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The Motivation

• AB32 Global climate change

– Reduce green house gasses

– Reduce global carbon foot print

• Title 24 Net-Zero

– In a zero net energy building the annual energy consumption of the building is equal to the building’s annual onsite generation. Title 24 has as a goal that all new residential buildings be zero net energy by 2020 and all new commercial buildings will reach this ZNE goal by 2030.

Energy

• Can not be created or destroyed

• You can transfer energy

• Decrease in energy requires release of

energy

• An increase in energy requires energy

absorption

• One form of energy is heat

7.2 trillion degrees

In the Beginning

Trane Variable Frequency Drives

VariTrac Changeover Bypass

Voyager or Reliatel

Roof Top Unit TCI

Delivered VAV System

Commercial Voyager VAV

Roof Top Unit with TCI-V

The VFD

Benefits of VFD

• Efficient means of modulating the output of conventional induction motors

and synchronous motors.

• Make it practical to use precise motor speed in a wide variety of applications.

• VFDs offer the best turndown ratio.

• Some of the new models approach the near-zero-speed capability of DC

drives.

• Low maintenance—no moving parts other than push-buttons.

• Ease of installation and retrofit.

• Improved power factor

• Better control of variables

Limitations • VFDs waste more energy as heat, particularly when there is significant speed reduction.

• The VFD does not deliver a true sine wave voltage to the motor. Harmonics may be an

issue.

• VFDs increase losses in the transformers that feed them because of distortion of the

input waveform.

• Some VFDs may cause existing motors to run substantially hotter.

• Not usable with conventional ac motors in applications where the motor must maintain

high torque as the speed is reduced.

• Conventional motors lose their ability to get rid of heat as speed is reduced (limitation of

the motor rather than a limitation of the drive.)

• Motors need to have cooling independent of motor speed, which is typically a special

requirement.

• Overall system efficiency of modern dc drive systems and variable-pulley drives can be

higher than the system efficiency of VFDs on induction or synchronous motors.

• Can lead to system power problems

• Can lead to system component or equipment failures

• Will not fix system problems

• More complexity more problems

• Need for qualified people to install, maintain and service

Types of VFD’s

• Variable Voltage Input (VVI)—This is the simplest type of VFD. The output

switching devices approximate a sine wave voltage for the motor by a series of

square waves at different voltages. VVI drives use a large capacitor in the DC

link to provide a relatively constant DC voltage to the inverter.

• Current Source Input (CSI)—Similar to a VVI, the main difference with

CSI is that the CSI drive is able to force a square wave of current, rather than

voltage, through the motor. CSI drives use a large inductor to keep the DC

current relatively constant.

• Pulse Width Modulated (PWM)—This is the most complex VFD design, but

also offers the most potential for increasing motor efficiency. The PWM

inverter uses transistors to switch the direct current at high frequency to

deliver a series of voltage pulses to the motor. The width of each pulse is

tailored so that the voltage pulses interact with the reactance of the motor

windings to produce current flow in the motor that approximates a sine wave.

• Vector Drives-(VVFD)-- Vector drive is like an inverter drive except the

Vector drive has feedback on rotor position. Feedback includes motor speed,

current and back EMF. This takes place with open or closed loop control.

Part II installation

Control

• Analog Inputs

• Analog Outputs

• Binary Inputs

• Binary Outputs

• Communicating system interfaces

VFD sections

• Regulator—Controls the rectifier and

inverter to produce the desired ac frequency

and voltage.

• Rectifier—Converts the fixed 60 Hz ac

voltage input to dc.

• Inverter—Switches the rectified dc voltage

to ac, creating variable ac frequency (and

controlling current flow, if desired).

Components

• Rectifier

• Inverter

• Power Quality

Drive Layout Input PWR

Quality

Output

TR200 Layout

Fault Relay

240 V AC, 2 A

Analog

Inputs and

Outputs

Digital Inputs

12 & 18: Run Command

12 & 27: Interlock

(MUST be Connected to 24

V supply)

RS-485

Run Relay

30 V AC, 1 A

Wiring the Drive

• Control Wiring

• Terminal blocks can

be unplugged

Digital Inputs:

12 & 27: Interlock

(MUST be Connected to

24 V supply)

Wiring the Drive • Control Wiring

• Terminal blocks

can be

unplugged

Plus 24 VDC

Safety Contact

Fire / Freeze / Etc.

Parameter 304 ( Coast Inverse)

Display reads “UN READY” in

lower right corner.

Digital Inputs:

12 & 18 (Start / Stop)

(MUST be Connected to

24 V supply)

Wiring the Drive • Control Wiring

• Terminal blocks

can be

unplugged

Plus 24 VDC

Start Command From Automation

Parameter 302 ( Start )

Note: When Contact Opens Unit Ramps to a Stop

Wiring the Drive • Control Wiring

• Terminal blocks

can be

unplugged

Drive Fault Indication

Use Terminals 01 and 03

Registers a Drive Fault if not Powered up

Terminal Block Located under Power Terminals

Drive Run Indication

Contacts are Low Voltage ( 30 VAC)

Signals Automation Drive is Running

Parameter 326

(No Alarm)

Parameter 323

(Running)

Wiring the Drive • Control Wiring

• Terminal blocks

can be

unplugged

Positive Voltage scaled 0 to 10 VDC

Analog Input 53

Para 308 ( Reference)

Para 309 (Low Scaling) 0 VDC

Para 310 ( High Scaling) 10 VDC

Common for Input Follower Signal

Para 314

Terminal 60 Function set for (No Operation)

FROM AUTOMATION

Input Testing Meter set to diode test

• Meter + Lead to DC Buss +

– Meter – to L1 ,L2, L3 ≈ ∞ (infinity) (After Charge

Cap.)

• Meter - Lead to DC Buss +

– Meter + to L1, L2, L3 ≈ .48

• Meter + Lead to DC Buss –

– Meter – lead to L1, L2, L3 ≈.48

• Meter – lead to DC –

– Meter + lead to L1, L2 L3 ≈ ∞ (infinity) (After

Charge Cap.)

Input Testing • Meter + Lead to DC Buss +

– Meter – to U, V, W ≈ ∞ (infinity) (After Charge

Cap.)

• Meter - Lead to DC Buss +

– Meter – to U,V, W ≈ .39

• Meter + lead to DC Buss –

– Meter – Lead to U, V, W ≈ .39

• Meter – Lead to DC Buss –

– Meter + lead U, V, W ≈ ∞ (infinity) (After

Charge Cap.)

Brushless DC motors

ECM Controller

ECM wiring

What is ECM

• An Electronically commutated Motor

• Three phase wound stator

• Permanent Magnet Rotor

• DC brushless motor

• Synchronous motor

• Incorporated inverter

ECM motor Parts

Types of ECM motors

Trane ECM motors

1. On OFF

2. Multiple speed

1. High

2. Medium

3. Low

3. Variable speed

1. 0-100%

ECM motor characteristics

• Torque linear with speed

• Maximum torque when stationary

• High efficiency

• Permanent magnets on rotor

• Fixed armature

ECM rotor position detection

• Hall effect sensors A transducer that varies its output voltage in response to a magnetic field

• Rotary encoder An electro-mechanical device that converts the angular position or motion of a shaft or axle to an analog or digital code

Can be based on BACK-EMF ♥

ECM Module Replacement

ECM Troubleshooting

Power connections

Models 2.0/ 2.3 / 2.5

Jumper 1 and 2 for 120 VAC no jumper for 240 VAC

Modle X13 Speed inputs 1-5

ECM motor

Aprx. >12 Ω Winding to

Winding

3 PH DC Motor

One way to test motor & drive

24

VAC

Hot

24

VAC

Comm

on

Some Furnaces Units Req.

Jumper

Power (4 &5) &

ground (3)

One more way to test motor & drive

Runs to 50%

9 VDC 9 VDC

Comm

on

Some Furnaces Units Req.

Jumper

Power (4 &5) &

ground (3)

EBM plenum Fan

Take top of to get to

motor

Fan Speed Control

Speed Setup

ECM Engine Controller

Adapter Board

Customer Supplied Terminal

Interface

Options Module

EBM plenum Motor Wiring

EBM plenum Motor Wiring

With PWR

to motor

place 10

volts to 8

and 7 and

fan will run

Economizers

Economizers ?

• Job 1

– Reduce operating costs in cooling mode

• Draw backs

– The OSA may not meet the needs of occupants

• Cool but clammy

• They can waste energy if not working or setup

properly

• Many dampers and systems are not working as

designed or design is wrong

Savings

• Intel IT conducted a proof-of-concept test that used an air-side economizer to cool servers with 100% outside air at temperatures of up to 90°F. Intel estimates that a 500kW facility will save $144,000 annually and that a 10MW facility will save $2.87 million annually. Also, the company found no significant difference between failure rates using outside air and an HVAC system.38

• A San Jose, California, data center estimates it can reduce its cooling costs by 60% through air-side economization. A Sacramento, California, data center projects a 30% savings over conventional data centers.39

Space Control

Control Types

1. Fixed dry-bulb temperature

2. Differential (or duel) dry-bulb temperature

3. Fixed enthalpy

4. Differential ( or duel) Enthalpy

5. Combination of each of the other four

CO2

• Used for demand ventilation

– Reduced OSA requirements

• Damper minimum position based on actual need

– Will drive OSA damper based on indoor air

quality

Exhaust fan

• Will turn on anytime the economizer

damper positon is equal to or greater than

the exhaust fan setpoint

Savings

• Intel IT conducted a proof-of-concept test that used an air-side economizer to cool servers with 100% outside air at temperatures of up to 90°F. Intel estimates that a 500kW facility will save $144,000 annually and that a 10MW facility will save $2.87 million annually. Also, the company found no significant difference between failure rates using outside air and an HVAC system.38

• A San Jose, California, data center estimates it can reduce its cooling costs by 60% through air-side economization. A Sacramento, California, data center projects a 30% savings over conventional data centers.39

Reference Change Over

Setting

• Dry Bulb/Reference Enthalpy Setpoint

Mode Temp Enthalpy

– A 73 °F 27 btu/lb

– B 70 °F 25 btu/lb

– C 67 °F 23 btu/lb

– D 63 °F 22 btu/lb

Know the sensors

Trane Economizers

Reference Dry Bulb

• Economizer control:

– Enabled when the OA Temperature is less than

the Reference setpoint

– Disabled when the OA Temp is greater than the

Reference setpoint (plus 5 °F)

• Requires MA Temp and OA Temp sensors

Reference Enthalpy

• Economizer control:

– Enabled when OA Enthalpy is less than

Reference setpoint (minus .5 btu.lb)

– Disabled when OA Enthalpy is greater than

Reference setpoint (plus .5 btu/lb)

• Requires OA Temp, OA Humidity and MA

Temp sensors

Comparative Enthalpy

• Economizer control:

– Enabled when OA Enthalpy is less than RA

Enthalpy (minus 3 btu/lb)

– Disabled when OA Enthalpy is greater than RA

Enthalpy

• Requires RA Temp, RA Humidity, MA

Temp, OA Temp and OA Humidity sensors

• On units with the optional economizer the damper

is driven open for 15-20 seconds, and then closed

for approximately 90 seconds. This assures proper

damper calibration.

Economizer Calibration

Economizer Actuator w/

Module (ECA) • Can be used with or without the RTOM

• Has a detachable communicating module

• Sensors connected:

– Mixed Air Sensor

– Return Air Sensor

– OA/RA Humidity Sensors

– CO2 Sensor

VAV operation

5 DC

4-20 MA DC

0-10 VDC

RTEM

Economizer actuator

Electromechanical Economizer

% OUTSIDE AIR

((RA-MA) / (RA-OA)) X 100 = % OA

EXAMPLE:

RA = 75

MA = 70

OA = 55

((75-70) / (75-55)) X 100

= 25% OA

Honeywell Jade

Economizer Sequence

Constant volume systems

VAV SYSTEMS

Economizer Maintenance

At least Annually

• Setting & operation of the outdoor

thermostat or enthalpy controls

• Checking condition of out door air controls

• Checking damper operation, clean, lubricate

and adjust.

• Check, adjust and maintain minimum

damper positon

• Test system operational sequence

• Check all electrical connections and wiring