Trane Cvhe User manual

March 20, 2009 AFDH-SVN01A-EN

Installation

AFDH Retrofit Air-Cooled

Adaptive Frequency™ Drive

For UCP2™, Tracer™ CH531, and Tracer

AdaptiView™ Centrifugal Chiller Controllers

Models: CVHE, CVHF, AFDH

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 may 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.

Important

Environmental Concerns!

Scientific research has shown that certain man-made chemicals can affect the earth’s naturally

occurring stratospheric ozone layer when released to the atmosphere. In particular, several of the

identified chemicals that may affect the ozone layer are refrigerants that contain Chlorine, Fluorine

and Carbon (CFCs) and those containing Hydrogen, Chlorine, Fluorine and Carbon (HCFCs). Not all

refrigerants containing these compounds have the same potential impact to the environment.

Trane advocates the responsible handling of all refrigerants-including industry replacements for

CFCs such as HCFCs and HFCs.

Responsible Refrigerant Practices!

Trane believes that responsible refrigerant practices are important to the environment, our

customers, and the air conditioning industry. All technicians who handle refrigerants must be

certified. The Federal Clean Air Act (Section 608) sets forth the requirements for handling,

reclaiming, recovering and recycling of certain refrigerants and the equipment that is used in these

service procedures. In addition, some states or municipalities may have additional requirements

that must also be adhered to for responsible management of refrigerants. Know the applicable

laws and follow them.

WARNING

Contains Refrigerant!

System contains oil and refrigerant and may be under positive pressure. Recover refrigerant to

relieve pressure before opening the system. See unit nameplate for refrigerant type. Do not use

non-approved refrigerants, refrigerant substitutes, or refrigerant additives.

Failure to follow proper procedures or the use of non-approved refrigerants, refrigerant

substitutes, or refrigerant additives could result in death or serious injury or equipment damage.

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.

WARNING

Hazardous Voltage with Capacitors!

Disconnect all electric power, including remote disconnects 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

WARNING

Ground Wire!

All field-installed wiring must be completed by qualified personnel. All field-installed wiring

must comply with NEC and applicable local codes. Failure to follow this instruction could result

in death or serious injuries.

WARNING

Grounding Required!

Follow proper local and state electrical code on requirements for grounding. Failure to follow

code could result in death or serious injury.

WARNING

Heavy Objects!

Only attach cables (chains or slings) to the designated lifting points. 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.

WARNING

Improper Unit Lift!

An AFDH cabinet assembly is top heavy. Test lift unit to an approximate height of no greater than

24 inches to verify proper center of gravity lift point. To avoid dropping the unit, reposition lifting

point if unit is not level. Failure to properly lift unit could result in death or serious injury or possible

equipment or property only damage.

WARNING

Conform to all applicable national, state, and local electrical codes!

Users MUST conform to all applicable national, state, and local electrical codes during the

electrical installation and servicing of this product. 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.

NOTICE:

Conform to all applicable national, state, and local electrical codes!

The user is responsible for conforming to all applicable national, state, and local electrical codes

during the electrical installation of this product. Failure to observe this precaution could result in

an arc flash event or other forms of uncontrolled electrical discharge, explosion, or fire, which

could result in damage to, or destruction of the equipment.

4AFDH-SVN01A-EN

Introduction

NOTICE:

Use Copper Conductors Only!

Unit terminals are not designed to accept other types of conductors. Failure to do so could

cause damage to the equipment.

NOTICE:

Stand-mounted AFDH supported by equipment room floor!

A stand-mounted version of an AFDH drive is designed to be rigidly supported by the equipment

room floor. Therefore, a stand-mounted AFDH drive is not recommended for use with a chiller

that is equipped with spring-type vibration or seismic isolators. Trane recommends using a

remote floor-mounted AFDH drive in this application. Trane assumes no responsibility for

equipment damage caused by the installation of an AFDH drive version that is specified as being

incorrect for the application.

NOTICE:

Incorrect application! Adapting a floor stand kit to an E-Frame AFDH!

When properly installed, the part number 50689890010 Floor Stand Kit is designed to safely

support the weight of D-Frame model AFDH drives only. The largest model D-Frame drive

weighs 872 pounds. The smallest model E-Frame drive weighs 1193 pounds. Any attempt to

adapt the 50689890010 Floor Stand Kit to an E-Frame model AFDH drive will be considered an

unsupported field modification to the drive unit design. Trane assumes no responsibility for the

equipment damage caused by a stress or fatigue failure of the floor stand kit due to any use

outside of its intended application.

NOTICE:

Excessive cable lengths between AFDH drive and compressor motor!

The variable frequency drive industry recommends that the length of the electrical cables

connecting a drive unit to a motor should be kept to less than 50 feet to protect the motor from

reflected voltage waves that can cause the motor to fail. Cable lengths that exceed 50 feet

between the drive and the motor create the potential for damage to occur to the motor

windings and/or insulation. Trane assumes no responsibility for equipment damage caused by

use of improper cable lengths.

NOTICE:

Route incoming power conduit to the roof of the AFDH cabinet!

The air-cooled AFDH drive is designed to have the incoming power conduit routed vertically into

the unit through the removable conduit connection cover located on the left-hand rear corner of

the cabinet roof. If the starter that is being replaced by the AFDH drive has the incoming power

conduit routed horizontally across the top of the starter, or connected to the side or to the

bottom of the starter cabinet, an electrician will be required to reconfigure the conduit and

wiring. Routing the incoming power conduit into the AFDH cabinet anywhere other than

through the specified location on the cabinet roof, will be considered an unsupported field

modification to the cabinet design.

Introduction

The step-by-step instructions outlined in this manual describe the procedures required to

successfully install an AFDH Retrofit Air-Cooled Adaptive Frequency™ Drive package in place of an

existing starter on a Trane® CVHE or CVHF model centrifugal chiller. This only applies to chillers

having either a UCP2™ or UCP2 FastPak™ Controller, a Tracer™ CH531 Controller Retrofit, or a

Tracer AdaptiView™ Controller.

AFDH-SVN01A-EN 5

Introduction

D-Frame size AFDH drive packages can be ordered in a unit-mounted, stand-mounted, or remote

floor-mounted cabinet configuration. The D-Frame units can be equipped with a drive having a

maximum rating of 302 amps, 361 amps, or 443 amps.

The E-Frame size AFDH drive packages can be ordered in either a unit-mounted or a remote-floor

mounted cabinet configuration. The E-Frame units can be equipped with a drive having a

maximum rating of 540 amps, 590 amps, 678 amps, or 730 amps.

Important: The unit-mounted versions of AFDH Retrofit Air-Cooled Adaptive Frequency™ Drive

packages are not suitable for installation on chillers having direct-mount starters. To

determine if a specific unit-mounted starter is in fact a direct mount starter, please

refer to Figure 2, p. 12.

Note: Prior to July 1994, early version UCP2™ and UCP2 FastPak™ controls did not have AFD

compatible software in their Chiller Modules or their Clear Language Display Modules.

Between July 1994 to June 1998 the first release of AFD compatible UCP2™ hardware/

software allowed a speed reduction down to as low as 42 Hz. In June 1998, the second

version UCP2™ software release allowed speed reduction down to 38 Hz, which resulted in

slightly improved energy savings. To determine if a specific UCP2™ control type is

equipped with AFDH compatible hardware and software, please refer to “UCP2

compatibility with AFDH drives,” p. 16.

Note: The factory installed Tracer™ CH530 chiller controller system will not support an AFDH Air-

Cooled Adaptive Frequency™ drive. The controller system must first be upgraded to Tracer

AdaptiView™ before an AFDH retrofit package can be installed.

Note: At the time of writing of this manual edition (March 2009) only the D-Frame version of the

AFDH drive packages had been officially released for sale.

Note: The AFDH series of retrofit air-cooled Adaptive Frequency™ drive packages are only

intended for installation on existing Trane®chillers with CVHE or CVHF model centrifugal

compressors. Trane makes no claim of suitability or performance regarding retrofit AFDH

drives on older Trane®centrifugal compressor models or on chillers made by other

manufacturers. Although there may exist successful drive retrofits to these units, users are

cautioned that Trane has not evaluated these installations. Accordingly, Trane cannot

provide assurances regarding performance, reliability or suitability of retrofit AFDH

installations to other than Trane® model CVHE and CVHF compressors.

Other literature required before ordering or installing an AFDH retrofit

This manual must be used in conjunction with the following publications:

ECTV-PRB009-EN Engineering Bulletin, Chiller Upgrades Selection and Application Guideline for

Air-cooled Adaptive Frequency™ Drive Retrofit

TR1-SVX10A-EN TR1™ Series VFD Variable Frequency Drive Installation and Operation manual

CVRD-SVP01A-EN Tracer™CH531 Chiller Controller Retrofit Replacement Panel Startup and

Programming manual.

CVRE-SVP01A-EN Tracer AdaptiView™Panel Upgrade Programming Guide.

CTV-SVP02A-EN Tracer™TU Service Tool for Water-Cooled CenTraVac™Chillers with Tracer

AdaptiView™Controls Programming Guide.

CVHE-M-7 Water-Cooled Hermetic CenTraVac® Models CVHE and CVHF 50 and 60 Hz Cooling-Only

and Heat-Recovery Direct-Drive CenTraVacs with UCP2 Control Panels, Operation and

Maintenance manual.

Trademarks

Trane® and the Trane logo are trademarks of Trane in the United States and other countries. All

trademarks referenced in this document are the trademarks of their respective owners.

Table of Contents

AFDH-SVN01A-EN 6

Warnings, Cautions and Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Other literature required before ordering or installing an AFDH retrofit . 5

Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unit Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Model Number Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Figure 1. AFDH nameplate example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Confirming the AFDH package can be properly installed . . . . . . . . . . . . . . . 12

Installation considerations for unit-mounted AFDH drives . . . . . . . . . . . 12

Figure 2. Example of a direct-mount chiller starter panel . . . . . . . . . . . . . . . . 12

Figure 3. Comparison of unit-mounted AFDH to typical unit-mounted starter. 13

Installation considerations for stand-mounted AFDH . . . . . . . . . . . . . . . 14

Figure 4. Example of a stand-mounted version of an AFD drive . . . . . . . . . . . 14

Installation considerations for remote floor-mounted AFDH . . . . . . . . . 15

Confirm chiller controller system compatibility with AFDH drive . . . . . . . . 16

UCP2 compatibility with AFDH drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Table 1. AFDH compatible UCP2 module hardware & software part numbers 17

Equipment room ambient temperature considerations . . . . . . . . . . . . . . . . . 17

Chiller upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Electrical cable size specifications for AFDH drives . . . . . . . . . . . . . . . . . . . . 18

Table 2. Input/output power wire cable sizes AFDH D-Frame drives . . . . . . . 18

Table 3. Input/output power wire cable sizes AFDH E-Frame drives . . . . . . . 18

Requirements for installation technicians . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Miscellaneous field provided material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Recommended rigging and lifting procedures for AFDH drive units . . . . . 20

Unit lifting points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Figure 5. Unit lifting points and center of gravity . . . . . . . . . . . . . . . . . . . . . . 20

Preferred lifting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Figure 6. Preferred lifting method using two identical individual hoists . . . . . 21

Alternative lifting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Figure 7. Alternative lifting method using a single hoist and spreader bar . . . 21

AFDH Drive Package Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

D-Frame drive unit dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Figure 8. Top, front, and side view of D-Frame AFDH cabinet with dimensions 22

Figure 9. Rear view of D-Frame AFDH cabinet with dimensions . . . . . . . . . . . 23

E-Frame drive unit dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Figure 10. Top, front, and side view of E-Frame AFDH cabinet with dimensions 24

Figure 11. Rear view of E-Frame AFDH cabinet with dimension . . . . . . . . . . . . 25

Drive unit weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

AFDH-SVN01A-EN 7

Table 4. AFDH D-Frame unit weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Table 5. AFDH E-Frame unit weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

D-Frame and E-Frame Drive unit components . . . . . . . . . . . . . . . . . . . . . . . . 26

Drive unit component parts housed within the custom enclosure . . . . . 26

Figure 12. Mounting location of D and E-Frame custom enclosure parts . . . . . 26

Table 6. Custom enclosure parts; D-Frame 302 amp model drives . . . . . . . . 28

Table 7. Custom enclosure parts; D-Frame 361 amp model drives . . . . . . . . 28

Table 8. Custom enclosure parts; D-Frame 443 amp model drives . . . . . . . . 29

Table 9. Custom enclosure parts; E-Frame 540 amp model drives. . . . . . . . . 30

Table 10. Custom enclosure parts; E-Frame 590 amp model drives. . . . . . . . . 30

Table 11. Custom enclosure parts; E-Frame 678 amp model drives. . . . . . . . . 31

Table 12. Custom enclosure parts; E-Frame 730 amp model drives. . . . . . . . . 31

Control box components for UCP2 version AFDH . . . . . . . . . . . . . . . . . . 32

Figure 13. D and E-Frame AFDH UCP2 control box components . . . . . . . . . . . 32

Table 13. UCP2 control box component part numbers . . . . . . . . . . . . . . . . . . 32

Additional hardware shipped with all UCP2 AFDH packages . . . . . . . . . 33

Table 14. UCP2 miscellaneous hardware package contents . . . . . . . . . . . . . . 33

Figure 14. Buss bar specifications; UCP2 miscellaneous hardware packages . . 33

Control box components for CH531/AdaptiView version AFDH . . . . . . . 34

Figure 15. D and E-Frame AFDH CH531/AdaptiView control box components . 34

Table 15. CH531/AdaptiView control box component part numbers . . . . . . . . 34

Additional hardware shipped with CH531/AdaptiView AFDH packages 35

Table 16. CH531/AdaptiView miscellaneous hardware package contents . . . . 35

Figure 16. Buss bars specifications; CH531/AdaptiView hardware packages . . . 35

Other AFDH drive package accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Figure 17. Floor stand kit parts for stand-mounted D-Frame AFDH. . . . . . . . . . 36

Figure 18. D and E-Frame floor-mounted AFDH; corner support kit parts . . . . . 37

Table 17. Part numbers for motor panel transition covers . . . . . . . . . . . . . . . 37

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Removal of electrical connections to the existing starter . . . . . . . . . . . . . . . 38

Mechanical removal of the existing unit-mounted starter . . . . . . . . . . . . . . 39

Mechanical removal of the existing remote-mounted starter . . . . . . . . . . . . 40

Mechanical installation of a Unit-Mounted AFDH drive . . . . . . . . . . . . . . . . . 40

Figure 19. Removal of Z-bracket weldment nuts . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 20. Position cabinet base over evaporator brackets and install clips . . . 42

Figure 21. Leveling the AFDH drive cabinet against the Z-bracket . . . . . . . . . . 42

Mechanical installation of a stand-mounted D-Frame AFDH . . . . . . . . . . . . 43

Figure 22. Assembly of floor stand kit components . . . . . . . . . . . . . . . . . . . . . 44

Figure 23. Attach assembled floor stand to drive unit. . . . . . . . . . . . . . . . . . . . 45

Mechanical installation of a remote floor-mounted AFDH . . . . . . . . . . . . . . 46

Figure 24. Assembly and installation of corner support kit components. . . . . . 47

Electrical installation (all AFDH models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Install shorting buss bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Figure 25. Buss bar installation on compressor motor terminal board . . . . . . . 49

Input power wire installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Figure 26. Conduit shroud and two-piece incoming wire access cover . . . . . . . 50

Figure 27. Factory installed input disconnect circuit breaker . . . . . . . . . . . . . . 51

Grounding AFDH cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Figure 28. Location of AFDH cabinet ground terminal . . . . . . . . . . . . . . . . . . . 52

Output wiring from the AFDH to the CTV motor . . . . . . . . . . . . . . . . . . . 52

8AFDH-SVN01A-EN

Figure 29. Output wiring from AFDH to CTV motor . . . . . . . . . . . . . . . . . . . . . 53

Routing of control wiring to AFDH cabinet (all models) . . . . . . . . . . . . . . . . 54

Figure 30. Factory provided conduit holes in AFDH control box . . . . . . . . . . . . 54

Control wiring connections (UCP2 model AFDH only) . . . . . . . . . . . . . . . . . . 55

Figure 31. UCP2 wiring connections to 2X1 terminal strip in AFDH control box 55

Control wiring connections (CH531/AdaptiView model AFDH only) . . . . . . 56

Figure 32. CH531 wiring connections to 2X1 terminal strip in AFDH control box 56

AFDH drive program parameters used with all Trane controls . . . . . . . . . . 57

Table 18. Trane specific AFDH program parameters and settings . . . . . . . . . . 57

Required reprogramming of UCP2 controls . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Table 19. UCP2 menu parameters for proper chiller operation with AFDH . . . 58

Figure 33. AF PC Constant formula and sample calculation . . . . . . . . . . . . . . . 59

Required reprogramming of CH531 controls . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Table 20. CH531 CVR firmware parameter settings with a retrofit AFDH . . . . . 61

Table 21. CT meter scales for TechView or Tracer TU. . . . . . . . . . . . . . . . . . . 62

Required reprogramming of AdaptiView controls . . . . . . . . . . . . . . . . . . . . . 62

Reprogramming retrofit AdaptiView controls (CVR firmware) . . . . . . . . 62

Table 22. UC800/AdaptiView CVR parameter values with a retrofit AFDH . . . . 63

Reprogramming factory installed AdaptiView controls (CTV firmware) 64

Table 23. UC800/AdaptiView CTV parameter values with a retrofit AFDH . . . . 64

AFDH-SVN01A-EN 9

Unit Model

Number

For service purposes, Trane Model

AFDH Air-Cooled drive upgrade

packages are assigned a multiple

character alphanumeric model

number that precisely identifies each

unit.

An explanation of the identification

code that appears on the unit

nameplate is shown below. Use of the

service model number will enable the

owner/operator, installing

contractors, and service technicians

to define the operation, components,

and options for any specific unit.

Refer to the model number printed on

the nameplate when ordering

replacement parts or requesting

service.

Example model number:

AFDH0312FA0C10D1010

Digit 1, 2, 3, 4— Unit Model

A = Adaptive

F = Frequency

D = Drive

H = Design Sequence H

Digit 5, 6, 7, 8— Nameplate RLA

0312 = 312 Rated Load Amps

Digit 9— Voltage

F = 460 Volts/60 Hz/3 Phase

G = 480 Volts/60 Hz/3 Phase

Digit 10, 11— Design Sequence

A0) = Initial Design

Digit 12— Enclosure Type

C = Retrofit Standard Enclosure

Digit 13— Agency Listing

1 = UL (Underwriters Laboratory) & CSA

(Canadian Standards Association)

Digit 14— Harmonic Attenuation

0 = Standard Attenuation

1 = 414 Max RLA Line Reactor

2 = 643 Max RLA Line Reactor

3 = 500 Max RLA Line Reactor

4 = 1200 Max RLA Line Reactor

5 = 12 Pulse Autotransformer

Digit 15— VFD Frame Size

C = 302 Maximum RLA

D = 361 Maximum RLA

E = 443 Maximum RLA

G = 540 Maximum RLA

H = 590 Maximum RLA

J = 678 Maximum RLA

K = 730 Maximum RLA

Digit 16— Control Type

1 = UCP2

2 = CH531 / AdaptiView

Digit 17— Motor/Panel Transition

0 = None

A = 6-inch Transition

B = 18.5-inch Transition

C = 12-inch Transition

Digit 18— Mounting Type

1 = Unit Mount

2 = Floor Mount

3 = Remote Mount

Digit 19— Floor Mount Options

0 = None

A = Floor Mount Corner Brackets

B = Floor Mount Corner Brackets & Legs

Model Number Descriptions

AFDH-SVN01A-EN 10

Nameplates

A nameplate is installed on each AFDH Air-Cooled Drive unit. Always provide the model number

and serial number that is printed on this nameplate when making warranty inquiries, ordering

parts, or ordering literature for the unit

Figure 1. AFDH nameplate example

AFDH-SVN01A-EN 11

Nameplates

Note: This page has been intentionally left blank.

AFDH-SVN01A-EN 12

Pre-Installation

Confirming the AFDH package can be properly installed

This chapter details potential interference fit problems, mechanical incompatibility situations,

electrical code stipulations, and electrical conduit and wiring issues that can prevent the successful

installation and/or operation of an AFDH retrofit drive package.

Installation considerations for unit-mounted AFDH drives

Unit-mounted AFDH drives are incompatible with direct-mount starters

Certain chillers larger than 800 tons in size that were built after 2001, were equipped with direct-

mount starters. A direct-mount starter differs from a standard unit-mounted starter in that it is

bolted directly to the motor flanges and the motor terminal board is flush with the back of the starter

panel box. Refer to Figure 2.

A direct-mount starter also lacks the Z-brackets and transition cover that are an integral part of the

standard unit-mounted starter and which are also necessary for the correct installation of a unit-

mounted AFDH drive.

When a chiller that is equipped with a direct-mount starter is being upgraded with an AFDH retrofit

drive, the drive package must either be a stand-mounted or a remote floor-mounted version of the

AFDH.

Figure 2. Example of a direct-mount chiller starter panel

1. Motor terminal access in left-center quadrant of

cabinet. Motor terminal access in an AFDH drive

cabinet is located to the left in the upper third portion

of the cabinet

2. Compressor motor terminal board. Flush to back of

direct-mount starter cabinet

3. Hidden by direct-mount starter cabinet is the fact that

there are no Z-brackets available for mounting an

AFDH drive

AFDH-SVN01A-EN 13

Pre-Installation

Evaluate space available for rigging/installing unit-mounted AFDH

All models of the D-Frame and E-Frame AFDH unit-mounted retrofit drives are taller, wider, and

deeper than the typical Wye Delta unit-mounted starter they are intended to replace. Accordingly

any project should start with a careful evaluation on whether there is ample enough space to rig

the AFDH into place and if any of the existing building piping and conduit will not interfere with

its mounting.

NOTICE:

Route incoming power conduit to the roof of AFDH cabinet!

The air-cooled AFDH drive is designed to have the incoming power conduit routed vertically into

the unit through the removable conduit connection cover located on the left-hand rear corner of

the cabinet roof. If the starter that is being replaced by the AFDH drive has the incoming power

conduit routed horizontally across the top of the starter, or connected to the side or to the

bottom of the starter cabinet, an electrician will be required to reconfigure the conduit and

wiring. Routing the incoming power conduit into the AFDH cabinet anywhere other than

through the specified location on the cabinet roof, will be considered an unsupported field

modification to the cabinet design.

Important: NEC codes require that electrical disconnect switches can be no higher than 72

inches above the surface of the operator area floor or platform. Check the potential

mounted height of the AFDH disconnect switch, especially if the chiller has large

shells or is mounted on structural steel.

Important: Other factors that affect the space required to successfully install a stand-mounted

AFDH drive include the clearance distances specified by the local electrical codes.

Typical code regulations require an average of 36-inches clearance from the panel

to nonconducting surfaces and 47-inches to a conducting surface. Check and confirm

that when installed, the drive clearances will conform to all local codes. Do not forget

to account for cabinet door swing clearances.

Note: Refer to manual section “AFDH Drive Package Specifications,” p. 22 for the dimensions and

weights of all models of AFDH drives”

Figure 3. Comparison of unit-mounted AFDH to typical unit-mounted starter.

1. Typical Wye Delta unit-mounted starter (60

in. tall x 38 in. wide x 14 in. deep)

2. Unit-mounted D-Frame AFDH

superimposed over the outline of the unit-

mounted starter

3. Unit-mounted E-Frame AFDH

superimposed over the outline of the unit

mounted starter

4. Ensure sufficient overhead clearance space

is available for drive installation

5. Electrical disconnect switch for drive unit.

Note: Center of switch assembly is 24-

inches above the base of the cabinet. Refer

to Figure 8, p. 22 for D-Frame cabinets and

Figure 10, p. 24 for E-Frame cabinets

14 AFDH-SVN01A-EN

Pre-Installation

Installation considerations for stand-mounted AFDH

NOTICE:

Stand-mounted AFDH supported by equipment room floor!

A stand-mounted version of an AFDH drive is designed to be rigidly supported by the equipment

room floor. Therefore, a stand-mounted AFDH drive is not recommended for use with a chiller

that is equipped with spring-type vibration or seismic isolators. Trane recommends using a

remote floor-mounted AFDH drive in this application. Trane assumes no responsibility for

equipment damage caused by the installation of an AFDH drive version that is specified as being

incorrect for the application.

NOTICE:

Route incoming power conduit to the roof of AFDH cabinet!

The air-cooled AFDH drive is designed to have the incoming power conduit routed vertically into

the unit through the removable conduit connection cover located on the left-hand rear corner of

the cabinet roof. If the starter that is being replaced by the AFDH drive has the incoming power

conduit routed horizontally across the top of the starter, or connected to the side or to the

bottom of the starter cabinet, an electrician will be required to reconfigure the conduit and

wiring. Routing the incoming power conduit into the AFDH cabinet anywhere other than

through the specified location on the cabinet roof, will be considered an unsupported field

modification to the cabinet design.

Important: Other factors that affect the space required to successfully install a stand-mounted

AFDH drive include the clearance distances specified by the local electrical codes.

Typical code regulations require an average of 36-inches clearance from the panel

to nonconducting surfaces and 47-inches to a conducting surface. Check and confirm

that when installed, the drive clearances will conform to all local codes. Do not forget

to account for cabinet door swing clearances.

Important: The design intention of a stand-mounted AFDH drive, is for the drive to be installed

in front of the chiller with the motor terminal access cover of the drive cabinet lined

up with the compressor motor terminal box. The cable connections between the

drive and the motor terminals will be shrouded by an extended sheet-metal

transition cover. Refer to Figure 4.

Note: Refer to the manual section “AFDH Drive Package Specifications,” p. 22 for the dimensions

and weights of all models of AFDH drives”

Figure 4. Example of a stand-mounted version of an AFD drive

1. Example of a stand-mount AFD drive

2. Motor terminal access cover of drive lined up with

compressor motor terminal box. Cable connections

between drive and the motor terminals shrouded by

an extended sheet-metal transition cover

AFDH-SVN01A-EN 15

Pre-Installation

Installation considerations for remote floor-mounted AFDH