Trane CVRD User manual

PART-SVN82C-EN

Models: CVRD, KIT09437, CVHE

Installation

Replacement of RLY00765

with KIT09437 using Tracer

CH531 Components

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

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