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M C. 60. D1. 02 - VLT is a registered Danfoss trademark

Why use VSD in existing HVAC installations
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I Introduction.......................................................... 2
Saving energy....................................................... 2
- Controlling capacity to actual need .................... 3
- Examples ............................................................. 5
- Variable speed duty ............................................ 8
- Constant speed duty .......................................... 9
- Reducing maximum kW demand ....................... 9
- Removing unneccessary energy loss caused
by vanes and valves ......................................... 10
Reduction in mechanical wear and tear ......... 10
Increasing comfort level.................................... 10
- Controlling comfort & reducing fan and pump
noise .................................................................. 11
Calculation of pay back time............................ 12
Conclusion.......................................................... 13
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
Why use VSD in existing HVAC installations
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C ontrolling comfort: C ontrolling comfort: C ontrolling comfort: C ontrolling comfort: C ontrolling comfort:
When using a VSD, accurate temperature and pres-
sure control can be maintained.
C alculation of pay back time: C alculation of pay back time: C alculation of pay back time: C alculation of pay back time: C alculation of pay back time:
The energy savings will ensure a short pay back time
of the investment in VSDs. Typically 1-2 years.
Regarding Singapore (M arch 1996): Regarding Singapore (M arch 1996): Regarding Singapore (M arch 1996): Regarding Singapore (M arch 1996): Regarding Singapore (M arch 1996):
The Singaporean government has introduced a
writing off scheme for equipment used for energy
saving purposes, via the taxes. This will make it even
more attractive to invest in energy saving equipment.
T TT TTypical advantageous applications: ypical advantageous applications: ypical advantageous applications: ypical advantageous applications: ypical advantageous applications:
Experience shows that the payback time for the
following applications is very short:
VAV AHUs (fans and pumps)
Secondary chilled water pumps
Constant pressure ventilation fans
Condenser fans
Saving energy
Save energy and reduce costs by:
1. Controlling the HVAC systems capacity to match
the actual need.
2. Reducing maximum kW demand of the building.
3. Removing unnecessary energy loss caused by
vanes and valves.
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Introduction
Saving energy: Saving energy: Saving energy: Saving energy: Saving energy:
Energy savings can be obtained by reducing the
speed of some of the most energy consuming instal-
lations in buildings: pumps and fans, used in HVAC
applications.
Pumps and fans in old, existing HVAC installations,
normally run at full speed all the time.
Adjustment to actual flow or pressure demands is
usually performed by valves, dampers or guide vanes.
This is not energy efficient.
When using a VSD to control the speed of a pump or
fan, considerable energy savings can be gained.
Reduction of mechanical wear and tear: Reduction of mechanical wear and tear: Reduction of mechanical wear and tear: Reduction of mechanical wear and tear: Reduction of mechanical wear and tear:
Besides the energy savings, fitting VSDs on fans and
pumps will reduce the wear of belts, bearings and
valves, reducing the overall maintenance costs.
Increasing comfort level: Increasing comfort level: Increasing comfort level: Increasing comfort level: Increasing comfort level:
By reducing the speed of a centrifugal fan or pump,
the acoustic noise level as well as the draught from
fan systems are reduced. Water hammer from pump
systems can be totally avoided.
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
Why use VSD in existing HVAC installations
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Energy savings of up to 50% , or even more, is often
possible in a typical installation, but only by using a
VSD.
Fig. 1, on this page, shows the typical power con-
sumption of valve control and VSD control.
Energy savings according to the actual need, will of
course depend on the variations in need.
O n very warm days, aircon and ventilation systems
will have to run at full speed, but this will only happen
a few days over the year or a few hours a day. The rest
of the year or during off-peak periods every day,
energy will be saved.
Variable air systems using constant speed fans with
dampers or guide vanes controlling the airflow,
consume a lot of energy by constantly running the
motor at full speed.
Pumping circuits, e.g. chillers, running at constant
speed waste chilled water by using by-pass loops,
returning the excess chilled water not used by the in-
stallation.
Energy is wasted both in pump motors and in
unnecessarily cooled water.
In comparison to power consumption in constant
speed systems, power consumption in variable speed
systems using VSD, can be calculated according to
the actual need (P = n
3
):
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Valve
control
Controlling capacity to actual need
Centrifugal pumps and fans run according to a Varia-
ble Torque characteristic. Changing the speed of a
pump or fan will change the torque demand by the
square of the speed (n): T = f (n
2
).
By changing the speed to 80% of the nominal value,
the torque demand will thus only be about 64% of the
nominal value.
The power consumption, however, of a pump or fan
motor is according to a cube law, P = f (n
3
).
This means that by reducing the speed to 80% of the
maximum value, the power consumption will be
reduced to about 50% of nominal value.
E.g.: At 80% speed the power consumption is
= 0. 8
3
= 0. 512 = 51. 2%
Fig. 1 Fig. 1 Fig. 1 Fig. 1 Fig. 1
Area of
saved energy
100 %
52 %
Valve
control
% Power
% Power
80% 100%
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
Why use VSD in existing HVAC installations
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How many hours at a speed (i. e. flow requirement) of:
100% = Power consumed 100%
90% = 72.9%
80% = 51.2%
70% = 34.3%
60% = 21.6%
50% = 12.5%
M ultiplying the number of hours (h) running at the
various speeds by the associated amount of power
(kW), and adding the values, will show the total
energy consumption (kWh) per year for the actual mo-
tor driven by a VSD.
Fig. 2, below, shows a typical capacity characteristic
of a pump as well as the associated motor shaft out-
put in kW. Practical figures may vary with different
pump designs.
Fig. 2 Fig. 2 Fig. 2 Fig. 2 Fig. 2 Pump characteristics:
Compared to constant speed operation, the diffe-
rence from the above mentioned variable speed
calculations, represents the savings in energy.
By repeating this calculation for other pump and fan
systems, within a building, the total energy saving of
the whole building can be calculated.
Two theoretical examples based on general
experience as well as one practical example, all
showing the necessary calculations, are given on the
following pages.
Valve regulation follows A
1
to B
1
curve.
By speed regulation it is possible to utilize the pumps
characteristic. Thereby power consumption follows
the dotted curve from A
1
to C
1
.
Fig. 2, below, shows a typical capacity characteristic
of a pump as well as the associated motor shaft out-
put in kW. Practical figures may vary with different
pump designs.
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
Why use VSD in existing HVAC installations
a) a) a) a) a) Energy cost at constant speed: Energy cost at constant speed: Energy cost at constant speed: Energy cost at constant speed: Energy cost at constant speed:
Energy consumption per week: 15 kW x 66h = 990 kWh
Electricity rate is US$ 0. 10 / kWh.
Energy cost per year: 990 kWh x US$ 0. 10 x 52 = US$ 5, 148
b) b) b) b) b) Energy cost at variable speed: Energy cost at variable speed: Energy cost at variable speed: Energy cost at variable speed: Energy cost at variable speed:
Assume average speed is 75%
corresponding to 42% power
consumption.
Energy consumption per week: 42% of 15 kW x 66h = 416 kWh
Energy cost per year: 416 kWh x US$ 0. 10 x 52 = US$ 2, 163
c) c) c) c) c) Value of energy saved by using variable speed: Value of energy saved by using variable speed: Value of energy saved by using variable speed: Value of energy saved by using variable speed: Value of energy saved by using variable speed:
US$ 5, 148 - US$ 2, 163 = US$ 2, 985
e) e) e) e) e) Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures):
VSD price :
Transmitter for closed loop operation
(e. g. 1 pressure transmitter) : US$ 300
Labour hours for mounting of drive and transmitter ( 4 h) : US$ 200
Installation of drive and transmitter (20 m of ctrl. cable) and
test run of application : US$ 100
Total installation cost : US$ 4, 300
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(Calculations on pay back time for all three examples
will be shown at the end of part 1).
Example 1
A 15 kW AHU operating for 12 hours during week
days and 6 hours during week-end.
In total 66 hours per week In total 66 hours per week In total 66 hours per week In total 66 hours per week In total 66 hours per week.
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US$ 3, 700
Note: Note: Note: Note: Note:
All calculations are shown in US$, as a neutral
currency. When you convert the figures to your
currency, you will see that the energy savings and
pay-back time are just as favourable.
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
Why use VSD in existing HVAC installations
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Example 2
A 15 kW AHU operating for 24 hours during week
days and week-ends.
In total 24h x 365 days = 8760 hours per year In total 24h x 365 days = 8760 hours per year In total 24h x 365 days = 8760 hours per year In total 24h x 365 days = 8760 hours per year In total 24h x 365 days = 8760 hours per year. .. ..
a) a) a) a) a) Energy cost at constant speed: Energy cost at constant speed: Energy cost at constant speed: Energy cost at constant speed: Energy cost at constant speed:
Energy consumption per year: 15 kW x 8760h = 131, 400 kWh
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Electricity rate is US$ 0. 10 / kWh.
Energy cost per year: 131, 400 kWh x US$ 0. 10 = US$ 13, 140
b) b) b) b) b) Energy cost at variable speed: Energy cost at variable speed: Energy cost at variable speed: Energy cost at variable speed: Energy cost at variable speed:
Assume average speed is 80%
corresponding to 51. 2% power
consumption.
Energy consumption per week: 51. 2% of 15 kW x 8760h = 67, 276 kWh
Energy cost per year: 67, 276 kWh x US$ 0. 10 = US$ 6, 728
c) c) c) c) c) Energy cost saved by using variable speed: Energy cost saved by using variable speed: Energy cost saved by using variable speed: Energy cost saved by using variable speed: Energy cost saved by using variable speed:
US$ 13, 140 - US$ 6, 728 = US$ 6, 412
e) e) e) e) e) Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures): Investment for running variable speed (Approximate figures):
VSD price : US$ 3, 700
Transmitter for closed loop operation
(e. g. 1 pressure transmitter) : US$ 300
Labour hours for mounting of drive and transmitter ( 4 h) : US$ 200
Installation of drive and transmitter (20 m of ctrl. cable) and
test run of application : US$ 100
Total installation cost : US$ 4, 300
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
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Example 3
Shows the design calculations for the Asian M useum
of History, Hong K ong. G iven is the buildings cooling
load curve for a period of 24 hours:
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Fig. 3 Fig. 3 Fig. 3 Fig. 3 Fig. 3
Fig. 4 Fig. 4 Fig. 4 Fig. 4 Fig. 4
Based on fig. 3, a block cooling load profile was
made, giving some expected average fan speed
requirement values in % , using VSDs, to meet the
cooling load:
% is expected fan speed to meet cooling load
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
Why use VSD in existing HVAC installations
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From G ood Practice G uide book no. 2 issued by the
UK Department of Energy, graphs were used to
convert the fan speeds [% ], found in fig. 4, to power
consumption [% ].
Fig. 5 Fig. 5 Fig. 5 Fig. 5 Fig. 5
Fig. 6 Fig. 6 Fig. 6 Fig. 6 Fig. 6
Variable Speed Duty
Based on avg. fan speeds as noted in fig. 4 and the
power consumption (kW) relating from fig. 5, the
energy consumption in the different periods, as well
as the total energy consumption (kWh), for Variable
Speed Duty can be calculated:
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Period Av. Fan Speed % Power Actual Hours kWhs
In period % Power kW R un Used
1 12 5 2 8 16
2 50 18 6 3 18
3 80 50 17 3 51
4 90 70 23 2 46
5 78 48 16 3 48
6 35 10 4 5 20
Per day 24 199
1. VSD
2. G uide vane
3. Damper
4. Hydraulic/Eddy current
coupling
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
Why use VSD in existing HVAC installations
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For the alternative, Constant Speed Duty, calculations
of the energy consumption were also made:
Constant Speed Duty (Average values):
Assume 50% of fan load (16 kW) for 24h = 384 kWh (O ne group of fans constantly running)
Assume 50% of fan load (16 kW) for 12h = 192 kWh (O ne group of fans running day time only)
Energy consumed per day: 576 kWh
Now the energy savings energy savings energy savings energy savings energy savings from running V VV VVariable Speed Duty ariable Speed Duty ariable Speed Duty ariable Speed Duty ariable Speed Duty, as opposed to Constant fan Speed Duty Constant fan Speed Duty Constant fan Speed Duty Constant fan Speed Duty Constant fan Speed Duty,
can be calculated:
Based on running 365 days / year:
Constant Speed Duty 365 x 576 kWh = 210, 240 kWh
Variable Speed Duty 365 x 199 kWh = 72, 625 kWh
Saving = 137, 615 kWh
Savings in energy costs per year: 137, 615 kWh at US$ 0. 1 / kWh = US$ 13, 762 US$ 13, 762 US$ 13, 762 US$ 13, 762 US$ 13, 762
This saving represents a 65% reduction of the energy bill ! This saving represents a 65% reduction of the energy bill ! This saving represents a 65% reduction of the energy bill ! This saving represents a 65% reduction of the energy bill ! This saving represents a 65% reduction of the energy bill !
Total cost of Danfoss VLT

6000 HVAC drives in this case were = US$ 17, 406

Reducing maximum kW demand
When using dedicated types of Variable Speed Drives,
the high starting current of the motors will be avoided,
as these drives include soft starting feature whereby
zero starting current is produced, apart from the
magnetising current. Thereby the maximum
demand current is reduced. This adds to the energy
savings already obtained with the pumps and fans.
Fig. 7, on this page, shows the differences in starting
current for various types of drive systems.
In Singapore M aximum Demand is today charged on
the highest continuous power consumption, lasting at
least half an hour, over a period of one month.
In a retrofit situation existing starters (f.ex Y/-starters)
and power factor correction equipment (PFC
capacitors) can be removed reducing energy-loss and
maintenance relating to these components.
I Fig. 7 Fig. 7 Fig. 7 Fig. 7 Fig. 7
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1 = VLT 6000 HVAC
2 = Star-Delta
3 = Soft Starter
4 = Direct-on-line
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
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I Removing unnecessary energy loss caused by
vanes and valves
Dampers, guide vanes and valves in fan or pump sy-
stems cause a pressure drop across them dependent
on the speed of the air- or water flow passing through.
When retrofitting with VSDs dampers, guide vanes or
valves can just be left fully open, or simply removed .
Using a VSD, reduces or even eliminates the
unnecessary pressure drops and thereby the
unnecessary power consumption caused. This
improves overall efficiency and capacity.
I Reduction in mechanical wear and tear
When a HVAC installation no longer runs at full speed,
additional benefits are provided:
Besides the energy savings, fitting VSD on fans: Besides the energy savings, fitting VSD on fans: Besides the energy savings, fitting VSD on fans: Besides the energy savings, fitting VSD on fans: Besides the energy savings, fitting VSD on fans:
Increases lifetime of belt drives on fans
Less wear on bearings, as the shock load on belt
and bearings is removed through soft start/stop.
M odern VSDs include belt monitoring, meaning
longer intervals between maintenance.
and because vanes, dampers and actuators are no and because vanes, dampers and actuators are no and because vanes, dampers and actuators are no and because vanes, dampers and actuators are no and because vanes, dampers and actuators are no
longer needed: longer needed: longer needed: longer needed: longer needed:
No more jammed guide vanes / dampers
No more loss of performance
No guide vane maintenance costs
Lower noise levels / better air quality control
Longer intervals between air filter changing
(lower speed = less dirt)
O n pumps, fitting VSD will: O n pumps, fitting VSD will: O n pumps, fitting VSD will: O n pumps, fitting VSD will: O n pumps, fitting VSD will:
Remove water hammer ( at start/stop situations)
Prevent blown valves
Reduce leakages as pressure is kept constant
As it appears from the above, several nuisance pro-
blems can be avoided and considerable savings can be
gained.
Increasing comfort level
Noise from fans:
As a by-product of the energy saving from reducing fan
speeds, acoustic air movement noise from the fan is
reduced.
Noise from fans in a quiet environment can be very
annoying. If a fan, sized for full occupancy, for example,
is supplying a partly occupied room, the acoustic noise
level can be as high as e. g. 70 dBA. The noise level will
vary dependent on the throttling with dampers or
guide vanes. The more throttling the more noise.
K eeping dampers or guide vanes fully open and
reducing the speed from 100% to f. ex. 50% , reduces
the noise by 16. 5 dBA. (A reduction of 10 dBA
corresponds to a 50% reduction of the noise level),
according to standard fan catalogues.
The following formula shows how to calculate the
above.
Calculating noise reduction:
55 x Log (dBA) New speed
O ld speed
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In constant speed pump systems bypass loops are
commonly used as part of the regulating function,
keeping constant pressure at varying flow. Bypass sy-
stems for pumps can be equally eliminated by using a
VSD to control the flow of the pump according to the
actual need.
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
Why use VSD in existing HVAC installations
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The relationship is explained as follows:
Fig. 8 Fig. 8 Fig. 8 Fig. 8 Fig. 8
Sound level on air quantity regulation
Noise is a determining factor in for example central
Airconditioning for hotels, hospitals etc.
Draught: Draught: Draught: Draught: Draught:
By reducing the speed of a centrifugal fan or pump, the
acoustic noise level as well as the draught from fan sy-
stems, can be very much reduced too. That increases
comfort and may reduce sickness leave.
Leaks: Leaks: Leaks: Leaks: Leaks:
Leaking water from pump systems, usually caused by
water hammer, can be totally avoided by using a VSD
with zero starting surge and a ramp to allow an exten-
ded starting period. This also extends quality and life
time on pipework and fittings.
C ontrolling comfort: C ontrolling comfort: C ontrolling comfort: C ontrolling comfort: C ontrolling comfort:
When using a VSD, accurate temperature and pres-
sure control can be maintained. See Fig. 9.
Fig. 9 Fig. 9 Fig. 9 Fig. 9 Fig. 9
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
Why use VSD in existing HVAC installations
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I Calculation of pay back time
When considering energy savings it is important to
know the investments necessary to obtain the
expected energy savings. And most interesting of all,
maybe, to know about the pay back time of the
investment.
Calculation of the pay back time is initially done for
each VSD installed and eventually the data for other
frequency converters are added.
First of all the investment necessary for obtaining
energy savings has to be calculated:
- The price of the frequency converter together with
necessary transmitters.
- The cost of installing the frequency converter incl.
wiring of power and control signal as well as the
necessary changes in pipe- and/or duct work.
Secondly:
- The energy savings, calculated as the difference
between the energy consumption in a constant
speed system compared to a frequency converter
controlled system, based on the examples
described on pages 7, 8 and 9, multiplied by the
electricity rate per kWh, has to be established.
Thirdly:
- The savings on maintenance, has to be added to
establish the total savings.
Eventually the pay back time can be calculated as the
total cost of having a VSD installed, divided by the total
savings (energy and maintenance) for one year:
Pay back time (simple):
Total cost of installing VSD
Total energy savings for one year
Pay back time (real):
Total cost of installing VSD
(Total energy sav. pr. year +
savings on maintenance/spare parts)
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Example 2:
Pay back time Pay back time Pay back time Pay back time Pay back time based on theoretical example 2:
Total installation cost of VSD =
Energy saving per year
US$ 4, 300 = 0. 67 years 0. 67 years 0. 67 years 0. 67 years 0. 67 years
US$ 6, 412
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Note: Note: Note: Note: Note:
Savings on maintenance has not been added
in this example, as it depends on the actual si-
tuation, but the formula indicates that the pay back
time will be even shorter, than estimated here.
Note: Note: Note: Note: Note:
Savings on maintenance has not been added
in this example, as it depends on the actual si-
tuation, but the formula indicates that the pay back
time will be even shorter, than estimated here.
Example 3:
Pay back time based on practical example 3:
Total cost of VSD =
Energy saving per year
US$ 17, 406 = 1. 26 years 1. 26 years 1. 26 years 1. 26 years 1. 26 years
US$ 13, 762
Note: Note: Note: Note: Note:
Savings on maintenance has not been added
in this example, as it depends on the actual si-
tuation, but the formula indicates that the pay back
time will be even shorter, than estimated here.
Example 1:
Pay back time Pay back time Pay back time Pay back time Pay back time based on theoretical example 1:
Total installation cost of VSD =
Energy saving per year
US$ 4, 300 = 1. 44 years 1. 44 years 1. 44 years 1. 44 years 1. 44 years
US$ 2, 985
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
Why use VSD in existing HVAC installations
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Conclusion
As described in the various sections of this paper, the
majority of existing HVAC installations, which are
running with constant speed pumps and fans, can be
converted into profitable, cost efficient, energy saving
(money saving) installations, by investing in Variable
Speed Drives and a few transmitters.
Furthermore, the cost reduction for maintenance and
replaceable parts is obvious and the improved comfort
level will enhance the indoor climate and eventually
increase the human work output.
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All together, a huge reduction of the energy bill, often
50% or more, a very short pay back time of the
investment, typically 1 or 2 years and increased
comfort level are obtained.
Typical applications where substantial energy savings
can be achieved by using VSD:
G Supply fans
G Return fans
G Exhaust fans
G Smoke extract fans
G Condenser fans
G Induced draft boiler fans
G Cooling tower fans
G Condenser pumps
G Chilled water pumps
G Hot water/domestic water pumps
G District heating supply pumps
G District cooling pumps
G Pressure booster pumps
Simple retrofit with VSD is possible with modern
dedicated HVAC drives including basic and vital HVAC
components.
The booklet, HO W HO W HO W HO W HO W to use VSD in Existing HVAC Instal-
lations M A. 35. J1. 02, Retrofit G uideline Part II, will
explain in details how a VSD is installed in the easiest
possible way. The HO W booklet will also describe how
unnecessary problems can be avoided.
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Next step
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
Why use VSD in existing HVAC installations
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
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M C. 60. D1. 02 - VLT is a registered Danfoss trademark
Why use VSD in existing HVAC installations
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