DC CIRCUITS Part I of III Parts. Part II installation. Part III troubleshooting
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1 DC CIRCUITS Part I of III Parts Part II installation Part III troubleshooting
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5 Trane ComfortSite is a user-friendly Internet site designed to save you time and it s FREE for Trane Customers. Order Equipment, Parts, Literature and track Order Status Register for Training Programs Complete Warranty requirements online Search for specific Product Information Use interactive Product Support functions View account history and print invoices through Account Track Online And More! Make every business day more productive by using Trane ComfortSite. ComfortSite website: Not a registered user and want to learn more? Contact your local Trane Parts Distributor at (800) Need help locating your distributor? us at: support@comfortsite.com Class information available at:
6 What is a Variable Frequency Drive? A Variable Frequency Drive is an electronic device designed to vary the speed of a motor while maintaining power factors that are comparable to that of the motor at it s synchronous speed
7 VFD Cooling Tower Fan Control ALTIVAR 66 VLT 6000 Dan Foss ALTIVAR 58 Adjustable Speed Drives
8 HVAC Applications - Trane Equipment M Series Air Handlers T Series Air Handlers Orderable with Factory Mounted & Commissioned VFDs IntelliPak Rooftops Commercial Self-Contained Voyager III Rooftops CenTraVac Chillers Have VFDs installed and commissioned right at the Trane factory
9 HVAC Applications - Field Applied Cooling Towers Primary & Secondary Pumping Applications General Purpose HVAC Fans Special Purpose such as Parking Garage Fans Buildings are rich with Field Applied VFD opportunities
10 Simplified Operation TR1 TR200 Larger, easier-to-read display graphs Plain text Icons Up to 5 data items displayed Real Time Clock Free text displays Redesigned intuitive keypad LEDs indicate Hand/Off/Auto Mode One-touch alarm log key Usability enhanced with the TR200 local control panel
11 Read The Tag!
12 The VFD
13 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
14 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
15 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.
16 Control Analog Inputs Analog Outputs Part II installation Binary Inputs Binary Outputs Communicating system interfaces
17 Control Testing
18 TR-1 Control
19 TR-200 Control
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21 Safety Stop
22 Control MCB 101 General Purpose MCB 105 Relay On-Board: Modbus RTU Johnso N2 Siemens FLN BACnet MS/TP (2Q 2009) MCB 115 Analog I/O Optional Modules: LonWorks FTP BACnet MS/TP DeviceNet (future) PROFIBUS DP (future) BACnet will be offered on-board as standard Easy-to-install, plug-in optional I/O
23 Magic Component's Regulator Electronic controls Filters Lots of Magic in the boxes which in realty is just electronics switching between 0 and 1.
24 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).
25 Components Rectifier Inverter Power Quality
26 Input Drive Layout PWR Quality Output
27 TR200 Layout
28 TR-1
29 The Value of a Drive Return on investment 1. Drive Horsepower 746 watts equals 1 horsepower Horsepower Srpm = synchronous revolutions per minute. 120 = constant F = supply frequency (in cycles/sec) P = number of motor winding poles» Srpm = 120 x F P» HP = Torque x rpm Power Factor 3. Performance
30 TR-200
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32 Safety Stop
33 An adjustable frequency drive converts AC to DC and then back to AC. AC DC AC Rectifier Inverter
34 AC PWM Drive: Diode Bridge Rectifier Rectifier DC
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40 Rectifier
41 Half-Wave Rectifier
42 The Full Wave Rectifier
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44 The Full Wave Rectifier
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48 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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50 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.
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52 DC BUSS CAPACITORS: THE GOOD, THE BAD, AND THE UGLY!
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54 Inductors (Chokes) Inductors are simple coils of wire Stores energy in the form of magnetic fields Unit of measure is Henries Used to delay and reshape alternating currents
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56 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.
57 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
58 Inductor Applications Coils resist rapid changes in the current flowing through them. Inductors freely pass steady dc current.
59 The Inverter Section Controls the frequency applied to the motor. Controls the speed of the motor.
60 A/C Power
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63 Position A B C T T T T T T T
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69 VFD Introduction How they do it: Change the frequency of the electricity to the AC motor to change its speed Change the voltage to the AC motor as appropriate for the frequency and load Voltage High Speed Frequency Voltage Low Speed Frequency Half the Frequency, Half the Synchronous Motor Speed
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71 Input Harmonics VFD meets IEEE harmonic distortion voltage and current limits. VFD is supplied with a minimum 18 pulse input. VFD manufacturer guarantees compliance to IEEE by offering on-site testing. Institute of Electrical Engineers L'institut des ingénieurs électroniciens et électriques, inc..
72 If a drive must be supplied with an input harmonic filter to meet IEEE , 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).
73 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.
74 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).
75 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
76 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.
77 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
78 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
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