Trane AFDW Series Installation Instructions Manual
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Trane AFDW Series Installation Instructions Manual

Trane AFDW Series Installation Instructions Manual

Retrofit air-cooled adaptive frequency drive
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Installation Instructions
AFDW Retrofit Air-Cooled Adaptive
Frequency Drive™
For Use with RTAC Chillers with Symbio™ controls
Model Number:
RTAC
This document applies to service offering applications 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.
November 2024
product image goes here, centered on page
SAFETY WARNING
SO-SVN063A-EN

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Summary of Contents for Trane AFDW Series

  • Page 1 Installation Instructions AFDW Retrofit Air-Cooled Adaptive Frequency Drive™ For Use with RTAC Chillers with Symbio™ controls product image goes here, centered on page Model Number: RTAC This document applies to service offering applications 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: Warnings, Cautions, And Notices

    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

    Table of Contents General Information ....Installation – Electrical ..... . . 5 Other Required Manuals .

  • Page 5: General Information

    UPS on the chiller controls. This manual describes installation of an AFDW retrofit air- cooled Adaptive Frequency Drive™ package in place of an existing starter on a Trane RTAC helical rotary liquid chiller with ® Tracer UC800 and Symbio 800 controllers. If the chiller has ®...

  • Page 6: Model Number Descriptions

    Model Number Descriptions Digit 1, 2, 3 — Unit Function Digit 13 — Condenser Ambient Digit 26 — Circuit Breaker (Compr 2A) AFD= Adaptive Frequency Drive Standard Ambient Low Ambient Circuit Breaker; 10K SCWR: Digit 4 — Development Sequence High Ambient 10K, 3P, 600V, 250A (LA) Frame Development Sequence Wide Ambient...

  • Page 7: Environmental Conditions

    Environmental Conditions Important: The location of the AFDW is important for proper performance and operating life. Unless designed for special environments, install the drive controller in an area where the following conditions exist: • Sufficient Airflow: Minimum clearance for air circulation is 6 inch (15.25 cm) at each cabinet vent location.

  • Page 8: Nameplates

    The AFDW nameplate label (Trane Motor Controller Nameplate) is customized for each AFDW order and is specific to each unit. The Trane Motor Controller Nameplate must be installed on the Trane TR200 drive. Remove the adhesive backing and locate the label on the TR200 drive next to the AFD nameplate.

  • Page 9: Dimensions

    Dimensions Unit Submittal Drawings Figure 1. Unit mount submittal drawing Control Panel SO-SVN063A-EN...

  • Page 10: Pre-Installation

    Pre-Installation Required Tools Standard service tools are required to perform the majority of • 3/8-inch Drill Bit for Display Arm the work. Following is a partial list of field supplied hardware/ • 25-inch Hole Saw (Close Mount Kit Only) software components and special tools required to perform the •...
  • Page 11 Pre-Installation Table 2. RTAC AFD upgrade kit – standard kit components (continued) Kit Part Number Part Number Mnemonic Description X39003759010 Label, Technical support X39001352010 18503790100 Nameplate (a) See Table 5, p. 12 for enclosure components. Table 3. RTAC AFD upgrade kit – configurable components Category Kit Part Number Part Number...
  • Page 12 Pre-Installation Table 4. RTAC AFD upgrade kit – optional unit mount add-on kit Kit Part Number Part Number Mnemonic Description 127500340001 Unit Mount Kit Components 572289790001 Frame; RTAC AFD Enclosure, Unit Mount 507120520001 Screw; hex head 1/2 inch x 1-1/2 inch, Grade 8 507120510001 Washer;...

  • Page 13: Afd Sizing

    Pre-Installation Table 6. Components – AFD enclosure, optional unit mount frame assembly (572289790001) Part Number Description 572289790001 Assembly; AFD Mount 572289740001 Channel; C3 X 4P1 X 29.2" 572289750001 Channel; C3 X 4P1 X 22.7" 572289760001 Channel; C3 X 4P1 X 15" 572289770001 Channel;...

  • Page 14: Global Connector Harnesses

    Pre-Installation Table 7. AFD sizing chart (continued) Standard or Low Ambient High or Wide Ambient Unit Size AFD Sizing AFD Sizing (Tons) Compr 1A Compr 2A Compr 1A Compr 2A N110 N110 N132 N132 N110 N110 N110 N110 N110 N110 N132 N132 (a) Model number digit 13 = N or L.

  • Page 15: Required Parts - Not Supplied

    Configuration and setpoint values are exported from the Drive and Compressor Motor! DynaView control in order to successfully configure the Trane assumes no responsibility for equipment upgraded Symbio™ 800 controller. Using KestrelView™ on a damage caused by use of improper cable lengths. The...
  • Page 16 Pre-Installation Figure 5. Select reports Figure 6. Accessing chiller service report Figure 7. Chiller service report (example) SO-SVN063A-EN...

  • Page 17: Oil And Refrigerant Removal

    Pre-Installation Oil and Refrigerant Removal each compressor oil filter (13 and 35). Otherwise, add the entire charge for single compressor circuits. 13. Repeat steps 6 through 12 for circuit 2. WARNING 14. Perform pressure test. Refrigerant under High Pressure! 15. Evacuate the unit to a minimum of 500 microns and perform pressure rise test.

  • Page 18: Component Location

    Pre-Installation Component Location Figure 8, p. 18, for RTAC circuits with a single compressor. Figure 9, p. 19, for circuits with dual compressors. Table 8, p. 20, for component number descriptions. Figure 8. Component locations – RTAC single compressor circuits SO-SVN063A-EN...
  • Page 19 Pre-Installation Figure 9. Component locations – RTAC dual compressor circuits SO-SVN063A-EN...
  • Page 20 Pre-Installation Table 8. Components Ref Number Description Notes All Circuits (single and dual compressor) – See Figure 8, p. 18 Figure 9, p. Suction Pressure Transducer Suction Service Valve Relief Valve - 200 psi Leaving Water Temperature Sensor Service Valve 3/8” Liquid Level Sensor Oil Return Shutoff Valve Freeze Protection Plug...

  • Page 21: Installation

    For variable frequency drives The AFDW kit has the following options: or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s • Unit mounting kit for mounting the AFD enclosure directly literature for allowable waiting periods for discharge of to the RTAC chiller base.
  • Page 22 Installation Figure 10. Enclosure dimension drawing AFD Drive Enclosure Unit Mount Option 2. After determining the location for the enclosure, use the template provided in the kit to mark the drilling locations for Figure 1, p. 9 for unit mount dimensions. the mounting holes on the RTAC chiller base.
  • Page 23 Installation Figure 13. Drill pilot holes in base Table 9. Weights (lb) AFD Drive Enclosure Combined AFD Drive Unit Mounting Weight Weigh and Enclosure Weight Bracket 5. Using a suitable lifting device, hoist the mounting bracket into place and secure to the unit using four grade 1/2-inch bolts and washers.

  • Page 24: Rigging And Lifting Procedures For Afdw Drive

    Installation Mounting the AFD Inside the Enclosure 3. Remove the top cover of the enclosure as shown in figures below. 1. Remove the bottom front access panel of the enclosure as shown in figures below. Figure 20. Remove top cover of the enclosure Figure 17.

  • Page 25: Unit Lifting Points - Preferred Lifting Method

    Installation Unit Lifting Points – Alternative Lifting WARNING Method Improper Unit Lift! For single hoisting device lift, a spreader bar must be used to allow adjustment of rigging for a balanced lift around its center Failure to properly lift unit in a LEVEL position could of gravity and full control.

  • Page 26: Block Off Plate Installation

    Installation Note: The brackets on the enclosure can be used to lift the 2. Install block off plates at the top of the drive using the existing screw (removed previously) and the provided enclosure with the drive mounted inside. See figure hardware.

  • Page 27: Weather Proofing Enclosure

    Installation Weather Proofing Enclosure 1. Apply sealing gasket to the front door of the AFD enclosure. Figure 31. Gasket installed 2. Apply supplied caulking sealant to all seams and gaps of the inside of the AFD enclosure as shown in figures below. Figure 32.

  • Page 28: Installation - Electrical

    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 29 Installation – Electrical Figure 38. Circuit breaker installed Figure 40. Conduit holes 4. Route wire and conduit to the AFD enclosure as shown below. Figure 41. Route power wire to AFD WARNING Conform to All Applicable National, State, and Local Electrical Codes! Failure to follow all applicable codes could result in an arc flash event, electrocution, explosion, or fire, which could result in death or serious injury.

  • Page 30: Afd Enclosure Wiring

    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 31 Installation – Electrical 3. Install load side wire to the input of the AFD. 6. Cut the bottom portion of the touch safe covers to the correct size for both input and output power wire for the Figure 46. Load side AFD wiring AFD.

  • Page 32: Compressor Wiring

    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 33: Control Wiring

    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: Equipment Damage

    Installation – Electrical 4. Connect global connector buss from the AFD to the Figure 64. Use thermal paste on sensor Symbio™ 800 module. Figure 63. Connect global connector buss to Symbio 800 iii. Use insulating tape to cover the sensing element as shown in figures below.
  • Page 35 Installation – Electrical Control Device Wiring Tables Note: For most connections, existing unit wiring can be used. See existing unit schematic and RTAC AFD retrofit schematic. Circuit 1 Connections Table 10. Relay 1K20, 2-compressor units Terminal Relay 1K20 Description Mating Connection Description Notes 9/11...
  • Page 36 Installation – Electrical Table 14. 1U1 AFD, all units Terminal - AFD Description Mating Connection Description Pin 61 Modbus (RS485) Com (BLK) Pin 2 (IMC1) Symbio™ 800 Modbus (RS485) Com (BLK) Pin 68 Modbus (RS485) + (BLU) Pin 3 (IMC1) Symbio 800 Modbus (RS485) + (BLU) Pin 69 Modbus (RS485) - (GRY)
  • Page 37 Installation – Electrical Table 18. Relay 2K20, 4-compressor units (continued) Terminal Relay 2K20 Description Mating Connection Description Notes 6/24 N.O. Contact 2TS4 Temp Switch, Control Panel 2 Ventilation 11/31 N.O. Contact 1TB5 1-8 115 V Hot 7/34 N.O. Contact 4TS1 Temp Switch 2U1 AFD Enclosure 13/A1 Coil - Hot...

  • Page 38: Symbio 800 Software Installation

    A0 through V0) or RTAC-SVC026*- saved chiller service report. EN (for units with design sequence W0 through Z0) has been completed. 4. Obtain the latest Symbio 800 firmware from the Trane software download site. Reference Documents 5. Upgrade controller firmware as follows: •...
  • Page 39 Installation – Electrical 7. After the configuration is saved, Tracer TU will navigate to LLID Binding view. Check for red boxes, which indicate a listed device has not been bound. Figure 69. Binding view of LLIDs SO-SVN063A-EN...

  • Page 40: Drive Settings

    Table 22. Compressor specific parameters (motor frame/ voltage/Hertz) Important: Any AFDW drive module menu parameter numbers not listed in this manual are non- Compressor Size Trane specific program parameters. All non- N1, N3 N2, N4 or Trane specific program parameter values have Description or M3...
  • Page 41 Installation – Electrical Table 23. Non-compressor specific parameters Description Values 3-02 Min Reference 30Hz 3-41 Ramp 1 Ramp Up Time 3-42 Ramp 1 Ramp Down Time 4-10 Motor Speed Direction [0] Clockwise 4-12 Motor Speed Low Limit [Hz] 30Hz 4-18 Current Limit 128% 4-19...

  • Page 42: Chiller Setting Logs

    Chiller Setting Logs Start-Up Test Log Note: For start-up procedure, see Series R® Air-Cooled Helical Rotary Liquid Chillers, Model RTAC Installation, Operation, and Maintenance (RTAC-SVX01*-EN). Table 24. RTAC start-up test log RTAC START-UP TEST LOG Model # Job Name Job Location CRC # Serial # Job Elevation (ft.

  • Page 43: Operator Log

    Chiller Setting Logs Operator Log Table 25. RTAC operator log RTAC CHILLER LOG Job Name Job Location Model # Serial # Status View: * Chiller Tab: 15 min 30 min 45 min 15 min 30 min 45 min Operating Mode Outdoor Air Temperature °F or °C Active Chill Water Setpoint...
  • Page 44 Chiller Setting Logs Table 25. RTAC operator log (continued) RTAC CHILLER LOG Compressor 2A Tab Compressor 2B Tab Operating Mode Hours Hrs/mins Hrs/mins Starts 15 min 30 min 45 min 15 min 30 min 45 min Phase A - B Voltage volts Average Line Current %RLA...

  • Page 45: 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 46: Recommended Annual Maintenance And Inspection

    For variable frequency drives the cabinet at door and cabinet vents, to avoid electrical or other energy storing components provided by Trane or others, refer to the appropriate manufacturer’s hazards.

  • Page 47: Wiring Information

    Wiring Information Wiring Diagram Matrix Table 26. Wiring diagrams Wiring Diagram Number Description 5071-3116 RTAC AFD Retrofit for Symbio™ 800 Controls, 2-Compressor Schematic 5071-3117 RTAC AFD Retrofit for Symbio 800 Controls, 3-Compressor Schematic 5071-3118 RTAC AFD Retrofit for Symbio 800 Controls, 4-Compressor Schematic Note: Wiring diagrams are available via e-Library.

  • Page 48: Field Wiring

    Wiring Information Field Wiring Figure 70. Field wiring connections (a) See “Control Device Wiring Tables,” p. 35 for connections. See tables in section “Parts,” p. 10 for harness part numbers. SO-SVN063A-EN...
  • Page 49 Notes SO-SVN063A-EN...
  • Page 50 Notes SO-SVN063A-EN...
  • Page 51 Notes SO-SVN063A-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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