Trane CVRD User manual

PART-SVN82C-EN
Models: CVRD, KIT09437, CVHE
Installation
Replacement of RLY00765
with KIT09437 using Tracer
CH531 Components
© 2004 American Standard Inc. All rights reserved.

2PART-SVN82C-EN
Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings and Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Literature change history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Field provided material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of existing components . . . . . . . . . . . . . . . . . . . . . . . . 5
Mounting and wiring of LLIDs on backpanel. . . . . . . . . . . . . . . 6
Wiring from backpanel components to starter components . . . 9
Mounting the DynaView human interface . . . . . . . . . . . . . . . . 12
Connecting LLIDs to the inter-processor communication bus . 13
Current transformer (CT) work . . . . . . . . . . . . . . . . . . . . . . . . . 13
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Typical original wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . 15
Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
New control system wiring diagrams. . . . . . . . . . . . . . . . . . . . 18
Appendix C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Configuration view options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Appendix D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Binding view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Appendix E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Setpoint view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

PART-SVN82C-EN 3
General Information
Warnings and Cautions
Literature Change History
PART-SVN82A-EN (March 2004)
Original issue of manual. Describes the installation procedures required to replace
Trane motor protection module, RLY00765. This new KIT09437 uses a portion of the
Tracer™ CH530 controls system.
PART-SVN82B-EN (July 2004)
Revisions to original issue of manual. Updated wiring diagrams and detailed wiring
instructions. Updated to improve layout, content and diagrams.
PART-SVN82C-EN (September 2004)
Minor revisions to manual. Updated ship with list in Table 1 and wiring instructions
found in Table 2. Added information in removal of components.
About this manual
RLY00765, the Trane Motor Protection Module (also called the Electronic Overload,
A1), is no longer available.
KIT09437 is a functional replacement utilizing components used with Tracer CH531
control systems. It is not a complete CH531 controls package installation. It does not
provide distribution fault protection. As configured this kit does not provide
momentary power loss. It can provide phase loss and phase rotation protection along
with standard motor protection features relating to currents and load. This kit will
measure motor currents and provide an analog output to be used as input for existing
temperature control device like the MOD00182.
To properly install this replacement, the technician must have a good, working
knowledge of Tracer CH530 or CH531 control systems.
Three (3) new current transformers (CTs) are required to complete this installation.
They are not included in this kit. They must be ordered separately based on unit RLA.
See Table C4 or C5 in Appendix C for CT sizing details and part numbers.
NOTICE: Warnings and Cautions appear at appropriate sections through-
out 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, may result in minor or moderate injury. It may also be used to
alert against unsafe practices.
CAUTION: Indicates a situation that may result in equipment or property-
damage only accidents.

4PART-SVN82C-EN
General Information
Note 1: Three (3) new current transformers (CTs) are required to complete this
installation. They are not included in this KIT. They must be ordered separately based
on unit RLA. See Table C4 or C5 in Appendix C for CT sizing details and part
numbers.
Field provided material
Some field provided material will be required to perform the replacement. This is a
partial list in addition to normal tools and hardware.
• Wire-red #16 AWG control wire will be required to make the connections
between LLIDs and between LLIDs and existing components.
• Computer and cable for CH530 system programming.
• Wire markers, wire nuts, cable ties, and wire splicers-wire markers will be
required to identify field installed wiring. Wire nuts and splicers may be needed
to splice wires to complete wiring runs. Cable ties may be needed to “clean up”
wiring runs.
• Digital multi-meter, with phase detection capability.
Table 1. Main components of KIT09437
Qty PRIDE part # Description
1 TRR01701 2T5, 120 Vac to 27 Vac transformer
1 BRD02102 2A50, CH531 Power supply
1 BRD02945 2A54, Dual Analog Input/Output (DAIO) LLID
1 BRD02944 2A56, Dual Relay Output (DRO) LLID
1 BRD02942 2A53, Dual Binary Input (DBI) LLID
1 MOD01404 2A55, DynaView human interface
1 BRD02950 2A1, Starter Module
1 TRR01860 2K40, Signal Conditioner [2-10 Vdc to 0-(-8.25) Vdc]
1 BLK00855 8 pin mounting base for Signal Conditioner, TRR01860
2 RLY02547 2K12, Relay, SPDT, 10 amp rating
1 RLY01710 2K11, Relay, DPDT, 12 amp rating
1 no part number Terminal block on Din Rail
3 Not Included
(see note 1)
Current Transformers (CTs)-See note 1

PART-SVN82C-EN 5
Installation
Removal of Components
WARNING
Hazardous Voltage!
Disconnect all electric power, including remote disconnects before
servicing. Follow proper lockout/tagout procedures to ensure the
power can not be inadvertently energized. Failure to disconnect power
before servicing could result in death or serious injury.
It is assumed that all work can be done inside the starter panel. No wiring should
have to be done in the control panel. However, access to the control panel to verify
wiring origins may be necessary.
Removal of Motor Protection Module (A1 or MPM), and Circuit Breakers CB11 and
CB15
1. Before removing the MPM, mark wires landing on V1, V2, D1 (wire #125B) & D2
(wire #127A). These wires will be re-landed on CH531 components.
2. Remove wires from CTs that land on C1-C6. The existing CTs can be removed
and discarded. New CTs will be used with CH531 components. The new CTs are
not included in this KIT. They must be ordered separately. See Table 1 in Appendix
C for details.
3. Remove wires (#130 and #131) for CB11 (Compressor Motor Current Overload)
from F1 and F2. Remove wires (#132 and #133) for CB15 (Distribution Fault) from
E3 and E4. These two circuit breakers, CB11 and CB15, in the starter panel door
will have to be removed as they will no longer be required, the functions will be
performed by the CH531 components.
See Appendix B for wiring details.
A sheet of black vinyl is included so that “patches” may be cut to fit and be placed
over the holes in the starter door where these breakers were mounted.
The Starter Circuit Fault Indicator (CB13) can remain as wired.
Remove the remaining wires from the MPM and remove the module.
When complete the bottom bracket should be left attached to the starter backpanel.
The new component sub-panel sent in this kit will attach to the tapped holes on the
flanges of the existing bottom bracket.

6PART-SVN82C-EN
Installation
Mounting and wiring of LLIDs on backpanels
Install the LLIDs and components on the backpanels provided as shown in Figure 1.
Figure 1. Component layout, top and bottom panels

PART-SVN82C-EN 7
Installation
Figure 2. Panel assembly detail
Assemble the two backpanels using the standoffs and screws provided. The
standoffs must be attached to the bottom panel before it can be mounted in the
starter panel.
First wire the connections between the LLIDs and components on the backpanels
and the terminal block, 2X1 according to the following table. Note this wiring could
be done prior to arrival on jobsite.

8PART-SVN82C-EN
Installation
Note 1: Jumper wire W2 required if Emergency Stop feature not used.
Table 1. Point to point wiring instructions for sub panel
From To
Wire
Number
Component
Number
Terminal Number
(or Wire)
Component
Number
Terminal
Number
(or Wire)
711 Power supply, 2A50 J2-2 Transformer, 2T5 X1
712 Power supply, 2A50 J2-1 Transformer, 2T5 X2
710 Power supply, 2A50 J2-3 2X1, terminal block 2X1-G
713 Transformer, 2T5 H1 2X1, terminal block 2X1-1
714 Transformer, 2T5 H3 2X1, terminal block 2X1-2
708 Signal conditioner, 2K40 1 2X1, terminal block 2X1-1
709 Signal conditioner, 2K40 3 2X1, terminal block 2X1-2
704 Signal conditioner, 2K40 6 Dual Analog
Input/Output, 2A54
J2-3
705 Signal conditioner, 2K40 5 Dual Analog
Input/Output, 2A54
J2-1
706 Signal conditioner, 2K40 8 2X1, terminal block 2X1-V2
707 Signal conditioner, 2K40 7 2X1, terminal block 2X1-V1
Yellow Relay, 2K41 Yellow wire Dual Binary Input,
2A53
J2-1
Orange Relay, 2K41 Orange wire Dual Binary Input,
2A53
J2-2
White/
Yellow
Relay, 2K41 White/Yellow wire 2X1, terminal block 2X1-2
White/
Black
Relay, 2K41 White/Black wire 2X1, terminal block 2X1-14
W2 Dual Binary Input, 2A53 J2-3 Dual Binary Input,
2A53
J2-4
(See Note 1)
700 Starter Module, 2A1 J12-2 2X1, terminal block 2X1-2
702 Starter Module, 2A1 J10-3 2X1, terminal block 2X1-14
none Starter Module, 2A1 J10-1 2K11 Interlock Relay 1
none 2K11 Interlock Relay 3 2K12 Start Relay Yellow
none 2K12 Start Relay Orange 2K11 Interlock Relay Coil
none 2K11 Interlock Relay Coil 2X1, terminal block 2X1-2
703 Starter Module, 2A1 J8-1 2K11 Interlock Relay 3
none Starter Module, 2A1 J8-1 2K12 Start Relay White/Black
none 2K12 Start Relay White/Yellow 2X1, terminal block 2X1-2

PART-SVN82C-EN 9
Installation
Wiring from backpanel components to starter components
Wiring from the terminal block and starter module can be run to various existing
starter terminals. The terminal numbers used for the starter panel assume a Trane-
provided, unit-mounted wye-delta starter. Other starter types may use different
terminal numbering. See Appendix A for a copy of existing wiring diagrams used for
this replacement.
The Starter Module will not control the entire starting process. The original sequence
of events of the existing starter will be preserved. The starter module will initiate the
start signal, provide a transition signal (for wye-delta starters), and monitor motor
currents just as the MPM did. CH531 requires a “transition complete” signal back
from the starter, which the MPM did not.
Note 1: See Figure 3 for details
Note 2: The V1 and V2 terminals refer to the terminals on the U1 Capacity Control
Module located in the unit control panel. These wires were connected to the MPM
terminals V1 and V2. Re-land these wires on terminal block 2X1-V1 and -V2. See
Figure 4 for details.
Note 3: The J2-1 & -3 connections on the starter module are to initiate transition. This
function was performed by the D1 and D2 terminals on the MPM. Wire #125 was
previously connected to D1. Re-land this wire on J2-3. Wire #127 was previously
connected to D2. Re-land this wire on J2-1.
Note 4: The J12-1 input is indicating the starter has transitioned. It is wired on the
NO contacts for the K28 Delta (run) contactor. On some starters, this is listed as
Table 2. Point to point wiring for backpanel to starter components
From To
Wire # Component # Terminal #
(or Wire)
Component # Terminal #
(or Wire)
715, 120 Vac “hot”
in starter
2X1,Terminal block 2X1-1 2TB1, T. block 2TB1-H1 or F1
716, 120 Vac
“neutral” in starter
2X1,Terminal block 2X1-2 2TB1, T. block 2TB1-N or 2
14 2X1,Terminal block 2X1-14 2TB1, T. block 2TB1-14
(see note 1)
V1 2X1,Terminal block 2X1-V1 2TB1, T. block 2TB1-V1
(see note 2)
V2 2X1,Terminal block 2X1-V2 2TB1, T. block 2TB1-V2
(see note 2)
125B Starter Module, 2A1 J2-3 Wire #125B See note 3
127A Starter Module, 2A1 J2-1 Wire #127A See note 3
701 Starter Module, 2A1 J12-1 2TB1- 2TB1-22
(see note 4)
101A-106A Starter Module, 2A1 J7-1…6 CTs See Appendix B
for wiring details.
123 CB13 123 2K11 4
124 K28 contacts 124 2K11 6

10 PART-SVN82C-EN
Installation
terminal 2TB1-7. On other starters this is shown as the terminal where the wire from
the control panel terminal #22 is landed. It needs to be wired “downstream” of a set
of the NO contacts of K28.
Figure 3. Wiring detail for start connection, 5068-8481, revision B

PART-SVN82C-EN 11
Installation
Figure 4. Wiring detail for 2X1-V1 and 2X1-V2 connections, 5068-8480, revision B
WARNING
Live Electrical Components!
During installation, testing, servicing and troubleshooting of this product, it
may be necessary to work with live electrical components. Have a qualified
licensed electrician or other individual who has been properly trained in
handling live electrical components perform these tasks. Failure to follow all
electrical safety precautions when exposed to live electrical components may
result in death or serious injury.

12 PART-SVN82C-EN
Installation
Mounting the DynaView (2A55) human interface
Figure 5. Installing the DynaView and tilt bracket
1. If the tilt bracket is not required (DynaView mounted directly to door) skip Steps
2, 3, 6, and 8.
2. Attach the grommet in the 1" hole in the flat mounting panel (tilt bracket).
3. Mount the tilt bracket base to the door using the two screws provided.
4. Attach the Phoenix connector to the three foot long DynaView cable.
5. Attach the Phoenix connector on the DynaView cable to the DynaView (red-1,
black-2, green-3, and white-4).
6. Thread the other end of the DynaView cable through the hole in tilt bracket flat
mounting panel.
7. Attach the DynaView to the flat panel using the four screws/nuts provided. Watch
that the cable does not become pinched between DynaView and the flat mount-
ing panel. Only tighten enough to slightly compress the gasket. Be careful to
NOT bottom out the DynaView against the panel, only the gasket should touch
the panel.
8. Attach the flat mounting panel to the tilt bracket brace using the two threaded
adjustment wheels provided.
9. Thread the DynaView cable through the hole in door.
10. Attach the DynaView cable to the four pin connection on LLID 2A50, power sup-
ply. (Note: this cable can be attached to any LLID as all LLIDs will be connected
together on IPC bus.)

PART-SVN82C-EN 13
Startup
Connecting LLIDs onto the inter-processor communication
(IPC) bus
Starting at the power supply, connect all LLIDs together to form the IPC bus using
the IPC bus cable with connectors. Either the J1 or the J11 connection on each LLID
may be used. Cut off extra cable and seal ends using CAP00876 and ADH00023.
Current transformer (CT) work
Three new CTs must be installed to complete this installation. The new CTs are not
included in this KIT. They must be ordered separately. See Table 1 in Appendix C for
details.
Before installing these CTs use a digital multi-meter, with phase detection capability
to identify and mark incoming power, L1, L2 and L3 or phase A, B, and C.
Install the new CTs as shown on the wiring diagram in Appendix B. Pay careful
attention to the polarity dot and it's orientation.
Wire the leads from the spade connectors to the starter module as shown on the
wiring diagram.
Startup
The following table describes the steps to take the controls from “installed” to
“operational”. Specific details on certain steps (configuration, binding, etc.) are
contained in appendices referenced in the particular step.
WARNING
Live Electrical Components!
During installation, testing, servicing and troubleshooting of this product, it
may be necessary to work with live electrical components. Have a qualified
licensed electrician or other individual who has been properly trained in
handling live electrical components perform these tasks. Failure to follow all
electrical safety precautions when exposed to live electrical components may
result in death or serious injury.
1. Obtain CH530 Software: From http://www.trane.com/commercial/software/
tracerch530/, download the latest Java™ runtime, TechView™, and MP software.
Select CVR software from drop-down list. After downloading be sure to install all
files in the proper order following instruction provided on this website.
2. Run TechView on laptop and connect RS232 cable from laptop to DynaView.
3. Unplug the IPC bus (including DynaView) from the power supply LLID: this will
isolate the power supply LLID.
4. “Power Up” the existing control panel using auxiliary power.
5. Re-connect IPC bus to power supply and DynaView.
6. From the Chiller Software tab in TechView, download “CVR” MP software onto
DynaView.
7. Configure the software in TechView using the “Unit Type”, “CH530”, and “Starter”

14 PART-SVN82C-EN
Startup
tabs in Configuration View: See Appendix C for details on configuration items.
Write the selected values in the table provided in Appendix C for future refer-
ence.
8. Bind the LLIDs using Binding View: See Appendix D for binding details.
9. Adjust the setpoints using Setpoint view: See Appendix D for details on setpoint
items. Record the entered values in the table in Appendix E.
10. Dry run the starter:
• Make sure starter disconnect is locked open
• Use the manual override view to initiate starter test mode
• Observe correct operation of (if applicable for starter type present):
• Start relay
• Transition relay
• Disable starter test mode
11. Power up chiller:
• Remove 115 V temporary power from starter.
• Replace fuse in CPT.
• Energize starter panel with line voltage by re-closing starter disconnect.
12. Place clamp on ammeter on one of the L1, L2 or L3 legs.
13. Start chiller:
Note: it may be desirable to put the Current Limit Setpoint to 40% initially to
ensure items like CT Meter Scale are set correctly.
14. Observe startup:
Confirm that unit starts and loads as expected.
Note: If Contactor Integrity Test was enabled in Starter Configuration, contactors
may be heard prior to actual start sequence in starter cabinet.
15. Check current and voltage readings:
Verify that the current reading on the front panel matches that on the handheld
ammeter. If it does not, the CT meter scale may be set wrong.
16. Load Chiller:
Adjust Current Limit Setpoint to 80% and ensure that front panel readings match
handheld ammeter. Set final Current Limit Setpoint to desired operating level
(typically 100%)
17. Additional information is contained in Appendix F including the unit view screen.

PART-SVN82C-EN 15
Appendix A
Figure A1. Original classic black wiring, X39470376 Rev. D

PART-SVN82C-EN 16
Appendix A
Figure A2. Wiring diagram legend

PART-SVN82C-EN 17
Appendix A
Figure A3. Typical unit mounted starter electrical diagram, X39470320

PART-SVN82C-EN 18
C
A DIVISION OF AMERICAN STANDARD INC.
ALL RIGHTS RESERVED
Appendix B
Figure B1. RLY00765 to CH531 wiring details, 5068-8478, Rev. B

PART-SVN82C-EN 19
C
A DIVISION OF AMERICAN STANDARD INC.
ALL RIGHTS RESERVED
Appendix B
Figure B2. RLY00765 to CH531 wiring details, 5068-8486, Rev. C

PART-SVN82C-EN 20
Appendix C
Configuration View Items
Unit type tab
The figure below shows the TechView™ screen for selecting unit type. Default
values for Starter Only control are shown in the accompanying table. Options for
other selections are also shown in the table. Stand Alone Starter should be selected.
Make note of selections in the space available here and in the following tables.
Figure C1. Unit type configuration tab screen
Note: Entered values may differ from the recommended value depending on the
specific control scheme on your chiller. In most cases, the recommended value will
be adequate.
Table C1. Unit type configuration choices
Parameter Recommended value Other options Entered value
Unit Type (MODL) Stand Alone Starter CVRD
Control Sequence 1 none 1