Trane Voyager III Bedienungsanleitung

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)

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

PANELPANEL

SUPPLY FAN SECTION

EVAP COIL

FILTER

SECTION

O/A DAMPERSR/A DAMPERS

RETURN & EXHAUST

EXHAUSTEXHAUST

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

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

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