Trane Installation Instructions

Introduction

Read this manual thoroughly before operating or servicing this unit.

Warnings, Cautions, and Notices

Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this machine depend upon the strict observance of these precautions.

The three types of advisories are defined as follows:

• ⚠ 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.

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.

Important 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 according to local rules. For the USA, 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.

Copyright

This document and the information in it are the property of Trane, and may not be used or reproduced in whole or in part without written permission. Trane reserves the right to revise this publication at any time, and to make changes to its content without obligation to notify any person of such revision or change.

Trademarks

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

Revision History

Document updated to reflect Service Offering number.

General Information

Read this manual thoroughly before operating or servicing this unit.

The purpose of this bulletin is to advise customers of the parts and procedures required to replace the variable speed drive originally used to control condenser fans in RTAA and RTCA units. These parts were present on 70 to 125 ton, RTAA chillers and RTCA condensers when ordered with the low ambient operation option. The original drive will be phased out, and the parts mentioned below will be the most up-to-date and cost effective substitutes.

Notes:

• This upgrade has been designed for units in good working order. It is assumed that unit is charged with the correct amount of refrigerant and oil. Review all coils, fan blades, starters, and controls to determine if any other service procedures are required during equipment downtime.
• RTCA condensers are most commonly paired with RTUA chillers. These instructions have been written for this configuration.

Kit Selection and Contents

Obtain the required parts from the local Trane Parts Center. If the specific part number cannot be determined, contact the local Trane Parts Center with the unit model number or serial number. Two kits are available. Select the correct drive replacement kit based on the existing unit voltage per Table 1 below. In addition to the correct drive replacement kit, some additional field-provided material will be required. See "Field-Provided Material," p. 6 for a suggested list of materials.

Table 1. Kit selection

Each kit consists of an assembly and several loose parts. The assembly includes a variable speed drive and associated components mounted to a back plate. See Figure 1, p. 5 for physical dimensions and configuration. See Table 2, p. 6 for a list of service parts. See Table 3, p. 6 for a list of parts shipped loose.

Figure 1. Drive assembly

[Image of drive assembly with dimensions]

Table 2. Service parts

Table 3. Loose shipped parts

Tools Required

Common hand tools and hand-held power tools are required to perform the retrofit. A trained service technician with a well-stocked tool chest should have all of the necessary tools to perform the job. The following list is a sampling of the tools that one could expect to find inside the technician's tool chest:

• Electric drill and bit set
• Screwdrivers
• Wrenches
• Ratchet and socket set
• Nut driver set
• Wire cutter
• Wire stripper

The following special tools are also required to perform the retrofit:

• If possible, an EPROM extractor should be used to remove the existing EPROM. Suggested EPROM extractor is Digikey K158-ND. If an EPROM extractor is not available a small flat blade screwdriver may be used.

Field-Provided Material

Some field provided material will be required to perform the RTAA/RTCA fan controls retrofit. A partial list of material is provided here to help the technician plan ahead and to avoid material shortages at the job site.

• Wire, #16 AWG – Control wire will be required to make the connections between components.
• Wire markers will be required to identify field wiring.
• Wire nuts and splicers may be required if splicing wires in the control panel.
• Cable ties help to clean up wiring runs.
• Assorted fasteners for component mounting and/or relocation.

Trane has determined that inverter duty motors provide a much more robust system when combined with variable speed drives. As with the previous drive, the fan motor should also be replaced with an inverter duty rated motor if it is not already an inverter duty rated motor. The service part numbers for RTAA/RTCA inverter duty motors are found in the table below. For additional help, contact the local Trane Parts Center with the unit model number or serial number.

The fan drive retrofit kits have been sized to fit in the main RTAA control enclosure. Some existing components may need to be relocated. The standard RTCA control enclosure is not large enough for the drive retrofit kits. A separate enclosure is required for RTCA. PNL34974 is recommended. PNL34974 may optionally be used with RTAA if additional cabinet space is desired.

When using a separate enclosure, such as PNL34974, additional mounting hardware may be required depending on the selected mounting location. Additional conduit, fittings, and wire will also be required.

Previous applications of TR170 drives, including earlier versions of this kit, included a blanket heater and temperature control to protect the drives from low temperatures. This heater and control is no longer required and has been removed from this kit. These service parts, HTR16716 and CNT06627, may be purchased separately if desired.

Table 4. RTAA/RTCA fan motor part numbers

Pre-Installation

This retrofit consists of replacing and installing components and wiring in the control panel and in an electrical enclosure under the condenser coil. See Figure 2 and Figure 3, p. 8 for examples of original drive mounting.

Figure 2. Original drive enclosure

[Image of original drive enclosure]

Figure 3. Original drive installation

[Image of original drive installation]

Figure 4. Typical RTAA control panel

[Image of typical RTAA control panel with labels for modules]

1. Turn off power to the machine, water pumps, and any field provided control power. For RTCA units, also remove the power from the associate chiller (RTUA).
2. Secure all disconnect switches following lockout/tagout safety procedures.
3. Open the control panel doors and verify all power has been removed.
4. Remove any louvers or wire panels that may prevent access to the existing variable speed drives.
5. Verify the condenser fan motor is inverter duty rated. If it is not, replace the motor. See "Field-Provided Material," p. 6 for motor identification.
6. Record the following information from the condenser fan motor nameplate. This information will be needed during drive configuration.
   
   • Motor Power
   • Motor Voltage
   • Motor Frequency
   • Motor Current
   • Motor Nominal Speed
7. If using a new additional enclosure, such as PNL34974, for drive mounting, select a convenient location and mount. Avoid mounting the enclosure under the condenser coil or in any location that would prevent access to other serviceable components.

Control Panel Modifications

Removal of Existing Controls

1. Locate original drive enclosure underneath the condenser coil. See Figure 2, p. 8.
2. Remove the drive enclosure cover.
3. Remove the variable speed drive being replaced.
4. Speed and fault signal wiring may be pulled back into the control panel.
5. Locate the cover plate (PNL20506) in the loose parts of the kit.
6. Install the cover plate over the opening left by the drive.
7. Locate the DIN rail, DIN rail caps, terminal blocks, end plate, terminal labels, and end stops in the loose parts of the kit.
8. Mount the DIN rail and caps in a convenient location in the existing drive enclosure.
9. Mount the terminal blocks, end plate, terminal labels, and end stops onto the DIN rail. This terminal block may be labelled 2TB1.
10. The new drive in the control panel will require a direct ground connection from the motor to the drive. Run a new ground wire from the drive enclosure back to the control panel.
11. Connect the motor wires to the wires running back to the control panel. These wire are color coded. See Table 5 for connections.

Table 5. Drive enclosure connections

See Figure 5 for an example of the drive enclosure with one drive removed.

Figure 5. Enclosure with original drive removed

[Image of enclosure with original drive removed]

New Drive Installation

1. Locate a convenient location in the control panel for installation. This may be a new enclosure such as PNL34974. The front of the drive will need to be accessible for entering drive parameters. The top and bottom of the drive require 4 inches of clear space for ventilation. The drive assembly must be mounted directly to the back of the enclosure to allow the door to close.
   Some existing components may need to be relocated. For example, 575-V units have an autotransformer that may be moved to under the panel mullion.
   This kit is for a single drive replacement, however the other drive may need to be replaced in the future. Leave enough space for another drive to be installed in the future.
2. Place the drive assembly in the desired location and mark locations for the drive assembly mounting holes on the back of the enclosure. Remove the assembly.
3. The following hardware is provided for mounting the drive assembly. Drill a 3/16-inch pilot hole at each marked location. Lift the assembly back into place and mount using the included hardware.

Note: Field-provided hardware can be substituted, however, thread-rolling fasteners or sealing washers are required to prevent moisture from entering the control panel.

See Figure 6 for an example of a mounted drive assembly inside an RTAA control panel.

Figure 6. Mounted drive assembly

[Image of mounted drive assembly]

5. Place the module on a conductive bench, i.e. metal surface. While working, you and the module must be in contact with the bench to avoid you or the module from developing a damaging static discharge.
6. Remove the fish paper insulator.
7. Remove the screws securing the PCB assembly to the sheet metal cover. The screws are located under the fish paper. Touch the screw driver to the metal bench before use to avoid a damaging static discharge to the module.
8. There are eight #6-32 screws located under the compressor module. Remove all eight.
9. The EPROM is the chip that is installed in the socket. It is designated as U2 on the compressor module. This is shown below in Figure 7.
10. Note the orientation of EPROM before removing. The notch in the EPROM should line up with the notch in the socket and the notch drawn in the outline on the PCB.

Figure 7. EPROM location

[Image showing EPROM location on PCB]

EPROM Installation

For RTAA units, the following controls work should be completed in the unit control panel. For RTCA units, the EPROM work needs to be completed in the RTUA control panel.

1. Record the software part number and extension found on the EPROM provided in the upgrade kit, before installing into the module. These numbers will be used later to verify the correct EPROM was installed.
2. Disconnect power from the compressor module.
3. Before handling the compressor module, discharge yourself by touching the panel sheet metal or use an anti-static wrist strap.

Important: See Figure 4, p. 9 for module locations. Compressor modules 1U4 and 1U5 are located BEHIND other modules.

4. Remove 1U4 (compressor A) and 1U5 (compressor B) modules from the panel. The modules have key holes so the mounting screws need only be loosened but not removed. Note where the various wires are plugged into the module connectors. The plugs may be labeled to avoid confusion when reconnecting. If the module is beneath another, the connectors on just one side of the upper module may be removed and the module hinged out to access the lower module.
5. Install the new EPROM. Align the notch in the EPROM to the notch in the socket and on the PCB as the original EPROM was. Make sure that the PCB assembly is lying flat on the bench surface when pressing down on the EPROM. Press the EPROM firmly into place.
6. Inspect the EPROM and the socket to make sure that all pins are lined up and inserted correctly. Verify that there are no bent pins.
7. Install the sheet metal cover and fish paper. Torque screws 8 in-lbs minimum and 11 in-lbs maximum.
8. Install the module.
9. Verify that all of the connections are correct and that the mounting screws are tight.
10. The EPROM includes a sticky label that indicates the replacement of the EPROM. Apply the label to the outside of the compressor module. This will alert a technician that a replacement EPROM will need to be ordered in the event of module replacement.

Wiring

Power wiring, motor wiring, and drive signal wiring all must be relocated from the fan contactor and drive fuses to the new drive assembly. Table 6 indicates the wiring connections that must be made. Remove any existing wiring from terminals being reused.

Note:

• Wire numbering may vary from unit to unit. Wire identification numbers are provided for reference only, and must be verified in the field. Refer to the included kit schematics for a more detailed description of kit wiring.
• Replacement drives utilize a dry contact as an ENABLE signal. Connecting any external voltage source to drive terminals 12 or 18 will result in damage to the drives. When using a contactor to enable a drive, remove all existing wires connected to the line and load terminal before connecting these terminals to the drive. Use an individual pole as the ENABLE signal.

Table 6. Wiring connections

^(a) 575V units only.

General Start-Up Review

1. When all components have been mounted and wired, close all electrical enclosures.
2. Restore machine power.
3. Place the unit in STOP to prevent unintended operation.

4. Open the cover or door over the drive and verify the drive has powered up.

Note: The drive cooling fan may be operating, even if the unit is in standby mode.

5. Proceed to entering drive parameters.

Entering Drive Parameters

Drives are shipped with generic settings. These setting must be updated to reflect the drive application. Table 7 lists the drive parameters that must be changed for correct operation.

Notes:

• Pressing the MENU button once will enter the drive parameter wizard. The parameter wizard does not access all the required parameters.
• To access ALL parameters, press the MENU button twice.
• The parameters are set by different levels. Click OK to access Level 1 and Level 2.
• The default setting for Parameter 5-12 will cause a drive error. Parameter 5-12 MUST be set to (0) No Operation.

Table 7. Drive parameters

^(a) Parameter 0-40 may be enabled for drive/rotation troubleshooting.
^(b) Parameters are from motor nameplate.
^(c) Use when the frequency is either 50 or 60 Hz.
^(d) The default setting for parameter 5-12 will cause a drive error. Parameter 5-12 must be set to (0) No Operation.

General Start-Up Review

Optional Drive Parameter Copy Procedure

If chiller has multiple drives, the following procedure can be used to copy parameter settings from one drive to another.

Note: Step 2 can also be used to backup drive parameter settings.

1. Program first drive (#1) per Table 7, p. 13.
2. On the programmed drive, upload data to the local control panel (LCP #1) as follows:
   
   1. Go to 0-50 LCP copy.
   2. Press [OK].
   3. Select All to LCP.
   4. Press [OK]. A progress bar shows the uploading process.
   5. Press [Hand on] to return to normal operation.
3. Remove LCP #1 from programmed drive (#1).
4. Replace LCP on drive to be programmed (#2), with LCP #1, removed from drive #1.
5. Download data onto drive #2 as follows:
   
   1. Go to 0-50 LCP copy.
   2. Press [OK].
   3. Select All from LCP.
   4. Press [OK]. A progress bar shows the downloading process.
   5. Press [Hand on] to return to normal operation.
6. Remove LCP #1 and reinstall LCP #2 on drive #2.
7. Repeat Step 4 through Step 6 for any additional drives to be programmed.
8. Reinstall LCP #1 on drive #1.

Verify Fan Function

1. Place the drive in HAND mode.
   Note: Parameter 40 will need to be enabled.
2. Turn the fan to low speed.
3. Observe the fan rotational direction.

a. If the fan rotates in the wrong direction, turn off power to the machine, water pumps, and any field provided control power.

1. b. Secure all disconnect switches following lockout/tagout safety procedures.
2. c. Open the control panel doors and verify all power has been removed.
3. d. Switch the blue and black wire at the drive terminals.
4. e. Restore unit power.
5. f. Return to Step 1.

4. Increase speed and verify the fan operates over the full speed range.
5. Return drive to AUTO mode.
   Note: Change parameter 40 to Disable.
6. Close the control panel.
7. Return the machine to standard operating condition.