Energy Efficiency

Adjustable Speed Motor Drives

Description: Most
motors turn at nearly
constant speed. How-
ever, much of the time
the devices they drive
may operate at less than
maximum design speed.
This speed reduction can be
accommodated by an
Adjustable Speed Drive
(ASD) that varies the shaft speed to the driven load. Slowing a pump or
fan in this manner reduces energy consumption much more effectively
than allowing the motor to run at constant speed and then restricting or
bypassing the flow with a valve or damper.
In addition to providing speed control, ASDs provide soft starting, whereby a
motor starts slowly and then speeds up. This reduces the mechanical stress
on both the motor and equipment driven by the motor. This also reduces the
voltage sag that can occur when a large motor starts quickly. Voltage sags can
dim lights and cause other equipment to shut down or restart.
The newest and most efficient adjustable speed drive is the variable frequency
drive (VFD), sometimes called a variable speed drive. A VFD consists of an
electronic power converter that converts constant frequency AC (alternating
current) power input into a variable frequency output. The AC motor speed
varies in proportion to the drive output frequency.
Applications: The most common applications of ASDs are for pumps and fans—
to balance flows and meet changing system needs. For example, ASDs can be very
cost-effective in retrofit or new construction of HVAC systems. Many HVAC sys-
tems were designed with constant flow pumps and fans that are throttled to meet
changing operating conditions.
ASDs are also useful for loads such as elevators, water and wastewater pumps, boiler
fans, cooling towers, cranes and conveyors. The speed range, required precision of
speed control, and required torque at lower speeds dictate the type of ASD needed.
Performance/Costs: Savings from ASDs come from reduced load of the fan, pump, or
driven device. With fans and pumps, power consumed is proportional to the cube root
of shaft speed. If shaft speed is reduced by 10%, flow is reduced by 10%, while power
consumption is reduced by 27%. If speed is reduced by 20%, power is reduced by 49%.
Adjustable Speed Motor Drives Factsheet

Compared to throttling as a means of flow control, speed reduction provides dramatic energy
savings. Throttling to reduce flow in a fan or pump backs the device up on its operating curve,
increasing pressure and often increasing power consumption.
The following graphs of a typical circulating pump (75% efficient) demonstrate the difference in
energy use between throttling and ASD to reduce flow by 33%. The operating point for peak condi-
tions is at the intersection of the pump curve and the system head curve (925 gpm at 42-foot head)
and draws about 13 horsepower. Reducing flow through throttling to 600 gpm requires the pump
to produce about 45 feet of head, drawing about 9 horsepower. Reducing speed with ASD reduces
the head to less than 20 feet and draws less than 5 horsepower. This results in almost 70% reduc-
tion in power consumed.
Basic ASDs cost about the same as the motors they drive, but they are highly dependent upon
features and application requirements. Costs for basic variable torque drives start at around $520
per horsepower for a one HP drive and drop sharply to around $160 per horsepower for a 10 horse-
power drive. Costs level off more slowly after that with 40 horsepower drives at about $100, and
500 horsepower drives down to about $70. Installation costs, electrical filters and special features
for constant torque, special controls, or diagnostics can easily more than double the costs.
Availability: Electronic VFDs are readily available. There are many manufacturers producing units
ranging from integral to hundreds of horsepower. DC drives are available from most major motor
manufacturers.

For Additional Information:

Energy Star Purchasing Initiative
Contains purchasing and efficiency information for electric motors
http://www.epa.gov/appdstar/purchasing/non_res_equipment/electric_motors.htm
ASDMaster software
A description and ordering information for the software on U.S. DOE’s Industries of the Future
BestPractices website (scroll down to the ASDMaster entry under Software).
http://www.oit.doe.gov/bestpractices/just_need/motors.shtml
Motors—U.S. Department of Energy Industries of the Future BestPractices
This website contains tip sheets, case studies, and technical reports on motors and drives efficiency
practices.
http://www.oit.doe.gov/bestpractices/just_need/motors.shtml

2
Adjustable Speed Motor Drives Factsheet
Variable Frequency Drives
FEMP Greening Federal Facilities, section 3.3.2 http://www.eren.doe.gov/femp/greenfed/3.0/
3_3_2_var_frequency_drives.htm
The Drive for Energy Efficiency: Variable speed drives can help facilities maximize HVAC opera-
tions
From Maintenance Solutions, June 1996 http://www.facilitiesnet.com/fn/NS/NS3mg6e.html
©Washington State University

© 2003 Washington State University Cooperative

Extension Energy Program. This publication
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Washington State University Cooperative Extension
Energy Program. WSUCEEP00-129