TR1 Series VFD. Variable Frequency Drives TR1-SLB005-EN

Transcription

1 TR1 Series VFD Variable Frequency Drives April R5568

2 Introduction Trane TR1 Series VFD The most commonly used motor in HVAC installations today is the three-phase, asynchronous AC induction motor, which is both inexpensive and durable. Standard asynchronous AC induction motors are designed so that the operating speed of the motor is dependent on the frequency of the power applied. When operated from the power line, this frequency is fixed, resulting in two position control, either on or off. This means that your typical HVAC fan or pump is running at 100% speed even when the environment of the building is calling for something less than 100% heating or cooling! Enter the HVAC Variable Frequency Drive. A Variable Frequency Drive (VFD) is an electronic system which provides infinitely variable control of the speed of three-phase AC induction motors by converting fixed frequency and fixed voltage input power into adjustable frequency and adjustable voltage. With a VFD installed in your HVAC system, you control the speed of the AC pump or fan motor to meet the exact need of the building s environment. The Trane TR1 Series VFD is an advanced design VFD, fully dedicated to the optimum operation of HVAC applications. It offers energy savings, user-friendliness and builtin functionality to meet the rigorous demands of today s HVAC applications. Motor control is based on the VVC PLUS vector drive system, providing full motor power at rated speed without derating. The Automatic Motor Adaptation feature ensures optimum motor torque performance while the Automatic Energy Optimizer function optimizes the variable frequency drive s voltage output to the actual load of the motor, thus minimizing the power consumption. Controlling the flow of air and water in HVAC systems is the only effective way to meet the changing demands put on an HVAC system by the environment. Only Variable Frequency Drives can maximize the efficiency and energy savings in today s HVAC fan and pumping systems. The Trane TR1 Series VFD is your ultimate solution to reducing energy and maximizing occupant comfort. The following are trademarks or registered trademarks of their respective companies: TR1 from American Standard, Inc.; Apogee from Siemens Building Technologies Inc.; BACNet from ASHRAE (American Society of Heating, Refrigerating and Air-Conditioning Engineers); LonWorks from Echelon Corp.; Metasys from Johnson Controls; ModBus from Groupe Schneider; Profibus from Siemens A/G 2 American Standard Inc. 2003

3 Contents Introduction Design Features Application Considerations Network Communications Selection Performance Data Wiring Diagram Dimensions and Weights

4 Design Features Typical front view with front and side panels removed Balanced DC link reactors Surface mount components for compactness and reliability Microprocessor-based control system designed specifically for HVAC applications Thorough RFI/EMI noise shielding Removable keypad with on-board memory Removable control card for easy service Extensive use of electronic filters Programmable customer interface Removable terminal strips, angled for easy access Internal mounting provision for option card EIA-485 interface with standard communications protocols built-in High voltage isolated from low voltage control circuitry All power and control wires enter at the bottom of the enclosure 4

5 Design Features Energy Savings Energy savings of 50 to 70% are common when compared with constant flow systems When compared with other methods of flow control, savings to 40% are typical Control and Comfort Improvement The TR1 Series VFD precisely maintains exact flow required The TR1 Series VFD can accommodate two feedback signals and two setpoints each from different sources The controlled airflow creates a more pleasant environment by reducing drafts and noise The obvious change in airflow and sound level caused by cycling is eliminated entirely Reduction in Maintenance Costs Inherent soft start eliminates the stress on driven equipment caused by acrossthe-line motor starting Belt slip during start-up is eliminated Amount of make-up water and its treatment costs are reduced in cooling towers The need to trim impellers on oversized pumps may be eliminated Any oversized system can be fine tuned by setting the maximum speed to the maximum desired flow rate Compatible with Virtually all Building Automation Systems Harmonics Control Built-in DC link reactor provides harmonic control The DC link reactor will not reduce output voltage as an AC line reactor will Power Factor Near unity power factor Power factor higher than that of the motor Power factor constant regardless of speed and load Complete Range of Drives From 1-1/2 to 600 HP NEMA 1, 12, and 3R enclosures Complete Range of Options Trane TR1 Series VFDs and panels are assembled in a UL panel shop and an ISO 9001 and facility Full range of pre-engineered options Engineered-to-order capability to meet any HVAC panel requirement 5

6 Design Features Drive Feature User Benefit Interchangeable keypad with memory... All keypads are identical and easily removable. Four TR1 Series VFD set-ups can be uploaded to the keypad and saved. This allows the selection of summer/winter modes or return to previous settings. Operates without a keypad in place... Assures tamper-proof operation. TR1 Series VFD status shown even with the keypad removed. Keypad can be easily remote mounted... The standard keypad can be remotely mounted 10 feet from the TR1 Series VFD with a standard 9- pin cable. The remotely mounted keypad is gasketed and carries a NEMA 12 and NEMA 3R rating. Parameters can be uploaded and downloaded... In multiple TR1 Series VFD installations, only one keypad needs to be programmed. The settings are stored with the VFD. To program multiple VFDs, upload the parameter settings to the keypad, then place that keypad on each of the other drives and download these same settings to every other VFD. Preset typical HVAC defaults... Many installations require nothing more than scrolling through the twelve QUICK MENU items to confirm that these defaults are correct. Built-in two setpoint PID controller... Can look at two feedback signals, compare with two setpoints and make various process control decisions. Built-in EIA-485 interface... Fully equipped for serial communication. Up to 31 TR1 Series VFDs can be connected to one serial bus up to 5,000 feet long. Built-in N2 and FLN communication... Communicates directly with Johnson Controls Metasys N2 and Siemens Apogee FLN systems with no hardware changes or additional cost. Simplified automatic energy optimization... This automatic, dynamic control eliminates the need to select a V/Hz pattern. Automatic Energy Optimization continually monitors the motor s speed and load and adjusts the applied voltage to maximize energy savings. Even at full speed, voltage will be reduced if the load is less than 100%. This automatically compensates for oversized motors or systems that are not fully loaded. Automatic high ambient derate... If the ambient temperature exceeds the normal limit, the VFD can be set to warn of its overtemperature and continue to run, keeping the HVAC system functional. To control its temperature, the drive will reduce the output carrier frequency and then, if necessary, reduce the output current. Automatic motor adaptation... Automatic Motor Adaptation is a test algorithm that measures motor stator resistance and reactance. Knowing these, the VFD automatically optimizes performance and efficiency. The motor does not have to be run or decoupled from the load for the Automatic Motor Adaptation setup to be performed. 6

7 Design Features Drive Feature User Benefit Constant torque start and 160% breakaway current available... Constant torque start assures that the load accelerates to the commanded speed. Breakaway current can be set up to 160% for up to 0.5 seconds for breaking away high friction loads. Output switching pattern... Unique digital voltage vector control provides: Nearly perfect output sine wave Full rated motor voltage at rated frequency High efficiency for both TR1 Series VFD and motor Full motor performance without derate Automatic switching frequency modulation... Adjusts the carrier frequency based on the load Provides a quiet motor at critical low flow conditions Provides full rated output without derate at high load Protected from input or output switching... Input or output may be disconnected while the TR1 Series VFD is running without the need for interlocks to protect the drive. Full torque at any selected speed up to base speed... Direct driven fans can now be run without derating. The full output torque can be set to coincide with the maximum design operating speed of the driven equipment, up to 60 Hz. Auto ramping... Ensures no-trip acceleration and deceleration. Flying start... Allows starting into a windmilling fan at any speed, in either direction. Sleep mode... Automatically stops the TR1 Series VFD when its speed drops below the set sleep level for a specified time. Automatically restarts when the speed command exceeds the set wake level. Saves energy and reduces wear on driven components. Run permissive circuit... The ability to accept a system ready signal assures that dampers or other auxiliary equipment are in the proper state for drive operation. Safety interlock... Provides external fault indication. Temperature controlled cooling fans... All TR1 Series VFD cooling fans are controlled by actual heatsink temperature. VFDs run as quietly as possible, with minimized losses. UL and C-UL listed... All TR1 Series VFDs and options sold for US and Canadian applications carry this safety certification. CE marked... All TR1 Series VFDs through 460 volts carry the CE mark for sale into international markets. ISO All TR1 Series VFDs and options are built to ISO quality standards. Plenum rated... All TR1 Series VFDs and option panels are UL listed for installation in air handling compartments. 7

8 Design Features Harmonic Mitigation The TR1 Series VFD limits harmonic distortion on the power line with DC link reactors. DC link reactors on both DC bus lines are supplied standard in every TR1 Series VFD. These reactors reduce RMS input current by more than 40% compared to VFDs without input reactors. Other variable frequency drives address harmonics with AC line reactors, usually external to the VFD. Often, these optional AC line reactors are 50% larger than the DC link reactors standard on the TR1 Series VFD. This results in significant additional heat generation and reduced efficiency. Input Protection In addition, the TR1 Series VFD employs metal oxide varistors and R/C snubber circuitry to protect the drive from power line noise. User-Friendly Local Control and Set-up Every Trane TR1 Series VFD is equipped with the same easy-to-use keypad. No matter what size VFD or option and control package is specified, the same removable, interchangeable keypad comes standard with every unit. The TR1 Series VFD keypad offers more than simple Hand/Start, Off/Stop, Auto Start control. Transfer of parameters between different units A complete set of parameters can be programmed into one VFD, and using the keypad, can be downloaded into other VFDs. Remote mounting available The optional remote keypad kit allows remote mounting of the TR1 Series VFD keypad. The kit includes the standard 10 foot, nine pin cable. Removal of the keypad does not affect the VFD s NEMA 1 or NEMA 12 ratings, and the gasketed keypad itself carries a NEMA 12 and NEMA 3R rating. Operation without the keypad The keypad can be removed for tamper-proof operation. VFD status ON, WARNING, and ALARM lights are still shown, and the VFD will continue to run at the last commanded local speed or will operate in remote operation through network communication. Complete programmability of display The keypad s four line, backlit, alphanumeric display can be programmed to display four different measurements at a time. This includes F, C, %, Pa, bar, RPM, frequency, gallons/minute, ft 3 /sec, p.s.i., or 15 other measurements. These measurements can be displayed in any order, with one selected as the large, main display. Plain language alarms and warnings alarms and warnings are displayed in easy-to-understand alphanumeric form eliminating the need for decoding or referring to long tables in manuals. All VFD parameters are accessible through the keypad. The Quick Menu key offers immediate access to 12 start-up parameters, including Motor Power, Motor Voltage, Motor Nominal Speed, Ramp Up/Down Time, and Minimum/Maximum Frequency. TR1 Series VFDs are shipped with application-specific parameters pre-programmed; the Quick Menu allows input of motor nameplate data for speedy commissioning. Closed Loop Control The TR1 Series VFD includes a Proportional, Integral, Derivative (PID) controller with two setpoints and two feedbacks, a feature not offered anywhere else in the market. Not only does the built-in PID controller eliminate the need for extra I/ O modules to maintain closed loop control, but having two setpoints and feedbacks allows for two-zone regulation. The TR1 Series VFD built-in PID controller can greatly improve the efficiency of cooling tower systems. Once the VFD is programmed, it can automatically match the VFD s speed to the air flow requirements. The built-in PID controller is also useful in pump applications. The TR1 Series VFD, combined with a flowmeter, can measure and regulate flow to accurately maintain a given rate. The TR1 Series VFD, combined with a differential pressure transmitter, can work with throttling valves to provide more accurate control and energy savings. Trane also offers an optional cascade controller for pumps. This add-in board allows staging up to four additional drives and/or fixed speed motors. By using the PID controller in the master drive, this can provide an exceptionally wide range of efficient control in large pumping systems. The TR1 Series VFD can also operate in open loop control mode, where the drive receives a speed command signal from the building management system. Even in this mode, feedback signals from the controlled system can activate warnings on the display and the building management system. 8

9 Network Communication Facilities that employ BAS (Building Automation Systems) with a computerized communication control system can be thought of as Intelligent Buildings, combining centralized control with adaptable control components. The TR1 Series VFD offers out-of-the-box communication capabilities that are unmatched in adjustable frequency drives. Standard EIA-485 interface The TR1 Series VFD comes fully equipped for serial communication. Up to 31 VFDs can be connected to one serial bus up to 5,000 feet long. With an optional repeater, as many as 126 VFDs can be accommodated. LonWorks, Modbus, BACnet or Profibus communication can be provided as an option. A LonWorks, Modbus or Profibus board securely mounts inside the TR1 Series VFD. A BACLink portal can be remotely mounted in a NEMA 1 enclosure for control of multiple VFDs. Seventy-four points per VFD may be monitored or controlled. Serial communication for Johnson Controls Metasys N2 and Siemens Apogee FLN. Every TR1 Series VFD is equipped for communicating with each protocol. The Trane TR1 Series VFD can be seamlessly installed in N2 or FLN communication networks with no addons. 9

10 Application Considerations Configuring Drives for the Application Integrated three-contactor bypass with VFD and bypass fusing and input disconnect switch. The TR1 Series VFD can be built to meet any HVAC requirement. Pre-engineered HVAC option packages are available in a variety of configurations. Options include: Two-contactor bypass Three-contactor bypass Automatic bypass Motor selection Multiple motor operation Main power and VFD disconnect switches Main VFD, bypass and motor fuses or circuit breakers EMI/RFI filters to reduce the coupling of radio frequency electronic noise onto the AC Power line Input AC line reactors for harmonics control Output load reactors for reduced motor stress Pressure-to-electrical transducers Factory authorized start-up and extended warranties The TR1 Series VFD is available with an integrated bypass package. This NEMA 1 vertical design provides a compact unit that is an ideal fit in crowded equipment rooms. Available for 208 volt drives through 30 HP, 460 volt drives through 60 HP, and 600 volt drives through 75 HP, the entire VFD and bypass is no wider than the basic VFD. A side-by-side bypass package is also offered for all voltages and sizes. A broad range of standard and engineered-to-order configurations are available. All TR1 Series VFDs and option packages are factory-built and carry UL and C-UL listings. All VFDs and option packages are built in ISO 9001 and certified facilities. VFD with disconnect switch and input fuses. Side-by-side three-contactor bypass, contactor motor selection, with drive fusing and input disconnect switch. 10

11 Application Considerations Configuring Variable Frequency Drives for the Environment The TR1 Series VFD can meet the demands of the most rigorous HVAC environments. Indoor Environments NEMA 1 All VFDs are available as standard in a NEMA 1 enclosure. This enclosure is suitable for use in relatively clean, dry indoor environments. NEMA 12 All VFDs except the 600 volt units are also available in an optional NEMA 12 enclosure. This enclosure is suitable for use in indoor locations that may be too dirty for NEMA 1 enclosures. The side-by-side option packages are also available in both NEMA 1 and NEMA 12 enclosures. The integrated bypass is available only in NEMA 1 configuration. Plenum Rated All VFDs and option packages are UL listed for installation in air handling compartments. Moist or Corrosive Environments For moist or corrosive atmospheres, conformal coated circuit boards are available for all VFDs. Outdoor Environments VFDs through 75 HP at 460 or 600 volts and 30 HP at 208 or 230 volts may also be supplied with a UL listed Type 3R enclosure suitable for outdoor use. These rainproof enclosures allow the versatile TR1 Series VFD and all of its options to be located on a rooftop or other outdoor location. Regardless of the ambient temperature, enclosure fans and a thermostatically controlled heater help keep the VFD within its temperature limits, and help prevent condensation in cool, damp environments. A made-to-order outdoor enclosure may be supplied for larger VFDs. UL listed Type 3R outdoor enclosure with VFD and three-contactor bypass. 11

12 Selection 208 V Input 230 V Input 380 V Input 460 V Input 600 V Input Max Nominal Max Drive Max Drive Max Drive Max Drive Max Drive Model Number Output HP Output Current* Output Current* Output Current* Output Current* Output Current* TR / TR TR TR TR TR / TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR *Max drive output current rating of drive must always equal or exceed nameplate running amps of motor(s). 12

13 Performance Data Input Voltages, select model based on input voltage through 240; 380 through 460, or 550 through 600 V AC Motor Voltages , 208, 220, 230, 240, 380, 400, 415, 440, 460, 550 or 575 V AC Input Voltage Range for Full Output... Nominal ±10% Undervoltage Trip Point...164, 313, or 394 V AC Overvoltage Trip Point , 538, or 690 V AC Input Frequency or 60 Hz, ±2 Hz Output Frequency... Selectable 0 to 120 Hz Drive Efficiency... 97% or greater at full load and nominal motor speed Input Section... Full wave three phase bridge rectifier Output Section... Insulated gate bipolar transistors (IGBT) Input Displacement Power Factor or greater at all speeds and loads Follower Signal... 0 to 5 V DC, 0 to 10 V DC, 0 to 20 ma, 4 to 20 ma fully selectable, direct and inverse acting Lost Analog Reference Action... Selectable to go to a preset speed, go to maximum speed, stay at last speed, stop, turn off, or stop and trip Time Delay for Lost Analog Reference Action... 1 to 99 sec. Output Current Limit Setting... Adjustable to 110% of drive rating Current Limit Timer... 0 to 60 sec. or infinite Adjustable Maximum Speed... From minimum speed setting to 120 Hz Adjustable Minimum Speed... From maximum speed setting to 0 Hz Adjustable Acceleration Time... To 3,600 sec. to base speed Adjustable Deceleration Time... To 3,600 sec. from base speed Adjustable Auto Restart Time Delay... 0 to 600 sec. Starting Torque... Constant torque until commanded speed reached Breakaway Torque Time (1.6 times drive rated current) to 0.5 sec. Display Languages... English, Spanish, French, German, Italian, Portuguese, Swedish, Dutch, Danish Maximum Number of Preset Speeds Maximum Number of Frequency Stepovers... 4 Maximum Number of Accel/Decel Rates... 4 Number of Programmable Digital Inputs... 8 Number of Programmable Analog Inputs... Three: 2 voltage, 1 current Number of Programmable Analog Outputs... 2 Number of Programmable Relay Outputs... 1 standard Form A 30 V AC, 1 A, 1 standard Form C 240 V AC, 2 A, 1 or 4 additional optional Low Frequency and High Frequency Warnings... 0 to 120 Hz Low Current and High Current Warnings... 0 to maximum current Low Reference and High Reference Warnings ,999 to 999,999 Low Feedback and High Feedback Warnings ,999 to 999,999 Start Voltage... 0 to 10% Delayed Start... 0 to 120 sec. DC Braking Time... 0 to 60 sec. DC Braking Start... 0 to maximum frequency DC Braking Current... 0 to 50% of rated motor current Automatic Restart Attempts...0 to 20 or infinite Automatic Restart Time Delay... 0 to 600 sec. between each attempt Relay ON Delay and Relay OFF Delay (for the standard Form C relay and 4 relay option)... 0 to 600 sec. Drive and Options Enclosure... NEMA Types 1 and 12; 4 and 3R optional Ambient Operating Temperature Range F to 104 F (-10 C to 40 C) Humidity... <95%, non-condensing Maximum Elevation without Derate... 3,300 ft. (1000 m) 13

14 Typical Interconection Diagram Shown below is how a TR1 Series VFD typically interfaces with other components in the HVAC system. The terminal numbers and functions are identical on all TR1 Series VFDs. The analog and digital input terminals, and the analog and relay output terminals are all programmable. The functions shown here are typical, but show only a small portion of the total capability. An optional relay output card, not shown, can provide one or four additional Form C relays. The standard EIA-485 connections allow direct communication with the Johnson Controls Metasys N2 and Siemens Apogee FLN. 91 (L1) (U) 96 3-Phase Power Input 92 (L2) 93 (L3) (V) 97 (W) (PE) (PE) 95 Motor External DC Bus Connection +10 V DC 88 (-) 89 (+) 50 (+10 V OUT) Switch Mode Power Supply 10 V DC 17 ma 24 V DC 200 ma V DC Ref. Input* 53 (A IN) 0-10 V DC Ref. Input* 54 (A IN) 55 (COM A IN) (AUX RELAY) 01 (AUX RELAY) 02 Fault Indication* 240 V AC, 2 A 4-20 ma Ref. Input* 60 (A IN) (AUX RELAY) (+24 V OUT) 13 (+24 V OUT) (RELAY) 04 (RELAY) 05 Run Indication* 30 V AC, 1 A Reset* Lockout 16 (D IN) 17 (D IN) 5 V (COM A OUT) 39 (A OUT) 42 Output Current Indication* 4-20 ma Run/Stop* Reverse* 18 (D IN) 19 (D IN) SW2 0 V SW3 (A OUT) 45 Output Speed Indication* 4-20 ma Interlock 20 (COM D IN) 27 (D IN) SW4 EIA-485 Interface (P EIA-485) 68 (N EIA-485) 69 + EIA Preset Speed 29 (D IN) (COM EIA-485) 61 Setup Select* 32 (D IN) Setup Select* 33 (D IN) * The operation of all control inputs and outputs is programmable. Typical terminal functions are shown. 14

15 Dimensions and Weights NEMA 1 Basic TR1 Series VFD Drawing 1 Drawing 2 Drawing 3 Model Number NEMA 1 Dimensions (inches) Weight Dwg 208/230 VAC 380 VAC 460 VAC 600 VAC H W D a b c d (lbs) # TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR

16 Dimensions and Weights NEMA 12 Basic TR1 Series VFD Drawing 1 Drawing 2 Drawing 3 Drawing 4 Model Number NEMA 1 Dimensions (inches) Weight Dwg 208/230 VAC 380 VAC 460 VAC H W D a b c d (lbs) # TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR TR

17 Dimensions and Weights NEMA 1 and NEMA 12 Basic TR1 Series VFD Model Number Weight (lbs) 380 VAC 460 VAC NEMA 1 NEMA 12 TR TR ,312 1,334 TR TR ,339 1,411 TR TR ,488 1,510 TR TR ,543 1,565 17

18 Dimensions and Weights NEMA 3R Enclosure Drawing 1 Drawing 2 Enclosure houses TR1 Series VFD and all standard options. Model Number Dimensions (inches) WeightDwg 208 VAC 460 VAC 600 VAC H W D a b c d e f g h i j (lbs) # TR TR TR TR TR TR TR TR TR TR TR TR

19 Dimensions and Weights NEMA 1 Integrated Bypass Enclosure Contact Trane for options available with integrated bypass Model Number Dimensions (inches) Weight 208 VAC 460 VAC 600 VAC H W D a b c d e f g (lbs) TR TR TR TR TR TR TR TR TR TR TR TR NEMA 1 Integrated Fused Disconnect Enclosure Model Number Dimensions (inches) Weight 208 VAC 460 VAC 600 VAC H W D a b c d e f g (lbs) TR TR TR TR TR TR TR TR TR TR TR TR

20 Dimensions and Weights NEMA 1 Basic TR1 Series VFD with Side-by-Side Bypass Enclosure Model Number Dimensions (inches) Weight 208 VAC 460 VAC 600 VAC H W D1 D2 D3 a b c d e f g h j k l m (lbs) TR TR TR TR TR TR TR TR TR NEMA 12 Basic TR1 Series VFD with Side-by-Side Bypass Enclosure Model Number Dimensions (inches) Weight 208 VAC 460 VAC H W D1 D2 D3 a b c d e f g h j k l m (lbs) TR TR TR TR TR TR

21 Dimensions and Weights NEMA 1 Basic TR1 Series VFD with Side-by-Side Bypass Enclosure Inches Model Number Weight 208 VAC 460 VAC 600 VAC (lbs) TR TR TR The enclosure shown at right is required for dual motor or contactor motor selection. All other standard options will fit in the enclosure above. 21

22 Dimensions and Weights NEMA 1 Basic TR1 Series VFD with Side-by-Side Bypass Enclosure Inches Model Number Weight 460/600 VAC (lbs) TR ,026 The enclosure shown at right is required for dual motor or contactor motor selection. All other standard options will fit in the enclosure above. 22

23 Dimensions and Weights NEMA 12 Basic TR1 Series VFD with Side-by-Side Bypass Enclosure Drawing 1 Drawing 2 All Models Inches Model Number Weight Dwg 208 VAC 460 VAC (lbs) # TR TR Model Number Weight 460 VAC (lbs) TR ,048 23

24 Local Sales and Service Around the Globe Literature Order Number Trane A business of American Standard Companies For more information contact your local Trane office or us at comfort@trane.com File Number Supersedes Stocking Location New Commercial Communications, Inc. Trane has a policy of continuous product and product data improvement and reserves the right to change design and specifications without notice.