7resr022 VFO for Centitugal Cher Home » Applications» VEO for Centfugel Chiller VED for Centrifugal Chiller ‘VED techrology isnot new o the HVAC industry. Variable frequency drives have eon used extensively for air handling unt fans, cooling tower fans and water pumps fora lang ime. With state-of the-art compressor ‘twohnology and microprocessor based contol systems, manufacturers now offer variable Frequency aves. specialy designed for contfugal cher. Introduction ‘Applicaton of variable frequency srives to cenutugel chiles requires @ contol strategy that understands conta chiller and UFO operations, With advanced miroprocessor convo technology, the nigra of ‘atabl requoncy drvesin tho spocaloffcont offerings fs but a natural stp, Typical ARI condtions are {44154°F chill water and 85 95°F condenser watr temperatures. ARI also species Integrated Par Load ‘Values IPLV) we take info consideration the part load capactyopsration ofthe cantiugal hls with varying entering condonser water tomperatwas. Ona such standard used or contiuga chills is AR ‘Standard 550/590-98,Athough, his standard provides a commonly used formula to caleulale th operating costs forthe coninfugalchilor during ts fe span, th operating characteristics may nat be realistic for every applcaton paricularly for South East Asian counties (his standard allows 65°F minimum entering condenser water temperature) Energy Savings with variable frequency drive How does variable requency ve save energy? Controling two mechanics saves energy - impeller tp speed and inet guide vanes Impeller Tip Spoed ‘A centrfuga compresscr performance rales onthe impli design tip speed, which isthe tangential velocity the reigerant at he edge ofthe impeller wheel when ItTeaves the mpl (Fgue 1), tnerease the rofigerant pressure between evaporator and condenser. Ths pressure diference created betweon the ‘ovaporatorané condensers called Tit or te read (Figure 2} thatthe compressor must create to move the refigerantthyough As cycle. The head depends on many parameters such as chiled water and condenser ater temperatures and also the fulng factors, Impeller speed ' recy proporionsl othe head cated Obviously, greater te head, higher the energy input and hence higher impeller speeds. Howover, the head conditions may change witha change in fad par and ouside ambiontconions (reduced cononsor ‘water tripraturs), Constant speed VFD in tis case wil over-accelerate the reigarant ast eaves the impote, resuting na waste of input energy. Varabl frequency drives reduce the compressor speed a8 te head crops and move the compressor ino higher efceney region inthe comprossor map, often allowing the comprassor to oporato mor efcienty than a he fl load contin. wn. orgiv-fr-cantfugal-chiler-367780.himl Go Category Single Phase to Tivoe Prase VFO we Case study Vr Marke, “Troubleshooting Featured Articles arable roquscy dive aplication ss sete Vanaole Freqeaney Orve (VFO) ean be used nos ede, Varia requeney 27 eves ara widely use to {EHF onl pect of VED manufactures Rroweawas.org Riechas.rg Ww782022 VFO for Centitugal Cher — tnt guide vanes i Speed _- Evaporator Figure 1 : Centrifugal chiller components Pressure Lift/Head Compressor Evaporator enthalpy Figure 2 : Pressure vs Enthalpy diagram Inet Gut Ina fixed speed centfugal chill, inlet guide vanes are used to thot refigerant atthe ink ofthe compressor to var the compressor capacity. Whan the guide vanes move fom fully open to slighty close, compressor efeiancy can actually improve because the guide vanes prswt the refrigerant entering the impale. As tha vanes continue to cles, however, the vane acion quickly become a resco, lasing the pr-rotation eft and reducing the compressor capacty and effieney. Variable frequency dive slows the campressor to match the head condiions, without closing the guide vanes, Vanes wn. orgiv-fr-cantfugal-chiler-367780.himl an782022 VFO for Centitugal Cher Efficiency Islands Head tay Surge ZS CREE ee Es i _~ Speed Lines Flow(load) Figure 3: Centrifugal compressor map Keoping the Inet guide vanes open improves the compressor operating efiency, The elasle way to oxpin vatable frequency drei o relate fan laws tothe centugal compressor, + RPM~ CFM + RPM2~ STATIC HEAD + RPMG~ HP “Thoreor, every single unit crop in RPM wil reduce the HP ofthe motor by the cube reot Hence, the compressor Input HP drops to 73% at 90% and 42% at 75% leads respectvely, Having both inet guide vanes and speed cont allows more lexbiy tothe cennfuga chiller operation and ives the ability o keep the compressor within the best operaling range on the compressor map (Figure 3) Compressor Design Advantage (Open type compressors have an added advantage wth variable frequency drive as lower ECWT (Entering Condenser Water Tomperature) operation fs possible as compared to somi hermetic designs. Multstage compressors have the dod complexity of maintaining the approprate interstage pressure, usally through operation of ane or more sets of inet guide vanes. The indvdual impellers are matched, based on the design operating speed of the impor. Varying the speed wil upset this balance and th will peraise the performance ofthe compress. How does variable frequency drive work? “The variable frequency drive needs alt of formation o work. Varabl frequency drive has to continuously ‘monitor soveral operating conditions such as hiled water temperature, chiled water setpoint, eigerant pressures, pretation vane postion and the actual motor speed (figure 4). This information ston fed to 8 ricroprocessor hat determines the most effciant way to operate. It opsmises beth mator speed and the pro- rotation vane postion and changes the frequency othe power input othe motrin order to consume the luast amount of onoray wn. orgiv-fr-cantfugal-chiler-367780.himl air782022 VFO for Centitugal Cher Figure 4: How does VSD work? Electric Savings by VFO To calculate the operating cost of a cantugalchler during the ful year, al he operating conitons euch as condenser water temperatures as well as cooling load shouldbe considered, One can simulate a computor ‘modelto compars the operating costs. A 5 Star hotel was considered in China for @ A50TR central chiler wth and without the varableftaqueney dive. Reale centugalchiler running eondtons based on China ‘woathor data was considered forthe compatison. Since this entrfuglehiler was on of te two inthe plant room, we chose ths cntfugal chloro modulate to take care of the pat loads, Also the cooing towor ‘water temperature was allowed o drop according tothe weather data as well as het rection rom the centifgal chiles. The capacty and te number of hous of operation were considered at 10% capacty inervals wih varying entering condenser wate: tomperatures (Table 9) Table 1: Variable Fequency drive Operating kWh comparison food ecwr Mat sevens aes ane i) monn toon ata foo st tou azason rasa 250 a2 aod eosns nutes a8 moe Ter sezua | at03 2 eos orats 7000028 m0 tarsas sours aas2 15) 6a Toueas seat aes Tota esr ——nazsors——anease | —_s97675 ‘Alt Is forthe conitugalcller wth constant speed and 2 fr te variable fequency eve entttugal chiller. Comparing the costs over the year gives a saving of 187,675 Ki units wih the variable Frequency tive. Taking olctcty tari as $5 par kivh this equates to annual savings of $0.94 Millon. Th total savings willbe even higher demand tart costs are considered (ther Bonofits of Variable froquency dive on Centrifugal Chillor Soft Start ‘itn a vanble quency tive, power italy applied fr start-up ata very low frequency, which when sada increas, allows ite motor sp. The res a high torque per amp of eutont minimising the fexra amps requced lo start the moor. Therefore, tne inush amps for viable frequency drive never fexoseds the 100% FLA ofthe motor thar sof starters auch as Star Data or Sod Stata tartare have 200- 400% FLA asthe Invush amps atthe start-up (Figure 8). This makes variable requency dean Idea starter paricuat for applications wit nites ivush capabilities such as emergency generator systems, Also the {generators and cabling can be down sized, a they do at have to incorporate extra capacity required forthe startup wn. orgiv-fr-cantfugal-chiler-367780.himl a782022 VFO for Centeugal Chiller = ac oe pa Figure 5 : Starting characteristics of VSD Enhanced Unloading Capacity -Aasiton of varable frequency crve enances the unloading capably of a centifuglchilerby varying the pase part closing he gude vanes, This allows beter tracking olow load conatans, This algo eliminates unnecessary cyelng ofthe cantrugalenilar resulting in reduced maintenance and better contra ofthe ehllas water loop. Smoot starts enhance the motor and compressor I Quit Operation Most a the noise generated by the contifugal compressor is due tothe refrigerant cscharged at high veloc into the condenser Slowing down the compressor reduces the discharge velocty allow heads and hence reduces noise. Power Factor Correction ‘Variable frequency ave gives automatic power actor coraction to at last 85% a all operating condlons. A rnoemal centrifugal chill orscrow chiller has pow factor of 0.85 al 100% lead which further reduces at part load and can go down to 8s lw as 0.60 Many utes require corection, or impose facial penalties ‘when operating wt lower power factors, Factory installed or Fold Retrofit for Existing Installation ‘Most centrifugal chilers wth variable Fequency drive option wil have factory installed variable frequency ‘ve, saving ined installation costs (gure 6). ela rtroft variable frequency deve can ether be insaled an the entnfuga hile or nea” the unin place ofthe state. Fig 0 Fairy Hed VSD on Coma Chir “The Best Resl World Performance In thereat wold, energy performance at rel world condlions has ite todo with botlom tne energy costs ‘what happens al off design conditions is much mor important. Even witha relatively warm tomperature in Cina, VED energy savings of $0.94 Willon were possible when compared toa fixed speed av or even for ‘hat matter any postive displacement compressor ikea screw chil. This makes an excellent appartuny to attain quick payback and return onthe VFO investment, parteutay fr facies operating continuously such as oles, hospital, call contrs, software center an facores. \VFD on centifugl chiles is being used by mos ofthe major centrfugal suppliers as new equipment wn. orgiv-fr-cantfugal-chiler-367780.himl sn782022 VFO for Centeugal Chiller offering ortroft option. Considering the aver increasing cost of elec Ce a wiser choice 10 opt for nergy saving options tke VED on conttugal chiles. (Cen we ad VED to any existing ear? Please oars deta ne ring SSWUN777 Whores tat? 0.05 1a 0 281k maybe. Savings wi never be close a $M ona VED fra chiller. Howover, the remaining fhe exolanaton seams to make sense and is wall explained Thanks <-> by Mle Post a Comment: (Name* ] (Website (otion) | ED ccrconment wt show ater soerovea) ‘You may also uke: Understanding VED circuit ronal te captctorta ase fal charge domly 0 Probloms caused by Variable requoncy cives ‘sy boe ith ve of VED, Those WEDS can be vse tran plat AC ‘Whats Safe Torque OM in Variable roquoncy ais? Safe Tome OF (STO) nametroh rae Faquancy sv (VFO) abla wih crn or votage garg othe ‘vector VED VED fre pump controllers wn. orgiv-fr-cantfugal-chiler-367780.himl er7resr022 VFO for Centeugal Chiller wn. orgiv-fr-cantfugal-chiler-367780.himl m7