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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