Course # W 51 HVAC Motor Control Solutions

Presenter: John Polites - Automation Engineer

Wednesday, May 3rd - 9:00 AM 10:00 AM
State College Room
Topics of Discussion:

Motor Load & Starting Methods

Motor Control for HVAC Applications
Energy Savings with Variable Frequency Drives
Introduction to PF400 HVAC Drive

AC MOTOR LOADS

AC Motor Load Types

Constant Torque
Variable Torque
Constant Horsepower

Constant Torque Motor Loads

Variable Torque Motor Loads

Variable Torque Application Types

Typical of Centrifugal Pumps and Fans
Pumps: Hot Water, Chilled Water, Condenser
Water, Distribution
Fans: Supply, Return, Relief, Exhaust, Cooling
Tower Fans
Torque and Horsepower Drops As Square of Speed
Reduction;
Excellent Potential for Energy Savings with a VFD versus a
throttling Valves, Dampers or Inlet Vanes

HVAC Pump Types

Two Pump Types:
Positive Displacement Pumps
Move fluid chamber to cause fluid to flow
Constant Torque Load Profile
Centrifugal Pumps
Move fluid by rotation of an impeller
Variable Torque Load Profile
Hydronic Pumps: Hot Water, Chilled Water,
Condenser Water & Distribution

Components of the Pump System

Pump
Motor
Coupling
Base Plate
Piping
Valves
Inlet Source
Above Pump
Below Pump

Discharge Static Head

Pump Type and Applications

HVAC Systems

HVAC Systems
The purpose of an HVAC (heating, ventilating, and air-conditioning)
system is to provide and maintain environmental conditions within an
area called the "conditioned space."
The commercial system selected for a particular application should
endeavor to provide the optimum environment for employee comfort and
productivity, process function, and good indoor air quality with energy
efficiency and cost-savings

Types of HVAC Systems

Air Handling Systems

Air Handling Units (AHU), Rooftop Units (RTU), Makeup Air Units
(MUA), Exhaust Fans (EF), Variable Air Volume Boxes (VAV),,fan
unit (FU)

Hydronic Systems
Chilled Water (CHW) [Chillers and Pumping Packages]
Condenser Water (CW) [Cooling Towers]
Hot Water (HW) - [Boilers and Pumping Packages]

Building Automation System (BAS)

HVAC Controls, Direct Digital Controls (DDC), Energy Management
System (EMS), Facility Management System (FMS)

Typical Commercial HVAC Systems

HVAC Motor Control

(Starters or VFDs)

Traditional Variable Air Volume (VAV) Air Handling Unit

Controllers measure Static Pressure and send speed signals to both VFDs

Supply fan will be controlled by PF400

Return fan will be controlled by PF400

VAV boxes located in each

room distribute conditioned air

Chilled Water Pumping System

Variable Frequency drives Replace the wasteful Check valve system

These motors are controlled by a Variable Frequency Drive

Condenser Water Pump System

Valves replaced when drives are used

Motors controlled by VFDs in new applications

Building Automation Systems (BAS)

BAS SERVER
BAS PRINTER
BAS OWS

BUILDING
LOCAL AREA
NETWORK

NC
NETWORK CONTROLLER

ASC

APPLICATION SPECIFIC CONTROLLER

(HOT WATER SYSTEM)

ASC

APPLICATION SPECIFIC CONTROLLER

(CHILLED WATER SYSTEM)

ASC

APPLICATION SPECIFIC CONTROLLER

(AIR HANDLING UNITS)

ASC

APPLICATION SPECIFIC CONTROLLER

(ROOFTOP UNITS)

ASC

APPLICATION SPECIFIC CONTROLLER

(VARIABLE VOLUME BOXES)

TYPICALLY MOUNTED
IN NETWORK CLOSET

ETHERNET
FIELD BUS

> Controllers Send Output Commands to VFDs and Motor Starters: Start/Stop Control & Speed Commands
> Run/Fault Commands Sends Status Commands for Starter Device to Controllers.

Basic BAS Systems Control Strategies

A pressure sensor within an air duct or pipe measures the
system pressure
As the pressure changes an analog signal is sent to the
BAS
The BAS sends a start stop and speed command to variable
frequency drives (VFDs) or motor starters
When valves and dampers close, the pressure rises in the
ducts or pipes, which reduces the speed

Building Automation System Graphic

This is a typical view on a building automation computer
screen showing the status of various points in an air handling
system

Motor Starting Methods

Types of HVAC Motor Starting Methods

Full Voltage Starting

Reduced Voltage Starting

Wye - Delta Starters
Autotransformer
Soft Starters
SMCFlex

Variable Frequency Drives

Full Voltage Starting

Full Voltage Starting Characteristics

Contacts close immediately supplying full line

voltage to motor.

Advantages:

Lowest starter cost

Simple starter designs
Easy to maintain and troubleshoot

Disadvantages:

Inrush Current
6-10 times rated running current
L1
Issue when peak demand charges are enforced
by utilities
Initial Torque
Mechanically hard on system
Reduced life of belts, gears

L2

L3

Disconnect
Fuses
Contactor
Overload
Relay

T1

T2

T3

IEC & NEMA Motor Starters

NEMA Rated
Emphasis on:
Serviceability
Contacts Replaceable
Flexible Overload Selection

IEC Rated
Emphasis on:
Replacement
Contacts only replaceable on
large sizes only
Conserve panel space
Class 10 Overload Protection

Solid State Soft Starters

Use SCRs to ramp voltage supplied to
motor over a user defined time period
Advantages:
Reduces inrush current
Reduces starting torque
Reduces mechanical stress
on motor & loads

SMC-Fle

Soft Starter Speed Torque Curve

Reducing the Voltage

Reduces the Current

LRT

100%

Reduction In Torque!!
0

(.5)2 = .25 or
25%

100%
Percentage of Full Speed

Commercial OEM Products

Manual Starters
Range Overview
1HP, 115, 230, 277 VAC
0.75 HP, 115/230 VDC
1 or 2 Pole
Thermal Overload
Ideal for small Fan and
Pump Applications

Adjustable Speed Drives

Variable Frequency Drives Basics

Solid State AC Variable Frequency = Variable Speed
AC Input
Fixed
Frequency

Converter
DC
Bus

Benefits
Solid state technology
Wide control options
Small size power units
Good efficiency
Lower cost, smaller motors
Retrofit existing motors
Bypass capability

AC
Output
Variable
Frequency

Inverter

AC
Motor

460

Max
Frequency

Volts
230

30

60

Hertz

Voltage

Hertz

Motor RPM

115

15

438

230

30

875

345

45

1313

460

60

1750

Base
Voltage

Base
Frequency

V/Hz

460

60

7.67

230

60

3.83

208

60

3.47

Why Should I consider using a Variable Frequency Drive (VFD)?

To improve process control though speed

and torque control
To improve system efficiencies
To extend life of equipment by reducing
mechanical stress
To Achieve Energy Savings on Fan and Pump
Applications
To meet the ASHRAE Energy Standards 90.1 -2001
Variable flow control on fan & pump systems

Allen Bradley PF400 HVAC Drive

Integral RS485 Communications

Supports DSI Accessories
Integral LCD Keypad

Application Specific Features for

Fans and Pumps
Rated for Variable Torque Loads

Optimized for Commercial Fan and Pump Applications

Stand-Alone

Packaged

PF400 Ratings
Ratings
200-240V, 2.2-37 kW (3-50 Hp)
380-480V, 2.2-100 kW (3-150 Hp)

110% Overload for 60 seconds

Enclosure
IP20 / UL Open
3-10 HP (240V AC) & 3-20 HP (480V AC)
IP30 / NEMA 1 / UL Type 1
3-10 HP (240V AC) & 3-20 HP (480V AC)
(with optional kit)
15-50 HP (240V AC) & 25-150 HP (480V
AC)

Environment
IP20 rated for 50 C
IP30 rated for 45 C

Allen Bradley PF400 HVAC Drives

Standard VFD

Main Input
Disconnect

3 Contactor Full
Feature Bypass with
Disconnect

3 Contactor Basic
Bypass with
Disconnect

Variable Frequency Drive Control Capabilities

Configurable Keypad with local remote

start/stop and speed controls
Compatible with Building Automation
System Inputs/Outputs (Start/Stop, Speed
and Feedback)
Standard BAS Communications:
RS485, Modbus RTU, Johnson
Controls N2 & Siemens P1
Future Communications:
Lonworks & Bacnet
Process PI
Inertia Ride Through
Power Loss
Flying Start
S Curve, Accel & Decel profiles
V/Hz Control
Motor Overload protection
Communication interfaces to Building
Automation Systems
Analog & Digital inputs & outputs
Manual Bypass Capabilities
Purge Start Input and Frequency
Fire/Freeze Stat Interlock Inputs

Analog Output
Dip Switches
Analog Input
Dip Switches
24V DC
Source/Sink

Relay Outputs

Analog and
Discrete
Wiring

RS485
Ports

Motor Characteristics with Different Starting Methods

% Motor Starting Current
Starting
Method

% Voltage
at Motor
Terminals

Full Voltage

% Line Current

% Motor Starting
Torque

Lock
Rotor
Current

Full Load
Current

Lock Rotor
Current

Full Load
Current

Lock Rotor
Current

Full Load
Current

100

100

600

100

600

100

100

80 % tap

80

80

480

64

480

64

115

65 % tap

65

65

390

42

390

42

76

50 % tap

50

50

300

25

300

25

45

Part Winding

100

65

390

65

390

45

81

Star - Delta

100

33

198

33

198

33

60

Solid State

0-100

0-100

0-600

0-100

0-600

0-100

0-180

Variable
Frequency
Drive

0-100

0-100

0-200

0-100

0-200

0-100

0-180

Autotrans.

HVAC Motor Control Price Comparison

Motor HP

VFD

Soft Starters

NEMA Combination
Starters

IEC Combination
Starters

900

1,100

780

620

10

1,000

1,200

813

697

20

1,600

1,600

1,195

902

40

2,700

2,400

1,959

1,466

50

3,400

2,800

1,975

1,513

Standard Features:
480 VAC, 3-Phase
NEMA 1 Enclosure
Input Disconnect Switch
Motor Thermal Overload Protection

ENERGY SAVINGS WITH VFDs

Centrifugal Pump Energy Savings

There are two methods used to accomplish the continuously varying flow:
One method is throttling which changes the system curve by use of control or throttling valve.
The other method is to vary the speed of the pump which modifies the pump curve.
Building Automation System controls the pump starter or VFD and control valve based on HVAC
sequence of operation.

Centrifugal Pump Energy Savings

Typical Pump Curves

Pump Curves Controlled by a VFD

Energy Savings with VFDs

Pump Curves Throttled with Control Valves

(GPM Proportional Brake HP-Torque)

Fan Energy Savings

Many air handling systems require operation at a wide
variety of points. There are several methods used to
modulate or vary the flow (or CFM) of a system to achieve
the optimum points. These include:
Cycling As done in home heating systems. This produces
erratic airflow and is unacceptable for commercial or
industrial uses.
Outlet Dampers Control louvers or dampers are installed
at the outlet of the fan. To control airflow, they are turned to
restrict the outlet, which reduces the airflow.
Variable Inlet Vanes by modifying the physical
characteristics of the air inlet, the fans operating curve is
modified which
changes the airflow.

Typical Fan Curves

Variable Frequency Drives By changing the actual fan

speed, the performance of the fan changes producing a
different airflow.
Building Automation System controls the fan starter, control dampers
and air system sensors based on HVAC sequence of operation.

Fan Energy Savings

Fan Curves with Outlet Dampers

Fan Curves with Variable Inlet Vanes

Fan Curves with VFD

Sample Fan Energy Savings Report

Energy Savings Software
(www.sydist.com)

Energy Savings Report

VFD Specs
Energy Savings Calculations
Energy Savings Summary

VFD Energy Savings Software Tools

Schaedler Yesco Distribution

HVAC Market

Schaedler Yesco Distribution - HVAC Market

Plan & Spec Market
New Construction, Additions and Renovations
Track projects online through Harrisburg Builders Exchange
Mechanical plans/spec takeoffs for motor control thats
furnished by the HVAC contractor
Application coordination with mechanical equipment specs,
building automation system sequences of operations and
electrical power system plans
Retrofit Market
Provided electrical energy solutions/products to Design/Build
and Energy Service Teams i.e.: Variable Frequency Drives
and Lighting Retrofit Solutions
VFD Fan or Pump Energy Savings Reports www.sydist.com
VFD Replacement Program

Motor Control Support

Local Central PA Support with (5) Staffed Motor Control
Specialist
Product Guide Specifications & Submittal Packages
Certified VFD Startup
VFD Checklist and Reports
Onsite Training
Available Spare Parts
24/7 Emergency Service
Online Allen-Bradley Drives Technical Support
www.ab.com/support/abdrives

Questions ?

Please Take a Few Minutes

to Fill Out Seminar
Evaluation Form

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