12/6/2013

Variable Frequency Drives

(VFDs)

Ryan R. Hoger, LEED AP

Commercial HVAC Energy Consumption

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Opportunities

• On average building fan systems in the US are

oversized by 60%*
• Over 60% of industrial electricity demand is for
driving electric motors
– A large proportion of this is for driving fans & pumps

*John Hopkins Univ. AICGS Policy Report

Motor Replacement Opportunities

• High efficiency motors not utilized or oversized

– Do economic analysis and remove/replace with high
efficiency motors where economically
– Upon burnout, upgrade to high efficiency
– Do a motor load test and right-size the motor
– Due to increasing manufacturing standards, all motors
sold will be NEMA-premium Efficiency

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Variable Frequency Drives (VFDs)

• Retro-fit to fans and pumps

• Varies the power input to motor
• On average building fan systems in the US
are oversized by 60%*
• If a motor running at 100% speed costs
$1,000/month, what about:
– Running at 75% speed = $420
– Running at 50% speed = $125

*John Hopkins Univ. AICGS Policy Report

Variable Frequency Drives (VFDs)

• Soft start means less wear & tear on

couplings, belts, and motors
• Many utilities provide additional incentives to
install VFDs
• Paybacks less than 1 year for HVAC
fans/pumps and 2 years for chiller
compressors

*John Hopkins Univ. AICGS Policy Report

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What Is A Variable Frequency Drive?

• A standard electric motor is essentially a

fixed speed machine
• A Variable Frequency Drive provides the
ability to fully control the speed of a motor
from zero to maximum
• It also provides the ability to control the
torque produced by a motor

Advantages

• Better Control
– You drive the motor only as fast as you need to in
order to get the right air flow, water flow, space
temperature and more
• Energy Savings
– Just as you vary the amount of gas you put into your
car’s engine, the VFD varies the amount of power that
it puts into the motor
– 50% flow for 13% power
• Maintenance Savings
– Soft start/stop means less wear on couplings, belts
and motors
– Controls tell staff when system needs attention

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Cubed Exponential Load – Affinity Laws:

power is proportional to the change in speed cubed

If the speed of a device

(pump or fan) is increased
10%:

•Volume flow (GPM or CFM)

increases 10%

•Pressure (head or static)

increases 21%

•Power increases 33 %

If we want to increase the

volume flow GPM (or CFM)
of an existing system 10%
we have to increase the
power supply 33%

Cubed Exponential Load – Affinity Laws:

power is proportional to the change in speed cubed

Energy Savings
150 3/4 motor speed = 42% power
58% power saved
125
1/2 motor speed = 12.5%
100 power
75 87.5% power saved
Power

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Money Saved
25 Motor without VFD
At 100% speed = $1,000 Cost
0 Same motor with new VFD
25 50 75 100 125 150
At 75% speed = $420 Cost
% Speed $580 Savings
At 50% speed = $125 Cost
$875 Savings

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Cubed Exponential Load – Affinity Laws:

power is proportional to the change in speed cubed

For centrifugal pumps and

fans - power requirements 150
change sharply with small 125
speed changes
100

Power
75

50
Torque (mechanical force)
Power (energy consumed) 25

0
25 50 75 100 125 150
75% speed = 42% power (0.753)
% Speed
50% speed = 12.5% power (0.503)
(theoretical power reduction)
Reduced speed = HUGE $ Savings

Typical HVAC Load Requirements

12

10
% Operating Time

0
5 25 50 75 100
% Flow or Volume
Data Supplied by the U/K Dept of Trade & Industry.

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Energy Conservation

By controlling the fan or pump speed to

meet demand - sufficient flow - an enormous
amount of power can be saved.

On continuously running plant -

Over a 50% reduction has been achieved

Additional Benefits
• Improved control
• Reduced noise & vibration
• Simpler installation &
commissioning
• Lower maintenance costs
• Fewer complaints !

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Case Study – Merchandise Mart

• 29 VFDs installed on
chilled water pumps
and fans
– Incl. three 300 hp
• Metered measured 1st

Case Study – Bally’s Atlantic City

• 102 VFDs installed
• No adverse affects on
existing fan equipment
• Goals:
– Improve temp conditions
– Reduced “wind tunnel” &
building pressurization
issues
• Annual savings of
$175,000
– 2-year payback
– Payback longer due to extra
1st cost of bypasses

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Case Study – John Muir Medical Center

• VFD retro-fit to
compressors on
Carrier and York
chillers
• Goals:
– Reduce operating
expenses
– Correct electrical and
mechanical problems
associated with chillers
– Match speed of
compressors with
cooling demand
– Show significant ROI

Case Study – Applied Materials Research Facility

• VFD retro-fit to chiller

compressor plus
condenser water supply
temp optimization
• Goal was to optimize
chiller energy
performance which is
best at 25-75% load

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How Does a VFD Work?

• Converts AC power to DC power – Now we

can do something with it.
• Converts DC back to AC – When it converts
back, it switches power on and off to create
the AC wave and to vary the frequency. Vary
the frequency and you vary the speed.

Do I need a bypass?
• NO…..unless it is a critical application…..life or
death…..think hospital….
• It typically quadruples the price…..it would
actually be cheaper to buy a spare VFD
• VFD technology has become extremely
reliable…..don’t let a bad experience from 20
years ago make you think the drive will fail
• Bypass types
– Electronic – Switch is “soft”, made with relays and
software
– True Electrical – Hard, physical switch makes the
change

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Electrical Bypass Components

•“VFD Run” LED Indicating Light
•“Bypass Run” LED
Indicating Light
•Four Position Selector
Switch;
“Bypass/Off/Test/VFD”
•Drive Input Contactor

•Bypass Contactor
•Drive Output
Contactor

•Overload Relay

•Control Transformer
With Fusing

•Customer Terminal
Strip

•Main Fused
Disconnect

•Main Disconnect
Handle

What accessories do I need?

• Built-in filters to prevent harmonic
interference
• Built-in AC choke protection
– Ensures harmonic currents never make it
back to power grid to create problems with
other equipment and a low power factor that
costs customers money
• Industrial-quality RFI filters, immunizing
drive from the effects of interference
• Communication capabilities
• BACnet®, LONWORKS®, N2, Modbus, etc.

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What is NEMA?
• National Electrical Manufacturers
Association
– NEMA sets standards for VFD enclosures and the
protection they provide
– It’s typical to see NEMA 1, 12, 3R and 4X.
• What do they mean?
– NEMA 1: Protection against touching live parts and
falling dirt
– NEMA 12: NEMA 1 protection plus against circulating
dust, lint, fibers, and flyings, and against dripping and
light splashing of liquids

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Typical Pre-Engineered Apps

• Standard
– Waiting for speed comand signal from
external source (i.e., BAS controller)
– Accepts 4-20mA, 2-10vdc, etc.
• Local/Remote Control
• Multi-step Speed Control
• PID Control
• Multi-purpose Control
• Pump and Fan Control w/Auto
Changeover

Applications

Field Bus communications

supported
in all applications

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HVAC Energy Savings

Fans Pumps

• Supply and exhaust fan • Chilled and hot water

• Cooling tower • Booster pump
• Parking ramp ventilation • Irrigation and fountain
• Boiler FD and ID fan • Swimming pool circulation

Machines
• Refrigeration compressor
• Air compressor

Opportunities

Condenser Chiller Chilled Supply Air

Cooling
Water Pump Compressor Water Pump Fan
Tower Fan

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Variable Air Volume (VAV) Air Handler

Supply Fan Volume Control

Supply Air
Fan

Space
Static

Receiver
Controller

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Supply/Return Fan Capacity Control

Return Air
Fan

Supply Air
Fan

Receiver
Controller

Variable Air Volume Control Methods

Supply Fan
• Static pressure control - 2/3 distance down main
duct in a straight in the main duct
• Static high limit to prevent over pressurizing
system
• Use DDC controller or PID controller application
in VFD
Return Fan
• Common method is from a signal from the
supply fan VFD – doesn’t account for fan size
difference or other exhaust systems
• Best way – measure supply cfm, return cfm and
outside air cfm – expensive, most accurate, and
best control to provide

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Primary Chilled Water

Evaporator 1

CC1

CC2
Evaporator 2

Cooling Tower Fans

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Cooling Tower VFD Benefits

• Drive the condenser water as low as

possible for maximum chiller efficiency
• Reduced wear and tear on the electrical
equipment
• Improved control (straight line) – stable
chiller operation
• Energy savings

Variable Speed Pumping

• Add VFDs to pumps

• Hot or chilled water systems
• Control to differential pressure
at “farthest coil”
• Requires 2-way valves at each
zone
– Need bypass pipe/valve at end of
line or one far zone with 3-way
valve
– Consider Pressure Independent
Control Valves (PICV)

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Variable Speed Pumping

• For secondary loops, maintain

pressure in system by having a
min freq greater then zero -
look at the pump curve
• For primary loops thru chillers
and boilers
– Maintain minimum flow - use flow
meter
– Pay attention to maximum rate of
change rules

Energy Savings Estimation Tools

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Ryan R. Hoger, LEED AP

708.670.6383
ryan.hoger@tecmungo.com

Special Thanks to those who allowed me to use their graphics

today…

Ryan R. Hoger, LEED AP

708.670.6383
ryan.hoger@tecmungo.com

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