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Course # W 51 HVAC Motor Control Solutions
Presenter: John Polites - Automation Engineer
Wednesday, May 3rd - 9:00 AM – 10:00 AM
State College Room
Topics of Discussion:– Motor Load & Starting Methods – Motor Control for HVAC Applications– Energy Savings with Variable Frequency Drives– Introduction to PF400 HVAC Drive
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AC MOTOR LOADS
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– Constant Torque
– Variable Torque
– Constant Horsepower
AC Motor Load Types
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Constant Torque Motor Loads
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Variable Torque Motor Loads
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• Typical of Centrifugal Pumps and Fans• Pumps: Hot Water, Chilled Water, Condenser
Water, Distribution• Fans: Supply, Return, Relief, Exhaust, Cooling
Tower Fans• Torque and Horsepower Drops As Square of Speed
Reduction; • Excellent Potential for Energy Savings with a VFD versus a
throttling Valves, Dampers or Inlet Vanes
Variable Torque Application Types
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Two Pump Types:
• Positive Displacement Pumps
• Move fluid chamber to cause fluid to flow
• Constant Torque Load Profile
• Centrifugal Pumps
• Move fluid by rotation of an impeller
• Variable Torque Load Profile
• Hydronic Pumps: Hot Water, Chilled Water, Condenser Water &
Distribution
HVAC Pump Types
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Components of the Pump System
• Pump• Motor• Coupling• Base Plate• Piping• Valves• Inlet Source
– Above Pump– Below Pump
• Discharge Static Head
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Pump Type and Applications
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HVAC Systems
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• The purpose of an HVAC (heating, ventilating, and air-conditioning) system is to provide and maintain environmental conditions within an area called the "conditioned space."
• The commercial system selected for a particular application should endeavor to provide the optimum environment for employee comfort and productivity, process function, and good indoor air quality with energy efficiency and cost-savings
HVAC Systems
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• Air Handling Systems– Air Handling Units (AHU), Rooftop Units (RTU), Makeup Air Units
(MUA), Exhaust Fans (EF), Variable Air Volume Boxes (VAV),,fan unit (FU)
• Hydronic Systems– Chilled Water (CHW) – [Chillers and Pumping Packages]– Condenser Water (CW) – [Cooling Towers]– Hot Water (HW) - [Boilers and Pumping Packages]
• Building Automation System (BAS)– HVAC Controls, Direct Digital Controls (DDC), Energy Management
System (EMS), Facility Management System (FMS)
Types of HVAC Systems
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HVAC Motor Control (Starters or VFDs)
Typical Commercial HVAC Systems
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Supply fan will be controlled by PF400
Controllers measure Static Pressure and send speed signals to both VFD’s
VAV boxes located in each
room distribute conditioned airReturn fan will be controlled by PF400
Traditional Variable Air Volume (VAV) Air Handling Unit
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These motors are controlled by a Variable Frequency Drive
Variable Frequency drives Replace the wasteful Check valve system
Chilled Water Pumping System
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Valves replaced when drives are used
Motors controlled by VFD’s in new applications
Condenser Water Pump System
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NC
NETWORK CONTROLLER
TYPICALLY MOUNTEDIN NETWORK CLOSET
ETHERNETFIELD BUS
BAS SERVER
BAS OWS
BAS PRINTER
BUILDINGLOCAL AREA
NETWORK
ASC APPLICATION SPECIFIC CONTROLLER(HOT WATER SYSTEM)
ASC
ASC
ASC
ASC
APPLICATION SPECIFIC CONTROLLER(CHILLED WATER SYSTEM)
APPLICATION SPECIFIC CONTROLLER(AIR HANDLING UNITS)
APPLICATION SPECIFIC CONTROLLER(ROOFTOP UNITS)
APPLICATION SPECIFIC CONTROLLER(VARIABLE VOLUME BOXES)
Building Automation Systems (BAS)
> Controllers Send Output Commands to VFDs and Motor Starters: Start/Stop Control & Speed Commands
> Run/Fault Commands Sends Status Commands for Starter Device to Controllers.
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• A pressure sensor within an air duct or pipe measures the system pressure
• As the pressure changes an analog signal is sent to the BAS
• The BAS sends a start stop and speed command to variable frequency drives (VFDs) or motor starters
• When valves and dampers close, the pressure rises in the ducts or pipes, which reduces the speed
Basic BAS Systems Control Strategies
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• This is a typical view on a building automation computer screen showing the status of various points in an air handling system
Building Automation System Graphic
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Motor Starting Methods
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• Full Voltage Starting
• Reduced Voltage Starting– Wye - Delta Starters– Autotransformer – Soft Starters
• Variable Frequency Drives
Types of HVAC Motor Starting Methods
SMC-Flex
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Full Voltage Starting
• Full Voltage Starting Characteristics– Contacts close immediately supplying full line
voltage to motor.• Advantages:
– Lowest starter cost– Simple starter designs
• Easy to maintain and troubleshoot• Disadvantages:
– Inrush Current• 6-10 times rated running current• Issue when peak demand charges are
enforced by utilities– Initial Torque
• Mechanically hard on system• Reduced life of belts, gears
DisconnectDisconnect
FusesFuses
ContactorContactor
Overload Overload RelayRelay
L1 L2 L3
T1 T2 T3
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NEMA Rated
ServiceabilityContacts Replaceable Flexible Overload Selection
Emphasis on:
IEC RatedEmphasis on:ReplacementContacts only replaceable on large sizes onlyConserve panel spaceClass 10 Overload Protection
IEC & NEMA Motor Starters
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SMC-Flex
Use SCR’s to ramp voltage supplied to motor over a user defined time period
Advantages:• Reduces inrush current• Reduces starting torque• Reduces mechanical stress on motor & loads
Solid State Soft Starters
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Reducing the VoltageReducing the Voltage
Reduces the CurrentReduces the Current
Reduction In Torque!!Reduction In Torque!!
LRT
100%
100%0Percentage of Full Speed
(.5)2 = .25 or 25%
Soft Starter Speed Torque Curve
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Manual Starters
• Range Overview– 1HP, 115, 230, 277 VAC – 0.75 HP, 115/230 VDC– 1 or 2 Pole– Thermal Overload
• Ideal for small Fan and Pump Applications
Commercial OEM Products
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Adjustable Speed Drives
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Solid State AC Variable Frequency = Variable Speed
AC Motor
DC Bus
AC InputFixedFrequency
InverterConverter AC OutputVariableFrequency
Variable Frequency Drives Basics
Benefits• Solid state technology• Wide control options• Small size power units• Good efficiency• Lower cost, smaller motors• Retrofit existing motors• Bypass capability
460
60
Hertz
230
Volts
MaxFrequency
30
Voltage Hertz Motor RPM
0 0 0
115 15 438
230 30 875
345 45 1313
460 60 1750
Base Voltage
Base Frequency V/Hz
460 60 7.67
230 60 3.83
208 60 3.47
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• To improve process control though speed and torque control
• To improve system efficiencies• To extend life of equipment by reducing
mechanical stress• To Achieve Energy Savings on Fan and Pump
Applications• To meet the ASHRAE Energy Standards 90.1 -2001
– Variable flow control on fan & pump systems
Why Should I consider using a Variable Frequency Drive (VFD)?
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• Integral RS485 Communications• Supports DSI Accessories• Integral LCD Keypad
Optimized for Commercial Fan and Pump Applications
Stand-Alone
• Application Specific Features for Fans and Pumps
• Rated for Variable Torque Loads
Packaged
Allen Bradley PF400 HVAC Drive
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• Ratings– 200-240V, 2.2-37 kW (3-50 Hp)– 380-480V, 2.2-100 kW (3-150 Hp)
• 110% Overload for 60 seconds• Enclosure
– IP20 / UL Open• 3-10 HP (240V AC) & 3-20 HP (480V AC)
– IP30 / NEMA 1 / UL Type 1• 3-10 HP (240V AC) & 3-20 HP (480V AC) (with optional kit)• 15-50 HP (240V AC) & 25-150 HP (480V
AC)• Environment
– IP20 rated for 50° C– IP30 rated for 45° C
PF400 Ratings
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Main Input Disconnect
3 Contactor Full Feature Bypass with
Disconnect
3 Contactor Basic Bypass with Disconnect
Allen Bradley PF400 HVAC Drives
Standard VFD
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• Configurable Keypad with local – remote start/stop and speed controls
• Compatible with Building Automation System Inputs/Outputs (Start/Stop, Speed and Feedback)
• Standard BAS Communications: – RS485, Modbus RTU, Johnson Controls
N2 & Siemens P1• Future Communications:
– Lonworks & Bacnet• Process PI• Inertia Ride Through• Power Loss• Flying Start• S Curve, Accel & Decel profiles• V/Hz Control• Motor Overload protection• Communication interfaces to Building
Automation Systems• Analog & Digital inputs & outputs• Manual Bypass Capabilities• Purge Start Input and Frequency• Fire/Freeze Stat Interlock Inputs
Variable Frequency Drive Control Capabilities
Analog Output Dip Switches
Analog Input Dip Switches
24V DC Source/Sink
Relay Outputs Analog and Discrete Wiring
RS485 Ports
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Starting Method
% Voltage at Motor
Terminals
% Motor Starting Current % Line Current % Motor Starting Torque
Lock Rotor
Current
Full Load Current
Lock Rotor Current
Full Load Current
Lock Rotor Current
Full Load Current
Full Voltage 100 100 600 100 600 100 100
Autotrans.
80 % tap 80 80 480 64 480 64 115
65 % tap 65 65 390 42 390 42 76
50 % tap 50 50 300 25 300 25 45
Part Winding 100 65 390 65 390 45 81
Star - Delta 100 33 198 33 198 33 60
Solid State 0-100 0-100 0-600 0-100 0-600 0-100 0-180
Variable Frequency
Drive0-100 0-100 0-200 0-100 0-200 0-100 0-180
Motor Characteristics with Different Starting Methods
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HVAC Motor Control Price Comparison
Motor HP VFD Soft Starters NEMA Combination Starters
IEC Combination Starters
5 $ 900 $ 1,100 $ 780 $ 620
10 $ 1,000 $ 1,200 $ 813 $ 697
20 $ 1,600 $ 1,600 $ 1,195 $ 902
40 $ 2,700 $ 2,400 $ 1,959 $ 1,466
50 $ 3,400 $ 2,800 $ 1,975 $ 1,513
Standard Features:
•480 VAC, 3-Phase
•NEMA 1 Enclosure
• Input Disconnect Switch
•Motor Thermal Overload Protection
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ENERGY SAVINGS WITH VFDs
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Centrifugal Pump Energy SavingsThere are two methods used to accomplish the continuously varying flow:
• One method is throttling which changes the system curve by use of control or throttling valve.
• The other method is to vary the speed of the pump which modifies the pump curve.
• Building Automation System controls the pump starter or VFD and control valve based on HVAC sequence of operation.
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Typical Pump Curves
Pump Curves Throttled with Control Valves
Pump Curves Controlled by a VFD
Energy Savings with VFD’s
(GPM Proportional Brake HP-Torque)
Centrifugal Pump Energy Savings
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Many air handling systems require operation at a wide variety of points. There are several methods used to modulate or vary the flow (or CFM) of a system to achieve the optimum points. These include:
• Cycling – As done in home heating systems. This produces erratic airflow and is unacceptable for commercial or industrial uses.
• Outlet Dampers – Control louvers or dampers are installed at the outlet of the fan. To control airflow, they are turned to restrict the outlet, which reduces the airflow.
• Variable Inlet Vanes – by modifying the physical characteristics of the air inlet, the fans operating curve is modified which changes the airflow.
• Variable Frequency Drives – By changing the actual fan speed, the performance of the fan changes producing a different airflow.
Typical Fan Curves
Fan Energy Savings
Building Automation System controls the fan starter, control dampers and air system sensors based on HVAC sequence of operation.
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Fan Curves with Outlet Dampers Fan Curves with Variable Inlet Vanes Fan Curves with VFD
Fan Energy Savings
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Sample Fan Energy Savings Report
• Energy Savings Software– (www.sydist.com)
• Energy Savings Report– VFD Specs– Energy Savings Calculations– Energy Savings Summary
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VFD Energy Savings Software Tools
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Schaedler Yesco Distribution
HVAC Market
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Plan & Spec Market– New Construction, Additions and Renovations– Track projects online through Harrisburg Builders Exchange– Mechanical plans/spec takeoffs for motor control that’s
furnished by the HVAC contractor– Application coordination with mechanical equipment specs,
building automation system sequences of operations and electrical power system plans
Retrofit Market– Provided electrical energy solutions/products to Design/Build
and Energy Service Teams i.e.: Variable Frequency Drives and Lighting Retrofit Solutions
– VFD Fan or Pump Energy Savings Reports www.sydist.com– VFD Replacement Program
Schaedler Yesco Distribution - HVAC Market
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• Local Central PA Support with (5) Staffed Motor Control Specialist
• Product Guide Specifications & Submittal Packages
• Certified VFD Startup – VFD Checklist and Reports
• Onsite Training
• Available Spare Parts
• 24/7 Emergency Service
• Online Allen-Bradley Drives Technical Support– www.ab.com/support/abdrives
Motor Control Support
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