  • Page 33 AFDH Drive Package Specifications Table 23. Custom enclosure parts: D-Frame 242 amp model drives(575V/600V) Trane Assembly Part Numbers for all Optional Model Versions of 575V/600V D-Frame 242 Amp AFDH Figure 13 Trane X-Code Part Quantity Callout Part Description Number Supplier Part Number...

  • Page 34: Additional Hardware Shipped With Tracer® Adaptiview™ Afdh Packages

    AFDH Drive Package Specifications Table 26. Custom enclosure parts: D-Frame 400 amp model drives(575V/600V) Trane Assembly Part Numbers for all Optional Model Versions of 575V/600V D-Frame 400 Amp AFDH Figure 13 Trane X-Code Part Quantity Callout Part Description Number Supplier Part Number...

  • Page 35: Other Afdh Drive Package Accessories

    AFDH drive, and connect to the compressor motor terminal board. Table 29. Part numbers for motor panel transition covers...

  • Page 36: Installation

    WARNING inadvertently energized. For variable frequency drives or other energy storing components provided by Trane Heavy Objects! or others, refer to the appropriate manufacturer’s Failure to properly lift unit could result in death or literature for allowable waiting periods for discharge of serious injury.

  • Page 37: Mechanical Removal Of The Existing Remote-Mounted Starter

    These welds can break if not lifted straight up. To ensure a safe lift, Trane recommends 4. Remove the bolts securing the bottom of the starter to drilling a hole and bolting the tabs to the enclosure to the brackets on the evaporator.
  • Page 38 AFD. 8. Remove the bottom panel bracket from the starter panel brackets as shown in Figure 16. If panel brackets are not removed, the AFDH cooling airflow will be blocked. AFDH-SVN005B-EN...

  • Page 39: Mechanical Installation Of A Unit Mounted D-Frame Afdh

    1. Use a saw-zaw to remove the right tab (when facing the 3. Prepare lifting equipment and rigging. back of the AFDH panel). The left tab will be used to a. Depending upon the model type, a unit-mounted mount the drive to the brackets and must not be AFDH can weigh up to 1400 pounds.
  • Page 40 AFDH panel 7. Keep the upper part of the AFDH panel flush with the 5. Attach other end of adapter bracket to the bottom of the Z-bracket face. Keep tension on the lift rigging to hold AFDH panel using the remaining tab on the bottom left the AFDH panel in position.
  • Page 41 10. Once the upper Z-bracket is secured, leave the lift rigging in place and attach a C-clamp to the adapter bracket and panel supports to hold the adapter bracket in place. AFDH-SVN005B-EN...

  • Page 42: Mechanical Installation Of A Transition-Mounted D-Frame Afdh

    An AFDH cabinet assembly is top heavy. Test lift unit approximately 24 inches to verify proper center of gravity lift point. To avoid dropping of unit, reposition lifting point if unit is not level.
  • Page 43 2. Prepare lifting equipment and rigging. a. Depending upon the model type, a unit-mounted AFDH can weigh up to 1400 pounds. Confirm the weight of the AFDH unit to be installed. For D-Frame Lining up slots in drive cabinet base with slots in evaporator brackets.

  • Page 44: Mechanical Installation Of A Direct-Mounted D-Frame Afdh

    Installation Figure 28. Leveling the AFDH drive cabinet against the NOTICE: Z-bracket Improper Unit Lowering! Do not drop the drive cabinet assembly onto the evaporator mounting brackets when setting it into position! Dropping the cabinet onto the brackets could result in damage to the drive cabinet, the brackets, and/or the evaporator shell.

  • Page 45: Mechanical Installation Of Remote-Mounted D-Frame Afdh And Harmonic Filter

    An AFDH cabinet assembly is top heavy. Test lift unit approximately 24 inches to verify proper center of gravity lift point. To avoid dropping of unit, reposition lifting point if unit is not level.

  • Page 46: Electrical Installation (All Afdh Models)

    2. Prepare lifting equipment and rigging. a. Depending upon the model type, a unit-mounted AFDH can weigh up to 1400 pounds. Confirm the NOTICE: weight of the AFDH unit to be installed. For D-Frame Use Copper Conductors Only! units refer to Table 5, p.

  • Page 47: Install Shorting Buss Bars (Unit Mount Only)

    Install Shorting Buss Bars (Unit Mount Only) Note: Shorting buss bars must be installed since the AFDH is a three-lead device while the starter was a six-lead device. 1. Remove the motor terminal lug from all six terminals on the compressor motor terminal board.

  • Page 48: Grounding Afdh Cabinet

    1. Run a suitable, unbroken, grounding conductor from the drive cabinet’s ground connection terminal to the motor’s ground terminal, and then on to earth ground. Figure 32. Location of AFDH cabinet ground terminal Input disconnect circuit breaker Nameplate. Input power terminals. Terminal connections should be torqued to 31 ft·lb.

  • Page 49: 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. Optionally, the AFDH may be ordered with a passive harmonic filter. While the filter is passive, it adapts to 2. Feed the six motor leads through the back of the drive various loads in order to optimally reduce current cabinet to the compressor motor terminal board.

  • Page 50: Environmental Conditions And Location

    9. Connect the power leads between the filter and the means of lifting and transporting may be used. Sling in a drive components. Connections are listed in the manner that will equalize the load at the pickup points. Use following table. AFDH-SVN005B-EN...

  • Page 51: Routing Of Control Wiring To Afdh Cabinet

    If the starter that is being replaced by the AFDH drive has the incoming power conduit routed horizontally across the top of the starter, or connected to the side or to the bottom of the starter cabinet, an electrician will be required to reconfigure the conduit and wiring.

  • Page 52: Control Wiring Connections (Tracer® Adaptiview™ Model Afdh Only)

    Field installed wiring Actual wire designators may vary depending upon the specific model/version of chiller control that the AFDH drive is being linked with. Please refer to the original chiller control wiring diagrams and the wire descriptions listed in Figure Callouts 4–11 if an actual wire designator does not match the one shown in this graphic.

  • Page 53: Required Reprogramming Of Tracer® Adaptiview™ Controls

    Note: CTV MP firmware is always used in factory installed Tracer® AdaptiView™ control systems or in Tracer® AdaptiView™ display upgrades to factory installed CH530 control systems. Table 32. UC800/Tracer® AdaptiView™ CTV parameter values with upgrade AFDH Tracer TU Service Setpoints View: Adjustable Frequency Drive Setpoints Range...

  • Page 54: Afdh Startup Procedure

    AFDH Startup Procedure Follow the procedure below when starting the water chiller default setpoints that are the same on all AFDH air- and drive. cooled drives. 1. The CenTraVac™ chiller control starts, stops, and Note: If the set values do not match, contact the monitors all unit and AFDH run functions.

  • Page 55: Tr200 Drive Configuration

    Motor Current Set to nameplate NMRA After all settings are made save a copy chiller service report for future use. Recommend that Trane Techs load to Motor Nominal speed Set to nameplate TRPM ComfortSite by chiller serial number. Torque limit mode...

  • Page 56: 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 57: Startup Test Log

    AFD Output Power (KW) Speed Frequency Tracer TU Field Startup View: AFD Maximum Frequency Minimum Frequency AFD Surge Capacity Increase Tracer TU Status View: Motor Average Line Current Motor Winding 1 temp Motor Winding 2 temp Motor Winding 3 temp AFDH-SVN005B-EN...

  • Page 58: Recommended Periodic Maintenance And Inspection

    Frequency drives for centrifugal chillers equipped with AFDH starters. All UC800 chillers will be equipped with the 4. Ensure the drive interior and exterior is clear of any LCP as standard on the drive power module. This is for dust or debris.
  • Page 59 Wiring Diagram Matrix Wiring Diagram Description Number 50712127 CenTraVac™ Wiring Diagram with Danfoss Adaptive Frequency Drive Note: Wiring diagrams are available via e-Library. AFDH-SVN005B-EN...
  • 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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