BLDC Inverters Usage

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3rd EHPA European Heat Pump Forum | Brussels | 20.05.2010

Inverter and programmable controls in heat pump

applications

Biagio LamannaApplication Competence Centre ManagerProduct Development Process

CAREL INDUSTRIES Srl


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Page 23rdEHPA European Heat Pump Forum | Brussels | 20.05.2010

Why BLDC inverter compressors?

Carel pCOsistema+ for HP application

Features & Benefits of an integrated solutionVS a stand alone inverter

Compressor motor technologies

Partial load and seasonal efficiency

Conclusions

Summary

Ready to use solution approved by the compressor manufacturers

Full customizable hardware and software

(for CAREL algorithm details see the end of the presentation)


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BLDC(brushless direct current) motorBPM(brushless permanent magnet) motor

DC(direct current) inverter

IPM(interior permanent magnet) motor

SPM(surface permanent magnet) motor

EC(electronic controlled) motor

What does BLDC means?

Different NAMES for theSAME technology


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Electric motor evolution:

AC asynchronous induction motor

DC brushless motor (SPM)

DC brushless motor (IPM)


!The magnets of SPM motors are inside the rotor

!

Highest efficiency and performances!High speed

!Requires a top level BLDC inverter

!Both compatible with standard on-off technology and inverter use

!Good performances only for motors developed specifically for inverter use

!Energy waste due to the need to create the rotor magnetic field

!The rotor is a permanent magnet, there no energy waste

!The magnets of SPM motors need to be fixed on the rotor surface using adhesive,high speed is not allowed


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The motor structures of the IM (induction motor), SPM (Surface permanentmagnets, IPM (Interior permanent magnets)

Comparison table of IM, SPM and IPM motors


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Page 63rdEHPA European Heat Pump Forum | Brussels | 20.05.2010Confidential

The efficiency improvement of the brushless motor technology versus

the induction motor can be estimatedon 4-5%



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Speed controlled BLDC compressors

Scroll or twin rotary, up to 35kWcooling capacity, mainly R410a

refrigerant, up to 65Ccond. temperature with no liquid injection


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New unit testing andrating proceduresbased on partial load

and seasonal efficiency


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Variable speed compressorscanmatch the partial load giving anextremely high unit efficiency due to

the improved efficiency of thecompressor at partial load as motorperformance and basic COP

together with improved efficiency ofboth heat exchangers

P

ressure

Enthalpy

Increased

efficiency



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Unit performances with BLDC compressors


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Unit performances with BLDC compressors

Energyco

streduct

ion:

500!/

year

(0.225!/kwh)


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Makes DC inverter technology available


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pCOsistema+: off the shelf technology

Thanks to the experiences ofCAREL Labs

1toollibrary provides a widerange of turn key solutionsto make DC invertertechnology available to heatpump manufacturers.


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Development time forBLDC inverter compressor

management:

8 months


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Development time for EEV

management:

3 months


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Development time forbrushless sensorless

technology drive:

12 months


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pCOsistema+: user interfaces range for deep

customization


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pCOsistema+: wide range of programmable controllers


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Complete HP control


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Saving more than 40 development weeks

Makes DC inverter technology available


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Features & Benefits of an integrated solution

Developm

enttime:

10-12mo

nths


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Compressor safeguard

Managed function

Compressor start up procedure

Compressor working envelope

Compressor timings

Compressor minimum pressure drop

Suction superheat

Discharge superheat

Discharge gas temperature

Extrafea

tures


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Unit safeguard and performance

Managed function

Compressor start failure management

Compressor equalization at start-upDrive alarm managementSpeed regulation according to theapplication needsDrive parameter pre-set for differentcompressors

Drive custom parameters load andsave managementDrive complete user interface

Extrafea

tures


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Conclusions

Conclusions

A BLDC inverter compressor unit:

Has the top level compressor motortechnology

Meets all present and future efficiency ratingspecifications

Grants high performances due to the wide range of coolingcapacity modulation that allows the best application

temperature control


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Conclusions

Conclusions

A full integrated system for HP application:

Meets ALL compressor manufacturer specifications (with their

official approval!)

Allows to use the compressor in the full speed rangein all theworking envelope conditions

Avoids the unit OEM to spend months of R&D development

Grants a full control on the unit with plenty of extra featurescompared with a stand alone inverter drive that allow to reach

the best performance level


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Conclusions

Conclusions

A full customizable system for HP application:

Meets all unitmanufacturer needsin terms of performance/cost

compromise

Allows the unit manufacturers to keep their knowledge about theapplication and customize any part of the software and userinterface

Has many user interface solutionsfor each different user profile


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Inverter and programmable controls in heat pump

applications

Biagio LamannaApplication Competence Centre ManagerProduct Development Process

CAREL INDUSTRIES Srl

[email protected]

+390499716611www.carel.com

THANK YOU FOR YOUR KIND

ATTENTION


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CAREL control algorithm details

Compressor working envelope:

Min/Max compressor ratio

Min pressure differential

Max motor current

Max/min discharge pressure Max/min suction pressure

Max discharge temperature(different for each zone)

Min/Max compressor speed(different for each zone)

Different management foreach compressor!


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Compressor working envelope management:

! Unit capacity reduction by EEV control in caseof low compressor ratio, high suctionpressure, high motor current, etc

!

Compressor capacity reduction in case of highdischarge pressure and/or temperature, lowsuction pressure, etc

! Drive acceleration/deceleration ramp controlto avoid going outfrom the safety workingareas


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Compressor windings temperature management:

By means of measuring:

compressor shell temperature

compressor discharge gas temperature and superheat

compressor motor current

The control system can:!

stop the compressor due to high shell temperatureseven if

! the drive can manage the compressor speed incase of high motor current without stopping it and

! both EEV and compressor control modules canregulate the discharge superheat or temperature for

optimal compressor performance with maximumcompressor speedby means of the safety liquid

injection


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Unit start-up management:

The synchronization between compressor, driveand EEV management allows the take care of:

! Pressure differential before start

! Equalization, if needed or

! compressor start-up even with up to 10bargpressure difference.

!

Pressure differential after start ( greater than theminimum allowed)

! Oil recoveryafter start

! Compressor warm up

! Compressor timings (minimum ON time, minimum

OFF time, minimum time between different starts)

! Start-up quick retry in case of start failure

!

Wrong wiring, blocked rotor, damaged motorwindings, or any start-up problem.


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Compressor alarm management:

Centralized alarm management for all unitcomponents:

The unit can work even with broken probes

Critical alarms manual reset by user interface or remote

monitoring system

Automatic to manual alarm reset after a defined number

of attempts

All alarms in the same UI:

! Unit alarms (i.e. low temperature, low water flow,high pressure, etc)

! Compressor alarms (i.e. high discharge temperature,out of envelope, low compressor ratio, etc.)

! Drive and motor alarms (i.e. high motor current, lowsupply voltage, communication offline, etc.)

!

Valve alarms (i.e. stepper motor damaged, lowsuction superheat, etc.)

BLDC Inverters Usage

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