VFD Training Preso - Yorkland Controls · PDF fileDesign 5. Engineering and Commissioning. ... • Under Sized Piping or Ductwork puts additional load ... A manual 25 HP exhaust fan

YORKLAND CONTROLS

Yorkland Controls Ltd.

WelcomeWelcomeGerry CellucciGerry CellucciPartickPartick FarkasFarkasMark WasherMark Washer

YORKLAND CONTROLS

Housekeeping

•• Phones, Pagers off or on Vibrate. If you must answer Phones, Pagers off or on Vibrate. If you must answer the phone wait until you are outsidethe phone wait until you are outside

•• Facilities are on the right as you exit this roomFacilities are on the right as you exit this room•• Binder material reviewBinder material review•• Lunch and breaks served in this roomLunch and breaks served in this room•• Do not turn on Demos until askedDo not turn on Demos until asked

YORKLAND CONTROLS

YORKLAND

•• Distributor / Systems Solutions Provider with over Distributor / Systems Solutions Provider with over 35 years of controls experience35 years of controls experience

•• Represent major control manufacturesRepresent major control manufactures•• Uniquely positioned to offer integrated control Uniquely positioned to offer integrated control

systems from various control manufacturerssystems from various control manufacturers•• Support contractors as they offer control solutionsSupport contractors as they offer control solutions

YORKLAND CONTROLS

Distribution Channels

1.1. ““ ABCSABCS”” Systems (BAS) Distributor Systems (BAS) Distributor

1.1. Johnson ControlsJohnson Controls

2.2. HoneywellHoneywell

2.2. Parts SalesParts Sales

3.3. Energy Management SalesEnergy Management Sales

4.4. DesignDesign

5.5. Engineering and CommissioningEngineering and Commissioning

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Yorkland ControlsValue Added Services

•• High level of technical supportHigh level of technical support

•• Engineering Engineering

•• Sales & Marketing SupportSales & Marketing Support

•• Panel BuildingPanel Building

•• TrainingTraining

•• CommissioningCommissioning

“parts & smarts”

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AGENDAVariable Speed Drives (VFD)

•• Why VFD use is increasingWhy VFD use is increasing•• Energy Saving ExamplesEnergy Saving Examples•• ApplicationsApplications•• TerminologyTerminology•• Setup ExamplesSetup Examples•• Labs and QuizzesLabs and Quizzes•• QuestionsQuestions

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Variable Speed (Frequency) Drive What is it ?

VFDPower

Converts Motor from Fixed to Variable Speed

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Fixed Speed System - Typical

Motor/Pump

Control ValveDuty RequiredPower Input

YORKLAND CONTROLS

Variable Speed System - Typical

VFD

Motor/Pump

Control Valve Removed or locked open

Duty RequiredPower Input

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How does it Work ?•• Changes the speed of an AC HVAC fan or pump motor Changes the speed of an AC HVAC fan or pump motor

by adjusting or varying the by adjusting or varying the frequencyfrequency and voltage. For and voltage. For comparison, a DC motor speed is adjusted by only comparison, a DC motor speed is adjusted by only varying voltage.varying voltage.

•• Typical frequency adjustment range in Typical frequency adjustment range in HVAC applications is from 10 HVAC applications is from 10 -- 60Hz AC. 60Hz AC. A VFD is wired in series between main A VFD is wired in series between main power and motor.power and motor.

•• A Bypass is added to A Bypass is added to ““BypassBypass”” the VFD the VFD and run on main line power so HVAC and run on main line power so HVAC operation is not interrupted if the VFD operation is not interrupted if the VFD needs servicing needs servicing

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How Does it Vary Frequency ?

Switches (IGBT’s)

“Insulated Gate Bi-Polar Transistors

VFD Block Diagram VFD Block Diagram

Motor

Main Power

Rectifier

Capacitor

Motor

•• A VFD, AC inverter, or electronic speed controller for A VFD, AC inverter, or electronic speed controller for AC motors converts the AC supply to DC using a AC motors converts the AC supply to DC using a rectifier (diode), then converts it back to a variable rectifier (diode), then converts it back to a variable frequency by using a frequency by using a inverterinverter bridge.bridge.

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VFD Evolution to Reliability•• 1896 1896 –– Manual Adjusted DC Motor Speed ControlManual Adjusted DC Motor Speed Control•• 1924 1924 –– Variable Speed Control for AC MotorsVariable Speed Control for AC Motors•• 1960 1960 –– Commercially Viable Variable Speed DriveCommercially Viable Variable Speed Drive

1993 2007Expensive

Large

Inaccurate

Cost Effective

Compact

Reliable

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Variable Speed Drives

•• ReliableReliable•• Lower Costs, Lower Costs,

–– Hardware Cost has dropped by 2/3Hardware Cost has dropped by 2/3

•• ““SmallerSmaller”” &&““ SmarterSmarter””, Feature , Feature -- Rich DrivesRich Drives

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Smaller

20 HP with By-Pass

YORKLAND CONTROLS

YORKLAND CONTROLS

“Smarter” Tools for VFDs• PID Control, Multiple Sensor and Relays

• SVXDrive™– Set Parameters

• ONLINE/OFFLINE mode– Print-Outs of Parameter Settings– Copying of Parameter Settings– Trend Display– Operate the VS Series Drive– Monitoring

• SVXLoad™– Upload/Download

• Custom Application Software• System Software Updates• Option Board Software

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Network Ready

•• BacnetBacnet•• LONLON•• MODBUSMODBUS•• N2/MetasysN2/Metasys•• ProfibusProfibus

Control

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Why Use ?

1.1. To Save Energy !!!To Save Energy !!!2.2. Reduce Mechanical Reduce Mechanical ““wear and tearwear and tear””3.3. Increased PerformanceIncreased Performance

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Benefits of Variable Frequency Drives

•• Gives continuous, precise control of Gives continuous, precise control of acceleration, deceleration, and motor acceleration, deceleration, and motor speed under varying conditions (better speed under varying conditions (better than phase modulation)than phase modulation)

•• Reduced energy costReduced energy cost•• Does not rely on cycling motors Does not rely on cycling motors

(reduces wear)(reduces wear)•• Noise ReductionNoise Reduction

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Motor Facts

• Electric motors account for more than two-thirds of all energy used in industry

• 63% of the energy consumed is linked to air & liquid flow

• A typical 50HP industrial motor, with an efficiency of 90%, costs over $50,000 to operate continuously over a year.

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Motor Facts - Typical

Other17%

Ventilation& Cooling

52% Lighting31%

More than half the energy consumed by AC motors powers air conditioning equipment.

Electrical energy costs are often the largest expenditure for building owners

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Energy Savings with Variable Speed Drives

•• Energy Savings result from the following facts:Energy Savings result from the following facts:

–– Equipment (Fans/Pumps) are designed for Equipment (Fans/Pumps) are designed for worst case conditions (oversized for 20% of worst case conditions (oversized for 20% of the time)the time)

–– Affinity LawsAffinity Laws–– Variable Flow ApplicationsVariable Flow Applications

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Affinity Laws% Flow, Torque, HP

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Air Handlers and VFDs

Inpu

t Pow

er

(%)

For a 50 Hp , this means that only 6.26 Hp is required for 50% flow.

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Fan Duty Cycle (Variable)

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MOTOR FACTS - Size Matters

•• Under Sized Piping or Ductwork puts additional load on Under Sized Piping or Ductwork puts additional load on motorsmotors

•• Motors are designed to operate at full rated output ( 24/7 ).Motors are designed to operate at full rated output ( 24/7 ).•• In most cases the motor will be operating below itIn most cases the motor will be operating below it’’s rated s rated

outputoutput•• Efficiency drops at partial loadsEfficiency drops at partial loads

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Motor Power

•• Name Plate PowerName Plate Power•• Measured Power Measured Power –– measure power using a RMS measure power using a RMS

power Meterpower Meter•• Load is the actual work (power) by the motor in KW Load is the actual work (power) by the motor in KW

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Energy Calculations

•• Energy Usage = DEMAND x Daily Operating Hours x Energy Usage = DEMAND x Daily Operating Hours x 365 days365 days

•• DEMAND = Motor HP x .746 x Load/ Motor Efficiency DEMAND = Motor HP x .746 x Load/ Motor Efficiency (%)(%)

•• KW = HP x .746KW = HP x .746

YORKLAND CONTROLS

Sample Calculation

•• 5 HP Motor Operates 100% Load at 100% efficiency5 HP Motor Operates 100% Load at 100% efficiency•• DEMAND = 5 HP x .746 x 100%/100%DEMAND = 5 HP x .746 x 100%/100%•• DEMAND = 3.715 DEMAND = 3.715 KwKw•• Energy Use = 3.715 Energy Use = 3.715 kwkw x 24 hr x 365 dayx 24 hr x 365 day•• Energy Use = 32,543 Energy Use = 32,543 kwkw•• Energy Cost = 32,543 x .10 per Energy Cost = 32,543 x .10 per kwkw•• Energy Cost = $ 3,254.00Energy Cost = $ 3,254.00

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Sample Calculation - 2

•• 5 HP motor operates at 100% Load at 95 % 5 HP motor operates at 100% Load at 95 % EfficiencyEfficiency

•• DEMAND = 5 hp x .746 x 100% / 95%DEMAND = 5 hp x .746 x 100% / 95%•• DEMAND = 3.93 DEMAND = 3.93 kwkw•• Energy Use = 3.93 x 24hr x 365Energy Use = 3.93 x 24hr x 365•• Energy Use = 34,427Energy Use = 34,427•• Energy Cost = 34,427 x .10Energy Cost = 34,427 x .10•• Energy Cost = $3443.00Energy Cost = $3443.00

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Sample Calculation - 3

•• 5 HP motor operates at 80% Load at 95% 5 HP motor operates at 80% Load at 95% EfficiencyEfficiency

•• DEMAND = 5 hp x .746 x 80% / 95%DEMAND = 5 hp x .746 x 80% / 95%•• DEMAND = 3.14 DEMAND = 3.14 kwkw•• Energy Use = 3.14 x 24hr x 365Energy Use = 3.14 x 24hr x 365•• Energy Use = 27,516Energy Use = 27,516•• Energy Cost = 27,516 x .10Energy Cost = 27,516 x .10•• Energy Cost = $2,752.00Energy Cost = $2,752.00

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Calculation Summary

$ 2,752.00$ 2,752.00$ 3,443.00$ 3,443.00$ 3,254.00$ 3,254.00Energy Cost Energy Cost @ @ .10/kwh.10/kwh

27,516 27,516 kwkw34,427 34,427 kwkw32,543 32,543 kwkwEnergy UseEnergy Use

3.14 3.14 kwkw3.93 3.93 kwkw3.175 3.175 kwkwDEMANDDEMAND

Calc # 3Calc # 3Load = 80%Load = 80%EffEff = 95 %= 95 %

Calc # 2Calc # 2Load = 100 %Load = 100 %EffEff = 95 %= 95 %

Calc # 1Calc # 1Load = 100 %Load = 100 %EffEff = 100 %= 100 %

YORKLAND CONTROLS

Savings Calculation Example

•• Worksheets Under Binder Tab 1Worksheets Under Binder Tab 1

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Exhaust Fans•• Situation : A manual 25 HP exhaust fan is found to run 24 hours Situation : A manual 25 HP exhaust fan is found to run 24 hours -- 7 7

days a week in a baking facility. The exhaust fan is NOT tied idays a week in a baking facility. The exhaust fan is NOT tied into a nto a MakeMake--Up Air Unit as it is general exhaust for the plant. The plant ruUp Air Unit as it is general exhaust for the plant. The plant runs ns on 2 shifts on 2 shifts –– 7am to 12:00am for 5 days of the week7am to 12:00am for 5 days of the week

•• Calculate the savings if the exhaust fan was shut off by an autoCalculate the savings if the exhaust fan was shut off by an automatic matic timer for the hours of 1:00am to 6:00am for 5 days of the week. timer for the hours of 1:00am to 6:00am for 5 days of the week. Note Note that the plant is shut down for 2 weeks of the year in August anthat the plant is shut down for 2 weeks of the year in August and d closed for Christmas and New Year.closed for Christmas and New Year.

$

Motor efficiency = 93%

Load = 90 %

Energy Cost Per kw = .11

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Exhaust Fans

•• Calculate Current Cost to RunCalculate Current Cost to Run•• Calculate Cost to Run with TimerCalculate Cost to Run with Timer•• Difference is SavingsDifference is Savings

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Calculation & Payback

•• Savings= $ 8052.70.74Savings= $ 8052.70.74•• Installation= $2500.00Installation= $2500.00

•• PayBackPayBack = .31 years= .31 years

•• 365 Day Timers = $600365 Day Timers = $600•• Real Time Clocks = $1000Real Time Clocks = $1000•• Installation = $1500 approxInstallation = $1500 approx

YORKLAND CONTROLS

VFD Savings Example

•• 30 HP Pump in a constant flow (non30 HP Pump in a constant flow (non--VFD) system VFD) system runs 250 days a year and has a duty cycle of 80%.runs 250 days a year and has a duty cycle of 80%.

•• Converting to a VFD and an assumed 60% fan speed Converting to a VFD and an assumed 60% fan speed and fan running 22 hours /dayand fan running 22 hours /day

•• Estimated savings = 270.6 Estimated savings = 270.6 KwKw/day = $18.94 / day/day = $18.94 / day

•• Savings = $ 4,735.00 Savings = $ 4,735.00 (energy at .07 / (energy at .07 / KwKw))

•• 30 HP VFD List Price = $7500.0030 HP VFD List Price = $7500.00–– ( 5 years ago 30HP VFD = $ 12,500 )( 5 years ago 30HP VFD = $ 12,500 )

YORKLAND CONTROLS

Manual Example

•• An Air Handler running on constant volume is An Air Handler running on constant volume is considered to be retrofitted with a VFD. Yearly considered to be retrofitted with a VFD. Yearly operating hours are estimated at 2500hrs.operating hours are estimated at 2500hrs.

•• Calculate Savings if the AHU runs:Calculate Savings if the AHU runs:–– 100% speed for 25% of the time100% speed for 25% of the time–– 80% speed for 50% of the time 80% speed for 50% of the time –– 60% speed for 25% of the time60% speed for 25% of the time

•• Estimate Savings for VFD retrofit with $/Estimate Savings for VFD retrofit with $/KwHrKwHr at .08 .at .08 .

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Manual Calculation

•• ExampleExample

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“Choice” – Eaton Electric

YORKLAND CONTROLS

YORKLAND CONTROLS

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YORKLAND CONTROLS

Patrick FarkasTest Drive Software

•• ChoiceChoice

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Applications

•• FanFan•• HydronicHydronic

YORKLAND CONTROLS

Constant Fan to Variable Flow

H

C

C

C

T

FanFigure 1

H

C

C

C

T

Fan

DA-T

Figure 2

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10

10 20 30 40 50 60 70 80 90 100

2030405060708090

100110120130140

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AHU Conversion – From Constant Volume

•• ExampleExample

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AHU Conversion from Inlet Vane

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Flow Control ComparisonFLOW CONTROL TYPE COMPARISONS

0%

20%

40%

60%

80%

100%

% FLOW (VOLUME)

% O

F R

ATE

D H

P

CONSTANT VOLUME 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00

DAMPERS 1.00 0.97 0.93 0.88 0.83 0.77 0.71 0.63 0.56

INLET VANES 1.00 0.82 0.69 0.59 0.53 0.47 0.45 0.42 0.40

VARIABLE SPEED 1.00 0.82 0.65 0.51 0.38 0.27 0.18 0.11 0.05

100% 90% 80% 70% 60% 50% 40% 30% 20%

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MUA

Ө VFDs can be interlocked with time clocks or exhaust fan contacts to enable the programmed speed. For example, the VFD may be programmed to run at 60% flow during weekdays from 2 to 4 PM and from 1:00am to 5:00am. And 100% flow at all other times.

Ө Indoor Air Quality (IAQ) sensors can be used to override and increase the speed of the VFD when the carbon dioxide (Co2) increases above the override IAQ setpoint ( 800 to 1200 ppm Co2)

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Estimating Fan Curves

•• Mixed UseMixed Use•• Interior Supply FansInterior Supply Fans•• Exterior Supply fansExterior Supply fans

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Software DOE QuikFan 4.0

YORKLAND CONTROLS

QuikFan 4.0

YORKLAND CONTROLS

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YORKLAND CONTROLS

DOE-QuikFan 4.0

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Cooling TowerVFD Savings Potential

•• Cooling Tower fans obey the Affinity LawsCooling Tower fans obey the Affinity Laws–– 20% reduction in speed = 50% reduction in HP20% reduction in speed = 50% reduction in HP

•• Towers are designed for High Load ConditionsTowers are designed for High Load Conditions–– High Humidity, High temperatureHigh Humidity, High temperature

•• On Low Load days, On Low Load days, ““Low FanLow Fan”” may cyclemay cycle–– Increased wear and maintenanceIncreased wear and maintenance–– Lowers Cooling Tower Efficiency, therefore the Chiller Lowers Cooling Tower Efficiency, therefore the Chiller

efficiencyefficiency•• 1.2 % in chiller efficiency for every 1 degree in condenser wate1.2 % in chiller efficiency for every 1 degree in condenser water r

temperaturetemperature

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VFD & Cooling Tower

Rated CFM (RPM) %Typically the fan will run at 40-70% of full speed,

thus saving 50% or more of the energy consumed by

a fixed speed (constant volume) system.

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YORKLAND CONTROLS

Variable Air Volume

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Static Pressure Reset

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Carbon Monoxide

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Optimization

YORKLAND CONTROLS

Mark Washer – Johnson Controls

•• Product Sales Manager, CanadaProduct Sales Manager, Canada

YORKLAND CONTROLS

Case Study: Condo MUA

•• 100% OA100% OA•• DxDx CoolingCooling•• Glycol Heating CoilGlycol Heating Coil•• 25HP Supply Fan25HP Supply Fan•• Operates 24 hours / DayOperates 24 hours / Day

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Condo MUA

YORKLAND CONTROLS

Condo MUA

•• Modulating Hot Gas Bypass Valve was used on Modulating Hot Gas Bypass Valve was used on DxDxcoil. Allowing use of VFD on fan.coil. Allowing use of VFD on fan.

•• Fan run between 40Fan run between 40--80% depending on time day.80% depending on time day.•• Better control of Supply Air Temp.Better control of Supply Air Temp.•• Because of HW from central boilers triggered an Because of HW from central boilers triggered an

Enbridge rebateEnbridge rebate

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Condo MUA / Savings

•• Installed Cost $10,000Installed Cost $10,000•• Savings $8000 / yearSavings $8000 / year•• Payback just over 1 yearPayback just over 1 year•• Less if Enbridge Rebate Factored in.Less if Enbridge Rebate Factored in.

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Case Study: VAV AHU

•• Mixed AirMixed Air•• Cooling CoilCooling Coil•• 25 HP Supply Fan25 HP Supply Fan•• 15 HP Return Fan15 HP Return Fan•• Variable Inlet VanesVariable Inlet Vanes

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Case Study VAV AHU

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•• Reduced operating cost by 40%Reduced operating cost by 40%•• Installation cost $15,000Installation cost $15,000•• Payback around 18 monthsPayback around 18 months

VAV AHU / Savings

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Hydronic Applications

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Pump CurvesLess Pressure, More Flow

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Pump Duty CycleDuty Point

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Pump Duty Cycle. Pump Sized for End of the Curve (EOC)

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Pumps Curves & Throttling Valve

1200 GPM700 GPM

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Pumps with VFD

Flow (GPM)

DesignOperating Point

P3 P2P1

V3V2

V1

CP

SH

P1, P2, P3 = Outlet Valve Flow PositionsV1. V2, V3 = VFD Operating PointsSH = Static HeadCP = Constant Pressure

Same Flow – Less Pressure

3 way valve operates at “CP”

YORKLAND CONTROLS

VFD on Pumps

•• Three important facts to consider about variableThree important facts to consider about variable--torque type pumps. The affinity laws:torque type pumps. The affinity laws:

–– Flow Flow produced is proportional to the motor speed. produced is proportional to the motor speed. –– PressurePressure produced is proportional to the motor speed produced is proportional to the motor speed

squared. squared. –– Horsepower Horsepower required is proportional to the motor speed required is proportional to the motor speed

cubed. cubed.

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Example - 100 hp Pump•• Compare 100Compare 100--hp pump energy use on systems withhp pump energy use on systems with

–– Bypass valveBypass valve–– Throttling ValveThrottling Valve–– Variable Frequency DrivesVariable Frequency Drives

•• Looking at a 100Looking at a 100--hp pump. hp pump. If the flow neededIf the flow needed is only oneis only one--half of half of rated, then the motor could be operated at half speed and the rated, then the motor could be operated at half speed and the pressure would become (0.5)2 = 25% of rated. The horsepower pressure would become (0.5)2 = 25% of rated. The horsepower needed to operate the pump would be (0.5)3 = 12.5 hp. needed to operate the pump would be (0.5)3 = 12.5 hp.

1010

1515

2525

2020

1515

1515

5050

6060

7070

8080

9090

100100

% of Day% of DayLoad %Load %

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YORKLAND CONTROLS

Annual Dollars Comparison

Total Annual Dollars at .10$ / Kwhr

Bypass vlv $71,032 Throttle vlv $61,727

VFD $39,565

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Variable Flow from Constant Flow

Flow (GPM)

Operating Point

Zero-Bypass

System Curve

Pump CurveConstant Pressure

Coil

VLV

Hand or Balancing Valve

SupplyFigure: 3

Operating Point

Maximum-Bypass

3 way valve converted to 2 way operation

Coil Coil Coil

YORKLAND CONTROLS

VFDs and Pumps

Flow Rate (%)

Inpu

t Pow

er (%

)

10

10 20 30 40 50 60 70 80 90 100

20

30

40

50

60

70

80

90

100

110

120

130

140

Energy Saving Potential

YORKLAND CONTROLS

Differential Pressure

DP

DP

VFD

Position 1

Position 2

Flow (GPM)

DesignOperating Point

Pump Curve at Part LoadConditions

1200 GPM700 GPM

Flow (GPM)

1200 GPM

“worst-case” setpoint

VFD Application Sensor at Position 1

VFD Application Sensor at Position 2

HeadOr

Pressure

HeadOr

Pressure

YORKLAND CONTROLS

Pressure Sensor

HI Lo

Field Installed

YORKLAND CONTROLS

By Pass Conversion

Boiler

N/CDifferentialBypass Valve

Boiler

Coil

Coil

Coil

PPressureSensor

Boiler

N/CDifferentialBypass Valve

“Locked” Closed

Boiler

Coil

Coil

Coil P

PressureSensor

VFD

Figure : 2

YORKLAND CONTROLS

Booster Pumps

Savings from “oversized” pumps matched with demand

Supply added pressure to a building’s water supply – washrooms, bathrooms, etc

Pressure Valve regulates pressure as flow decreases and avoid over pressurization

YORKLAND CONTROLS

Duplex Pumps

YORKLAND CONTROLS

Heat Pumps

FluidCooler

M

Boiler 1 Boiler 2See Selection Chart

N O

HP

N O

HP

N O

HP

DDC Heat Pump

Control

Outdoor Air

DPDifferential Pressure Sensor

Heat Pump Supply

Heat Pump Return

Figure: 2

P2P1

P3

P4

other heating zones

V1

VFD

VFD

Solenoid Valve

YORKLAND CONTROLS

Three Way Valve Conversion

Boiler Boiler

N 0

C N C

Loop VLVTo BuildingT

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Demand Savings with VFDs

YORKLAND CONTROLS

Refrigeration – Condenser Fan Control

YORKLAND CONTROLS

Why Are Condenser Fan Controls Necessary?

Demand on refrigeration system Demand on refrigeration system changes with:changes with:•• Ambient temperatureAmbient temperature

–– Time of dayTime of day–– SeasonsSeasons

•• Refrigeration loadRefrigeration load–– More frequent opening of doorsMore frequent opening of doors–– Warm items placed in refrigerated areaWarm items placed in refrigerated area

YORKLAND CONTROLS

3-Phase Condenser Fan Control Strategies

•• Fan Cycling (On/Off)Fan Cycling (On/Off)•• Phase ModulationPhase Modulation•• Variable Frequency DrivesVariable Frequency Drives

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Fan Cycling•• Benefits of Fan CyclingBenefits of Fan Cycling

–– SimpleSimple–– Uncomplicated interfaceUncomplicated interface–– ReliableReliable–– Easy to set and adjustEasy to set and adjust

•• Drawbacks of Fan CyclingDrawbacks of Fan Cycling–– Less stable system pressure than with other methodsLess stable system pressure than with other methods–– Pronounced wear on equipment, especially on motors Pronounced wear on equipment, especially on motors

and electrical contactsand electrical contacts–– More electricity used than with other methodsMore electricity used than with other methods

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Normal ACSupply to Motor

Phase-modulated ACSupply to Motor

Phase Modulation – “Works Like a light dimmer”

YORKLAND CONTROLS

Drawbacks of Phase Modulation

•• Requires special motorsRequires special motors•• Hard on motors at low speedsHard on motors at low speeds•• Heat buildHeat build--up in motor windingsup in motor windings

YORKLAND CONTROLS

Variable Frequency Drives

•• Sends voltage to 3Sends voltage to 3--phase motor in pulsesphase motor in pulses•• Approximates a sine waveApproximates a sine wave•• Controls frequency Controls frequency andand voltagevoltage•• Motor speed is proportional to frequencyMotor speed is proportional to frequency

YORKLAND CONTROLS

Normal AC Supply to Motor

VFD DC Supply to Motorin Pulses (Mimics AC)

VFD DC Supply to Motorin Pulses (Mimics AC)

Variable Frequency Drives

YORKLAND CONTROLS

Results of Using a VFD

•• System effectsSystem effects–– Less fluctuation in head pressureLess fluctuation in head pressure–– Less fluctuation in evaporator temperatureLess fluctuation in evaporator temperature–– More uniform air flow over condenser coilMore uniform air flow over condenser coil

•• Visible effectsVisible effects–– Increased system efficiencyIncreased system efficiency–– Lower electricity costsLower electricity costs–– Reduced maintenanceReduced maintenance

YORKLAND CONTROLS

Energy Savings

•• Variable frequency drives have greatest energy Variable frequency drives have greatest energy savings of all condenser fan control methodssavings of all condenser fan control methods

•• Greater Energy Savings = Lower Energy CostsGreater Energy Savings = Lower Energy Costs•• Over time, a VFD can pay for itself by money saved Over time, a VFD can pay for itself by money saved

on energy costs!on energy costs!

YORKLAND CONTROLS

50%

60%

70%

80%

Average Fan Duty Cycle

Annual Savings with 6 hp fan total, $0.07/KWH

$1048.57

$1073.74

$998.24

$805.30

Payback Period

Comparison to On/Off switch function

YORKLAND CONTROLS

Applications•• Refrigeration Racks Refrigeration Racks

•• Air ConditionersAir Conditioners

•• WalkWalk--in Coolersin Coolers

•• Cooling Towers Cooling Towers

•• Evaporative Evaporative CondensersCondensers

•• Reciprocating ChillersReciprocating Chillers

•• Process Water Chillers Process Water Chillers

•• Condensing UnitsCondensing Units

•• Packaged Roof TopsPackaged Roof Tops

•• Packaged (Water) Packaged (Water) ChillersChillers

•• Computer Room ACComputer Room AC

•• Environmental (Test) Environmental (Test) Chambers Chambers

YORKLAND CONTROLS

Additional Benefits

•• Inherently Inherently ““Soft StartSoft Start””•• Integral PID Control Integral PID Control •• Self DiagnosticSelf Diagnostic

–– Belt BreakageBelt Breakage–– Shaft BreakageShaft Breakage

•• BuiltBuilt--in control curves for in control curves for ““linearlinear”” controlcontrol

YORKLAND CONTROLS

Match VFD with Motor

•• Review motor horsepower and load to be operated. Review motor horsepower and load to be operated. –– Review existing motor insulation classReview existing motor insulation class–– SeviceSevice factor of Motor 1.15 of higherfactor of Motor 1.15 of higher

•• Enclosure type required for environmentEnclosure type required for environment•• First cost, lifeFirst cost, life--cycle cost and operating cost. cycle cost and operating cost. •• Available and preferred voltage. Available and preferred voltage. •• Phase and frequency. Phase and frequency.

YORKLAND CONTROLS Quiz Quiz

10.646011.235307.612010.546022.317707.56010.5---22.3903.54

AMPSVOLTSTORQUERPMHPHz

Cont.DUTY1.1SF

21.4/10.7FL AMPS1770FL RPM230/460VOLTS

H3INSTRFTYPE4POLES

212LFRAMEawe213THFaalMODEL #

Motor Name Plate Example

PHASE INVERTER DUTY AC INDUCTION MOTOR

YORKLAND CONTROLS

Control Arrangements for a VFD

•• Local ( Hand Control )Local ( Hand Control )•• Remote (Auto) ControlRemote (Auto) Control•• MultiMulti--motor Operationmotor Operation•• Master/Slave ( Lead/Follower)Master/Slave ( Lead/Follower)•• PID ControlPID Control•• Cascade ControlCascade Control•• BAS Enable and ControlBAS Enable and Control•• BAS SerialBAS Serial

YORKLAND CONTROLS

Typical Functions

•• StartStart--Stop / Manual / AutoStop / Manual / Auto•• RampingRamping

–– AccelerationAcceleration–– DecelerationDeceleration

•• Setting up Motor ProfileSetting up Motor Profile•• Operating LimitsOperating Limits•• Optional Input and Output ConfigurationsOptional Input and Output Configurations

YORKLAND CONTROLS

Function - Start-Stop

YORKLAND CONTROLS

Local Control Operation through keypad

YORKLAND CONTROLS

Function – Speed Control

•• Change SpeedChange Speed–– Manual or AutoManual or Auto

•• Maintain Speed Maintain Speed

YORKLAND CONTROLS

Remote or Auto ControlDI – Digital On/Off Input

• 2 Position On/Off for Start –Stop –Enabling

AI – Modulating

• 0-10/4-20ma signals from external controls

AO – Modulating

• Signal(s) sent by the VFD to another device

DO – Digital On/Off Output

• On/Off relay output sent by the VFD to lights etc. (alarms)

YORKLAND CONTROLS

Remote – Auto Continued

•• Multiple inputs and outputs are available for other Multiple inputs and outputs are available for other functions:functions:

–– Speed adjustment with potentiometers (AI)Speed adjustment with potentiometers (AI)–– Essential Service (DI)Essential Service (DI)–– Preset Preset Speed(sSpeed(s) (DI)) (DI)–– Alarms Alarms –– Visual, Buzzer (DO)Visual, Buzzer (DO)–– Enable other devices when VFD is enablesEnable other devices when VFD is enables

YORKLAND CONTROLS

Terminals

YORKLAND CONTROLSVFD

T1-Temp

Proportional (PID) Control

OVR

OVR

OVR

OVR

Multiple Motors

One VFD may control multiple motors.

Total Amp draw from all the motors can not be greater than the rated VFD amps

Each motor to have protection

YORKLAND CONTROLS

Master/Slave

One VFD is designated as the “Lead” or Master and set up to send signals (on/off and reference) to the “follower” or Slave VFD.

Slave may be set up to be a % of the Master VFD.

Typical application:

• Supply and Return Fan volume matching

MasterSlave

YORKLAND CONTROLS

Function - Limits

•• Max and Min FrequencyMax and Min Frequency–– Because of the possibility of Because of the possibility of

overheating, fans overheating, fans should not beshould not berun less than 6Hz.run less than 6Hz.

–– For lubrication purposes a pump For lubrication purposes a pump should have a should have a minimum speed minimum speed of at least 18Hz. of at least 18Hz.

•• Torque LimitsTorque Limits–– If the fans gets stuck, there are If the fans gets stuck, there are

torque limits that the VFD torque limits that the VFD monitors stopping the motor if monitors stopping the motor if they are exceeded. they are exceeded.

•• Current Limits for Motor Current Limits for Motor ProtectionProtection

YORKLAND CONTROLS

Function -Ramping

•• Acceleration, it is important Acceleration, it is important that there is no sudden jump that there is no sudden jump to the reference speed, to the reference speed,

–– stress on the gear boxes. stress on the gear boxes.

•• Prevent the drive trip on an Prevent the drive trip on an overover--current alarm or torque current alarm or torque limit. Many limit. Many VFDsVFDs have an have an automatic reset setting of 1 automatic reset setting of 1 time to infinite times. time to infinite times.

•• Ramping is very important for Ramping is very important for pumps, to avoid water pumps, to avoid water hammer.hammer.

To reduce mechanical wear, it is important to control the acceleTo reduce mechanical wear, it is important to control the acceleration, ramp up and deceleration, ramp downration, ramp up and deceleration, ramp down

YORKLAND CONTROLS

Ramping – Cont’d

•• All ramp times are based on motor speedAll ramp times are based on motor speed•• If the ramp time is set for 60 seconds as in the picture If the ramp time is set for 60 seconds as in the picture

above, but the reference is set to 30Hz (1/2 of 60Hz), above, but the reference is set to 30Hz (1/2 of 60Hz), it takes 30/60 x 60seconds (it takes 30/60 x 60seconds (½½ the time) or 30 seconds the time) or 30 seconds to ramp upto ramp up

YORKLAND CONTROLS

Motor Profile Parameters

•• Voltage InputVoltage Input•• Frequency Frequency •• BreakBreak--away or Starting torque (the first 0.5 seconds away or Starting torque (the first 0.5 seconds

after start after start –– parameter usually set to 110% of amps)parameter usually set to 110% of amps)

YORKLAND CONTROLS

BAS Enable and Control

•• DDC Controller sends a Start/Stop command and may DDC Controller sends a Start/Stop command and may also send a reference. also send a reference.

In the example theIn the example theController only sends Controller only sends an Enable (on/off) an Enable (on/off) SignalSignal

Controller

YORKLAND CONTROLS

Serial Communications

JCI N2

LON

Bacnet

YORKLAND CONTROLS

Cascade or VernierPr

essu

re d

eman

d

100%

2 31Cascade - Vernier

P

Contact out 2

Contact out 1

YORKLAND CONTROLS

Linear Flow Control Feature

10%

50%

20%

30% 100 %

100%

Control Signal

Control Signal

55 Hz

100 %50 %

Flow Curve withStandard 1 to 1 Control

Flow Curve withVFD Curve Feature

Standard 1 to 1 Control

VFD Curve Feature

Figure: 2

Figure: 1

YORKLAND CONTROLS

Belt & Shaft Detection Feature

Speed

Torque

Both speed and torque are compared to a user-defined tolerance band. If the parameters do not match, the drive trips in the event of belt or pump failure.

YORKLAND CONTROLS

•• Configurable Inputs and Configurable Inputs and Outputs for:Outputs for:

•• -- StatusStatus•• -- AlarmingAlarming•• -- ControlControl•• -- Preset SpeedsPreset Speeds

Input – Output Configuration

YORKLAND CONTROLS

Power Input Terminology

•• Protect the VFDProtect the VFD–– Swell/SagSwell/Sag–– Switching the InputSwitching the Input–– Transient and SpikesTransient and Spikes–– Phase ImbalancePhase Imbalance–– Fuses, Connectors and VoltagesFuses, Connectors and Voltages

•• Protect the Supply LineProtect the Supply Line–– RFI RFI –– ““NoiseNoise””–– HarmonicsHarmonics

YORKLAND CONTROLS

Basic Drive Components

Switches (IGBT’s)

“Insulated Gate Bi-Polar Transistors

VFD Block Diagram VFD Block Diagram

Motor

Main Power

Rectifier/Converter

Capacitor

Motor

YORKLAND CONTROLS

Protect The Drive

Fuses & Disconnect

Transformer

Numerous Stray Voltages and power changes from incoming power can effect the VFD.

YORKLAND CONTROLS

Protect the Drive –Excessive Switching

Fuses & Disconnect

Transformer

Recommended maximum switching on input is 2 times per minute

Charge circuits may heat up with excessive starts, and charging and discharging of the capacitors needs to be limited.

YORKLAND CONTROLS

Voltage Sag & Swell

Fuses & Disconnect

Transformer

Swell is an incoming voltage above its expected levelSag is an incoming voltage below its expected levelFrequency shifts between 45Hz to 65Hz, can also occur.

YORKLAND CONTROLS

Voltage Spikes and Transients

Fuses & Disconnect

Transformer

YORKLAND CONTROLS

Phase Imbalance

Fuses & Disconnect

Transformer

L1 L2 L3

Voltage Imbalance on one of the Phases causes excessive stress on filter capacitors, so the VFD shuts down and sends out an alarm.( 2% Phase imbalance or more ) CH can tolerate 50% phase imbalance

The closer to maximum load of the VFD the more sensitive it becomes to an incoming voltage imbalance.

YORKLAND CONTROLS

Protecting Supply Line

•• Voltage and current distortions caused by the VFD Voltage and current distortions caused by the VFD can effect incan effect in--coming power.coming power.

•• High Noise above 450kHz is called Radio Frequency High Noise above 450kHz is called Radio Frequency Interference (RFI) and low noise below 3kHz is called Interference (RFI) and low noise below 3kHz is called Harmonics.Harmonics.

Fuses & Disconnect

Transformer

YORKLAND CONTROLS

RFI – Radio FreqencyInterference

AC

YORKLAND CONTROLS

Harmonics – Tab5

YORKLAND CONTROLS

Interference

•• Generally if total VFD load is less than 100 Generally if total VFD load is less than 100 h.ph.p. on any . on any separately derived power segment (after a separately derived power segment (after a transformer) no special harmonic remediation transformer) no special harmonic remediation methods are needed.methods are needed. RFI mitigation may be needed RFI mitigation may be needed to protect sensitive electronic equipment (health care to protect sensitive electronic equipment (health care facilities for example).facilities for example).

•• Both Harmonics and RFI can travel down cable and Both Harmonics and RFI can travel down cable and conduit runs, and following proper grounding practices conduit runs, and following proper grounding practices is crucial for successful VFD installations.is crucial for successful VFD installations.

YORKLAND CONTROLS

How a Drive Works – the Parts

•• Line Reactor and input filtersLine Reactor and input filters•• Converter/Rectifier SectionConverter/Rectifier Section•• DC BusDC Bus•• Inverter SectionInverter Section

YORKLAND CONTROLS

Rectifier – AC to DC

If 240 Vac is coming in, 324 Vdc is generated. If 380 Vac is coming in, 513 Vdc is generated. If 460 Vac is the line voltage, 621 Vdc is generated. If 575 Vac is the line voltage, 776 Vdc is generated.

YORKLAND CONTROLS

Inverter – DC to PWM

The Motor responses to the PWM as if it were sinusoidal wave

YORKLAND CONTROLS

YORKLAND CONTROLS

Carrier Frequency - PWM

•• PWM frequency can vary from 1.0 KHz to 16 kHz, which means it PWM frequency can vary from 1.0 KHz to 16 kHz, which means it is audible.is audible.

•• It is also known as the Carrier Frequency.It is also known as the Carrier Frequency.•• A low carrier frequency can have an annoying noise, A low carrier frequency can have an annoying noise, •• A higher carrier frequency generates more heat in the drive and A higher carrier frequency generates more heat in the drive and

motor. motor. •• If the carrier frequency noise is too loud particularly with supIf the carrier frequency noise is too loud particularly with supply ply

fans, filters can be placed between the VFD and motor and the fans, filters can be placed between the VFD and motor and the noise stops at this filter.noise stops at this filter.

YORKLAND CONTROLS

Protection of the Drive

•• Input Filters or Reactors Input Filters or Reactors –– Protect the VFD from transient incoming AC voltageProtect the VFD from transient incoming AC voltage

•• Phase Imbalance Phase Imbalance –– A voltage imbalance on one of the phases causes excessive A voltage imbalance on one of the phases causes excessive

stress on filter capacitors. stress on filter capacitors. –– Beyond 2%, the VFD shuts down and alarms the operator Beyond 2%, the VFD shuts down and alarms the operator

letting him know that there is a problem with the incoming letting him know that there is a problem with the incoming power.power.

–– Maintenance Maintenance –– Keep it Dry, Keep it CleanKeep it Dry, Keep it Clean

YORKLAND CONTROLS

Motor Protection

•• Start with an Start with an ““InverterInverter”” rated motorrated motor•• In retrofit applications, motor should have an In retrofit applications, motor should have an

insulation class F or betterinsulation class F or better•• Service Factor 1.10 or HigherService Factor 1.10 or Higher•• Use Use ““filtersfilters”” when in doubtwhen in doubt

Filter dT/dV – “wave trap”

YORKLAND CONTROLS

Why dT/dV Filters ?

•• Also known as Reflective Wave TrapAlso known as Reflective Wave Trap•• One size fits all One size fits all –– fits all voltages and HPfits all voltages and HP•• Better voltage peak suppressionBetter voltage peak suppression•• Cost EffectiveCost Effective•• Can have longer lead lengthCan have longer lead length•• Because of metal content, filters have gone up in cost. Because of metal content, filters have gone up in cost.

(consider a new higher efficiency motor)(consider a new higher efficiency motor)

YORKLAND CONTROLS

Protecting the Motor – dV/dT Filters

YORKLAND CONTROLS

The Product

•• ““House BrandsHouse Brands””–– Cutler Cutler -- HammerHammer

•• AccessoriesAccessories–– FiltersFilters–– MotorMotor

YORKLAND CONTROLS

VS Series Drives

•• .5 Hp .5 Hp –– 200 Hp @ 690V200 Hp @ 690V

•• 11--400 Hz Freq range400 Hz Freq range

•• Sensorless VectorSensorless Vector

•• Constant or Var TorqueConstant or Var Torque

•• Removable KeypadRemovable Keypad

•• PID controlPID control

YORKLAND CONTROLS

VS Series Parts Modules

=+

YORKLAND CONTROLS

Menu-driven Quick Commissioning

-Set point DC 0...10 V

- Start / stop

- Running / fault

- Fault acknowledge

- w/ P1: More than 95

parameters

BAS

3 wire AC

“Hard wiring”

Commissioning Time ~ 10 Minutes

P1

or

YORKLAND CONTROLS

Removable Keypad/Display

•• Backlit DisplayBacklit Display•• Explorer Type Menu Explorer Type Menu

•• Navigation indicatorNavigation indicator•• Operates the same for the all H.P. Operates the same for the all H.P. •• HVAC defaults for PID loops; W.C., Deg F., HVAC defaults for PID loops; W.C., Deg F.,

PSI, etc.PSI, etc.•• Operate Display can show 3 at the same Operate Display can show 3 at the same

time time •• Speed (Hertz), Amps, VACSpeed (Hertz), Amps, VAC……

YORKLAND CONTROLS

Removable Keypad/Display

•• Language Choice for Operate Language Choice for Operate MenuMenu

•• Lights for Run, Fault, ReadyLights for Run, Fault, Ready•• Ready Flashes during Bypass Ready Flashes during Bypass

OperationOperation

YORKLAND CONTROLS

3 VFD Control Modes•• Manual KeypadManual Keypad

–– StartStart--Up WizardUp Wizard–– Start Start ––StopStop–– Hand/Off/AutoHand/Off/Auto–– Electronic Bypass Electronic Bypass –– Fault ResetFault Reset–– One Touch MenuOne Touch Menu

•• TerminalTerminal to BASto BAS•• Closed loop I/OClosed loop I/O•• Run/faultRun/fault

•• FieldbusFieldbus --N2, LONN2, LON……

YORKLAND CONTROLS

HVAC Startup Wizard for JCI

Enter Motor ParametersEnter Motor ParametersChoose one of PID AppsChoose one of PID Apps

–– Remote (External BAS) Remote (External BAS) –– PIDPID--Duct Static (WC)Duct Static (WC)–– PIDPID--Building Static(WC)Building Static(WC)–– PIDPID--Temperature (T)Temperature (T)–– PIDPID--Pressure (PSI)Pressure (PSI)–– Generic PIDGeneric PID

Wizard loads Wizard loads –– at first power up at first power up ––or hold stop/reset for 5 seconds & cycle poweror hold stop/reset for 5 seconds & cycle power

YORKLAND CONTROLS


YORKLAND CONTROLS


YORKLAND CONTROLS


YORKLAND CONTROLS


YORKLAND CONTROLS


YORKLAND CONTROLS

Competitive Analysis

YORKLAND CONTROLS

VFD Application Guide

•• Application Guide Sources: Application Guide Sources: (I didn(I didn’’t just make them up !)t just make them up !)

–– ManufacturersManufacturers–– ASHREAASHREA–– Case StudiesCase Studies

•• DOE DOE -- USAUSA•• OEE OEE –– CanadaCanada

•• www.yorkland.netwww.yorkland.net –– Download Energy Saving Download Energy Saving SoftwareSoftware

YORKLAND CONTROLS

Quizzes

•• Tab 4Tab 4

YORKLAND CONTROLS

Labs

•• A word about the DemosA word about the Demos•• Review Quick Reference Guide ( tab 4 )Review Quick Reference Guide ( tab 4 )•• Lab 1 and Lab 2 ( use the Quick Reference and if Lab 1 and Lab 2 ( use the Quick Reference and if

needed the VS manual ( tab 2)needed the VS manual ( tab 2)•• Example 1 Example 1 •• Example 2Example 2

YORKLAND CONTROLS

Applying VFDs - Examples

Exercise #:Application:

.85.851.101.10177517757.27.224024055

EffEff..S.F.S.F.RPMRPMAmpsAmpsVoltsVoltsHPHP

Motor Information:

Control Specifications:

KeypadKeypad44--20ma from PLC20ma from PLCSpeed ControlSpeed Control

KeypadKeypadN/O from PLCN/O from PLCStart/Stop ControlStart/Stop Control

HandHandAutoAuto

I/O Requirements:1. N/C that will cause the drive to fault when the building fire alarm system is

activated.

2. A relay output to the PLC to indicate drive run.

3. A relay output to the PLC to indicate drive fault.

4. A 0-10VDC analog output representing motor rpm.

1

Customer has an existing supply fan that requires a new drive. It will be mounted in the same location in the equipment room as the original.

Drive Selection:Application Selection:

Exercise #: 1

Connection Drawing

YORKLAND CONTROLS

Exercise #1:

Programming List:

Relay 2Relay 2

Relay 1Relay 1

Digital OutputDigital Output

Analog OutputAnalog Output

DIDI--66

DIDI--55

DIDI--44

DIDI--33

DIDI--22

DIDI--11

Analog Input 2Analog Input 2


SettingSettingParameter #Parameter #Input/outputInput/output

Notes:


.85.851.101.101785178521.221.2600 600 2020

EffEff..S.F.S.F.RPMRPMAmpsAmpsVoltsVoltsHPHPMotor Information:


Door mounted 0Door mounted 0--10VDC pot10VDC potDDC DDC –– 44--20mA20mASpeed ControlSpeed Control

Door mounted 3 position Door mounted 3 position HH--OO--AA switchswitchDDC DDC –– N/O contactN/O contactStart/Stop ControlStart/Stop Control

HandHand

(Local)(Local)

AutoAuto

(Remote)(Remote)

I/O Requirements:

2

This application is a chill water pump. Customer requires a rapid acceleration to ensure quick opening of the pump’s check valve, and slow deceleration to prevent sudden closing of the check valve and the resulting water hammer. This drive will require bypass.

1. N/O contact that indicates “drive run” when closed.

2. 0-10VDC analog output representing “Output Frequency”.

3. Digital output that energizes when drive is “at speed”.

4. Acceleration rate required: 10 Seconds.

5. Deceleration rate required: 1 minute 30 seconds.

6. Minimum pump speed required is 600 RPM.

Drive Selection:

Exercise #: 2

Connection Drawing

Exercise #:

Programming List:

Relay 2Relay 2

Relay 1Relay 1

Speed Speed SrcSrc HandHand

Speed Speed SrcSrc AutoAuto

Start Source HandStart Source Hand

Start Source AutoStart Source Auto

Digital OutputDigital Output

Analog OutputAnalog Output

DIDI--66

DIDI--55

DIDI--44

DIDI--33

DIDI--22

DIDI--11



SettingSettingParameter #Parameter #Input/outputInput/output

Notes:


.851.1017754857550

Eff.S.F.RPMAmpsVoltsHP

Motor Information:


Keypad4-20ma from BASSpeed Control

KeypadN/O from BASStart/Stop Control

HandAuto


activated.

2. A relay output to the BAS to indicate drive run.

3. A relay output to the BAS to indicate drive fault.


1




.851.1017754857550


Motor Information:


Keypad4-20ma from BASSpeed Control

KeypadN/O from BASStart/Stop Control

HandAuto


activated.

2. A relay output to the BAS to indicate drive run.

3. A relay output to the BAS to indicate drive fault.


1


Drive Selection: VS050510A-00000

Application Selection: Remote

Exercise #: 1

Connection Drawing

To BAS 4-20 ma

To BAS Start command

To Fire Alarm system

To BAS 0-10VDC Motor Speed

To BAS “Drive Fault”

To BAS “Drive Run”

Exercise #:

Programming List:

Relay 2

Relay 1

Speed Src Man

Speed Src Auto

Start Source Man

Start Source Auto

Digital Output

Analog Output

DI-6

DI-5

DI-4

DI-3

DI-2

DI-1

Analog Input 2

Analog Input 1

SettingParameter #Input/output

Exercise #:1

Programming List:

Relay 2Relay 1Speed Src ManSpeed Src AutoStart Source ManStart Source AutoDigital OutputAnalog OutputDI-6DI-5DI-4DI-3DI-2DI-1Analog Input 2Analog Input 1


Notes:

1.2.11 Value=1, AI-2 Range (4-20ma), (Default setting)

1.2.4 Value=2, External fault opening contact

1.3.1 Value=3, AO-1 Function, use 500ohm Resistor or set Dip Switches

1.1.14

1.1.121.1.15

1.1.13

1.3.8

1.3.7

Value=2, DI-1 Start (default)

Value=1, Keypad (Default)

Value=2, Speed Set point From Keypad

Value=1, AI-2

Value=3, RO-2 Function

Value=2, RO-1 Function


.851.10178563230 25


Motor Information:


Door mounted 0-10VDC potBAS – 0-10VDCSpeed Control

Door mounted two position switchBAS – N/O contactStart/Stop Control

HandAuto

I/O Requirements:

2

This application is a chill water pump. Customer requires a rapid acceleration to ensure quick opening of the pump’s check valve, and slow deceleration to prevent sudden closing of the check valve and the resulting water hammer. This drive will be mounted in an enclosure provided by the customer.







Drive Selection:


.851.10178563230 25

Eff.S.F.RPMAmpsVoltsHPMotor Information:



Door mounted two position switchBAS – N/O contactStart/Stop Control

HandAuto

I/O Requirements:

2

This application is a chill water pump. Customer requires a rapid acceleration to ensure quick opening of the pump’s check valve, and slow deceleration to prevent sudden closing of the check valve and the resulting water hammer. This drive will be mounted in an enclosure provided by the customer.







Drive Selection: VS025210A-00000

Exercise #: 2

Connection Drawing

Application Selected: Remote

To BAS 0-10 VDC

BAS Start

Door Mounted Switch

To BAS

0-10VDC =

Output Freq

To BAS = Drive Run

To BAS = “At Speed”

Exercise #:

Programming List:

Relay 2

Relay 1

Speed Src Man

Speed Src Auto

Start Source Man

Start Source Auto

Digital Output

Analog Output

DI-6

DI-5

DI-4

DI-3

DI-2

DI-1

Analog Input 2

Analog Input 1


Notes:

Exercise #:2

Programming List:



Notes:

1.3.1 Value=1, Output Frequency (Default)

1.1.14

1.1.121.1.15

1.1.13

1.3.8


Value=2, DI-1 Start

Value=0, AI-1

Value=1, AI-2, use 500 ohm resistor or set dip switches

Value=2, Set to Drive Running

1.3.6 Value=11, Drive ‘At Speed”

1.1.31.1.4

1.1.1

Set to 10 Seconds (Default 60s)

Set to 20Hz Aprox 1/3 full speed

Set to 90 Seconds (Default 60s)Accel TimeDecel Time

Min Frequency


.851.10178552230 20


Motor Information:



KeypadBAS – N/O contact closed in run.Start/Stop Control

HandAuto

I/O Requirements:

3

This drive is a running #1 return fan and will be mounted in the #2 equipment room on the wall near the motor. It is critical that the return fan not beginning running until the return fan damper is open. The customer wants to the return fan damper to open when the fan is commanded to run by the BAS. In hand operation the damper will be opened by the operator.


2. Relay outputs for lighting a “drive run”, “drive stopped”, and “drive fault”indicator lights at the BAS control panel. (115VAC lights).

3. Customer requires a digital input to be programmed for “external fault” when the fault contact is closed.

4. Customer requires auto restart to occur when the external fault is cleared.



.851.10178552230 20




KeypadBAS – N/O contact closed in run.Start/Stop Control

HandAuto

I/O Requirements:

3

This drive is a running #1 return fan and will be mounted in the #2 equipment room on the wall near the motor. It is critical that the return fan not beginning running until the return fan damper is open. The customer wants to the return fan damper to open when the fan is commanded to run by the BAS. In hand operation the damper will be opened by the operator.


VS020210A-00000Remote


2. Relay outputs for lighting a “drive run”, “drive stopped”, and “drive fault”indicator lights at the BAS control panel. (115VAC lights).

3. Customer requires a digital input to be programmed for “external fault” when the fault contact is closed.

4. Customer requires auto restart to occur when the external fault is cleared.

Exercise #: 3

Connection Drawing

From BAS 0-10VDC

To BAS =

“At Speed”

To BAS = Open Damper command

BAS Start Damper Status

115VAC from BASDrive Stopped

Drive Run

Drive Fault

Exercise #:

Programming List:

Relay 2

Relay 1

Speed Src Man

Speed Src Auto

Start Source Man

Start Source Auto

Digital Output

Analog Output

DI-6

DI-5

DI-4

DI-3

DI-2

DI-1

Analog Input 2

Analog Input 1


Notes:

Exercise #:3

Programming List:



Notes:

1.1.14

1.1.121.1.15

1.1.13

1.3.8


Value=1, Keypad (default)

Value=0, AI-1

Value=1, AI-2, use 500 ohm resistor or set dip switches

Value=2, Set to Drive Running

1.3.6 Value=11, Drive ‘At Speed”

1.3.111.2.4

1.7.6

Value=3, Drive Vault

Value=1, Auto restart enabled

Value=2, Can also be set as external Fault open, Drive will be offUntil damper is open.

Relay 3DI-2

Auto Restart

1.2.4 Value=14, External Interlock Open

1.3.7 Value=24, Relay to Energize External element


.851.1011751857520


Motor Information:


KeypadKeypad Speed Control

Drive KeypadThree wire control using a n/c stop button and a n/o start switch

Start/Stop Control

HandAuto

I/O Requirements:

4

This drive is running a supply fan in an HVAC system. Because this project is on a shoestring budget, the drive will be required to maintain a positive pressure in the building automatically (No building automation). The building static pressure is being sensed via a pressure transducer that is providing a 4-20ma (-.5 to .5 wc) actual building static pressure feedback to the drive. The drives keypad is used to set the building pressure.

1. Customer wishes to monitor Pressure set point, actual pressure, and motor speed on the keypad.

2. Configure to run at 80% speed when Fire mode is activated.

3. Fire mode is activated with a N/O key switch.

4. A N/C contact is needed to light a 230 VAC “Drive Fault” lamp.

5. A digital output is activated when the drive is placed in “Fire Mode.”



.851.1011751857520


Motor Information:


KeypadKeypad Speed Control

Drive KeypadThree wire control using a n/c stop button and a n/o start switch

Start/Stop Control

HandAuto

I/O Requirements:

4

This drive is running a supply fan in an HVAC system. Because this project is on a shoestring budget, the drive will be required to maintain a positive pressure in the building automatically (No building automation). The building static pressure is being sensed via a pressure transducer that is providing a 4-20ma (0-20 psig) actual building static pressure feedback to the drive. The drives keypad is used to set the building pressure.

1. Customer wishes to monitor Pressure set point, actual pressure, and motor speed on the keypad.

2. Configure to run at 80% speed when Fire mode is activated.

3. Fire mode is activated with a N/O key switch.

4. A N/C contact is needed to light a 230 VAC “Drive Fault” lamp.

5. A digital output is activated when the drive is placed in “Fire Mode.”


VS020510A-00000Building Static

Exercise #:

Connection Drawing

Pressure Transducer

0-20 PSIG

Fire Mode Key Switch

BAS Fire mode status

BAS Drive Fault Status

Exercise #:

Programming List:

Relay 2

Relay 1

Speed Src Man

Speed Src Auto

Start Source Man

Start Source Auto

Digital Output

Analog Output

DI-6

DI-5

DI-4

DI-3

DI-2

DI-1

Analog Input 2

Analog Input 1


Notes:


.961.017752557525



KeypadBuilding Automation (N2)Speed Control

KeypadBuilding Automation (N2) Start/Stop Control

HandAuto

I/O Requirements:

5

1. N/C relay contact that is closed when the drive is faulted.

2. N/O relay contact that is closed when the drive is running.

3. Customer wishes to monitor the hot water temperature, circulating pump speed, and motor output power on the keypad.

Drive Selection:

A new drive is needed for a circulating pump for a hot water heating system. The goal is to maintain 105 degree F water during the winter heating season automatically with the drive. With this system, as the water temperature rises, the circulating pump speed must decrease. The customer will select the desired water temperature using their building automation (N2). Water temperature is detected from a temperature transducer providing a 0-10VDC signal (0-150 degree range).

Application Selection:


.961.017752557525


Motor Information:


KeypadBuilding Automation (N2)Speed Control

KeypadBuilding Automation (N2) Start/Stop Control

HandAuto

I/O Requirements:

5

1. N/C relay contact that is closed when the drive is faulted.

2. N/O relay contact that is closed when the drive is running.

3. Customer wishes to monitor the hot water temperature, circulating pump speed, and motor output power on the keypad.

Drive Selection:

A new drive is needed for a circulating pump for a hot water heating system. The goal is to maintain 105 degree F water during the winter heating season automatically with the drive. With this system, as the water temperature rises, the circulating pump speed must decrease. The customer will select the desired water temperature using their building automation (N2). Water temperature is detected from a temperature transducer providing a 0-10VDC signal (0-150 degree range).

Application Selection: Temperature

VS025510A-N0000

Exercise #:

Connection Drawing

Actual Temperature Feedback

0-150 Degree Transducer = 0-10VDC

Drive Fault

Drive Running

Exercise #:

Programming List:

Relay 2

Relay 1

Speed Src Man

Speed Src Auto

Start Source Man

Start Source Auto

Digital Output

Analog Output

DI-6

DI-5

DI-4

DI-3

DI-2

DI-1

Analog Input 2

Analog Input 1


Notes:

YORKLAND CONTROLS

Service and Maintenance

YORKLAND CONTROLS

Review VFD and it’s connected load for proper installation

Incoming power, outgoing motor, and control wiring are each in their own conduit.

The source of power for the VFD and it’s connected load is of sufficient size to operate the equipment.

All wiring has been accomplished according to local codes and toEaton Electrical specifications for the size of the VFD and it’s connected load.

The VFD is clean and free of installation debris, equipment, or tools.

If installed, remove line and motor connections at the VFD in preparation for pre-power checks.

YORKLAND CONTROLS

Static Checks of the Converter/Rectifier Section

Using a digital multimeter with a diode and resistance scale:

a. Select the diode scale of the multimeter.

b. Use the (B+) and (B–) bus as the reference point for both converter and inverter checks.

c. Start with the positive meter lead on the B+ terminal and check each VFD line connection with the negative lead.

YORKLAND CONTROLS

Static Checks of the Converter Section

This checks these diodes or SCRs in

the converter section

Start with the positive meter lead on the B+ terminal and check each VFD line connection with the negative lead.

YORKLAND CONTROLS

+

_

.OL

Power OFFValue should increase until “OL” is reached


YORKLAND CONTROLS

+

_

.OL



YORKLAND CONTROLS

+

_

.OL



YORKLAND CONTROLS




Switch the positive lead to the (B-) bus connection and test VFD line connections again with the negative lead.

YORKLAND CONTROLS


+

_

.350vdc

Power OFF

0.25vdc to 0.40vdc

+/-10% range

YORKLAND CONTROLS

+

_

.350vdc

Power OFF

0.25vdc to 0.40vdc

+/-10% range


YORKLAND CONTROLS

+

_

.350vdc

Power OFF

0.25vdc to 0.40vdc

+/-10% range


YORKLAND CONTROLS




Switch to negative meter lead to the (B+) bus connection and test VFD line connections with the positive lead.

YORKLAND CONTROLS

+

_

.350vdc

Power OFF

0.25vdc to 0.40vdc

+/-10% range


YORKLAND CONTROLS

+

_

.350vdc

Power OFF

0.25vdc to 0.40vdc

+/-10% range


YORKLAND CONTROLS

+

_

.350vdc

Power OFF

0.25vdc to 0.40vdc

+/-10% range


YORKLAND CONTROLS

Switch to negative meter lead to the (B-) bus connection and test VFD line connections again with the positive lead.




YORKLAND CONTROLS

+

_

.OL



YORKLAND CONTROLS

+

_

.OL



YORKLAND CONTROLS

+

_

.OL



YORKLAND CONTROLS

Static Checks of the Inverter Section

YORKLAND CONTROLS

Return the positive meter lead to the (B+) bus connection and test VFD motor connections with the negative lead.


This checks these IGBTs and Diodes in the Inverter section

YORKLAND CONTROLS

+

_

.OL



YORKLAND CONTROLS

+

_

.OL



YORKLAND CONTROLS

+

_

.OL



YORKLAND CONTROLS

Move the positive meter lead to the (B-) bus connection and again test VFD motor connections with the negative lead.



YORKLAND CONTROLS

+

_

.350vdc

Power OFF

0.25vdc to 0.40vdc

+/-10% range


YORKLAND CONTROLS

+

_

.350vdc

Power OFF

0.25vdc to 0.40vdc

+/-10% range


YORKLAND CONTROLS

+

_

.350vdc

Power OFF

0.25vdc to 0.40vdc

+/-10% range


YORKLAND CONTROLS

Move the negative meter lead to the (B+) bus connection and testVFD motor connections with the positive lead.



YORKLAND CONTROLS

+

_

.350vdc

Power OFF

0.25vdc to 0.40vdc

+/-10% range


YORKLAND CONTROLS

+

_

.350vdc

Power OFF

0.25vdc to 0.40vdc

+/-10% range


YORKLAND CONTROLS

+

_

.350vdc

Power OFF

0.25vdc to 0.40vdc

+/-10% range


YORKLAND CONTROLS

Return the negative meter lead to the (B-) bus connection and test VFD motor connections with the positive lead.



YORKLAND CONTROLS

+

_

.OL



YORKLAND CONTROLS

+

_

.OL



YORKLAND CONTROLS

+

_

.OL



YORKLAND CONTROLS

Static Checks of the DC Bus

YORKLAND CONTROLS

+

_

.OL


Static Checks of the DC Bus Section

YORKLAND CONTROLS

+

_

Meg

Power OFFValue should be in the Meg Ohm range.


YORKLAND CONTROLS

+

_

Meg


Power OFFValue should be in the Meg Ohm range.

YORKLAND CONTROLS

Perform Initial power on safety checks.a. Confirm that all power is still tagged and locked out to the VFD.

b. Reconnect the line and motor cables to the proper VFD terminals.

c. Ensure all appropriate control wiring has been reconnected.

d. Once all electrical connections are restored conduct a walk around of the VFD and it’s connected load.

e. Remove tags and locks for the disconnect supplying power to the VFD disconnect.

YORKLAND CONTROLS

Perform initial power on safety checks.f. When safe to do so, keeping the VFD disconnect locked and

tagged, energize the disconnect that supplies power to the VFD disconnect.

g. Using the DVM measure the AC line voltage at the supply side of the VFD disconnect.

h. Record phase to phase voltage and phase to ground voltage.

• Phase to phase are balanced within < 5%.

• Phase to ground are balanced within < 5%.

YORKLAND CONTROLS

Perform initial power on checks.

a. When it is safe to do so remove all tags and locks from the VFD disconnect.

b. Re-install any covers that have been removed from the VFD or motor.

c. When it is safe to do so close the VFD disconnect.

d. Conduct the Power on checks.

YORKLAND CONTROLS

Perform power on checks.

Measure phase to phase voltage at L1, L2 and L3.

Readings should be <= 5% of each other.

Measure phase to ground at L1, L2, and L3.

Readings should be <= 5% of each other.

YORKLAND CONTROLS

Measure phase to phase and phase to ground at L1, L2, and L3

+

_

466Vac

Power ON

460Vac

-15% / +10%

Vac

YORKLAND CONTROLS

+

_

466Vac

Vac

Measuring the Supply Voltage

Power ON

460Vac

-15% / +10%

YORKLAND CONTROLS

+

_

466Vac

Vac

Measuring the Supply Voltage

Power ON

460Vac

-15% / +10%

YORKLAND CONTROLS

Perform DC bus voltage check.

a. Measure DC bus voltage at terminals B+ and B-.

b. Compare reading to the calculated DC bus voltage using the following formula:

Bus Voltage = line voltage x 1.414 (CutlerHammer)

c. The voltage value measured in the previous step should correspond to the DC Bus Voltage Value displayed in the Monitor section

They should be within +/- 10Vdc.

YORKLAND CONTROLS

+

_

687Vdc

Power ON

680Vdc

-15% / +10%

Vdc

Measuring the DC Bus Voltage

YORKLAND CONTROLS

Measuring the Terminal Voltages

+

_

10.0Vdc

Vdc

Power ONTerminal Blocks 1 and 3 are the supply for the speed pot.

Terminal 1 is 10Vdc and 3 is GND

YORKLAND CONTROLS

+

_

24.0Vdc

Vdc

Power ONTerminal Blocks 6 and 7 are the supply for the Digital Inputs.

Terminal 6 is 24Vdc and 7 is GND

Measuring the Terminal Voltages

YORKLAND CONTROLS

Check motor direction of rotation

Bump the motor to check it’s direction of rotation in the following order:

If a bypass is connected check it first.

After checking bypass check VFD rotation.

YORKLAND CONTROLS

Solving Rotation Errors

Problem:

Drive Rotation is Wrong.

Bypass Rotation is Wrong.

Solution:

Swap any 2 leads at the “T”leads or motor terminal block.

YORKLAND CONTROLS

Problem:

Drive Rotation is Right.

Bypass Rotation is Wrong.

Solution:

Swap any 2 leads on the supply wires to the enclosure.


YORKLAND CONTROLS

Problem:

Drive Rotation is Wrong.

Bypass Rotation is Right.

Solution:

Swap any 2 leads of the incoming supply.

&

Swap any 2 leads at the “T” leads or motor terminal block.


YORKLAND CONTROLS

Measure Motor VoltageMeasure the voltage Phase to Phase on the output terminals and record this reading in the commissioning documentation.

Compare this Value with the drive display for Motor Voltage and record.

YORKLAND CONTROLS

Measure the Current on each Phase to the motor and record this reading in the commissioning documentation.

Compare this Value with the drive display for Motor Current and record.

Measure Motor Current

YORKLAND CONTROLS

Measure the voltage Phase to Phase on the input terminals and record this reading in the commissioning documentation.

Measure Line Voltage

YORKLAND CONTROLS

Measure the Current on each Phase to the drive and record this reading in the commissioning documentation.

Measure Line Current

YORKLAND CONTROLS

Back up Slides

YORKLAND CONTROLS

Documents

VFD Training Preso - Yorkland Controls · PDF fileDesign 5. Engineering and Commissioning. ... • Under Sized Piping or Ductwork puts additional load ... A manual 25 HP exhaust fan