Sporlan I Speed Inveter 100-80 iSpeed

Sporlan iSpeed Inverter SeriesDrive Systems for Refrigeration Compressors, Fans, and Pumps

OCTOBER 2008

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Sporlan iSpeedIntelligent InvertersFor Refrigeration and Air Conditioning Systems

Conventional refrigeration and air conditioning systems consist of one or more compressors that are simply staged in an on-and-off manner to approximately meet the refrigeration needs of the system. Although some systems use compressors of differing sizes in an attempt to more closely tailor capacity, even these systems are step-control and can lead to overcooling, rapid compressor cycling, system instability, loss of control and wasted energy.

Sporlan iSpeed Inverter systems overcome these limitations and save up to 40% of the energy used in traditional systems. The Sporlan system is not just an add-on set of hardware, it is a total system solution consisting of hardware, specifically designed and proven software, and guidelines for designing the most efficient system possible. Thousands of field installations and over 10 years of experience have supported the energy savings described. Years of consulting with major compressor manufacturers allow specific recommendations of models for each application.

Software packages include: supermarket rack refrigeration, chillers, glycol coolers, heat pumps, transcritical and subcritical CO

2, drycoolers, condensers and pumps. The iSpeed Inverters can also be

used in conjunction with existing controllers to increase energy efficiency.

Why Sporlan iSpeed Intelligent Inverter Systems?•Saveupto40%ofenergyusageinSupermarketrefrigerationsystems

•Assuresproductintegrityandshelflifebyreducing dehydrationandshrinkage

•Canreduceinstalledequipmentfirstcosts

•Reducescompressorwarrantyfailurerates

•DesignedtomeetthestringentEMCDirectives

Page 1 / Bulletin 100-80

Higher Evaporating TemperaturesSporlan iSpeed Inverters provide very stable suction pressures that ensure proper product temperature even at higher suction pressures.

•Energysavingbysteplesscontrol of refrigeration capacity:

- Up to 40% with refrigera-tion installations using a single compressor

- Up to 25% with conven-tional multi-stage com-pressor racks

•Operationatahigherevaporation temperature with the same refrigera-tion capacity

•HigherCOPfactorunderpartial load conditions

A 5°F or 2.5 K raise in suction pressure can yield a 10.2% increase in EER (Energy Effi-ciency Ratio). The steadiness of the suction pressure also allows

the TEV (Thermostatic Expan-sion Valve) or EEV (Electric Expansion Valve) to be run at lower superheats, adding to coil and system efficiency. Table 1

shows representative operating range based on a 3 compressor rack with 50 kW (14.3 tons) total refrigeration capacity.

67%

33%

0

20

40

60

80

Com

pres

sor O

utpu

t

Refrigeration requirement

100

120

140[%]

100%

iSpeed Software Conventional installation(multi-step control)Sporlan iSpeed Inverter(closed-loop suction pressure control)

Figure 1

Bulletin 100-80 / Page 2

Table 1 – Power Savings

Comparison based on a 3 Compressor Multi-stage rack with 50 kW (14.3 tons) total refrigeration capacity

Frequency Inverter

Without WithkW Tons kW Tons

Qmin 17 4.8 6-8* 1.7-3.2*

Qmax 50 14.3 53-55* 15.1-15.7*

* depending on compressor

Energy Savings

Load Matching

Refrigeration and air condi-tioning systems are sized for the largest total load expected under extreme conditions. The compressors and condenser fans are then chosen to meet this maximum capacity need.

However, almost 95% of system run time is at a reduced load,

and fixed speed compressors must be cycled to attempt to meet the load. Since the com-pressors and fans run at fixed speeds, their energy use is high-er than needed to satisfy system requirements. Sporlan iSpeed Inverters with onboard software, efficiently tailor compressor and fan speed to match the

exact load. Since motor current draw is linear to motor speed, reduced speed means reduced energy use.

Figure 1 shows how iSpeed Software enables the system to match capacity better than conventional step control.

Air conditioning systems are designed to provide comfort cooling and humidity control for building occupants and while these are important, slight variations of either are gener-ally acceptable. Sporlan iSpeed Inverters minimize variations in

these systems. Food storage and process cooling have more criti-cal temperature control require-ments. According to ASHRAE, temperature variations of only 2-3°F or 1-2 K is enough to dam-age most products. Variations and lowering of humidity levels

leads to “shrinkage” and further product loss. Sporlan iSpeed Inverters, due to their smooth suction pressure control prevent spoilage and shrinkage. Figure 3 is a graph of an actual installa-tion showing the improvement of suction pressure stability.

Figure 3

30

20

10

0t

Conventional pressuredeviation

P0

Setpoint

bara

Conventional installation(multi-step control)

3.4 bar maximum pressure deviation with Sporlan iSpeed

Sporlan iSpeed(closed-loop suction pressure control)

•Almostidealconstantpressure characteristic in the suction line even with changing requirements of the refrigeration installation

•Reducedtemperature deviation

•Higherrelativehumidity

•Lessicingofthe evaporator

•Reductionofswitch-on current surges

•Lowernumberofcompressor starts – in particular at low refrigeration capacity

•Smoothbuild-upofsupply current

•Smoothstartreducesstress on pipes and fittings

Many power utility companies impose higher electrical rates based on “demand” or surge currents. Ordinary fixed speed compressors are started by Direct-on-Line (DOL) or Across the Line wiring. The inrush current can be 5 to 6 times normal running current.

This surge may trigger higher electrical costs and stress the installation and possibly the electrical grid infrastructure. Sporlan iSpeed Inverters smoothly increase starting current and limit the power used to that required by the system at that moment. Electrical costs

are minimized and electrical supplies are not stressed.

Soft starting also reduces stress on the motor winding and prelongs working life.

Figure 2 illustrates typical starting currents.

700

600

500

400

300

200

100

[%]

t

Rated current

Switch-on surge

Mot

or C

urre

nt

Sporlan iSpeedSoft Starter

Star/Dlta startingPart Winding starting

DOL starting

Smooth Starts

Product Integrity

Figure 2

Energy SavingsPage 3 / Bulletin 100-80

Compressor specific selection tables can be provided for:

•Bitzer•Dorin•Carrier•Carlyle•DWM-Copeland•others

Fast and simple commissioning without prior knowledge of Fre-quency Inverter Technology:

•Noprogrammingrequired•Quicksetupguideanddetailed

technical literature

Plain-language display on user keypad:

•Suctionpressureset-point•Motoroperatingdata(current,

frequency, etc.)•Systemtestorsystemcharging

without a pressure sensor

Universal setpoint of suction pressure:

•Twoselectableinternaladjustablesetpoints

•Externalsetpoint(analog,fieldbus system etc.)

Suitable for almost all compressor types:

•Semi-hermeticreciprocatingcompressors

•Screwcompressors•Fullyhermeticreciprocatingcom-

pressors of some manufacturers•Scrollcompressorsofsome

manufacturers•Open-typecompressors

Controls variable speed compressor and stages up to 7 additional fixed speed compressors:

•Canbeusedwithcompressorswith cylinder bank off-loading (capacitycontrol)

Selection AssistanceSporlan makes choosing and installing iSpeed Inverters easy by providing selection tables, based on specific compres-sors, from over 14 different manufactures. The tables have been generated from real world experience, manufacturer cooperation and systematic analysis of specific compressor

characteristics. Sporlan can also provide guidance in applying iSpeed Inverters to compres-sors from other manufacturers. Compressors sized and selected to optimize the control “Factor F”* will guarantee the maximum system balance, energy efficien-cy and compressor life. Figure 4 shows that a system with three compressors sized with a high control “Factor F”* can replace four compressors to meet the same maximum load and provide almost infinite variable control down to much lighter loads as well.

Installation Savings & Ease of Use

Properlysizedsystemsmayrequire fewer compressors to match load.

33%

67%

100% 100% 100%

33%

100%

18%12%

100%

75%

50%

25%

Number of Compressors Number of Compressors

Without a Frequency Inverter With a Frequency Inverter

3 4 1 2 3

Figure 4


* Control “Factor F” =Maximum Compressor Frequency — Minimum Frequency of Variable Speed Compressor

Frequency of Fixed Speed Compressor

EMC DirectiveLow-VoltageDirective

MachineryDirective

EG Declaration of Conformity with CE marking based on:• RFinterference EN50081-1/-2• Immunity EN50082-1/-2

ClassBinterferencelimit–suitableforunrestricted operationonpublicelectricitysupplies

EG Declaration of Conformity with CE marking:

Standardsused:• EN50178

Manufacturer’s Declaration available

Installationto:• EN60204-1

UL Standards

ULc-UL

Standardsused:• UL508C •UL873• UL840

Table 2 – Product Conformity

Control of multi-stage compressor racks:

•Adjustabletimersforoptimumoperation of the compressors without unnecessary cycling

Special functions of the speed-controlled compressor:

•Skipspeedstopreventmechanical resonances

•Adjustableminimumandmaximumspeedofthespeed-controlled compressor

•Controlofoilpressureswitchorcrankcase heater, unloaded start, or condenser fans

High system pressure limiting by reducing the speed of the variable-speed master compressor.

Fault processing:

•Processingofthermistorwindingprotection

•Detectionofpressuresensorfailure

•Processingofsafetytripcircuit(e.g.withHP/LPpressurecut-out switches)

Automatic delayed autostart following a supply or installation fault, 10 start attempts.

Available electronic soft starters for the smooth starting of the fixed-speed compressors:

•Preventionofcurrentandpressure surges on starting

Generally motors have the longest service life if the number of starts and stops is limited. Compressor life is even more compromised by frequent

cycling because of the high torque needed to start, the heat of inrush current, and poor lubrication flow. Sporlan iSpeed Inverter systems not only keep the lead compressor smoothly running as much as possible, but the proprietary software limits cycling of the fixed speed compressors, where fitted. The ability of the Sporlan iSpeed Inverters to safely increase the speed of the compressor adds up to 20% capacity, helping to prevent unnecessary starts of the fixed speed compressors.

The variable speed compressor current is smoothly ramped up to avoid excessive current surges and heating of the windings. Available Sporlan iSpeed Soft Start Kits can add this benefit to the fixed speed compressors as well. Contact Sporlan for more information, sizing and model numbers.

EMC Compliance

Increased Compressor Life

Sporlan iSpeed Inverters keep lead compressors running smoothly and proprietary software limits cyclingofthefixedspeedcompressors - reducing compressor wear.

Page 5 / Bulletin 100-80

Sporlan iSpeed Kits provide all necessary components for the system. Refer to table 2. Additional accesso-ries, software packages and some complete panels are also available.

Table 3 – Sporlan iSpeed Inverter Series

Table 4 – Soft Start Kits for use with Sporlan iSpeed Inverter Series

Model

Rated current

Nominal Compressor Included

EMC filter

Dimensions W x H x D Weight

Amps kW hp mm inches kg lbs

3 phase AC, 400-460VAC supply

iSRCF+9.5E13/14 9.5 4.0 3.0 Class B 177 x 233 x 181 7.0 x 9.2 x 7.1 4.4 9.68

iSRCF+14E13/14 14 6.0 4.5 Class B 177 x 233 x 181 7.0 x 9.2 x 7.1 5.1 11.22

iSRCF+14C2E13/14 14 14.0 10.4 Class A 177 x 233 x 181 7.0 x 9.2 x 7.1 4.5 9.9




iSRCF+59E13/14 59 30.0 22.4 Class B 252 x 453 x 245 9.9 x 17.8 x 9.6 22 48.4



iSRCF+105E13/14 105 55.0 41.0 Class B 257 x 669 x 312 10.1 x 26.3 x 12.3 40 88



iSRCF+205E13/26 205 110.0 82.1 Class B 257 x 720 x 355 10.1 x 28.3 x 14.0 60 132

iSRCF+260C3E13/14 260 132.0 98.5 Class A ** 569 x 1384 x 465 22.4 x 54.5 x 18.3 158 347.6


iSRCF+361C3E13/14 361 200.0 149.2 Class A ** 569 x 1384 x 465 22.4 x 54.5 x 18.3 170 374




3 phase AC, 230 VAC supply (except iS RCF +10.5S230E13/14 is 1 phase)

iSRCF+10.5S230E13/14 11 2.2 — — 177 x 233 x 181 7.0 x 9.2 x 7.1 4.6 10.12

iSRCF+16.5T230E13/14 17 4.0 — — 177 x 233 x 181 7.0 x 9.2 x 7.1 4.7 10.34

iSRCF+42T230E13/14 42 11.0 — — 201 x 348 x 208 7.9 x 13.7 x 8.2 12.5 27.5

iSRCF+54T230E13/14 54 15.0 — — 252 x 453 x 245 9.9 x 17.8 x 9.6 22 48.4

iSRCF+68T230E13/14 68 18.5 — — 252 x 453 x 245 9.9 x 17.8 x 9.6 23 50.6

iSRCF+104T230E13/14 104 30.0 — — 257 x 669 x 312 10.1 x 26.3 x 12.3 40 88

iSRCF+130T230E13/14 130 37.0 — — 257 x 720 x 355 10.1 x 28.3 x 14.0 56 123.2

iSRCF+192T230E13/14 192 55.0 — — 257 x 720 x 355 10.1 x 28.3 x 14.0 60 132

ModelRated Current Dimensions W x H x D Weight

Amps mm inches kg lbs

3 phase AC, 400-460VAC supply *400 VAC Only

iSRCS5.5T400M/16* 6 45 x 75 x120 1.8 x 3 x 4.7 .42 .92

iSRCS12T400M/16* 12 45 x 75 x120 1.8 x 3 x 4.7 .43 .93

iSRCS16T400M/16* 16 45 x 75 x120 1.8 x 3 x 4.7 .48 1.0

iSRCS18E/27 18 168 x 220 x 110 6.6 x 8.7 x 4.3 2.2 4.8

iSRCS40E/27 40 168 x 220 x 145 6.6 x 8.7 x 5.7 3.5 7.7

iSRCS65E/27 65 168 x 320 x 145 6.6 x 12.6 x 5.7 4.2 9.2

iSRCS95E/27 95 168 x 320 x 145 6.6 x 12.6 x 5.7 15.7 35

iSRCS180E/27 180 260 x 415 x 250 10.2 x 16.3 x 9.8 30 66

iSRCS350E/27 350 350 x 450 x 435 13.8 x 17.8 x 17.2 43 93

iSRCS500E/27 500 376 x 570 x 365 14.8 x 22.4 x 14.4 71 156

3 phase AC, 230 VAC supply (except iS RCS 12S230M/16 is 1 phase)

iSRCS12S230M/16 12 45 x 75 x120 1.8 x 3 x 4.7 .43 .93

iSRCS12T230M/16 12 45 x 75 x120 1.8 x 3 x 4.7 .43 .93

iSRCS18E/27 18 168 x 220 x 110 6.6 x 8.7 x 4.3 2.2 4.8

iSRCS40E/27 40 168 x 220 x 145 6.6 x 8.7 x 5.7 3.5 7.7

iSRCS65E/27 65 168 x 320 x 145 6.6 x 12.6 x 5.7 4.2 9.2

iSRCS95E/27 95 168 x 320 x 145 6.6 x 12.6 x 5.7 15.7 35

iSRCS180E/27 180 260 x 415 x 250 10.2 x 16.3 x 9.8 30 66

iSRCS350E/27 350 350 x 450 x 435 13.8 x 17.8 x 17.2 43 93

iSRCS500E/27 500 376 x 570 x 365 14.8 x 22.4 x 14.4 71 156

* Amperage rated with 10% overload** includes supply choke to reduce harmonic currents

Note: Nominal kW and hp ratings are shown for reference only.

All models include: Sporlan iSpeed Inverter, EMC filter, Programming Keypad, 5 output relays, Refrigeration software and external control (0-10 VDC) software, high and low pressure transducers

Contact Sporlan for more information about these sizing guidelines.


102008© 2008 Parker Hannifin Corporation

Parker Hannifin CorporationSporlan Division206 Lange Drive • Washington, MO 63090 USAphone 636 239 1111 • fax 636 239 9130www.sporlan.com

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