Electric Drive

Go Green with AC
Drives
Identify Energy Savings

opportunities with AC Drives
SM
Make the most of your energy
Copyright 2008 Schneider Electric. All rights reserved
Go Green with AC Drives
I.
Energy Opportunities
II. Description AC Drives

III. Affinity Laws
IV. Building Applications
V. Conclusion
Energy Savings Opportunities

Increasing cost of energy, especially oil and gas
Worlds expanding energy consumption from developing
countries i.e. China, India
World events creating security concerns in oil producing
areas of the world
U.S Electrical power grid black-outs
Northeast and West Coast
Hurricane effects felt in oil producing Gulf of Mexico
region
Oil and gas prices
July 2006
July 2008
$75.00 dollars per barrel

$150.00 dollars per barrel
$2.00 / gallon
$4.00 / gallon
U. S. Department of Energy
Energy Star Program
Heating and cooling systems are the largest consumers
of energy in buildings.
64% of electricity used in industrial facilities
For electric motors to power centrifugal pumps and fans
Source: U.S. Department of Energy

Where are the savings ?

Industry &
infrastructure
Data centers &

networks
Buildings
Residential
Average facility can

reduce consumption by
10 to 20%
Power & cooling can

reduce power
consumption by 20 to
30%
Renovation can yield

up to 30% of energy
savings
EE products may save

10% to 40% in
electricity
z 25% savings would

save 7% of the worlds
electricity
z Power & cooling systems

comprise 50% of
electricity usage
z Consume 20% of total

energy
z 20% to 25 % of consumed
energy (EU & US)
z Motors, account for

over 60% of electricity
usage
z Saving energy improves

DC infrastructure
efficiency
z 3 key areas: HVAC,

lighting &
integrated building
solutions
z Lighting & appliances over

40%
U.S. Green Building Council

36% of total energy consumed in the United States is
used for buildings
Includes natural gas, electricity and steam
65% of the electricity consumed in the United States is
consumed for buildings
Source: US Green Building Council


United States Government
Single largest user of energy in the world
45% of energy consumed by the US government is
used to heat, ventilate and cool buildings.
Energy Bill Legislation

Energy Policy Act 0f 2005 (EPAct 2005) signed into law
September 2005
Mandates federal facilities to reduce energy consumption
by 2% per year, every year
Extended Daylight Savings time period
Source: NEMA
International Facility Management Association

Overall cost of running a facility is 10 percent higher than it
was four years ago
IFMA Benchmarks V Study
Utility costs have jumped 19 percent in two years
Includes electricity, gasoline, fuel oil, steam water and sewage
Compared to similar data from 2006.
Source: International Facility Management Association
Energy used in Healthcare Facilities is for

Ventilation Fan Energy
Ventilation Air Cooling
Reheating / Space Heating
Outside Air / Cooling / Dehumidification / Humidification
Energy for hospital HVAC systems

59% to 64% of the annual energy cost
(typical healthcare facility based on location)
Source: ASHRAE Winter Meeting 2008

Best Practice HVAC Systems-Healthcare
15 Steps to a More Sustainable Hospital

Recommends VFDs on all motors 3 hp and higher
Installation of VFDs on smaller motors
Reduced cost of drives
Increased distribution and power of Direct Digital Control
(Building Automation Systems)
New drives may be controlled in two modes;
Modulate flow based on a variable sensor input
(PID feedback control)
Controlled to balance a constant speed system
valves fully opened to reduce system head loss.
VFDs have the potential to save energy even on smaller motors.

Source: Engineered Systems Magazine July 2008
Author: Steven Furgeson, PE
10

LEED
Leadership in Energy and Environmental Design
Certification for Buildings
Recommends ASHRAE 90.1-2004 to set minimum
HVAC requirements
Promotes effective energy conserving designs for
buildings and building systems
ASHRAE
American Society of Heating Refrigeration and Air
Conditioning Engineers
Recommends HVAC systems be equipped with Variable
Speed Drives if they have:
Variable Air Volume fan control
Individual fan motors greater than 5 hp
11
Today, variable speed drives are

widely used in buildings and are
reliable and proven electronic
technology.
12
I.

III. Affinity Laws
V. Conclusion
13
Typical Drive System
Input Power
Drive
Control
Motor
Machine
Adjustable
Frequency Drives
are just one piece of
the system
14
Typical AC Drive
AC Line
DC Bus
Motor Leads
Converter
Inverter
_
Constant
Frequency
Adjustable
Frequency
15
Typical AC Drive
Six Pulse AC to DC Converter

+
i
V
t
AC Line Voltage
(non-rectified)
Rectifier
DC Voltage
(rectified)
Converter uses solid state devices to change AC to DC
16
Typical AC Drive
Six Pulse AC to DC Converter

+
i
V
t
AC Line Voltage
(non-rectified)
Rectifier
t
DC Voltage
(rectified)
Converter uses solid state devices to change AC to DC

17
Typical AC Drive
DC to AC Inversion
V
DC Voltage
(non-inverted)
Inverter
t
t
AC Voltage
(inverted)
18
Typical AC Drive
DC to AC Inversion
V
DC Voltage
(non-inverted)
Inverter
t
t
AC Voltage
(inverted)
19
New Technology for AC Drives

Optimized power section
DC bus capacitor section is reduced
95%-97% less typical AC drive capacitor value
Three
Phase Power
Input current waveform characteristics are

optimized
reduction in current spikes typically observed

due to capacitance charging
Total input current draw is reduced

lower input current harmonics
Rectifier
D C Link
Inverter
Motor control algorithms and powerful

microprocessors
engineered to produce sinusoidal wave form to
the motor
20

Typical AC drive
100HP
Typical 6 pulse AC drive
without line reactor
Input voltage: orange

Input current: cyan
Large current spikes due to capacitors
charging
Peak currents = 300 amps
Harmonic current distortion

Large double humped current waveform
significantly contributes to harmonic
content.
Total Harmonic Distortion Current (THDI)

= 80%
21

AC drive
with line reactor
100HP
Typical 6 pulse AC drive
With 3% line reactor
Input current: cyan
Lower current spikes due to
capacitors charging
Significant double humped current
waveform contributes to harmonic
content
Total Harmonic Distortion Current = 38%
22

Optimized power section
100HP
Input current: cyan
Low current spikes due to capacitors charging

Input current is a square shaped waveform
Eliminating the large double humped
waveform
Reducing harmonic content
Total Harmonic Distortion Current = 33%
23
Enclosed AC Drives Products
S-Flex
Range:
208/230V 1-40hp
460V
1-100hp
Target Market:
Residential high rise
Commercial office buildings
Government facilities
Schools and Universities
E-Flex
Range:
208/230V 1-50hp
460V
1-100hp
Target Market:
Commercial buildings
Hospitals
M-Flex
PowerGard
Range:
208/230V 1-50hp
460V
1-500hp
Target Market:
Hospitals
Pharmaceutical
Industrial
Municipal pumping
Range:
460V 50-500hp
Target Market:
Industrial
Municipal pumping
24
MCC Total Solution
Upstream
Electrical
Network
208-480V
Schneider Electric applied and
packaged solution for single point

of responsibility
Reduced installation costs
MCCEnclosure
Can be used for active harmonic

AccuSine
PCS
VFD VFD
M
CorrectedLoads
filtering of non-linear loads both within

and outside the MCC (based on CT
installation)
Multiple units can be paralleled for
larger RMS ratings
No harmonic study required to size
Accusine PCS for a particular
application
25
AC Drives Products
Altivar 21
Range:
208/230V 1-40hp
460V
1-100hp
Applications
Centrifugal Pumps
Fans
Target Market
OEMs
Control Panel Builders
Altivar 61
Range:
208/230V 1-125hp
460V
1-900hp
600V
1-900hp
Applications
Centrifugal Pumps
Fans
Target Market:
OEMs
System Integrators
26
I.

III. Affinity Laws
V. Conclusion
27
Affinity Laws for Centrifugal Loads
Adjustable Speed Drives

increase system efficiency
provide means to reduce motor speed
for pumps and fans
based on the needs of the building
environment
28
Significant energy savings at lower motor speeds can be realized

based of the Affinity laws;
Flow = f (motor speed)

Pressure = f (motor speed)2
Horsepower = f (motor speed)3
29
Lower motor speed = less energy consumption
30
A motor running at 90% of full speed requires

73% of the electricity of a motor running at 100% speed.
(.9 x .9 x .9 = .729)
31

51% of the electricity of a motor running at 100% speed. (.8 x .8 x .8 = .512)
32

12.5% of the electricity of a motor running at 100% speed.(.5 x .5 x .5 = .125)
33
Customer Benefit Calculation
34
Cost Savings
Drives pay for themselves in a relatively short
period of time.
Typically < 2 years depending on applications
through savings on electricity bills.
35
A fan with a 20 horsepower motor supplies air

12 hours a day
260 days a year
Energy cost is of $0.09 cents per kilowatt-hour.
Cost of running a 20hp motor full speed 12 hours per day:

20 hp x 0.746 kW/hp x 3120 hours x $0.09/kWhr = $4190 per year
Typical Average Annual Utility Rates ($/kWh):*
San Francisco
Los Angeles
Dallas
Richmond
New York
Average
$0.1419
0.1266
0.0900
0.0689
0.2037
$0.1262
*Source: Syska Hennessy Consulting Group

Atlanta, GA
36

Assuming the fan does not need to run at full speed all of the day:
Running full speed (100%) for 25% of the day
80% speed for 50% of the day
50% speed for the remaining 25% of the day
Cost of running with an AC drive controlling the motor:

20 hp x (1)3 x 0.746 kW/hp x 780 hours x $0.09/kWhr = $1,047 per year
20 hp x (0.8)3 x 0.746 kW/hp x 1560 hours x $0.09/kWhr = $1,073
20 hp x (0.5)3 x 0.746 kW/hp x 780 hours x $0.09/kWhr = $131
Total = $2,251 per year
Annual savings: $4,190

20hp drive typical cost:
$2,251
$1,939
savings per year
$2,709
installed cost
(2709 cost per drive / 1939 savings per year) x 12 months = 17 months payback
Payback for the cost of the drive is less than two years
37
Energy Savings Calculator
38
39
40
41
42
Energy Savings Calculator
www.squaredleantools.com
43
Case Study
Actual Cost Savings Example
44
Case Study Food Manufacturer, Tennessee
Customer replaced motor soft start device with AC Drive
Actual measurable savings in cost of electricity achieved was $148.00 dollars per week
$7,696.00 dollars electricity saved per year
Cost of drive and metering:
$4,500 installed cost
Payback for the cost of the drive and meter - 7 months

45
Case Study JC Penney, Atlanta, GA*

Background
Air distribution system for 155,000 square foot clothing store provided by five air handling units
located in penthouse equipment room.
Two return fans vented air from first and second floors through ductwork to air handling units
Air handling units provided conditioned air through out the building through ductwork to
diffusers.
Fans operated at two speeds, high and low, adjusted manually.
Fans usually operated at high speed setting, occasionally at low speed setting.
Testing was conducted to determine airflow at high speed.
Data collected indicated actual airflow from each AHU was less than designed airflow;
therefore fans were larger than necessary for this facility.
Accumulation of dirt on the cooling coils in AHU 1 and 2 restricted airflow and wasted fan
energy.
Measurements of each motor indicated maximum load was less than horsepower rating.
Potential energy saver minimize outside air for ventilation.
Outside air has to be heated or cooled which require energy.
By monitoring carbon dioxide levels in building air intake could be reduced to minimum
quantity necessary.
*Energy Star Building Manual - Fan System Upgrades
46
Case Study JC Penney, Atlanta, GA*

Solution
Install variable frequency drives on supply air and return air fans to bring fan capacity nearer to
actual load.
Install carbon dioxide sensors to minimize intake of outside air.
Space thermostats were used to regulate fan speeds directly.
Before VFD installation, fans cycled on at maximum speed with high motor inrush currents,
then cycled off regularly. VFDs eliminated inefficient constant cycling.
Peak power was therefore less than maximum.
Projected electric demand savings was 36 kilowatts per month.
Cost of VFDs and carbon dioxide sensors: $17,000 installed cost
Projected electricity savings:
138,833 kilowatts
Projected annual savings:
$9,726.00
Payback period for project:
Project internal rate of return:
1.75 years
56.6%
JC Penney was able to realize substantial annual savings almost $10,000 per year
with relatively low investment.
*Energy Star Building Manual - Fan System Upgrades

47
Maintenance Benefits
48
Financial and Maintenance Benefits
Drives provide a soft start control for motors,

resulting in HVAC systems that:
Last longer
Reduce mechanical stress
Require less maintenance
Cause fewer instances of
unscheduled equipment downtime
Lower inrush current and peak power
demand
49
Network Communications
Network connectivity with the Building

Automation Systems
BACnet
LonWorks
Metasys N2
Apogee P1
Modbus
allows real time control of pumps and fans
based on climate demands of the building
environment under control and
increases occupant comfort
LonWorks
50
Energy Efficiency Programs
51
Energy Efficiency Incentives
Increase bottom line profit utilizing

Energy Efficiency Incentive Programs
Many energy efficiency programs offer incentives
for motors and adjustable frequency drives in
commercial and industrial facilities
Incentives may include rebates as well as funding
for feasibility audits and design assistance
52
Energy Efficiency Incentive programs
Consortium for Energy Efficiency

Provides information about energy
efficiency programs in industrial
and commercial facilities
www.cee1.org
Source: CEE Energy Efficient Programs-May 2007

53
Energy Star
EnergyStar.gov
Energy audit and energy management information
for industrial and commercial facilities
Energy Star Building Manual recommendations
Heating and Cooling System Upgrades
Fan System Upgrades
www.energystar.gov
Source: energystar.gov website

54
I.

III. Affinity Laws
V. Conclusion
55
Typical Building Applications
56

Air Handling Unit
57

Exhaust Fans
58

Cooling Tower Fans
59

Cooling Tower Water Pump
60

Hot Water Pumps
61

Secondary Loop
Chilled Water Pumps
62

Domestic Water Pump for
High Rise
63
Raleigh Convention Center, Raleigh, NC
Raleigh Convention Center

$220 million project
150,000 exhibit hall
Meeting rooms
Ballroom
Enclosed drives will control:
18 Air handling units 25hp, 30hp, 40hp, 50hp,
60hp, 75hp, 100hp
2 Hot water pumps 50hp
2 Chilled Water pumps 60hp
4 Cooling Tower Water pumps 40hp
7 Exhaust fans 7.5hp
Installed Square D enclosed drives
64
Proctor & Gamble, Cincinnati, Ohio
Proctor & Gambles headquarters

1.5 million square foot
Energy Star certified facility
Energy Star Certification
Reset supply air for air handling units
Use outside air to reduce heating and
cooling time by 60 hours per week
Upgrade existing motors to add
variable frequency drives
Source: Sustainable Facility Magazine, June 2008

65
Rex Healthcare, Raleigh, North Carolina

Surgical Expansion Project
Three story addition to hospital
12 operating rooms
Three new air handling units
New boiler
New chiller
New cooling tower
Square D enclosed drives will control
3 Supply air fans in AHU
3 Return air fans in AHU
2 Cooling tower water pumps
LonWorks Communications with Honeywell
Enterprise Building Integrator (EBI) building
automation system
66
Oak Ridge National Laboratory, Oak Ridge, Tennessee

United States Largest Science and Energy
Laboratory
58 square mile campus
4200 employees
Energy Conservation mandated EPAct 2005
Reduce building heating and cooling loss
through laboratory fume hoods
Reduce energy usage by adding variable
frequency drives to existing motors
Utilizing variable speeds drives to control motor speeds
and reduce energy usage was the first area to implement.
Greg Palko
Energy Efficiency Manager
Oak Ridge National Laboratory
67
Jefferson County Hospital Fairfield, Iowa
Acute care and nursing facility with 61 patent beds

15 Square D brand enclosed drives
Circuit breaker disconnect and
Bypass circuit at
460 volt
5hp to 40hp
The enclosed drives will control;
Supply air fans

15hp, 30hp and 40hp
Return air fans
5hp, 10hp, 20hp and 30hp
Hot water pumps
10hp
Chilled water pumps 20hp
68
Harrahs East Chicago, Indiana
15 floor high rise hotel

294 rooms
Six restaurants
53,000 square feet riverboat casino
28 Square D enclosed drives
Circuit breaker disconnect and
Bypass circuit at
460 volt,
2 to 40 horsepower
Drive applications include
Exhaust fans
40hp each
Hot water pumps 2 hp each
69
Bothell High School Shoreline, Washington
26 Square D enclosed drives with

Circuit breaker disconnect
Bypass circuit
460 volt
3 to 20 horsepower
BACnet building automation communications
70
Elementary School, Kinston, North Carolina
Elementary school scheduled to open Fall

2008
47 Square D enclosed drives
Circuit breaker disconnect
Bypass circuit
208 volt
1 to 3 horsepower
Installed by Trane partner
71
Available Resources
Website:
www.us.squared.com
Products and Services
- Motor Controls
- Adjustable frequency drives
AC Drives 24 / 7 technical and application assistance
1-888-SQUARED
Sales and application assistance

Regional Product Application Engineers
72
Energy Savings with Variable Speed Drives
Pump and Fan systems operating with

Variable Speed Drives provide:
4 main
messages
1.
Cost savings and conserve electricity
2.
Increase comfort in buildings
3.
Reduce equipment maintenance and downtime
4.
Additional savings through energy efficiency

rebate programs
73
Enclosed AC Drives Products
S-Flex
Range:
208/230V 1-40hp
460V
1-100hp
Target Market:
Residential high rise
Commercial office buildings
E-Flex
Range:
208/230V 1-50hp
460V
1-100hp
Target Market:
Commercial buildings
Hospitals
M-Flex
PowerGard
Range:
208/230V 1-50hp
460V
1-500hp
Target Market:
Hospitals
Pharmaceutical
Industrial
Municipal pumping
Wastewater
Range:
460V 50-500hp
Target Market:
Industrial
Municipal pumping
Wastewater
74
Altivar 61/71 MCC Drive Offering

Single Family Product Line
1-500 HP, 480 volt
1-50 HP, 240 volt
Compact, General Purpose Pkg
UL 845 Listed, 100K Amp Fault rating
NEMA 1, 1A, 12, and 3R (up to 40 HP)
75
AC Drives Products
Altivar 21
Range:
208/230V 1-40hp
460V
1-100hp
Applications
Centrifugal Pumps
Fans
Target Market
OEMs
Altivar 61
Range:
208/230V 1-125hp
460V
1-900hp
600V
1-900hp
Applications
Centrifugal Pumps
Fans
Target Market:
OEMs
System Integrators
76
T hank you
77
Make the most

of Your EnergySM
78

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Go Green with AC

Identify Energy Savings

Make the most of your energy

Copyright 2008 Schneider Electric. All rights reserved

Go Green with AC Drives

II. Description AC Drives

Copyright 2008 Schneider Electric. All rights reserved

Energy Savings Opportunities

Copyright 2008 Schneider Electric. All rights reserved

$75.00 dollars per barrel

Energy Savings Opportunities

Source: U.S. Department of Energy

Where are the savings ?

Data centers &

Average facility can

Power & cooling can

Renovation can yield

EE products may save

z 25% savings would

z Power & cooling systems

z Consume 20% of total

z Motors, account for

z Saving energy improves

z 3 key areas: HVAC,

z Lighting & appliances over

Copyright 2008 Schneider Electric. All rights reserved

Energy Savings Opportunities

U.S. Green Building Council

consumed for buildings

Source: US Green Building Council

Energy Savings Opportunities

Energy Bill Legislation

Copyright 2008 Schneider Electric. All rights reserved

Energy Savings Opportunities

International Facility Management Association

Copyright 2008 Schneider Electric. All rights reserved

Source: International Facility Management Association

Energy Savings Opportunities

Energy used in Healthcare Facilities is for

Energy for hospital HVAC systems

Source: ASHRAE Winter Meeting 2008

Best Practice HVAC Systems-Healthcare

Energy Savings Opportunities

15 Steps to a More Sustainable Hospital

VFDs have the potential to save energy even on smaller motors.

Author: Steven Furgeson, PE

Energy Savings Opportunities

Copyright 2008 Schneider Electric. All rights reserved

Energy Savings Opportunities

Today, variable speed drives are

Copyright 2008 Schneider Electric. All rights reserved

Go Green with AC Drives

II. Description AC Drives

Copyright 2008 Schneider Electric. All rights reserved

Typical Drive System

Copyright 2008 Schneider Electric. All rights reserved

Copyright 2008 Schneider Electric. All rights reserved

Six Pulse AC to DC Converter

Converter uses solid state devices to change AC to DC

Copyright 2008 Schneider Electric. All rights reserved

Six Pulse AC to DC Converter

Converter uses solid state devices to change AC to DC

Copyright 2008 Schneider Electric. All rights reserved

Copyright 2008 Schneider Electric. All rights reserved