ChallengeWhen the controls system for ADTRAN’s East Tower was

phased out by its manufacturer, the company sought to

quickly resolve the obsolescence issue to minimize downtime.

In alignment with its commitment to sustainability, ADTRAN

specified a replacement controls system that would integrate

with its current controls and allow connectivity between

existing systems, while also reducing its energy consumption.

SolutionImpressed with the energy saving strategies proposed by

Trane, and pleased with Trane’s previous work, competitive

product offering and local service presence, ADTRAN

selected the company to partner with them to find the best

solutions to address their control system needs.

Controls upgrade and seamless integration

Controls on chillers, cooling towers, variable air volume (VAV)

systems, fan coil and air handling units, head pressure valves,

heat exchangers, pumps and refrigerant purge fans were

upgraded. The programmable Tracer™ UC600 unit controllers

and Tracer™ UC400 terminal unit controllers use a common,

repeatable, consistent platform to provide greater flexibility,

making them an ideal solution for ADTRAN’s special

sequencing requirements.

ADTRAN, Inc.Controls upgrade results in 1.3M kWh energy savings/yr, $133,680 in rebatesHuntsville, Alabama

ADTRAN, Inc. is a leading global provider of networking and communications equipment. ADTRAN’s products enable voice,data, video and Internet communications across a variety of network infrastructures. ADTRAN solutions are currently in useby service providers, private enterprises, government organizations and millions of individual users worldwide.

The unit controllers are designed to work with the Tracer™ SC

System Controller. With a complete portfolio of applications

and an intuitive, easy-to-use interface, Tracer SC provides

ADTRAN with a cost-effective solution for programming and

managing facility climate. Accessible from any PC, tablet or

connected device, facility managers use the controller’s web-

based management tools for scheduling, reporting and

applications programming to improve efficiencies, increase

comfort and reduced energy costs. Tracer ES™ building

management software enables ADTRAN to manage its

multiple facilities as a single enterprise, integrating Trane

controls seamlessly with ADTRAN’s existing equipment,

controls and Tracer Summit® systems used in its other

buildings via LonTalk™ and BACnet®.

Committed to sustainability, ADTRAN strives to reduce the consumption

of natural resources throughout the company and the communities in

which it operates.

August 2013Case study

Out-of-the-box chiller plant control

A chiller plant automation system and cooling tower

sequence optimization provides the building operator with

the tools necessary to balance the needs of building comfort/

process requirements and the desire to lower energy use, and

operating and maintenance costs. System loads are monitored

to determine the amount of chilled water needed, assuring

that only the chillers required to maintain the load are

operating. Condenser water temperatures are continuously

checked to keep only the cooling tower fans that are needed

to meet setpoint running. Using chiller/tower optimization

the condenser water temperature setpoint is automatically

reset to provide optimum system operation, minimizing the

total energy consumption of the cooling tower fan and chiller

combination. Chiller and cooling tower rotation, provided by

automatic scheduling and operator request, allows the

facilities manager to set up a method to equalize the run-

time on all chillers and cooling towers.

Static pressure reset meets critical zone requirements

Static pressure reset automatically maintains the duct static

pressure setpoint of a VAV system at the lowest possible level

without sacrificing occupant comfort. The control system

automatically identifies and maintains required airflow to the

critical zones. Energy savings result from decreasing fan

energy consumption.

Demand control ventilation reduces cost

Wall and duct carbon dioxide sensors were installed

throughout the ADTRAN facility to help determine occupancy

rates in the various zones of the building. A demand control

ventilation strategy helps ADTRAN reduce operating costs by

programming the system to respond to the actual need for

ventilation in a zone by varying the rate at which outdoor air

is delivered to that zone. Constant volume outdoor air and

exhaust fans were converted to variable frequency drives,

saving energy by varying fan flow rates according to

occupancy or cooling loads.

Results

The replacement of the building controls system at the

ADTRAN East Tower building has lowered energy costs,

improved system reliability and now provides enhanced

comfort for building occupants. The upgrade is projected to

provide annual energy savings of 1.3 million kWh, even with

additional power loads resulting from the relocation of a data

center and fitness facility to the building, and the expansion

of engineering labs. ADTRAN was awarded energy rebates of

$133,680 from the Tennessee Valley Authority (TVA).

"The TVA requirements were very stringent and required

detailed modeling to satisfy their rigid verification process,"

said Greg Smith, ADTRAN facilities manager. "Trane worked

diligently with us and TVA to accomplish this unprecedented,

complex project."

Trane offers ADTRAN a local service presence and provides monthly

Tracer Summit User Group training sessions for facility managers.

industrial markets. Our people and our family of brands—including Club Car®, Ingersoll Rand®, Schlage®, Thermo King® and Trane®—work together to Ingersoll Rand (NYSE:IR) is a world leader in creating and sustaining safe, comfortable and efficient environments in commercial, residential and

enhance the quality and comfort of air in homes and buildings, transport and protect food and perishables, secure homes and commercial properties,

company and for our customers. For more information, visit www.ingersollrand.com.and increase industrial productivity and efficiency. We are a $14 billion global business committed to sustainable business practices within our

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© 2013 Trane All rights reserved

CASE-SLX296-EN August 4, 2013