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Trane Technologies Symbio CVRF UCP1 Installation Instructions Manual

Chiller retrofit replacement panel
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Installation Instructions
CVRF - Symbio™ Chiller Controller
Retrofit Replacement Panel UCP1
Model Number:
CVRF
This document applies to service offering applications only.
Distribution/use of this document is limited to the Trane sales and service organization in support of the Symbio™ control
panel upgrade and is not intended for independent third party use or for use apart from the Symbio™ control panel.
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-SVN035A-EN

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Summary of Contents for Trane Technologies Symbio CVRF UCP1

  • Page 1 Installation Instructions CVRF - Symbio™ Chiller Controller Retrofit Replacement Panel UCP1 Model Number: CVRF This document applies to service offering applications only. Distribution/use of this document is limited to the Trane sales and service organization in support of the Symbio™ control panel upgrade and is not intended for independent third party use or for use apart from the Symbio™...

  • Page 2: Warnings, Cautions, And Notices

    Introduction Read this manual thoroughly before operating or servicing this unit. WARNING Proper Field Wiring and Grounding Warnings, Cautions, and Notices Required! Safety advisories appear throughout this manual as required. Failure to follow code could result in death or serious Your personal safety and the proper operation of this machine injury.

  • Page 3: Revision History

    Introduction WARNING Refrigerant under High Pressure! Failure to follow instructions below could result in an explosion which could result in death or serious injury or equipment damage. System contains refrigerant under high pressure. Recover refrigerant to relieve pressure before opening the system.

  • Page 4: Table Of Contents

    Table of Contents General Information Communication Device Mounting ..25 ..... . . 5 About This Manual .

  • Page 5: General Information

    General Information About This Manual 4. Actuator mounting includes removal of the old actuator and installation instructions for the stepper IGV actuator. This manual is provided to support the factory-assembled 5. Accessories and options installation includes information CVRF complete control panel for former factory installed UCP1 on how to install and wire any optional LLIDs or control panels.

  • Page 6: Symbio™ Panel Conversion Kit Contents

    General Information If nameplate cannot be removed and relocated, copy Figure 1. Symbio nameplate example information from old nameplate onto new vinyl nameplate included in retrofit package. Symbio™ Panel Conversion Kit Contents TRACER® ADAPTIVIEW™ RETROFIT CONTROLS FOR USE ON LIQUID CHILLERS Each Symbio panel conversion kit includes a pre-assembled MODEL NO.: CVRF21000A01FFB0001000000C00010002...
  • Page 7 General Information Table 2. LLID legend and identification (continued) LLID Name Description Part Number AFD starter nodule on sub plate without power supply Assembly for unit mount UCP2 AFDB, AFDC, and non- 018504340100 or LV PTs communicating AFDH AFD starter nodule on sub plate with power supply Assembly for remote mount UCP2 AFDB, AFDC, and 018504370100 without LV PTs...

  • Page 8: Notes For Remote Starter And Afd Installations

    General Information Table 4. Field installed LLIDs for various options (continued) 0 to 50 Temp or 475 Starter Color DHVBI DBO HPRO QRO DAIO Sensor Module Display WiFi AirFi Heat Recovery / Aux Condenser Water Flow Display, Standard Accuracy Heat Recovery / Aux Condenser Water Flow Display, High...
  • Page 9 General Information • A heat conductive adhesive will be required when • A control power transformer may be required if the existing mounting the bearing temperature sensors to the bearing transformer in the starter panel does not have a minimum ®...

  • Page 10: Model Number Descriptions

    Model Number Descriptions For service purposes, Symbio™ 800 0T = >600 V, 24–144 A, 4" hole, CTs Digit 20 — Tracer Interface Control Panel Upgrade Kits are assigned a None 0U = >600 V, 120–252 A, 4" hole, CTs With generic BAS multiple character alphanumeric model ®...
  • Page 11 Model Number Descriptions Digit 33 — Starter Type No starter module Starter module current limit 3 phase Starter module with plate for low voltage unit starter Starter module with plate for low voltage remote starter Starter module with plate for unit AFD Starter module with plate for remote AFD...

  • Page 12: Installation

    Installation Control Panel Conversion 2. Determine how each of the field-adapted control functions just identified in Step 1 will be assumed by the new Symbio chiller control panel. The control panel conversion will consist of removing, marking, and retaining selected wires in the existing control panel. The 3.

  • Page 13: Oil Pressure Transducer Installation

    Installation Figure 3. Typical UCP1 panel before retrofit Figure 4. Typical existing UCP1 control panel assembly 7. Oil differential pressure switch (OPC) (1S2): The OPC will be replaced by individual oil pressure 5. Disconnect all field-installed wiring entering the control transducers outside the new control panel.

  • Page 14: Removal Of Existing Panel

    Installation 2. Remove oil differential pressure switch and wires from enclosure. Symbio does not require the switch function so WARNING the switch and associated wiring can be discarded. PPE for Arc/Flash Required! 3. Once the new panel is installed attach pressure Failure to wear appropriate PPE could result in death or transducers to the cabinet using adhesive pads and wire serious injury.
  • Page 15 Installation Table 6. Field wiring cross reference, UCP1 to new panel From Existing Wire # (in Existing Panel) (in New Panel) Description or Comments 1TB3-16 1A13 J2-1 External Auto/Stop 1TB3-17 1A13 J2-2 External Auto/Stop 118A 1TB3-18 1A20 J2-3 4B12 free cooling valve closed 119A 1TB3-19 1A20 J2-4...

  • Page 16: Motor Temperature Devices

    Installation Table 6. Field wiring cross reference, UCP1 to new panel (continued) From Existing Wire # (in Existing Panel) (in New Panel) Description or Comments 1X1-18 from 5K2, 5S3 flow switches Ground 1X1-Ground-21 Panel ground (from starter) 1TB5-1 1X1-1 120 Vac power to control panel from starter 2TB1-1 2B/F 1TB5-2 1X1-5...
  • Page 17 Installation Figure 7. Bolting display arm to the panel 2. Securely fasten the Tracer® AdaptiView™ display to the mounting plate on the end of the display arm with the hardware provided. Figure 8. Attaching Tracer AdaptiView display to arm 3. After the display is attached, recheck the arm tension. The arm tension should be set so that the display does not spring up or sag down out of the position it is moved to by the operator.

  • Page 18: Adjusting Tracer® Adaptiview™ Display Arm

    Installation 5. Use a 13 mm wrench to adjust the bolt (item labeled 4 in Figure 9, p. 18) that allows the entire display arm to swivel CAUTION to the left and right. Tension in Display Support Arm! Sensor Installation and Wiring Failure to follow instructions below could result in unexpected movement of the spring-loaded support arm which could result in minor to moderate injury.

  • Page 19: Mounting Sensors Externally

    Installation Locate sensor at the bottom of the condenser or on the Figure 11. Sensor mounting with Armaflex insulation condenser liquid line upstream of any orifices or float valves. Note: If unit has an EarthWise™ purge, PRGD (CH530 controls), the sensor bound as Condenser Saturated Refrigerant Temperature Sensor (used as Purge Liquid Temperature) cannot be used and will need to be unbound.

  • Page 20: Inlet Guide Vane Actuator Installation

    Installation Inlet Guide Vane Actuator CAUTION Installation Equipment Damage! Failure to ensure that the 0 degree vane position WARNING corresponds with the actuator fully closed when mounting the actuator could result in severe damage to Hazardous Voltage w/Capacitors! the machine. Failure to disconnect power and discharge capacitors before servicing could result in death or serious injury.
  • Page 21 Installation WARNING WARNING Hazardous Voltage w/Capacitors! PPE for Arc/Flash Required! Failure to disconnect power and discharge capacitors Failure to wear appropriate PPE could result in death or before servicing could result in death or serious injury. serious injury. Disconnect all electric power, including remote On this unit, if the handle shield is cracked the circuit disconnects and discharge all motor start/run breaker could arc/flash when reset.

  • Page 22: Purge Control Installation

    Installation Table 7. Cables shipped for various options CAB01146 CAB01150 branch M CAB01147 CAB01148 CAB01149 extension M CAB01152 CAB01154 CAB01155 to 2F 500 branch M to branch M to extension M to F 2000 extension M to extension M to extension F to 2F 1000 mm 3F 500 mm...

  • Page 23: Lontalk® Option Installation

    Installation Tracer® Symbio™ retrofit controls. If the purge is a new Figure 17. LON installation with the Tracer Symbio, then skip to Step 1. The Compressor running LLID (3A6) will not be needed, disconnect and remove. 2. The Condenser Saturated Refrigerant Temperature LLID (purge liquid temperature) will not be needed, disconnect and remove.

  • Page 24: Air-Fi Installation

    Installation Figure 19. Wi-Fi wiring, ref. 50712737 Figure 22. Air-Fi wiring, ref. 50712737 OPTIONAL OPTIONAL 4K48 WI-FI AIR-FI ANTENNA INTERFACE 1X3-1 1X3-2 BACKNET MODBUS MACHINEBUS 1X3-3 OPTIONAL SERVICE 1A22 SYMBIO800 UNIT CONTROLLE R TOOL ETHERNET MODEM BACKNET MODBUS MACHINEBUS Air-Fi Installation SERVICE 1A22 SYMBIO800 UNIT CONTROLLER TOOL...

  • Page 25: Communication Device Mounting

    Installation Communication Device Mounting Figure 24. Polycarbonate box with magnets There devices are intended to be mounted on polycarbonate boxes. There are two installation approaches, 1. Each device is mounted independently on a small box (0185-0426-0100). 2. Multiple devices are mounted on a large box (0185-0427-0100).

  • Page 26: Water Flow Measurement

    Installation Water Flow Measurement Figure 30. Fabricated marine - ¾ inch NPTI port Standard Accuracy Option Water flow is determined by measuring pressure drop across heat exchanger using water pressure transducer LLID’s. Standard flow measurement transducers can be ordered for condense, evaporator and auxiliary/heat recovery heat exchangers.The standard accuracy part is (0185-3475-0100), there are two transducer (0185-3475-0100) provided per heat...

  • Page 27: High Accuracy, Customer Provided Meter Option

    Installation Water Box Valve Mounting (Rosemont, etc.) This option allows monitoring of condenser, evaporator flow, and auxiliary heat exchangers. Install needed DAIO LLID(s) (BRD04873) in CVRF control panel. 1. LLID (1A21) is needed for EVAP and COND water flow. Connect flow meter wires to 1A21-J2-1 and 1A21-J2-1 for EVAP, 1A21-J2-4 and 1A21-J2-5 for COND.

  • Page 28: Energy Meter Option Installation

    Installation Energy Meter Option Installation Modbus communications is by shielded 14–26 AWG cable from meter to Symbio module. Please install 120 OHM resistors at first and last modules on Modbus daisy chain. The Trane energy meter provides instrument grade accuracy power, volts and amps monitoring of Symbio™...

  • Page 29: Oil Pump Control

    Installation Figure 41. Rogowski CTs Figure 43. 120 Vac oil pump starter capacitor and starter relay (left) Figure 42. Energy meter wiring, 480V and low application, ref. 50712756 DETAIL A ENERGY METER OPTION TO 1X3 LINE 99 2T50 Line Voltage Pump Installation 2T51 2T52 1.

  • Page 30: Installation Of Oil Pump Motor Wiring And Terminals

    Installation Installation of Oil Pump Motor 5. Attach Term-Lok adapters (KIT07955 included with kit)) and wire per schematic. Wiring and Terminals The CVRF installation will relocate the oil pump relay to the control panel. Follow the below steps for installation. 1.

  • Page 31: Starter Work

    Starter Work Important: Symbio™ 800 requires a closed transition WARNING starter. If the existing starter is an open transition style, it must be replaced. Electrical Fault! Starter Sub-Panel Failure to follow instructions below could result in death or serious injury from burns or electric shocks. Tracer® The Symbio starter module is provided on an assembled sub- AdaptiView™...
  • Page 32 Starter Work Figure 46. Mounting starter sub-box Figure 48. Low voltage potential transformer connections Starter control and power wires are connected to the terminal block on the right side of the sub-panel. CTs and starter module communications and power wires are connected directly to starter module on the left side.
  • Page 33 Starter Work Figure 50. Pilot relay switching configuration Figure 51. Wye delta interlock and pilot relay wiring SO-SVN035A-EN...

  • Page 34: Starter Sub-Box Installation

    Starter Work Figure 52. Autotransformer interlock and pilot relay wiring Starter Sub-Box Installation drilling holes in starter cabinet, take care to avoid getting metal shavings into starter cabinet. The starter sub-box is intended for remote mount starter c. Drill 3/4-inch or 1-inch hole through panel and starter installations where due to their custom nature there isn’t room cabinet, near top of cabinet, to accommodate wires for mounting the sub-panel in the starter enclosure and/or such...

  • Page 35: Starter Sub-Panel Installation

    Starter Work Starter Control Planning Figure 53. Starter sub-panel with PTs, CTs and power supply WARNING Electrical Fault! Failure to follow instructions below could result in severe injury and equipment damage. Tracer® Adaptiview™ requires the use of contactor auxiliary switches to prevent simultaneous closure of run and shorting contactors.

  • Page 36: Starter Sub-Panel

    Starter Work While this conversion procedure specifically applies to wye- All sub-panels have the option of a 24 Vdc power supply to be delta starters, it can be adapted to successfully modify other used on remote mounted starters. types of starters for operation with a Symbio™ starter module. Installation steps are as follows: 1.

  • Page 37: Control Power Transformer

    Starter Work Figure 55. Starter sub panel customer connections 5071-0496 Current Transformers, CTs Notes: • Be sure to refer to the wiring diagrams listed in “Wiring Diagram Matrix,” p. 43 as you review the following WARNING instructions. The wire numbers and component designations indicated in these steps appear in these Hazardous Voltage w/Capacitors! figures.

  • Page 38: Ct Work

    Starter Work transformer (CT) application, rather than a single CT which is Figure 56. Current transformer, single turn-down a common option on low voltage applications (600 Vac or less). Refer to CVRD-SVN11*-EN for wiring of medium voltage CT DIM “B” applications.
  • Page 39 Starter Work In some cases starters shipped with ammeters. The meters X13580048010 (TRR00448) and X13580048020 (TRR00449) can remain if they have their own CTs. (each of these CTs have a 5 amp secondary). The second stage consists of small CT transformers that reduce the When using existing CTs having a nominal chiller current to 5 nominal 3.6 amp signal to the 100 mA value used by the starter amp ratio (i.e., 200:5), it is necessary to install or have ordered...
  • Page 40 Starter Work Figure 57. Secondary CT used with 5 amp primary CT, X13580266-01, TRR00975 Primary Leads BLACK Primary Secondary WHITE BROWN Secondary Leads Front View / Primary Bottom View Schematic Front View / Secondary Figure 58. Dual CT wiring example SO-SVN035A-EN...

  • Page 41: Potential Transformers, Optional Pts

    Starter Work Potential Transformers, Optional WARNING PPE for Arc/Flash Required! Failure to wear appropriate PPE could result in death or WARNING serious injury. On this unit, if the handle shield is cracked the circuit breaker could arc/flash when reset. Hazardous Voltage w/Capacitors! To avoid being injured, technicians MUST put on all necessary Personal Protective Equipment (PPE), in Failure to disconnect power and discharge capacitors...

  • Page 42: Starter Wiring

    Starter Work Starter Wiring Table 13. Starter wiring (continued) Wire # From Terminal To Terminal 239A 2U1 J3-6 2A1 J5-4 WARNING 240A 2U1 J3-7 2A1 J5-5 Proper Field Wiring and Grounding 241A 2U1 J3-8 2A1 J5-6 Required! 101A 2U1 J5-1 2A1 J7-1 Failure to follow code could result in death or serious injury.

  • Page 43: Wiring Diagram Matrix

    Wiring Diagram Matrix Table 14. Wiring diagrams matrix Type Number Control Unit Controls 50712737 Unit and Option 50712743 Option 50712746 Option 50712747 Legend 50712748 Field Connection Dia 50712754 Comm Panel Dia 50712779 Starters Wye-Delta TS 50710488 X-Line TS 50710489 Primary Reactor TS 50710490 Auto X-Former TS 50710491...
  • Page 44 Trane - by Trane Technologies (NYSE: TT), a global climate innovator - creates comfortable, energy efficient indoor environments for commercial and residential applications. 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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