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VFD selection for refrigeration compressor Single Phase to Three Phase VFD

Choose a variable frequency drive (VFD) for refrigeration compressor control must be conducted with great Wiki
care, as a variable frequency drive selected too small-sized may present some disadvantages. These can be Case study
avoided by using the VFD selection software. Based on a process of individual selection and qualifying of the VFD Market
variable frequency drive suited for a given refrigeration compressor, safe and energy-saving operation of the
Troubleshooting
refrigeration compressor can be achieved.

Experiences made in over 10,000 VFD installations in refrigeration and A/C projects have led to a list of Featured Articles
priorities for the correct selection of a suitable variable frequency drive.
Variable frequency drive application ...
List of priorities for variable frequency drive selection Variable Frequency Drive
(1) The refrigeration compressor motor winding must not be overheated. This happens when the starting (VFD) can be used in lots
torque of a variable frequency drive dimensioned too small is not sufficient for starting the refrigeration of fields. Variable frequency
compressor. The consequence of a stalled start is insufficient cooling of the refrigeration compressor motor. drives are widely used to
The winding temperature will then rise quickly and at 120 °C or above it is in danger (see the Figure on control the speed of ...
right).

(2) A stalled starting attempt has to be detected immediately

and the variable frequency drive inhibited before the winding
temperature increases to a critical temperature. Restarting
of the variable frequency drive must be prevented for a
period of at least 1 minute.
VFD manufacturers
(3) With the starting current available, the highest possible starting torque must be achieved. The higher the buy@vfds.org
starting torque, the safer is starting. With the same current, the starting torque of the variable frequency tech@vfds.org
drives presented hereafter is 20 % higher than that of a conventional VFD intended for industrial use.

(4) Provided the refrigeration compressor motor is selected correctly with an appropriate reserve in motor
size, the maximum frequency of the refrigeration compressor can be increased to the mechanical limits until
the maximum motor current is reached. This enables a high so-called Control Factor can be reached. The
Control Factor is defined as follows:

Control Factor CF = Variation of Variable-speed Compressor refrigeration power / Fixed-speed

Compressor step

(5) Achieving the highest possible Control Factor is important for the following reasons:

A good Control Factor results in a good control of suction pressure. The suction pressure is stable and
the expansion valve can operate well with a high efficiency (i.e. energy saving), resulting in optimum
filling of the evaporator.
The reduced number of starts of the Fixed-speed compressors in a refrigeration compressor rack
leads to an extended working life of the refrigeration system
Maximum rack refrigeration power is relatively high.

(6) The smallest possible variable frequency drive allowing safe refrigeration compressor operation should
be selected for reasons of cost effectiveness.

Motor-current based variable frequency drive selection

The Technical Information describes a method for the safe selection of VFD, based on the following data
given:

Maximum motor current, as stated in the refrigeration compressor manufacturer's documentation.

Factor considering the number of cylinders with reciprocating compressors
Factors relevant for screw and scroll compressor units
Use of conventional industrial variable frequency drives

Based on the above data given, the variable frequency drive starting current required can be calculated. VFD
selection on the basis of this method will operate reliably and without any risk for the refrigeration
compressor. However, a disadvantage of this method is that in many cases the VFD chosen is too large and
therefore too expensive.
New method of VFD selection
By means of the new selection software, several new factors and criteria are considered in addition to
dimensioning on the basis of motor-current alone:

(7) Refrigeration compressor start scenario – establishing worst-case start-up conditions. A refrigeration
compressor start at a high ambient temperature after a long-term power-failure (>= 15 minutes) is
considered as the most difficult starting condition. In accordance with the information provided in the
software of most refrigeration compressor manufacturers the following starting points will be used:

Evaporating temperature: …10 °C (depending on the refrigerant used)

Condensing temperature: corresponding to the ambient temperature, e.g. 43 °C in summer

(8) Consideration of refrigerant characteristics. Starting with R134a for example requires less starting torque
than starting with R404A.

(9) Consideration of refrigeration compressor make and type. With reciprocating compressors the number of
cylinders is particularly important (see following figure). The starting torque of a 2-cylinder compressor e.g. is
twice as high as the average torque.

(10) Consideration of rack-assisted starting. With an intelligent control system, fixed-speed compressors are
started first. As soon as suction pressure is close to the setpoint, the VFD-controlled compressors are
activated.

(11) Calculating the starting current required.

(12) Selection of the smallest possible variable frequency drive able to supply the starting current needed.

For manual selection, a consideration of all above factors described above would be too complicated.
Detailed VFD and refrigeration compressor information stored in a data base accessed by a selection
software is necessary.

The following data are required to select a suitable refrigeration variable frequency drive:

Compressor manufacturer: Bitzer, Bock, Dorin, DWM-Copeland, etc.

Refrigerant: currently R 404A / R 507, R 134a, R 22, R 407C, R 410A, R 717, R 744_SC/TC
Compressor type: currently reciprocating, screw and scroll (semi-hermetic, hermetic or open)
Compressor selection list including all relevant electrical and refrigeration data.
Electrical supply voltage (380 V pre-selected)
Motor connection: Star, delta, part winding
Starting torque factor: Taking into account starting conditions such as the maximum ambient
temperature and/or rack-assisted starting

Project-based selection of electrical switchgear

In many cases information on electrical switchgear is included in the variable frequency drive manufacturers
technical documentation. However, switches and cables are usually over dimensioned, as variable frequency
 drive operating data are not suitable for the selection of switches and cables in refrigeration applications.

Sometimes too much copper is used. It is more economical to select electrical switchgear on the basis of the
refrigeration compressor's electrical operating data.

Conclusions
With the exact selection of refrigeration variable frequency drives and electrical controls and equipment is
made possible. The equipment suggested is often more economical than that chosen with conventional
methods.

TRYING TO GET UO WITH SOME TO HELP ME ON YOUR DRIVE PRODUCTS IM IN THE USA

- - - -> by: DWAYNE

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