VARIABLE SPEED COMPRESSOR TECHNOLOGY AND APPLICATIONS

Jay Eldridge
Business Development Manager – Applied Air Systems
Spring 2016
AGENDA

• Why Variable Speed

• Enabling Technologies - Variable Speed
Motors
• VRV/VRF Systems
• Rooftop Products
• Magnetic Bearing Chiller Technology

2
WHY VARIABLE SPEED

• Energy Savings
• BHP at Fan
• BHP at Pump
• BHP at Compressor
• Meet or exceed ever more challenging energy
codes
• LEED
• Sustainable
• Acoustics

3
FULL RANGE ENERGY PERFORMANCE
• Full range performance is almost always far more important than
full load performance
• Best designs take into account reduced load and reduced
condensing pressure (dry bulb or wet bulb relief) on refrigeration
systems
• Emerging technologies include;
– Full range compressors
– Permanent magnet synchronous motors
– Magnetic bearings
– Integrated controls
Full Range Full Load

Vs.

4
NEW TECHNOLOGY

• Motors: ECM, Reluctance DC, PMSM

• Inverter Scroll Compressor
• High Speed VFD with PMSM

5
BETTER THAN PREMIUM EFFICIENCY

93
92
91
90
Efficiency

89
88 NEMA
87 ECM
86
85
84
2 3 5 7.5
Motor HP

6
RELUCTANCE DIGITALLY COMMUTATED
ADVANTAGES OF THE RELUCTANCE DC MOTOR

 Rotating stator field

 Electrical field is in the stator
not the rotor; no need for
brushes Curved
 Based on the principles of a Iron

direct current motor

 Uses neodymium magnets Neodymium
 Benefits from an additional Magnet

reluctance torque when

loaded
 Extreme high performance in low and medium RPM

7
DC COMPRESSOR MOTOR TECHNOLOGY

 Digitally Commutated (DC) Motor

 The rotor uses neodymium magnets – 7 times the
magnetism of a common magnet
 Increased power with decreased electrical requirement

8
COMPRESSOR MOTOR TECHNOLOGY
100
95 18 %
90 30%
Efficiency (%)

85
80 Induction
Motor
75
70 Daikin Inverter
Motor
65
60
1800 3600 5400
RPM 

Core
N

S
Rare Earth
Interior S N N S
Magnet
Permanent S
Magnetic N

9
PMSM MOTOR TECHNOLOGY

PMSM Motor
90

SPM Motor
Efficiency

80
Induction Motor
（%）

70

60
Speed
（rpm）
0 1800 3600 5400 7200

Core
N
S
Rare Earth
S N N S Magnet
Ferrite S
Magnet N

Surface Permanent Magnetic Interior Permanent Magnetic

10

10
TRADITIONAL NON-INVERTER SYSTEM
CONTROLS TEMPERATURE WITH ON-OFF OPERATION AND
MINIMAL CAPACITY CONTROL
+V • 60 Hz AC input power
drives the compressor
T(sec) • The compressor must
operate at full RPM
under all load conditions
-V • Very limited efficiency
Frequency (Hz)
under part load
conditions

11
INVERTER DRIVE SYSTEM
+V
• The inverter control converts the
incoming ac voltage to dc voltage
• The inverter then smooths the sine
T(sec) wave to insure smooth motor rotation
• Reconverts dc to 3 phase ac voltage to
the compressor
• Vary the frequency applied to the
-V
Frequency (Hz) compressor motor to modulate the
rotational speed which increases or
decreases system capacity
Inverter
+V Circuit

T(sec)

-V
Frequency (Hz)

12
INVERTER TECHNOLOGY
+V

T(sec)

-V
Frequency (Hz)

+V

T(sec)

-V
Frequency (Hz)

13
COMFORTABLE COOLING OPERATION

Temp.

Set temp.
Time.

Inverter Non-Inverter: Inverter:

Cools a Large Small
room quickly temp.difference temp.difference

14
WHAT’S OUT THERE? COMPRESSOR OVERVIEW

Fixed scroll
• On/Off
Control Two stage scroll
• 2 thru 6 tons

Digital scroll VCC Variable Speed IPM

• 3 thru 15 tons • Variable Speed
• Load/unload Interior Permanent
20sec time step Magnet Motor

15
2 STAGE SCROLL
Unloads to about 67%
Fixed Scroll Sub-Assembly

Modulation Ring
And
By Pass Seals

Solenoid
Coil Locating & Hold
Assembly Down Pins

16
DIGITAL SCROLL

• Operates as loaded or unloaded

• Compressor pulses between
conditions
–100% loaded and 0% loaded

Unloaded Operation
Loaded Operation

17
HOW DIGITAL SCROLLS WORK

• Digital sounds better than “OFF/ON”
• 15‐20 second cycle times
• Compressor pulses between conditions
• 100% loaded and 0% loaded
• Head pressure rises quickly when compressor is ON

18
INVERTER SCROLL PERFORMANCE

• 60% savings @ 50% load

100%
90% Digital
% Compressor Power

80% Scroll
70% Variable
DPS
60% Speed
50%
40%
30%
20%
10%
0%
25%

35%

45%

55%

65%

75%

85%

% Cooling Capacity 95%

19
 VFD COMPRESSOR AND EFFICIENCY

• VFD compressors take

advantage of low lift
• Far better efficiency at
part load
• Minimize temp swings
• More efficiency gain
with fewer compressors
• One is biggest gain
• Two is a little less
• Four is still less
• Lots of low load hours Source: 50% Advanced Energy Design Guide, K-12,
ASHRAE

give best payback

20 20
INVERTER BENEFITS

• Capacity control
• Very low startup amperage
• Quiet compressor startup
• No compressor locked rotor amps
Capacity is adjusted as the load changes to
• Less stress on windings maximize temperature control
• Longer run cycles
• Better dehumidification in cooling
• Fewer start/stop cycles
• System pressures increase gradually reducing noise and stress on piping
• As room temperature nears set point,
capacity is automatically “throttled down”

21
 ADDITIONAL INVERTER BENEFITS

Electronic control of compressor speed for comfort and energy savings

– System capacity modulates up and down
• Capacity matches load conditions as they change
• Very high comfort levels
– High quality heating performance
• Compressor increases speed during cold outdoor ambient conditions
• Generates higher head pressure, which increases hot gas temperatures and discharge air
temperatures
• Produces approximately 20% more heat than a standard non-inverter compressor system
– Significant increased energy savings during part-load conditions
Heat & Cool loads change
• During a 12 month period, 75% of the total HVAC run time hours is at less than 70% of full
load. (Energy Star building simulation)
• Energy efficiency can increase from 40% to 60% during part-load
conditions with Inverter driven compressor at low to medium speeds.

22
SYSTEMS - PUTTING IT ALL TOGETHER

–VRF
–RTUs +V

T(sec)
–CHILLERS
-V
Frequency (Hz)

23
VRF: VARIABLE REFRIGERANT FLOW

• Inverter Scroll
• ECM Fan Motor
• Over speed
Inverter

24
24
WHAT IS VRF?

Outdoor Unit
Main features:
– Energy Saving / Inverter technology
– Low Noise Levels
– Individual control / Zoning
Indoor Units
– PPD: tenant billing
– Long refrigerant piping runs
– Wide range of indoor units
– Applied systems w/ 20 year life cycle
– Small installed footprint

25
VRF - OVERVIEW
Water Cooled Air Cooled
Boiler/Tower Outdoor / Indoor
Geothermal

26
VRF HEAT PUMP SYSTEM COMPONENTS

27
VRF HEAT RECOVERY SYSTEM COMPONENTS

28
INCREASE ENERGY SAVINGS DURING HEAT RECOVERY

Heat Pump Indoor temp :

o
67 FWB(Cooling)
o
70 FDB(Heating)
o
Outdoor temp : 95 FWB(Cooling)
o
6 Ton 47 FDB(Heating)
Power input

Heating
Cooling
6 Ton 6.08kW
5.39kW
(22519 btu)

Cooling Cooling Heating Heating

Heat recovery
Power input

Simultaneous Approx.
cooling & heating
4.8kW 58%
Down
12 Ton

Cooling Cooling Heating Heating

29
INVERTER CONTROL
(16 Tons) Multi unit VRF capacity control

100%

Capacity Control
Smooth control

7%
NON
INV NON NON
INV NON
Low
Load
High

30
30
 COMFORTABLE COOLING OPERATION

Temp.

Set temp.
Time
.

Inverter Non-Inverter: Inverter:

Cools a Large Small
room quickly temp.difference temp.difference

31
31
VRF PERFORMANCE
Complete SYSTEM IEER range: 16 ~20!

32
VRF: SUMMARY

FEATURES:
– Inverter Scroll
– ECM Fan Motor
– Over speed VFD

BENEFITS:
– Great SYSTEM efficiency
– Space comfort
– Flexibility
– Low sound

33
33
SMALL RTUS CAN BE AN APPLIED PRODUCT

• Constant or variable air flow

• Single Zone VAV
• Cooling only
• Cooling with heating
– Nat. gas, electric, hot water
• Heat pump
• Heat pump with auxiliary heating
• 100% outdoor air

34
 RTU VS VARIABLE SPEED CHILLER PLANTS

Chillers have used VFD for quite a while…

All variable speed components in a central plant

Why? For the Lowest Total System Energy

Now we have the same type of performance for RTUs
35
EER EQUIVALENT

kW/ton 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2

(I)EER 24 20 17 15 13 12 11 10

Variable speed RTU IEER range

++ Rooftop IEER includes all energy covered by chiller plant, plus..
• Supply fan energy (Coils, filters, etc)
• 0.75” Distribution static
Rooftops have much lower installed costs

36
APPLICATIONS FOR VARIABLE SPEED RTUS

• Better temp control • DOAS / 100% outside air

– Cooling • High efficiency RTU
– Heating – LEED
– Humidity – Stretch standards
• Dehumidification • Small space / tight control
– Recovered energy reheat • Sound sensitive RTU jobs
good for 90.1
• Medical
• Less cycling
– Medical office buildings
• Much quieter – Stand alone urgent care
• Applied options • Labs
– Built to order
• Process / manufacturing
– Customizable

37
ADVANTAGES OF INVERTER CONTROL TECHNOLOGY

38
TEMPERATURE CONTROL

• Fully modulating Single Zone VAV (SZVAV)

• Variable speed compressor controls air temperature
• Fan varies speed to match the load
120
110
100
Temperature

90
80
Discharge Air
70
60 Outdoor Air
50 Return Air
40

Time

Actual performance: Convenience store, Dallas TX

39 39
CYCLING EFFECTS

• Reduces latent removal

• Re-evaporates coil
moisture
• As cycling increases,
latent cooling goes to
zero
• As humidity goes up,
cycling is more
important

40 40
 HOW DIGITAL SCROLLS WORK (VARIABLE CAPACITY)

• Digital sounds better than “OFF/ON”

• 15-20 second cycle times
• Compressor pulses between conditions
- 100% loaded and 0% loaded
- Head pressure rises quickly when compressor is ON

41 41
LEAVING AIR CONTROL – VARIABLE SPEED VS DIGITAL

OA temp

Room
Lvg Air

kW Power

2013- Northwest Energy Efficiency Alliance; NBI: Report #E13-269: Variable Rate Rooftop Unit Test

• VFD vs digital scroll compressor (1 min increments)

• VFD gives lower kW, stable leaving air temp
• 57-75 LAT = 2.7 lbs/min water difference for 4000 CFM
42
DEFINING SINGLE ZONE VAV (SZVAV)
• What is Single Zone VAV (SZVAV)
– Fan speed controlled by zone temp vs VAV box pressure
– Compressor controlled by leaving air temp

• Minimum for requirements for SZVAV in 90.1?

– DX: 2-Stg supply fan, Min speed<66% and < 40% fan kW
– Chilled Water & other: Min capacity <50% and < 30% fan kW
– Hot gas bypass not allowed above min loading (66% for RTU)

• Fully modulating SZVAV will perform better

– Fan energy savings (2 speed vs VFD)
– Compressor savings (stepped vs VFD)
– Tighter control

43 43
ENERGY PLUS MODEL

› Energy Plus has a variable speed DX coils

— Up to 10 speed curves vs ambient
— Big savings at lower loads
› Building models by Pacific Northwest Natl. Labs

› Examples for Rochester

— 7000 ft2 retail space
– Lights = 8 W/ft2, 62.1 ventilation
— 15 ton RTU vs 90.1 baseline
— Rigid schedules

44
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09/08 04:00:00
09/08 06:00:00
09/08 08:00:00
09/08 10:00:00
09/08 12:00:00
09/08 14:00:00
09/08 16:00:00
ENERGYPLUS

09/08 18:00:00
09/08 20:00:00
09/08 22:00:00
09/08 24:00:00
09/09 02:00:00
09/09 04:00:00
09/09 06:00:00
09/09 08:00:00
09/09 10:00:00
09/09 12:00:00
09/09 14:00:00
Outdoor Air Temp (F)

09/09 16:00:00
09/09 18:00:00
09/09 20:00:00
09/09 22:00:00
09/09 24:00:00
09/10 02:00:00
09/10 04:00:00

45
09/10 06:00:00
09/10 08:00:00
Variable Speed

09/10 10:00:00
09/10 12:00:00
09/10 14:00:00
09/10 16:00:00
09/10 18:00:00
09/10 20:00:00
09/10 22:00:00
09/10 24:00:00
Single Stage

09/11 02:00:00
09/11 04:00:00
09/11 06:00:00
Compressor Energy (kW) - September, Rochester, NY

09/11 08:00:00
09/11 10:00:00
09/11 12:00:00
09/11 14:00:00
Two Stage

09/11 16:00:00
09/11 18:00:00
09/11 20:00:00
09/11 22:00:00
09/11 24:00:00
09/12 02:00:00
40
45
50
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60
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75
80
85
90
ENERGYPLUS
Compressor Energy (kW) - July Day in Rochester, NY

16

Variable Speed Two Stage

14

12

10

kW
8

0
8:00:00 10:00:00 12:00:00 14:00:00 16:00:00 18:00:00 20:00:00

46
 0
2
4
6
8
10
12
14
16
18

07/15 01:00:00
07/15 06:00:00
07/15 11:00:00
ENERGYPLUS

07/15 16:00:00
07/15 21:00:00
07/16 02:00:00
07/16 07:00:00
07/16 12:00:00
07/16 17:00:00
07/16 22:00:00
07/17 03:00:00
07/17 08:00:00
07/17 13:00:00
07/17 18:00:00
07/17 23:00:00
07/18 04:00:00
07/18 09:00:00

47
07/18 14:00:00
Variable Speed Compressor

07/18 19:00:00
07/18 24:00:00
07/19 05:00:00
07/19 10:00:00
07/19 15:00:00
07/19 20:00:00
07/20 01:00:00
07/20 06:00:00
07/20 11:00:00
07/20 16:00:00
Two Stage Compressor

07/20 21:00:00
07/21 02:00:00
07/21 07:00:00
07/21 12:00:00
07/21 17:00:00
07/21 22:00:00
Compressor Energy (kW) - A week July in Rochester, NY
WHAT TO WATCH OUT FOR…

• Size ranges may not be complete

– Offerings from manufacturers may change by capacity
• Consider multiple set points vs stepped changes
• Units are more complex than off/on
– Controls are different than stepped control
– Often integrated compressors & heat with dampers and
fans
– May tie-in to network, BAS, cloud, etc.
– Make sure your technicians are trained
• Variable speed RTUs cost more than stepped RTUs
– Better efficiency and payback
– Tighter air temperature control
– Applied equipment type sequences

48
VARIABLE SPEED RTU COMPRESSOR SUMMARY

1. Increase part load efficiency

2. Reduce operating costs
3. Increase comfort by running the unit longer
4. Reduce re-evaporation
5. Increase unit capacity
6. Remove more moisture to keep DOAS cost down
7. Keep unit operating with the envelope
8. Monitor refrigerant press./temps to take evasive
action

Unit stays on-line

49
CHILLERS

• Permanent Magnet Synchronous

Motor (PMSM)
• High Speed VFD

50
BASIC MAGNETIC BEARING COMPRESSOR DESIGN

High Speed
Permanent Magnet
Synchronous Motor

Impeller Front Rear

Radial Radial Axial
Bearing Bearing Thrust
Bearing

51
 MAGNETIC BEARING COMPRESSOR

Magnetic bearings VFD and controls

and sensors contained in
external panel

Inlet Guide
Vanes

Suction gas

Single Stage
Impeller Permanent magnet
synchronous motor
(refrigerant-cooled)
Discharge Port
52
MOTOR EFFICIENCY
110

Permanent Magnet Synchronous Motor

100
25- 40%
3-5%
Efficiency (%)

90 Efficiency
Gain Induction Motor Efficiency Gain

80

70

60

50
0 10 20 30 40 50 60 70 80 90 100 110
Percentage Speed
53
DRIVE TRAIN COMPARISON – FULL LOAD
High Speed Permanent Traditional Variable
Magnetic Motor Speed Centrifugal
Centrifugal Compressor Compressor
Bearing Windage 1.5% 5.0%
Efficiency
Loss

Motor 2.0% 4.7%

VFD 2.0% 2.4%
Gear -- 1.0%
Resulting
Compressor 94.5% 86.9%
Efficiency

7.6 Point Efficiency Gain!

54
 ENERGY SAVINGS EXAMPLE

900 1.2

800

Fixed Speed ~ $243,287/year 1

700
Cooling Load Profile
600 0.8
Operating Hours

kW / ton
500
0.6
400

Traditional VFD ~ $164,934/year

300 0.4

200
10% energy
reduction High Speed VFD w/ Mag Bearing ~ $131,709/year 0.2
100

0 0
0 10 20 30 40 50 60 70 80 90 100

Chiller Percent Load

55
OIL REDUCES SYSTEM EFFICIENCY

From ASHRAE Research Project 751-RP,

“Experimental Determination of the
Effect of Oil on Heat Transfer with
Refrigerants HCFC-123 and HFC-
134a”,

Conclusions and Recommendations:

“The heat transfer ratio drops steadily

with oil concentration and reaches a
value of 0.65 [from 1.0 normalized] at an
oil concentration of 10%.”
35% heat transfer reduction with 10%
oil concentration in refrigerant

56
IMPACT OF OIL ON SUSTAINABLE PERFORMANCE

Positive pressure, oil-free

design eliminates the
performance degradation
due to non-condensables
and oil contamination of the
refrigerant

Source: The News, 04/15/04, by Jack Sine

57
ADVANTAGES OF VFD AND MAGNETIC BEARING
TECHNOLOGY

• Resistant to Power Line Disturbances

– Rides through voltage drops
– Meets semi conductor industry standard SEMI F47

_____________________________________________

• Regenerative power system keeps bearings powered until

shaft stops spinning
• Rides through short duration power loss

58
CHILLERS: SUMMARY

PRO:
– Part load efficiency
– Oil Free Design
– Low Maintenance

CON:
– First cost typically higher

59
WRAP-UP

• Variable speed compressors have distinct

advantages for temperature control and efficiency

• A number of options are available for size and

configuration

• Modeling programs, studies and other resources are

being developed to estimate actual performance

60
REVIEW QUESTIONS
• What is the difference between a digital scroll and an
inverter scroll compressor?
• What are the advantages of modulating refrigerant
flow?
• What are the limitations of an AC Induction Motor?
• What is more efficient: Surface Permanent Magnetic
Motor or an Interior Permanent Magnetic Motor?
• What type of rare earth magnet is being used in
Interior Permanent Magnetic Motors?
• What are the benefits of removing oil from the system?
• Why are new products designed for full range?

61
THANK YOU.