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Trane ComfortSite is a user-friendly Internet site designed to
save you time and it’s FREE for Trane Customers.
· Order Equipment, Parts, Literature and track Order Status
· Register for Training Programs
· Complete Warranty requirements online
· Search for specific Product Information
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· And More!
Make every business day more productive by using Trane ComfortSite.
ComfortSite website: https://www.comfortsite.com/ebiz/
Not a registered user and want to learn more?
Contact your local Trane Parts Distributor at (800) 585-2591.
Need help locating your distributor?
E-mail us at: support@comfortsite.com
Class information available at:
www.trane.com/COMMERCIAL/Training
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
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