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Jay Eldridge
Business Development Manager – Applied Air Systems
Spring 2016
AGENDA
2
WHY VARIABLE SPEED
• Energy Savings
• BHP at Fan
• BHP at Pump
• BHP at Compressor
• Meet or exceed ever more challenging energy
codes
• LEED
• Sustainable
• Acoustics
3
FULL RANGE ENERGY PERFORMANCE
• Full range performance is almost always far more important than
full load performance
• Best designs take into account reduced load and reduced
condensing pressure (dry bulb or wet bulb relief) on refrigeration
systems
• Emerging technologies include;
– Full range compressors
– Permanent magnet synchronous motors
– Magnetic bearings
– Integrated controls
Full Range Full Load
Vs.
4
NEW TECHNOLOGY
5
BETTER THAN PREMIUM EFFICIENCY
93
92
91
90
Efficiency
89
88 NEMA
87 ECM
86
85
84
2 3 5 7.5
Motor HP
6
RELUCTANCE DIGITALLY COMMUTATED
ADVANTAGES OF THE RELUCTANCE DC MOTOR
7
DC COMPRESSOR MOTOR TECHNOLOGY
8
COMPRESSOR MOTOR TECHNOLOGY
100
95 18 %
90 30%
Efficiency (%)
85
80 Induction
Motor
75
70 Daikin Inverter
Motor
65
60
1800 3600 5400
RPM
Core
N
S
Rare Earth
Interior S N N S
Magnet
Permanent S
Magnetic N
9
PMSM MOTOR TECHNOLOGY
PMSM Motor
90
SPM Motor
Efficiency
80
Induction Motor
(%)
70
60
Speed
(rpm)
0 1800 3600 5400 7200
Core
N
S
Rare Earth
S N N S Magnet
Ferrite S
Magnet N
10
TRADITIONAL NON-INVERTER SYSTEM
CONTROLS TEMPERATURE WITH ON-OFF OPERATION AND
MINIMAL CAPACITY CONTROL
+V • 60 Hz AC input power
drives the compressor
T(sec) • The compressor must
operate at full RPM
under all load conditions
-V • Very limited efficiency
Frequency (Hz)
under part load
conditions
11
INVERTER DRIVE SYSTEM
+V
• The inverter control converts the
incoming ac voltage to dc voltage
• The inverter then smooths the sine
T(sec) wave to insure smooth motor rotation
• Reconverts dc to 3 phase ac voltage to
the compressor
• Vary the frequency applied to the
-V
Frequency (Hz) compressor motor to modulate the
rotational speed which increases or
decreases system capacity
Inverter
+V Circuit
T(sec)
-V
Frequency (Hz)
12
INVERTER TECHNOLOGY
+V
T(sec)
-V
Frequency (Hz)
+V
T(sec)
-V
Frequency (Hz)
13
COMFORTABLE COOLING OPERATION
Temp.
Set temp.
Time.
14
WHAT’S OUT THERE? COMPRESSOR OVERVIEW
Fixed scroll
• On/Off
Control Two stage scroll
• 2 thru 6 tons
15
2 STAGE SCROLL
Unloads to about 67%
Fixed Scroll Sub-Assembly
Modulation Ring
And
By Pass Seals
Solenoid
Coil Locating & Hold
Assembly Down Pins
16
DIGITAL SCROLL
Unloaded Operation
Loaded Operation
17
HOW DIGITAL SCROLLS WORK
• Digital sounds better than “OFF/ON”
• 15‐20 second cycle times
• Compressor pulses between conditions
• 100% loaded and 0% loaded
• Head pressure rises quickly when compressor is ON
18
INVERTER SCROLL PERFORMANCE
80% Scroll
70% Variable
DPS
60% Speed
50%
40%
30%
20%
10%
0%
25%
35%
45%
55%
65%
75%
85%
% Cooling Capacity 95%
19
VFD COMPRESSOR AND EFFICIENCY
20 20
INVERTER BENEFITS
• Capacity control
• Very low startup amperage
• Quiet compressor startup
• No compressor locked rotor amps
Capacity is adjusted as the load changes to
• Less stress on windings maximize temperature control
• Longer run cycles
• Better dehumidification in cooling
• Fewer start/stop cycles
• System pressures increase gradually reducing noise and stress on piping
• As room temperature nears set point,
capacity is automatically “throttled down”
21
ADDITIONAL INVERTER BENEFITS
22
SYSTEMS - PUTTING IT ALL TOGETHER
–VRF
–RTUs +V
T(sec)
–CHILLERS
-V
Frequency (Hz)
23
VRF: VARIABLE REFRIGERANT FLOW
• Inverter Scroll
• ECM Fan Motor
• Over speed
Inverter
24
24
WHAT IS VRF?
Outdoor Unit
Main features:
– Energy Saving / Inverter technology
– Low Noise Levels
– Individual control / Zoning
Indoor Units
– PPD: tenant billing
– Long refrigerant piping runs
– Wide range of indoor units
– Applied systems w/ 20 year life cycle
– Small installed footprint
25
VRF - OVERVIEW
Water Cooled Air Cooled
Boiler/Tower Outdoor / Indoor
Geothermal
26
VRF HEAT PUMP SYSTEM COMPONENTS
27
VRF HEAT RECOVERY SYSTEM COMPONENTS
28
INCREASE ENERGY SAVINGS DURING HEAT RECOVERY
Heating
Cooling
6 Ton 6.08kW
5.39kW
(22519 btu)
Heat recovery
Power input
Simultaneous Approx.
cooling & heating
4.8kW 58%
Down
12 Ton
29
INVERTER CONTROL
(16 Tons) Multi unit VRF capacity control
100%
Capacity Control
Smooth control
7%
NON
INV NON NON
INV NON
Low
Load
High
30
30
COMFORTABLE COOLING OPERATION
Temp.
Set temp.
Time
.
31
31
VRF PERFORMANCE
Complete SYSTEM IEER range: 16 ~20!
32
VRF: SUMMARY
FEATURES:
– Inverter Scroll
– ECM Fan Motor
– Over speed VFD
BENEFITS:
– Great SYSTEM efficiency
– Space comfort
– Flexibility
– Low sound
33
33
SMALL RTUS CAN BE AN APPLIED PRODUCT
34
RTU VS VARIABLE SPEED CHILLER PLANTS
(I)EER 24 20 17 15 13 12 11 10
36
APPLICATIONS FOR VARIABLE SPEED RTUS
37
ADVANTAGES OF INVERTER CONTROL TECHNOLOGY
38
TEMPERATURE CONTROL
90
80
Discharge Air
70
60 Outdoor Air
50 Return Air
40
Time
40 40
HOW DIGITAL SCROLLS WORK (VARIABLE CAPACITY)
41 41
LEAVING AIR CONTROL – VARIABLE SPEED VS DIGITAL
OA temp
Room
Lvg Air
kW Power
2013- Northwest Energy Efficiency Alliance; NBI: Report #E13-269: Variable Rate Rooftop Unit Test
43 43
ENERGY PLUS MODEL
44
0
2
4
6
8
10
12
09/08 04:00:00
09/08 06:00:00
09/08 08:00:00
09/08 10:00:00
09/08 12:00:00
09/08 14:00:00
09/08 16:00:00
ENERGYPLUS
09/08 18:00:00
09/08 20:00:00
09/08 22:00:00
09/08 24:00:00
09/09 02:00:00
09/09 04:00:00
09/09 06:00:00
09/09 08:00:00
09/09 10:00:00
09/09 12:00:00
09/09 14:00:00
Outdoor Air Temp (F)
09/09 16:00:00
09/09 18:00:00
09/09 20:00:00
09/09 22:00:00
09/09 24:00:00
09/10 02:00:00
09/10 04:00:00
45
09/10 06:00:00
09/10 08:00:00
Variable Speed
09/10 10:00:00
09/10 12:00:00
09/10 14:00:00
09/10 16:00:00
09/10 18:00:00
09/10 20:00:00
09/10 22:00:00
09/10 24:00:00
Single Stage
09/11 02:00:00
09/11 04:00:00
09/11 06:00:00
Compressor Energy (kW) - September, Rochester, NY
09/11 08:00:00
09/11 10:00:00
09/11 12:00:00
09/11 14:00:00
Two Stage
09/11 16:00:00
09/11 18:00:00
09/11 20:00:00
09/11 22:00:00
09/11 24:00:00
09/12 02:00:00
40
45
50
55
60
65
70
75
80
85
90
ENERGYPLUS
Compressor Energy (kW) - July Day in Rochester, NY
16
14
12
10
kW
8
0
8:00:00 10:00:00 12:00:00 14:00:00 16:00:00 18:00:00 20:00:00
46
0
2
4
6
8
10
12
14
16
18
07/15 01:00:00
07/15 06:00:00
07/15 11:00:00
ENERGYPLUS
07/15 16:00:00
07/15 21:00:00
07/16 02:00:00
07/16 07:00:00
07/16 12:00:00
07/16 17:00:00
07/16 22:00:00
07/17 03:00:00
07/17 08:00:00
07/17 13:00:00
07/17 18:00:00
07/17 23:00:00
07/18 04:00:00
07/18 09:00:00
47
07/18 14:00:00
Variable Speed Compressor
07/18 19:00:00
07/18 24:00:00
07/19 05:00:00
07/19 10:00:00
07/19 15:00:00
07/19 20:00:00
07/20 01:00:00
07/20 06:00:00
07/20 11:00:00
07/20 16:00:00
Two Stage Compressor
07/20 21:00:00
07/21 02:00:00
07/21 07:00:00
07/21 12:00:00
07/21 17:00:00
07/21 22:00:00
Compressor Energy (kW) - A week July in Rochester, NY
WHAT TO WATCH OUT FOR…
48
VARIABLE SPEED RTU COMPRESSOR SUMMARY
49
CHILLERS
50
BASIC MAGNETIC BEARING COMPRESSOR DESIGN
High Speed
Permanent Magnet
Synchronous Motor
51
MAGNETIC BEARING COMPRESSOR
Inlet Guide
Vanes
Suction gas
Single Stage
Impeller Permanent magnet
synchronous motor
(refrigerant-cooled)
Discharge Port
52
MOTOR EFFICIENCY
110
90 Efficiency
Gain Induction Motor Efficiency Gain
80
70
60
50
0 10 20 30 40 50 60 70 80 90 100 110
Percentage Speed
53
DRIVE TRAIN COMPARISON – FULL LOAD
High Speed Permanent Traditional Variable
Magnetic Motor Speed Centrifugal
Centrifugal Compressor Compressor
Bearing Windage 1.5% 5.0%
Efficiency
Loss
54
ENERGY SAVINGS EXAMPLE
900 1.2
800
kW / ton
500
0.6
400
200
10% energy
reduction High Speed VFD w/ Mag Bearing ~ $131,709/year 0.2
100
0 0
0 10 20 30 40 50 60 70 80 90 100
55
OIL REDUCES SYSTEM EFFICIENCY
56
IMPACT OF OIL ON SUSTAINABLE PERFORMANCE
57
ADVANTAGES OF VFD AND MAGNETIC BEARING
TECHNOLOGY
_____________________________________________
58
CHILLERS: SUMMARY
PRO:
– Part load efficiency
– Oil Free Design
– Low Maintenance
CON:
– First cost typically higher
59
WRAP-UP
60
REVIEW QUESTIONS
• What is the difference between a digital scroll and an
inverter scroll compressor?
• What are the advantages of modulating refrigerant
flow?
• What are the limitations of an AC Induction Motor?
• What is more efficient: Surface Permanent Magnetic
Motor or an Interior Permanent Magnetic Motor?
• What type of rare earth magnet is being used in
Interior Permanent Magnetic Motors?
• What are the benefits of removing oil from the system?
• Why are new products designed for full range?
61
THANK YOU.