Trane Voyager III User manual

July 2009 PART-SVN121A-EN
Installation
Variable Frequency Drive
Conversion TR1 to TR200
IntelliPak™ I and II and Voyager™ III only
Models: Only Clarksville built units with factory installed VFDs. This includes the following Voyager III
commercial units with the VAV option and IntelliPak I and II units with the VAV and/or Statitrac™
option built prior to Trane TR200 drive unit installation.
S*HF 20 to 75 ton (IntelliPak I) TC, YC and TE 27½ to 50 ton (VIII)
S*HG 90 to 130 ton (IntelliPak I)
S*HJ 90 to 150 ton (IntelliPak II)

© 2009 Trane All rights reserved PART-SVN121A-EN
Warnings, Cautions and Notices
Warnings, Cautions and Notices. Note that warnings, cautions and notices appear at
appropriate intervals throughout this manual. Warnings are provided to alert installing contractors
to potential hazards that could result in personal injury or death. Cautions are designed to alert
personnel to hazardous situations that could result in personal injury, while notices indicate a
situation that could result in equipment or property-damage-only accidents.
Your personal safety and the proper operation of this machine depend upon the strict observance
of these precautions.
Note: This document is customer property and must be retained by the unit's owner for use by
maintenance personnel.
WARNING
Personal Protective Equipment (PPE) Required!
Installing/servicing this unit could result in exposure to electrical, mechanical and chemical
hazards.
• Before installing/servicing this unit, technicians MUST put on all Personal Protective
Equipment (PPE) recommended for the work being undertaken. ALWAYS refer to appropriate
MSDS sheets and OSHA guidelines for proper PPE.
• When working with or around hazardous chemicals, ALWAYS refer to the appropriate MSDS
sheets and OSHA guidelines for information on allowable personal exposure levels, proper
respiratory protection and handling recommendations.
• If there is a risk of arc or flash, technicians MUST put on all necessary Personal Protective
Equipment (PPE) in accordance with NFPA70E for arc/flash protection PRIOR to servicing the
unit.
Failure to follow recommendations could result in death or serious injury.Introduction
This manual describes the installation procedures required to retrofit TR1 Variable Frequency
Drives (VFD).
Trademarks
Trane, the Trane logo, IntelliPak, Statitrac, and Voyager are trademarks of Trane in the United States
and other countries. All trademarks referenced in this document are the trademarks of their
respective owners.
ATTENTION: Warnings, Cautions and Notices appear at appropriate sections throughout this
literature. Read these carefully.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, could result in
minor or moderate injury. It could also be used to alert against unsafe practices.
NOTICE:Indicates a situation that could result in equipment or property-damage only accidents.

Table of Contents
PART-SVN121A-EN 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removing the Existing VFD and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VFD Removal from Back Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power Supply Wiring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control Wiring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TR1 Keypad Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation of TR200 VFD and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
VFD and Back Panel Assembly for TR200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TR200 Drive Installation instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power Supply Wiring to TR200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Control Wiring to TR200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Keypad and Cable Adapter Assembly Installation for TR200 . . . . . . . . . 16
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TR200 VFD Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
VFD Programming Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wiring Diagram Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4PART-SVN121A-EN
General Information
About This Manual
The step-by-step instructions outlined in this manual describe the procedures required to
successfully retrofit a TR1 on 20 ton to 150 ton IntelliPak™ I and II rooftop air conditioning and 27½
to 50 ton Voyager™ III rooftop air conditioning units to a Trane TR200 VFD drive. For help selecting
the proper parts for this work, refer to general service bulletin PART-SVB24A-EN or the most current
version of that same literature.
The installation instructions in this manual are divided into three general topic areas:
• Removal of existing TR1 VFD and components.
• Installation of replacement TR200 VFD and components.
• TR200 programming of parameters.
Follow start-up and trouble shooting procedures outlined in the service manuals of the unit and/
or the literature that is included with this TR200 control.
Tools Required
Very few tools are required to perform this installation. A service technician with a well-stocked tool
chest should have the right tools to perform the job; However, a large-frame VFD will require a
crimping tool for ring lugs and a drill with a #21 (4mm) drill bit sized to allow a #10-32 screw to
thread into sheet metal.

PART-SVN121A-EN 5
Removing the Existing VFD and Components
The section that follows will give the procedure to remove a TR1 VFD from its panel assembly and
remove the remote keypad in the IntelliPak I, IntelliPak II, and Voyager III main control panels.
Programming parameters are supplied with the VFD and a minimum of five must be set based on
unit specifications, see Table 4, p. 17.
VFD Removal from Back Panel Assembly
Locate the existing TR1 VFD unit enclosure near the return and exhaust section as shown in
Figure 1 and Figure 2, p. 5 for IntelliPak I units, adjacent to the supply/exhaust sections of IntelliPak
II Figure 3, p. 6 and opposite supply fans on the Voyager III units as shown in Figure 4, p. 6.
Identify the correct VFD for replacement. The IntelliPak I and II rooftops can have both supply and
exhaust/return VFDs. The IntelliPak I supply VFD is located on the back panel of the unit enclosure
and the exhaust/return VFD is located on the inner door of the unit enclosure which must be turned
to the open position for the VFD to be removed. The IntelliPak II supply VFD is adjacent to the supply
fan section, and the exhaust/return VFD is adjacent to the exhaust/return fan section. Voyager III
units only have supply VFDs and are located by the supply fan on the opposite side of the unit from
the control panel.
Figure 1. Typical IntelliPak I 20 to 75 ton configuration
SUPPLY FAN VFDSUPPLY FAN VFD
VARIABLE FREQUENCY DRIVEVARIABLE FREQUENCY DRIVE
ENCLOSUREENCLOSURE
EXHAUSTEXHAUST
FANFAN
VFDVFD
RETURN & EXHAUST SECTIONRETURN & EXHAUST SECTION
FILTER
SECTION
EVAP COIL
SUPPLY FAN SECTIONSUPPLY FAN SECTION
CONDENSER FANSCONDENSER FANS
COMPRESSOR SECTIONCOMPRESSOR SECTION
HEAT SECTIONHEAT SECTION
Figure 2. Typical IntelliPak I 90 to 130 ton configuration
HTG ACCESS
PANEL
HEAT SECTION
ELEC CONTROL
ELEC CONTROL
PANELPANEL
SUPPLY FAN SECTION
EVAP COIL
EVAP COIL
FILTER
SECTION
O/A DAMPERSR/A DAMPERS
RETURN & EXHAUST
EXHAUSTEXHAUST
FAN
FAN
VFDVFD
VARIABLE FREQUENCY DRIVEVARIABLE FREQUENCY DRIVE
ENCLOSUREENCLOSURE
SUPPLY FAN VFDSUPPLY FAN VFD
CONDENSER FANS
COMPRESSOR SECTION

6PART-SVN121A-EN
Removing the Existing VFD and Components
Figure 3. Typical IntelliPak II 90 to 150 ton configuration
Return/
Exhaust
Fan
Fresh Air
Dampers
Supply Fan
Condenser
Fans
Compressor
Section
Heating
Section
Exhaust Damper
Hood
Evap Coil
Evap Coil
Controls
Variable
Frequency
Drive (VFD)
Filter Section
Reheat Coil Option
Fresh Air
Dampers
Return Air Dampers
Variable
Frquency
Drive (VFD)
Variable
Frequency
Drive
Baysens set
2-Pc connection
tubings
Variable
Frequency
Drive
Figure 4. Typical Voyager III 27.5 to 50 ton configuration
VFD ACCESS

PART-SVN121A-EN 7
Removing the Existing VFD and Components
WARNING
Hazardous Voltage!
Disconnect all electric power, including remote disconnects and discharge all motor start/run
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 or others, refer to the appropriate manufacturer’s literature for
allowable waiting periods for discharge of capacitors. Verify with an appropriate voltmeter that
all capacitors have discharged. Failure to disconnect power and discharge capacitors before
servicing could result in death or serious injury.
Note: For additional information regarding the safe discharge of capacitors, see
PROD-SVB06A-EN or PROD-SVB06A-FR
Disconnect the following power supply and control wires from each VFD.
Power Supply Wiring Removal
The following instructions relate to either the IntelliPak I, II or Voyager III.
VFD with bypass
– Disconnect power supply wires 1A, 2A, 3A from VFD connection points 91, 92, 93 (L1, L2, L3
respectively) and wires 10A, 11A, 12A, 13A from VFD connection points 96, 97, 98, 95 (T1, T2,
T3, GND respectively).
VFD without bypass
– Disconnect power supply wire 1A, 2A, 3A from VFD connection points 91, 92, 93 (L1, L2, L3
respectively) and wires T1, T2, T3, 13A from VFD connection points 96, 97, 98, 95 (T1, T2, T3,
GND respectively).

8PART-SVN121A-EN
Removing the Existing VFD and Components
Control Wiring Removal
Disconnect all control wires from the TR1 VFD itself and note the connection point numbers. The
TR1 and TR200 have the same connection point numbers. See Tab l e 1 , p . 8 for common control
wires and their connection point numbers. See Ta bl e 2 , p . 8 for VFD keypad cables listed according
to product line and function.
Notes
1. * See Table 2, p. 8 for cable names.
2. ** IntelliPak I 90-130 ton units only.
3. ***VFD with bypass only.
Note: * IntelliPak I 90-130 ton units only.
Table 1. Listed are typical control wires to remove from the TR1 and reinstall on the TR200. This
applies to IntelliPak I, IntelliPak II, and Voyager III drives except as noted. Extra spaces
are included in the table so that any other control wires may be recorded
Control Wire
VFD Connection
Point
18B 12
28A 27
30A 53
31A 55
32A 18
34A*** 05
Jumper wire*** 39 and 04
VFD keypad cable* Sub D Connector (front
of VFD)
45A** 02*
46A** 01*
Table 2. Listed are VFD keypad cables according to product line and VFD function
Product/Function Keypad Cable
IntelliPak I/ Supply Fan CBL3U72-6
IntelliPak I/ Exh/Rtn Fan CBL3U74-6
IntelliPak I/ Supply Fan #1* CBL3U72-6
IntelliPakI/ Supply Fan #2* CBL3U73-6
IntelliPak II/ Supply Fan CBL5U16-6
IntelliPak II/ Exh/Rtn Fan CBL8U17-6
Voyager III/ Supply Fan CBLVFD-6

PART-SVN121A-EN 9
Removing the Existing VFD and Components
WARNING
Heavy Objects!
Do not use cables (chains or slings) except as noted. Each of the cables (chains or slings) used to
lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or
slings) may not be of the same length. Adjust as necessary for even unit lift. Other lifting
arrangements may cause equipment or property-only damage. Failure to properly lift unit could
result in death or serious injury. See details below.
After all cables and power supply wiring have been disconnected, locate and remove the 4
fasteners securing the TR1 drive to its back panel (retain fasteners). The weight of these drives can
vary from approximately 20 to 230 lbs (see Tab l e 3 for estimates). Verify actual weights before
lifting. Follow safe procedures for lifting and removing the supply fan VFD drive and back panel
assembly from the compartment and/or inner enclosure door if exhaust fan VFD is being removed.
TR1 Keypad Assembly Removal
Locate the existing VFD keypad display in the main control box as shown in Figure 5, p. 10.
Using the keypad cable number to verify which keypad is associated with the TR1 drive being
replaced, remove the keypad and keypad cradle (retain cradle screws) from the control box. Leave
the keypad cable as it will be used with the TR200 keypad.
Table 3. Estimated drive weights
Motor
Voltage
Motor
Horsepower
Estimated
Weight
Motor
Voltage
Motor
Horsepower
Estimated
Weight
VAC Hp lb kg VAC Hp lb kg
200 or 230 1.5 20 9 460 or 575 1.5 24 10
200 or 230 3.0 20 9 460 or 575 3.0 24 10
200 or 230 5.0 50 23 460 or 575 5.0 24 10
200 or 230 7.5 50 23 460 or 575 7.5 24 10
200 or 230 10 50 23 460 or 575 10 24 10
200 or 230 15 50 23 460 or 575 15 50 23
200 or 230 20 70 32 460 or 575 20 50 23
200 or 230 25 70 32 460 or 575 25 50 23
200 or 230 30 110 50 460 or 575 30 66 30
200 or 230 40 230 105 460 or 575 40 66 30
460 or 575 50 106 48
460 or 575 60 106 48
460 or 575 75 106 48
460 100 120 55

10 PART-SVN121A-EN
Removing the Existing VFD and Components
Figure 5. Typical existing remote keypad