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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
In the Beginning 7.2 trillion degrees
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.
Control Analog Inputs Analog Outputs Part II installation 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
Input Drive Layout PWR Quality Output
TR200 Layout
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
Wiring the Drive Control Wiring Terminal blocks can be unplugged 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.
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
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)
Control Wiring Terminal blocks can be unplugged Wiring the Drive 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)
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 3 PH DC Motor Aprx. >12 Ω Winding to Winding
One way to test motor & drive Some Furnaces Units Req. Jumper 24 VAC Hot 24 VAC Comm on Power (4 &5) & ground (3)
One more way to test motor & drive Runs to 50% Some Furnaces Units Req. Jumper 9 VDC 9 VDC Comm on 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
Economizer Calibration 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 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
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