Trane Variable Frequency Drives Troubleshooting

Transcription

1 Trane Variable Frequency Drives Troubleshooting

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7 ! DANGER Touching the electrical parts may be fatal even after the equipment has been disconnected from the AC line. To be sure that the capacitors have fully discharged, wait 14 minutes after power has been removed before touching any internal component!

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9 BASIC INFORMATION AND REQUIRED EQUIPMENT REQUIRED REFERENCE MATERIAL REQUIRED TOOLS POSSIBLE USEFUL EQUIPMENT WHAT IS TROUBLESHOOTING DIVIDE AND CONQUER PHYSICAL INSPECTION

10 Required Reference Material YOU MUST HAVE THIS! INSTALLATION, OPERATION AND MAINTENANCE MANUAL (GENERAL INFORMATION) CUSTOMER CONNECTION DIAGRAM (SPECIFIC FOR THE ORDER) SCHEMATIC DIAGRAM (SPECIFIC FOR THE ORDER)

11 Hand tools Tool s required Screwdrivers, Standard & Phillips Torx drivers T10-T50 Metric socket set, 7-17 mm Lon extension (20 ) Torque wrench, in./lb Magnet Nut starter

12 Meters PWM compatible voltmeter Clamp-on ammeter

13 Additional tools 1000 v Insulation tester Laptop with system software Cell phone Oscilloscope (with Isolated case)

14 First thing Do not apply power until you complete the static tests

15 The Troubleshooting approach Take the logical approach Take it all in Use all you senses Perform physical inspection Do a process of elimination Make alignment with sequence of operation Align with what is to what should be What does the display tell you check the programing How does the drive look on the inside

16 Check it out Installation Connection Environment Fuses Burnt marks or smell

17 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).

18 VFD Introduction VFDs convert AC to DC then DC to AC (at varying frequency and voltage) AC DC AC Rectifier Inverter 460 V, 60 Hz 640 V, DC 307 V, 40 Hz VFDs allow the motor to operate and consume electricity as if it were the right sized horsepower for the job.

19 TROUBLESHOOTING THE DRIVE THAT WORKS IN HAND MODE. Before moving on try taking a voltage and current reading on the input and output of the drive. Both should be balanced. The output voltage must be balanced within a volt phase to phase with the motor connected.

20 DOES THE DRIVE RUN THE MOTOR IN HAND? Questions to Ask About the Problem. Did the motor ever run? Did it have problems when it was running? What changed since it did run? Is the problem repeatable? Does the problem always happen at the same time or with consistent repeatability?

21 DOES THE DRIVE RUN THE MOTOR IN HAND? At this point try to run the motor using the hand start function of the drive. Press the hand start key and slowly begin to increase the speed of the motor by pressing the plus key.

22 TROUBLESHOOTING THE DRIVE THAT WORKS IN HAND MODE. If the drive works the motor up and down in speed when in the hand mode, the drive is probably good.

23 DOES THE DRIVE RUN THE MOTOR IN HAND? Questions to Ask About the Problem. Did the motor ever run? Did it have problems when it was running? What changed since it did run? Is the problem repeatable? Does the problem always happen at the same time or with consistent repeatability?

24 The Motor Won t Run in Bypass Is there power to the bypass? Are the main or bypass fuses OK? Is the safety interlock closed? (TB1: 1 & 2) Is the motor overload tripped? Is the motor connected? For some drives: Is the building automation system giving a run command? (TB1: 2 & 3) (Use the customer connection diagram and bypass schematic for the drive to determine this.)

25 DIVIDE AND CONQUER Where Is the Problem? NOTE! If the motor will not run in the drive mode or the drive is dead, before trying the bypass mode, MEGGER the motor and the wiring from the output of the drive or bypass first before continuing the process of troubleshooting!!!!

26 HOW TO MEGGER A MOTOR

27 Motor wiring

28 Know your motor wiring

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31 Position A B C T T T T T T T

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35 DIVIDE AND CONQUER Where Is the Problem? NOTE! If the motor will not run in the drive mode or the drive is dead, before trying the bypass mode, MEGGER the motor and the wiring from the output of the drive or bypass first before continuing the process of troubleshooting!!!!

36 HOW TO MEGGER A MOTOR

37 MOTOR PROBLEMS TWO MODES OF FAILURE: WINDING FAILURE BEARING FAILURE

38 MOTOR PROBLEMS COIL FAILURES Coil Breakdown at the point of exit from the core Coil Breakdown at the crown point due to high voltage spiking.

39 MOTOR PROBLEMS Ground Fault failure at the core.

40 MOTOR PROBLEMS Complete coil failure due to all or partial loss of phase.

41 MOTOR PROBLEMS BEARING FAILURES DUE TO POSSIBLE DRIVE RELATE PROBLEMS BEARING FLUTING CAUSED BY ELECTROSTATIC DISCHARGE

42 Electric Motor Design 460 VAC 60Hz = Most electric induction motors were designed for operation on 3 phase sign wave power either 50 or 60 Hz. The input power was balanced in frequency, phase (120 degrees apart) and in amplitude. Common mode voltage the sum of the 3 phases would always equal zero volts. 42

43 Electric Motor Operation by VFD + = When operated by VFD, the power to the motor is a series of pulses instead of a smooth sign wave. The input power is never balanced because the voltage is either 0 volts, positive, or negative with rapid switching between pulses. The Three phases of voltage pulses ensures that the common mode voltage is never equal to zero and instead is a square wave or 6 step voltage. 43

44 Shaft Voltage Readings 44

45 PWM Drives Cause 1. High frequency transients (dv/dt) can break down the insulation between windings and cause corona discharge arcing which can short out the windings. 2. Because of the inherent voltage imbalance and dv/dt, the voltage pulses are capacitively induced on the motor shaft and can overcome the dielectric of the oil film in the motor bearings. Electrical discharges result in pitting and fluting damage in the bearing, breakdown of lubrication, and fluting failure of the bearing.

46 Motor Reliability for Inverter Driven Motors Motor Winding Problems The motor winding insulation was changed to withstand the transient voltages and to prevent the corona discharges. NEMA MG1 specified motor design to meet what was known as class F, G or H insulation, and corona resistant wire was developed. The problem of electrical bearing damage was identified in the NEMA MG1 with for motors above and below NEMA frames NEMA recommended to use either ceramic bearings or shaft grounding. Shaft grounding also protects attached equipment. 46

47 VFD Drive VFD Induced Shaft Voltages and Bearing Currents in AC Motors VFD induced capacitive voltages from the high switching speed of the pulse width modulation (PWM) drives discharge through motor bearings and cause electrical discharge machining (EDM) effect in the bearing race. Rotor ground currents generated by PWM Drive will partly flow as rotor ground current through the bearings of the motor. These currents are caused by the rotor being connected to common ground with a significantly lower impedance path then the ground of the stator housing. Stator Shaft VFD Induced Voltages Rotor Groun d Groun d Groun d

48 NEMA MG1 section Motors below 500 Frame (NEMA 56 to 449T): More recently potentially destructive bearing currents have occasionally occurred in much smaller motors These drives can be generators of a common mode voltage which oscillates at high frequency and is capacitively coupled to the rotor. This results in peak pulses as high as volts from shaft to ground Interruption of this current therefore requires insulating both bearings. Alternately, shaft grounding brushes may be used to divert the current around the bearing. It should be noted that insulating the motor bearings will not prevent the damage of other shaft connected equipment.

49 High Frequency Circulating Currents in Large AC, DC Motors & Generators Induced by the magnetic flux imbalance around the motor shaft from the stator windings, these currents circulate through the motor bearings. Circulating currents are a problem in large AC and DC motors of over 100 hp. Because these currents circulate through the motor via the shaft and bearings, the current flow must be either broken or an alternate path established to prevent bearing failures. Stator Shaft Shaft Currents Rotor Groun d Groun d High Frequency Flux encircling the rotor causing shaft bearing currents Groun d

50 NEMA MG1 section Large Frame Motors (500 frame or larger): voltages may be present under sinusoidal operation and are caused by magnetic dissymmetry's in the construction of these motors current path is from the motor frame through a bearing to the motor shaft, down the shaft, and through the other bearing back to the motor frame. This type of current can be interrupted by insulating one of the bearings. When VFD is used, the circulating currents described above increase from 60 Hz to KHz or MHz frequencies and may effect motors rated at 150 kw (200 HP). This is referred to as High Frequency Circulating Current Reference: A. Muetze, A. Binder, H. Vogel, J. Hering, What can bearings bear? How much current is too much? How much current reduction enough? IEEE Magazine on Industry Applications, vol. 12, no. 6, pp , November/December 2006.

51 Bearing Failure March 2005 Journal of Electrostatics Statistical model of electrostatic discharge hazard in bearings of induction motor fed by inverter by Adam Kempski et. al. Electrical Discharge Machining (EDM) bearing currents have been found as the main cause of premature bearing damages in Pulse Width Modulation (PWM) inverter fed drives. February 2007: Pump and Systems Magazine How to Prevent Electrical Erosion in Bearings by Daniel R. Snyder, P.E., SKF USA Inc. An estimated 50 percent of all electric motor failures are attributed to bearings, but the bearings themselves are not usually the root cause. Other forces are at work, such as the increasingly common problem of stray currents.

52 Motor Bearing Damage from Electrical Currents Electrical Discharge Machining (EDM) Bearing Pitting Damage Electron Microscope (SEM) Image 1000x Magnified Bearing Fluting Damage EDM Pit EDM Pitting 52

53 Mitigation Strategies Isolate the shaft from the frame of the motor - Use insulated sleeve on the bearing journal - Replace steel bearings with ceramic bearings Ground the shaft with spring loaded brush Copper phosphor or bronze metal brush Carbon block brush 53

54 New Conductive Microfiber Shaft GroundingTechnology Uses several methods to transfer electrical currents* Direct Contact Conduction Electrical Contact without mechanical contact by field emission *IEEE paper, September 2007: Design Aspects of Conductive Microfiber Rings for Shaft Grounding Purposes, by Dr. Annette Muetze et. Al. 54

55 New Approach to Electrical Current Transfer Installation Difficulty Vibration due to stickslip Material Wear (not suitable at high surface rate) Shaft run-out is compensated by spring load Not effective above 2MHz signal Within the elastic limit No Spring load Negligible wear of microfibers even high surface rate Continuous contact despite shaft run-out Easy Installation Low cost Maintenance Free 55

56 Shaft Grounding Ring Construction Conductive Micro Fibers Unique Characteristics Encircles complete 360 degree shaft area Unaffected by dirt and grease providing continuous grounding No maintenance required after installation 56

57 Shaft Grounding Ring Bearing Current Mitigation motors to 100 HP Stator Shaft Rotor V F D Ground

58 EST-ITW 58 Copyright Large Low and Medium Voltage Motors over 100 HP AEGIS Shaft Grounding Ring on DE SKF Insocoat bearing bearing NDE Stator Shaft Rotor V F D Ground

59 MOTOR PROBLEMS One possible fix.

60 MOTOR PROBLEMS TRY GOOD HIGH FREQUENCY GROUNDING TECHNIQUES

61 MOTOR PROBLEMS OTHER WAYS TO CORRECT THE PROBLEM FARADAY SHIELDED MOTOR INSULATED BEARINGS

62 MOTOR PROBLEMS SHAFT GROUNDING SYSTEM OUTPUT FILTERS

63 The number one killer of electric motors is heat. Motors that run on variable frequency drives run hotter than motors that run across the line.

64 Voltage spikes can cause problems. Some drive manufactures are better at suppressing the spikes than others.

65 Premium efficient motors run cooler than standard general purpose motors

66 The Motor Won t Run in Bypass IS THERE POWER TO THE BYPASS? SAFETY INTERLOCK? OVERLOAD? START/STOP

67 If the Drive Blows Power Fuses Before plugging in another fuse... With power off, use the ohmmeter to check for input AND output shorts Line-to-bus and motor-to-bus, is desirable. Line-to-line if the bus connections aren t readily available

68 Check programing Example: Trane TR-200 Series Start-Up 1. Parameter 1-03, TORQUE CHARACTERISTICS (For single motor applications factory default is ok - AUTO ENERGY OPTIMUM. VT. For multiple motors change to VARIABLE TORQUE.) 2. Parameter 1-20 kw or 1-21 HP, MOTOR POWER parameter 0-03 will determine if parameter 1-20 OR- parameter 1-21 is accessible, other parameter is hidden 3. Parameter 1-22, MOTOR VOLTAGE 4. Parameter 1-23, MOTOR FREQUENCY 5. Parameter 1-24, MOTOR CURRENT 6. Parameter 1-25, MOTOR SPEED 7. Parameter 1-29, run AUTOMATIC MOTOR ADAPTATION

69 Start-Up Continued 1. Parameter 4-12, MIN. FREQUENCY (6Hz for fans, 18Hz for pumps) 2. Parameter 4-14, MAX. FREQUENCY (typically set to 60Hz) 3. Parameter 3-41, RAMP 1 UP TIME (60 sec for fans, 10 sec for pumps 4. Parameter 3-42, RAMP 1 DOWN TIME (60 sec for fans, 10 sec for pumps) 5. Parameter 5-12, COAST INVERSE (sets function of Terminal 27 set to NO OPERATION if external signal not required)

70 Input Drive Layout PWR Quality Output

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73 Period, range of q Diode Pair in conduction 30 o to 90 o D 1 and D 6 90 o to 150 o D 1 and D o to 210 o D 2 and D o to 270 o D 3 and D o to 330 o D 4 and D o to 360 o and 0 o to 30 o D 5 and D 6

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75 Magic Component's Regulator Electronic controls Filters Lots of Magic in the boxes which in realty is just electronics switching between 0 and 1.

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78 # Trane TR200 Variable Frequency Drive

79 Silicon diode = 0.7v Schottky diode = 0.3v Germanium diode = 0.2v Typical Schottky metals: Ti, Ni, Au, Pt, Pd

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83 AC PWM Drive: Diode Bridge Rectifier Rectifier DC

84 PWM Drive Output Waveform high speed low speed Time frame and Pulse width controlled by Microprocess or

85 Types of PWM Drives Drives using bipolar transistors use a low carrier frequency (1 to 4 khz). Drives Using IGBTs: Can use carrier frequencies greater than 10 khz. Some can be switched to use lower carrier frequencies.

86 TR200 Layout

87 Input/output Testing DC buss + DC buss -

88 DC Buss Voltage Test DC Buss + to DC Buss Input Voltage X1.3 = Minimum at Full load Input Voltage X 1.4 = Maximum Full load voltage

89 VFD Voltage A-B, B-C, C-A = Line Imbalance: ± 3% U-V, V-W, W-U= Balanced

90 BASIC ELECTRONIC TROUBLESHOOTING Ohm checking the power semiconductors. Ohm checking the gate driver circuits. Checking the gate driver circuits with a scope. Running the motor in hand mode.

91 Ohm checking the power semiconductors. Set the ohm meter on either the diode check scale or the 2K scale if you are using a standard LCD style meter with a 9 volt battery. Start the process by placing the positive lead of the ohm meter on the positive bus and then check each input connection with the negative lead of the ohm meter noting the value of the reading on each input line connection.

92 Ohm checking the power semiconductors. NOTE: When ohm checking the power semiconductors bus cap charging may be noticed. Do not be alarmed. This is normal. Now the ohm meter leads and repeat the process. Again note the readings. What should be observed if the power semiconductors are good, is that you will notice that in one direction the meter readings will be with in the range of 0.3 to 0.7 K ohms and out of scale in the opposite direction.

93 Ohm checking the power semiconductors. Repeat the same process to check the output semiconductors. Similar reading should be obtained with these devices. With these reading available, determine if the drive has sustained semiconductor damage and take the appropriate steps to repair the drive.

94 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.)

95 Checking the gate driver circuits with a scope. For those people who have access to an oscilloscope, below is the scope pattern you will see. This measurement is only available to you with drives sized 15 through 75 HP 460 Volt and 5 though 25 HP 208 Volt. Drives smaller and larger do not have access to the IGBT gate leads.

96 Drive Layout Input PWR Quality Output

97 An inductor stores energy in the magnetic field created by the current. When the current through a coil changes and an induced voltage is created as a result of the changing magnetic field, the direction of the induced voltage is such that it always opposes the change in current.

98 What reactions do you see in AC or DC. DC current Back EMF present during DC turn-on until stabilized, Back EMF present with polarity reversed during DC turn-off until decay is complete. AC current Back EMF present alternating in each direction due to on off action of AC

99 Inductor Applications Coils resist rapid changes in the current flowing through them. Inductors freely pass steady dc current.

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103 Reducing Harmonic Distortion DC link reactor AC line reactors

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105 AC Line Reactors

106 Input Reactor s Effect Distorted Ideal With reactor

107 Comparison DC Link Reactors Reduces harmonic distortion Built into the drive as standard Requires one or two coils, can reduce the size of the bus capacitor AC Line Reactors Reduces harmonic distortion Extra cost option increases the drive s size Requires three coils

108 Comparison, continued DC Link Reactors Does not affect the drive s AC line operating range Protects against current surges Voltage snubbers in the drive protect against voltage surges AC Line Reactors Reduces the AC voltage supplied to the drive Protects against current surges Protects against voltage surges

109 AC Line Reactors Drives with no DC link reactors generally require AC line reactors To reduce harmonic distortion More importantly, to keep the drive from being damaged by power line disturbances

110 Combining DC and AC Reactors Why not combine both? Typical example: (from drivesmag.com) no reactors 62% current distortion 3% AC reactor 37% current distortion 3% DC reactor 31% current distortion 3% DC reactor + 3% AC reactor 28% current distortion This isn t cost effective!

111 Reducing Harmonic Distortion DC link reactor AC line reactors Harmonic traps 12-pulse input Active filters

112 Harmonic Traps Designed to trap specific harmonic Specially designed for the individual building Often applied once, at the point of common coupling of all building power

113 12-Pulse Input Eliminates the 5th and 7th harmonics Needs a D-Y transformer and two rectifiers The transformer is expensive probably isn t supplied by the drive manufacturer D-Y transformer to the rest of the drive

114 Active Filter How it works Electronically monitors the AC power line Switches power from or to the line based on the line s condition Concerns Expensive Complex Adds high frequency noise (EMI and RFI) to the building

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117 Capacitors Pass A.C. Capacitors Block D.C.

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119 CAPACITOR A capacitor is an electronic device which consists of two plates separated by some type of insulator. A capacitor's value is commonly referred to in microfarads, one millionth of a farad. It is expressed in micro farads because the farad is such a large value of capacitance. When a DC voltage source is applied to the capacitor there is an initial surge of current, then the current stops. When the current stops flowing, the capacitor is in a charged state. If the DC source is removed from the capacitor, the capacitor will retain a voltage across its terminals. This charge can be discharged by connecting the plates together. Generally, if an AC voltage source is connected across the capacitor, the current will flow through the capacitor until the source is removed. The exceptions to the situation, where an AC voltage is applied to a capacitor, are going to be explained later.

120 Capacitors How much is it??? Parallel Circuit Ct=C1+C2 Series Circuits For 2 Capacitors Ct=(C1xC2)/(C1+C2) For more than 2 capacitors in series Ct=(1)/((1/C1)+(1/C2)+(1/C3))etc.

121 Capacitor Applications Power supply filters Spike Remover AC-DC Selective filter A Capacitor will pass the Fluctuation signal and completely block the steady DC level.

122 DC BUSS CAPACITORS: THE GOOD, THE BAD, AND THE UGLY!

123 Drive Layout Input PWR Quality Output

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126 The bipolar junction transistor consists of three layers of highly purified silicon (or germanium) to which small amounts of boron (p-type) or phosphorus (n-type) have been added. The boundary between each layer forms a junction, which only allows current to flow from p to n. Connections to each layer are made by evaporating aluminum on the surface; the silicon dioxide coating protects the nonmetalized areas. A small current through the base-emitter junction causes a current 10 to 1000 times larger to flow between the collector and emitter. (The arrows show a positive current; the names of layers should not be taken literally.) The many uses of the junction transistor, from sensitive electronic detectors to powerful hi-fi amplifiers, all depend on this current amplification. Microsoft Corporation. All Rights Reserved. "Bipolar Junction Transistors," Microsoft Encarta Encyclopedia Microsoft

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141 IGBT There are 2 Count them 2 IGBT S In Each module used in our VFD s

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146 Input/output test Setup Test for no input/output or DC bus voltage. Input and output drive wiring disconnected Set meter to Diode function Find Test Points (DC+, DC-, L1,L2,L3, U,V,W)

147 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.)

148 Input Testing Meter + Lead to DC Buss - Meter to L1 L3.48 Meter to U V.39 Meter - Lead to DC Buss Meter to L1, L2, L3 (infinity) (After Charge Cap.) Meter to U,V, W (infinity) (After Charge Cap.)

149 VFD Voltage A-B, B-C, C-A = Line Imbalance: ± 3% U-V, V-W, W-U= Balanced

150 Drive Control

151 Control Communication protocols Inputs and outputs Binary or digital AC or DC example: (0-24VDC, open or closed) Analog example: (4-20 ma 0-10 VDC, 0-5 VDC)

152 OPTO-COUPLER

153 EEPROM Electrically erasable programmable ROM With normal ROMs you have to replace the chip (or chips) when new BIOS instructions are introduced. With EEPROMs, a program tells the chip's controller to give it electronic amnesia and then downloads the new BIOS code into it. This means a manufacturer can easily distribute BIOS updates on floppy, for instance. This feature is also called flash BIOS, and you might also come across it in devices like modems and graphics/video cards.

154 Checking the gate driver circuits with a scope. For those people who have access to an oscilloscope, below is the scope pattern you will see. This measurement is only available to you with drives sized 15 through 75 HP 460 Volt and 5 though 25 HP 208 Volt. Drives smaller and larger do not have access to the IGBT gate leads.

155 Safety Stop

156 TR-200

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158 Wiring the Drive Control Wiring Terminal blocks can be unplugged Digital Inputs 12 & 18: Run Command 12 & 27: Interlock (MUST be Connected to 24 V supply) Run Relay 30 V AC, 1 A Analog Inputs and Outputs RS-485 Fault Relay 240 V AC, 2 A

159 Control Wiring Terminal blocks can be unplugged Wiring the Drive Safety Contact Fire / Freeze / Etc. Digital Inputs: 12 & 27: Interlock (MUST be Connected to 24 V supply) Plus 24 VDC Parameter 304 ( Coast Inverse) Display reads UN READY in lower right corner.

160 Wiring the Drive Control Wiring Terminal blocks can be unplugged Start Command From Automation Digital Inputs: 12 & 18 (Start / Stop) (MUST be Connected to 24 V supply) Plus 24 VDC Parameter 302 ( Start ) Note: When Contact Opens Unit Ramps to a Stop

161 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 Parameter 326 (No Alarm) Drive Run Indication Contacts are Low Voltage ( 30 VAC) Signals Automation Drive is Running Parameter 323 (Running)

162 Wiring the Drive Control Wiring Terminal blocks can be unplugged Analog Input 53 Para 308 ( Reference) Para 309 (Low Scaling) 0 VDC Para 310 ( High Scaling) 10 VDC Positive Voltage scaled 0 to 10 VDC FROM AUTOMATION Common for Input Follower Signal Para 314 Terminal 60 Function set for (No Operation)

163 Open Loop Analog Inputs Term V Term V Term ma FUNCTION * SCALE LOW SCALE HIGH * Set the FUNCTION of the terminal used for speed control to REFERENCE. Set the FUNCTION of unused terminals to NO OPERATION. Note: All Trane drives have term 53 set for default as Reference & 0-10 VDC # Trane TR200 Variable Frequency Drive

164 VFD testing

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