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Trane Variable Frequency Drives
DC CIRCUITS
Part II of III Parts
Part II installation
Part III troubleshooting
What to think about before installation
"STATIC ELECTRICITY" is not "static", it
really means "HIGH VOLTAGE
ELECTRICITY."
several thousand volts
200pF body capacitance
At humidity levels above 50%
•Nylon clothes: 21,000 volts
•Wool clothes: 9,000 volts
•Cotton clothes: 7,000
volts
Electro-
Magnetic
Interference
Radio
Frequency
Interference
Trane TR200 Variable Frequency Drive ‹#›
Harmonics
• A sine wave that is an integer
multiple of a base or
fundamental frequency.
• Or a sine wave composed of
a fundamental frequency and
harmonic frequencies.
Odd Harmonics
• Frequencies that are odd Multiples of the fundamental frequency.
• EX. Fundamental frequency is 1kHZ the odd harmonics would be 3kHz,5kHZ,7kHZ etc.
• The 3kHZ would be the 3rd harmonic,5kHZ would be 5th harmonic 7kHZ would be the 7 harmonic etc...
Even Harmonics
• Even multiples of the fundamental frequency.
• EX. If fundamental is 200 HZ than the second
harmonic is 400 HZ and 800 HZ is the fourth
harmonic and 1200 HZ is the sixth harmonic
etc….
Composite waveform
• Any variation from a pure sine wave produces
harmonics.
• A nonsinusoidal wave is a composite of the
fundamental and the harmonics.
• Some are only odd some only even and some a
mix.
• Square wave is an example of fundamental and
odd harmonics.
Harmonic Sequence
• We know about Odd and Even Harmonics
• Now we will think about Harmonic Sequence?
• The sequence is +, -, 0 ????
• The sequence of harmonics Ex. With a 60 HZ Fundamental. The First harmonic is 60 or Sequence +, 2nd harmonic is 120 or -,3rd harmonic is 180 or 0.
Name F 2nd 3rd 4th 5th 6th 7th 8th 9th
Frequency 60 120 180 240 300 360 420 480 540
Sequence + - 0 + - 0 + - 0
Sequence Rotation Effects
Positive Forward Heating of conductors,circuit breakers, etc.
Negative Reverse Heating as above and motor problems
Zero None Heating and problems in neutral of 3 phase 4 wire systems
Harmonic Spectrum
• Harmonic orders/amplitudes present:
• Even harmonics (Loads with half-wave rectifiers —
very old technology)
• 3rd harmonic (single-phase loads)
• 5th and 7th (Primarily three-phase loads)
THD Total Harmonic Distortion IEEE 519-1981: Voltage THD
• 3% Sensitive applications – Airports
– Hospitals
– Telephone companies
• 5% General applications – Office buildings
– Schools
• 10% Dedicated systems – Factories
• For Current, THD should not exceed 5-20%
What do you do on a startup
• What is the first thing that you should do when
receiving the drive? Check for damage.
• Where can the drive’s data label be found? How is
the “sales number” or the Label created? Found on
box, or drive. Created from catalog number.
• True or false? It is acceptable to use a 460 volt drive
to run a motor that is wired fro 230 volts
• Name two places that information can be found to
assist you with an installation. Manuals,
tranedrives.com
• Where can the “Motor Data” that will be programmed
into the drive be found? Motor name plate
• Name some things that need to be taken into
consideration prior to installation. Environment,
altitude, temperatues, space, proper tools and
equipment.
• True or false Side by side mountings are acceptable.
• True or false drives require no space above and below
them.
• Where does the power and control wiring enter the
drive? Bottom
• Which terminals are used to connect the input voltage
(91-92-93) and which ones for the motor output (96-
97-98)
• Why are circuit breakers unacceptable on the drive’s
input? Circuit breakers react too slow and the drive
could suffer unnecessary damage.
Input Harmonics
VFD meets IEEE-519 1992 harmonic
distortion voltage and current limits.
VFD is supplied with a minimum 18 pulse
input.
VFD manufacturer guarantees compliance
to IEEE-519 1992 by offering on-site testing.
Institute of Electrical Engineers L'institut des ingénieurs électroniciens et électriques, inc..
If a drive must be supplied with an input
harmonic filter to meet IEEE-519 1992, the
drive manufacturer must address if filter
must be modified if the user:
a. moves the VFD to a different power
system,
b. changes the present power system (e.g.
changes upstream transformers, cables,
etc.) or
c. operates the VFD on two different power
sources (e.g. normal operation and
generator operation).
VFD system efficiency shall be a
minimum of 96%. VFD system
efficiency includes losses in:
power conversion equipment
input transformers
output transformers (if needed)
power factor correction (if needed)
harmonic filters (if needed).
VFD system efficiency value is guaranteed by vendor.
A drive should have an efficiency rating of 95% or better at
full load.
Variable frequency drives should also offer a true system
power factor of 95% or better across the operational speed
range, to avoid penalties from the power utility, save on
energy bills, and to protect you equipment (especially
motors).
Motor Issues
Standard AC induction motors can be operated by the VFD system
without motor de-rating.
VFD system is supplied with input transformer to protect motor from
common mode voltages. VFD systems using an input line reactor in
lieu of an input transformer are unacceptable.
All output voltage harmonics in the motor waveform up to the 200th
harmonic are less than 10% of the fundamental.
The motor voltage maximum step size is less than 1200V in order to
reduce reflected wave insulation stress associated with long motor
cables.
All current harmonics in the motor waveform up to the 200th
harmonic are less than 3% of the fundamental at full load.
VFD system can produce at least 100% full load torque at locked
rotor conditions
Input Power Ridethrough
Capabilities
VFD can ride through a 5 cycle
loss of input power without
tripping.
VFD can ride through a 30%
voltage dip indefinitely without
tripping. A decrease in output
speed and power is allowable.
Power Component Replacement/Repair
Since minimizing drive down-time is essential
to maximizing the user’s profits, the time
required to replace a failed power component
or cell is critical. The drive vendor shall
provide a timed demonstration of the
replacement of a failed power module.
Power module replacement time shall be less
than fifteen (15) minutes.
Rear or side access to the equipment is NOT
required for troubleshooting or periodic
maintenance
Operating Experience
The VFD vendor shall provide a
users list of operating units in the
field. This list shall only include
those units that are similar in power
circuit topology to those being
proposed for the present project.
VFD vendor shall have units of
similar power circuit technology
operating in the field for at least two
(2) years
Pre-Installation Checks
a. Compare the drive model number to what was ordered.
b. Be sure the following are for the same voltage:
i) Drive.
ii) Power line.
iii) Motor.
c. Record the following motor data:
i) Voltage
ii) Frequency
iii) Full load current
iv) Full load speed
v) Power (convert HP to Kw – approximately 746 watts/HP)
d. Be sure that rated drive current is greater than or equal to the total full load current of
all motors which will be
driven at once.
e. Check motor wiring:
i) A disconnect or contactor between the drive and the motor may need to be interlocked to the
drive or
else nuisance trips may occur.
ii) Multiple motors have individual motor overload and short circuit protection.
iii) No power factor correction capacitors between the drive and the motor.
iv) Two speed motors must be wired permanently for full speed.
v) Y-start, ∆-run motors must be wired permanently for run.
vi) Part winding start motors must be wired permanently for run.
Grounding
Installation Checks
a. Verify appropriate short circuit protection is provided at the input of the drive. Specific fuse requirement
necessary for UL (see instruction manual)
b. Measure phase to phase line voltage and ensure measured voltage is within drive specification (see
instruction
manual)
c. Measure phase to ground voltage. If any measured phase voltage is greater than 60% of phase to phase
voltage, open RFI switch.
d. Environmental concerns.
i) Suitable for drive enclosure type, Chassis, NEMA/UL Type 1, 12, 3R or 4
ii) Max 95% relative humidity, non-condensing.
iii) 14oF to 113oF ambient temperature range (typical).
iv) 3300 foot maximum elevation with no de-rating.
v) Non-corrosive environment or unit conformal coated.
e. Mounting
i) No heat sink fins exposed out the back.
ii) Drive mounting clearances observed (see instruction manual)
iii) No excessive vibration.
iv) Keep dirt and debris out of the drive
v) Use knock-outs provided or conduit entry plates for wire entry
f. Connections and Wiring
i) Check all wiring connections are secure.
ii) Each drive grounded individually, no daisy chain grounds.
iii) 0-10Vdc and ma signal wires protected from noise.
iv) Separated runs for input power, motor power, and control wiring.
v) Note some control connections may be 115VAC.
vi) Motor thermistor wires separate from load wires.
Powering Drive
a. Double check all wire connections (correct terminal
connection, correct tightness)
b. All RUN commands off, all speed commands set to
zero.
c. Switch Power on.
d. Display and PWR LED on.
Basic Drive Set-up, Use Quick Menu — This step is
essential!
a. Parameter 0-01, LANGUAGE
b. Parameter 1-20, MOTOR POWER (Kw)
c. Parameter 1-22, MOTOR VOLTAGE (V)
d. Parameter 1-23, MOTOR FREQUENCY (Hz)
e. Parameter 1-24, MOTOR CURRENT (A)
f. Parameter 1-25, MOTOR NOMINAL SPEED (RPM)
g. Parameter 3-41, RAMP 1 RAMP UP TIME (S)
h. Parameter 3-42, RAMP 1 RAMP DOWN TIME (S)
i. Parameter 4-11, MOTOR SPEED LOW LIMIT (RPM)
j. Parameter 4-13, MOTOR SPEED HIGH LIMIT (RPM)
k. Parameter 1-29, AUTOMATIC MOTOR ADAPTATION
Set Application Related Parameters, Use Quick
Menu Function Set-ups
a. Parameter Q3-4, Application Set-ups
i) Parameter Q3-40, Fan Functions
ii) Parameter Q3-41, Pump Functions
iii) Parameter Q3-42, Compressor Functions
Operational Tests — HAND
a. Check the motor’s rotation from the drive. If incorrect,
reverse two leads between the drive and the motor.
b. If a bypass is provided, check the motor’s rotation in
bypass mode. If incorrect, reverse two input power
lines.
c. Accelerate the motor to full speed and verify
operation.
d. Decelerate the motor to a stop and verify operation.
e. Slowly operate the motor over the speed range and
check for resonance. Adjust parameters 1-64 and 4-60
thru
4-63 to set bypass frequencies to avoid resonance.
Operational Tests — AUTO, Open Loop
a. Ensure that the drive follows run/stop commands
from the system.
b. Ensure that the drive follows the speed command
from the system.
c. Set final MIN/MAX References as required –
Parameters 3-02 and 3-03
d. Set final RAMP UP/RAMP DOWN Times as required
– Parameters 3-41 and 3-42
Operational Tests — Auto, Closed Loop
a. Set up the PID control parameters as required.
b. Ensure that the drive follows run/stop commands
from the system.
c. Ensure that the drive responds to the feedback signal
from the system.
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
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)
Final Adjustments
a. Set up parameter 1-73, FLYING START, as required.
b. Copy parameters to other setups as required,
Parameter 0-51
c. Copy parameters to the LCP, Parameter 0-50
Safety Stop
TR-200
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
VFD testing
• No drive startup is complete until tested at FLA
• Watch Listen, and smell for anything unusual
• Allow system to run for a few hours before taking test
readings for future comparison.
• Check drive output with a scope to test output signals
• Verify control signals.
• Check inputs and outputs with a TRUE RMS VFD
rated meter.
Wiring the Drive
• Connect control
wiring shields to
ground at only one
end
• The shield should be
insulated at the
other end of the
control cable
• A clamp is provided
for grounding the
shield at the drive
end
Switch Settings
Use of USB connection
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