Trane RTHD Installation Instructions Manual
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Trane RTHD Installation Instructions Manual

Trane RTHD Installation Instructions Manual

Afdr retrofit air-cooled adaptive frequency drive
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Installation Instructions
AFDR Retrofit Air-cooled Adaptive
Frequency Drive™
For Use with RTHD Chillers
Model Number:
RTHD
This document applies to service offering application only.
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.
October 2023
SAFETY WARNING
SO-SVN048A-EN

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  • Page 1 Installation Instructions AFDR Retrofit Air-cooled Adaptive Frequency Drive™ For Use with RTHD Chillers Model Number: RTHD This document applies to service offering application only. 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 When working with or around hazardous chemicals, these compounds have the same potential impact to the ALWAYS refer to the appropriate SDS and OSHA/GHS environment. Trane advocates the responsible handling of all (Global Harmonized System of Classification and refrigerants. Labeling of Chemicals) guidelines for information on...
  • Page 3 Copyright regulations. This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part WARNING without written permission. Trane reserves the right to revise Conform to All Applicable National, State,...

  • Page 4: Table Of Contents

    Wiring Information RTHD ADF Line Weight Kit ... . 31 ......64 Wiring Diagram Matrix Installation Instructions .

  • Page 5: General Information

    ® This only applies to chillers having a Tracer AdaptiView™ controller. If the RTHD chiller has a 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.

  • 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 number Digit 16 — Mounting Type that precisely identifies each unit.

  • 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

    MOTOR CONTROLLER the AFDR drive. Manufactured by Danfoss Drives For TRANE LaCrosse, WI 54601-759 If the RTHD to be retrofitted to AFD already has a UC800 Tracer AdaptiView controller, that can be reused. TRANE P/O: Important: Regardless if it is new or existing, the UC800 TRANE Model No.

  • Page 9: Dimensions

    Dimensions Unit Submittal Drawings Figure 2. D1 drive, 2 conduit, 460 and 575V, below 185 amps - standard drive orientation SO-SVN048A-EN...
  • Page 10 Dimensions Figure 3. D1 drive, 2 conduit, 460 and 575V, below 185 amps - rotated drive orientation SO-SVN048A-EN...
  • Page 11 Dimensions Figure 4. D1 drive, 4 conduit, 460V, 185 to 334 amps - standard drive orientation SO-SVN048A-EN...
  • Page 12 Dimensions Figure 5. D1 drive, 4 conduit, 460V, 185 to 334 amps - rotated drive orientation SO-SVN048A-EN...
  • Page 13 Dimensions Figure 6. D2 drive, 4 conduit, 460 and 575V, 186 to 336 amps - standard drive orientation SO-SVN048A-EN...
  • Page 14 Dimensions Figure 7. D2 drive, 4 conduit, 460 and 575V, 186 to 336 amps - rotated drive orientation SO-SVN048A-EN...
  • Page 15 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 SO-SVN048A-EN...
  • Page 16 Dimensions 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...

  • 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 SO-SVN048A-EN...

  • Page 18: Pre-Installation

    Pre-Installation Required Tools – RTHD UC800 firmware build 3.03 or later (refer to “Preparing Tracer® TU on the Service Computer,” Normal service tools are required to perform the majority of the work. A service technician with a well stocked tool chest should •...
  • Page 19 Pre-Installation Table 2. Components – close mount 460 volts (continued) Kit Part Number Mnemonic Part Number Description 127500010001 507118300001 Motor Terminal Shield Conduit Kits X19038200000 Connector, 2-inch conduit X19120032060 2-inch Conduit sleeve 507118010001 PWR WIRE ASSEMBLY D1 - B 127500020001 2 Conduit Kit 507118030001 PWR WIRE ASSEMBLY D1 - D...
  • Page 20 RAL01142 X13260722010 Relay Socket, 4PDT, Din rail mount 127500050001 X13500224207 Din rail 4-inch X13491363010 Din Rail End Stop SO-SVN048*-EN 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 78.74-inch CAB01150 X19051623020 Extension Harness - 78.74-inch X39002507010 Label, Warning (AFD) 507117810001 Label, Nameplate SO-SVN048*-EN KIT IOM (supplied by Trane) 507117830001 Schematics Printed on mylar BAS-SVX54*-EN Drive IOM 507118200001 AFD Label X39003759010 Label, Technical support...
  • Page 22 1K14, 1K15 Relays 127500090001 X13260722010 Relay Socket, 4PDT, Din rail mount X13500224207 Din rail 4inch X13491363010 Din Rail End Stop SO-SVN048*-EN KIT IOM (supplied by Trane) 507117830001 Schematics Printed on mylar BAS-SVX54*-EN Drive IOM 507118200001 AFD Label 507118300001 Motor Terminal Shield...

  • Page 23: Global Connector Harnesses

    Pre-Installation Table 5. Components – remote mount 575 volts (continued) Kit Part Serviceable Number Mnemonic Part Number Description Package Label Component 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 OPTIONAL PEDESTAL...

  • Page 24: Required Parts - Not Supplied

    UC800 and a unique connection type for the AFD (listed above). The Global Connector Extension is used for spanning For RTHD units manufactured prior to 2012, Trane the rest of the wire distance between the panel and the AFD.

  • Page 25: Preparing Tracer ® Tu On The Service Computer

    Figure 18. KestrelView screenshot - accessing Chiller Service report Figure 19. Chiller service report (example) ® Preparing Tracer TU on the Trane Commercial Downloads - DL-TU - TU-Software (sharepoint.com). Service Computer 2. If it is not already present, install this version of Tracer TU on the service computer.
  • Page 26 Pre-Installation Figure 20. Figure 22. Figure 21. Figure 23. SO-SVN048A-EN...

  • Page 27: Oil And Refrigerant Removal

    It is acceptable to change the oil to the new oil and will already be embedded and present in recent Tracer still run the RTHD unit without the AFD installed, if it is more TU releases. This method is only required to obtain convenient to change to the new oil and operate the RTHD unit very recent releases for specific product firmware.
  • Page 28 16. Add the total oil charge according to Table 6. Adding an AFD to the RTHD chiller requires more oil than the original factory configuration. a. Add enough Solest 120 (OIL00315/317) to the oil filter (number 7) to fill the filter.
  • Page 29 Pre-Installation Table 6. Oil type and oil charge for RTHD chillers with AFD Unit Configuration B1B1B1 B1C1D1 B2B2B2 B2C2D2 C1D5E4 C1D6E5 C1E1F1 C2D3E3 Oil Type Solest 120 (OIL00315/317) Oil Charge, gal Oil Charge, L 28.5 28.5 28.5 28.5 Unit Configuration...
  • Page 30 Pre-Installation Figure 26. Component locations SO-SVN048A-EN...

  • Page 31: Installation

    Figure 28. Line weight installation location – B-frame Discharge Lines compressors The addition of an Adjustable Frequency Drive (AFD) on RTHD chillers may result in vibration resonance at low frequencies on the oil separator discharge line(s). Line weights are added to mitigate this vibration.

  • Page 32: Rthd Tracer ® Adaptiview™ Uc800 Controls Upgrade

    Install 2 weights (4 clamps) on EACH of the two oil separator the AFDR drive. discharge lines as shown in figure below. If the RTHD to be retrofitted to AFD already has a UC800 • Install on the candy cane line between the oil separator Tracer AdaptiView controller, that can be reused.

  • 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 Installation 1. Remove and discard high-fault bracing. Figure 34. Starter module location WARNING Backup Wrench Required! Failure to follow instructions below could result in death or serious injury. Use backup wrench to prevent twisting/stress on motor terminals when installing and removing wire or buss bars from terminals and inspect terminals to ensure that they are not damaged.

  • Page 35: Solid State Starter Panel

    Installation Solid State Starter Panel Figure 35. Solid state starter component locations Solid State 1K11 Starter 1T2-1 1T3-1 1T2-2 1T3-2 1T2-3 1T3-3 High Fault Line-Side 1F1/2/3 Fuse Bracing Harness 1F1/2/3 1. Remove and discard high-fault bracing. Note: The liquid level red power wire (64A) is connected to J3 Pin 1 of the starter module.

  • Page 36: Panel Preparation - Close Mount (Kit 2 - 4 Conduit)

    Installation Figure 36. Conduit hole locations 2X Holes Drilled Panel Front 2X Ø 2.5 Panel Bottom Note: See “Dimensions,” p. 9 for conduit location Notes: dimensions. • Test-fit the 2.5-inch conduit fittings at the locations to ensure the conduit and or fitting will not interfere with the Panel Preparation –...

  • Page 37: Panel Component Installation (All Kits)

    Installation Note: See “Dimensions,” p. 9 for conduit location dimensions. Panel Component Installation (All Kits) Install the following components listed in Table 8 at the approximate locations as shown in Figure Table 8. AFD panel component installation Index Description SUPPORT, CHOKE CORE DIN RAIL, 4 in.
  • Page 38 Installation 1. Install choke core support bracket (1) using 6 mm thread 5. Install motor terminal buss bars (5/6). Torque to 40 ft·lb. rolling screws (13) so that is centered between the motor Note: Motor terminal buss bars must be flush on motor terminals.

  • Page 39: Conduit Support And Conduit Installation (Kit 1 And Kit 2)

    Installation 6. Install 1K1 and 1K2 relay sockets and relays (8/9) on Figure 45. Strut channel assembly existing 7.5-inch din rail (10) where Fuse 1F1/2/3 was removed. 7. Install din rail end-stops (4) on din-rail (10). Figure 43. 1K1, 1K2 relay socket L-Bracket Strut Channel Strut Channel...
  • Page 40 Installation Figure 47. Control cable Cable Bushing Loop Clamp Conduit Connector ® Modbus Cable Control Power Conduit 4. Remove pedestal adapter plate and install 2-inch and 3/4-inch conduit connectors and 3/8-inch grommet; refer to Figure Figure 48. Pedestal Drive Pedestal 1.25-in.
  • Page 41 Installation ® Figure 49. Modbus cable and control power mounting Figure 51. Adaptor plate assembly 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. SO-SVN048A-EN...

  • Page 42: Drive Installation - Pedestal Mount (All Kits)

    Installation Drive Installation – Pedestal 4. Drill the four required holes for the anchor bolts and install the 3/8-inch anchor bolts. Mount (All Kits) Figure 54. Important: • For wall mount option, follow instructions for remote wall in TR200 New D-Frame, 110–400kW Operating Instructions (BAS-SVX54*-EN).

  • Page 43: Recommended Rigging And Lifting Procedures For Afdr Drive Units

    Installation Recommended Rigging and Figure 57. Preferred lifting method using two identical Lifting Procedures for AFDR individual hoists Drive Units WARNING Heavy Objects! Failure to follow instructions below or properly lift unit could result in unit dropping and possibly crushing operator/technician which could result in death or serious injury, and equipment or property only damage.

  • Page 44: Line Voltage

    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 45: Panel Power Wiring

    Installation Figure 61. 4. Replace the front panel of the pedestal base. Panel Power Wiring Figure 62. NOTICE Compressor Damage! Before connecting power wire to the motor terminals, with the motor terminal jumpers removed, verify proper phasing between the drive and motor terminals with an Ohmmeter for all connections.
  • Page 46 Installation Figure 63. Figure 65. 9. Align cover over motor terminals and drill four holes for mounting. Install cover over motor terminals using four 7. Use provided tie wraps to secure the cores to the core screws (provided); refer to Figure bracket and use tie wraps to keep the power wire Figure 66.
  • Page 47 Installation Panel Control Wiring 1. Using the provided 12 AWG, route wires 20A, and 21A from the 1F1 and 1F2 fuse to the control power wire transformer, terminals H1 and H2; refer to Figure Refer to schematic 5071-1783 for the following connections. Figure 67.
  • Page 48 Installation 4. Install wire tap case; refer to Figure Figure 72. Terminals 1X5-1 through -11 Figure 70. Wire tap case install 1X5-2 Primary 1X5-3 HP Tied 1X5-4 through -7 Electrically Tied Oil Sol (4Y3)/ Cutout (4829) (115V = “Hot”) Dual Relay (1A8) 1X5-8 through - 11 Electrically Tied (115V -...
  • Page 49 Installation ® • The red wire on the Modbus cable is NOT connected to Table 12. Pin-out, relay 1K15 the AFD. Terminal— Table 14. Pin-out, AFD Relay 1K15 Description Mating Connection Description Terminal— N/C contact 1X5-4 thru 7 115V “hot” Description Mating Connection Description N/O contact...

  • Page 50: Uc800 Software Installation And Configuration

    Stop the chiller before the software upgrade process begins. 1. Connect the service laptop computer to the target RTHD ® UC800 using an A/B type USB cable. Launch Tracer service tool software in the service computer.
  • Page 51 Application Software Download dialog box. Figure 83. 3. The Application Software Download dialog box appears, allowing selection of chiller products. For Product Name, select RTHD, and for Version, select 3.03 (or newer). Then click Upgrade Device. SO-SVN048A-EN...
  • Page 52 For Line Voltage Sensing, select Not Installed; refer Figure Figure 88. 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 53 • Current flowing into the unit (into the drive) remains at or below the previous RLA stamped on the original shipped RTHD nameplate; thus, there is no need to increase the upstream branch wiring or circuit protection. Figure 89. MOTOR CONTROLLER...
  • Page 54 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 55: Existing Uc800 With Software Already Installed

    Existing UC800 with Software Figure 95. Already Installed 1. If an AFDR retrofit is installed on an RTHD chiller with an existing UC800 controller/Tracer AdaptiView™ display, the software installation will be slightly different than in “UC800 Software Installation and Configuration,” p.
  • Page 56 Figure 98. 4. The Application Software Download dialog box appears, allowing selection of chiller products. For Product Name, select RTHD, and for Version, select 3.03 (or newer). Then click Upgrade Device. Note: If version 3.03 (or newer) does not appear for selection, obtain that or a newer version and install it into Tracer TU on the service computer.

  • Page 57: Drive Settings

    Important: Any AFDR drive module menu parameter numbers not listed in this manual are non- Trane specific program parameters. All non- Trane specific program parameter values have been set by the manufacturer before shipment, to provide optimum drive performance. Under...

  • Page 58: Installation And Startup

    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 59 Installation Table 17. Non-compressor specific parameters Description Values 0-03 Region Settings [1] North American 0-20 Display Line 1.1 Small [1612] Motor Voltage 0-24 Display Line 3 Large [1617] Speed [RPM] 0-40 [Hand on] Key on LCP [0] Disabled 0-41 [Off] Key on LCP [0] Disabled 0-60 Main Menu Password...

  • Page 60: Startup Test Log

    Start-Up Test Log Chiller Settings Note: For start-up procedure, see Optimus™ Water-Cooled Chillers, Model RTHD Installation, Operation, and Maintenance (RTHD-SVX01*-EN). Settings Settings Tab Chiller Front Panel Chilled Water Setpt (°F) Front Panel Current Limit Setpt (RLA) Differential to Start (°F) Differential to Stop (°F)

  • Page 61: Operator Log

    Start-Up Test Log Operator Log Chiller Log Run Time Main Tab 15 min 30 min 1 hr Chiller Mode Evap Ent/Lvg Water Temp Cond Ent/Lvg Water Temp Active Chilled Water Setpoint (°F) Average Line Current (%RLA) Active Current Limit Setpoint (%RLA) Software Type Software Version Reports Tab...

  • Page 62: 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 63: Recommended Periodic Maintenance And Inspection

    For variable frequency drives handling live electrical components perform these or other energy storing components provided by Trane tasks. or others, refer to the appropriate manufacturer’s literature for allowable waiting periods for discharge of 1.

  • Page 64: Wiring Information

    Wiring Information Wiring Diagram Matrix Table 18. Wiring Diagram Number Description 5071-1783 RTHD AFD, RETROFIT SCHEMATIC Note: Wiring diagrams are available via e-Library. Field Wiring Figure 103. Field wiring connections NOTES: DASHED LINES INDICATE FIELD WIRING BY OTHERS. PHANTOM LINES INDICATE ALTERNATE CIRCUITRY OR AVAILABLE SALES OPTIONS.
  • Page 65 Wiring Information Wire Harness Details Figure 104. Wire harness details HARNESS P/N INDEX WIRE NO. / DESCRIPTION GAUGE / SIZE LENGTH (IN) PWR - 1-L1, 1-L2, 1-L3 50711800 1 AWG FLEXIBLE CONDUIT 2.5 INCH 54.75 PWR - 2L-1, 2L2, 2L3 50711801 1 AWG FLEXIBLE CONDUIT...
  • Page 66 Notes SO-SVN048A-EN...
  • Page 67 Notes SO-SVN048A-EN...
  • Page 68 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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