electric drive

1Copyright © 2008 Schneider Electric. All rights reserved

Go Green with AC Drives

Make the most of your energySM

Identify Energy Savings opportunities with AC Drives


I. Energy Opportunities

II. Description AC Drives

III. Affinity Laws

IV. Building Applications

V. Conclusion



Increasing cost of energy, especially oil and gas

World’s expanding energy consumption from developing countries i.e. China, India

World events creating security concerns in oil producing areas of the world

U.S Electrical power grid black-outs Northeast and West Coast

Hurricane effects felt in oil producing Gulf of Mexico region

Oil and gas prices –July 2006 $75.00 dollars per barrel $2.00 / gallonJuly 2008 $150.00 dollars per barrel $4.00 / gallon

Energy Savings Opportunities


U. S. Department of Energy Energy Star Program

Heating and cooling systems are the largest consumers of energy in buildings.

64% of electricity used in industrial facilitiesFor electric motors to power centrifugal pumps and fans

Source: U.S. Department of Energy



Where are the savings ?

Industry & infrastructureAverage facility can reduce consumption by 10 to 20%

Data centers & networksPower & cooling can reduce power consumption by 20 to 30%

Buildings

Renovation can yield up to 30% of energy savings

Residential

EE products may save 10% to 40% in electricity

25% savings would save 7% of the world’s electricityMotors, account for over 60% of electricity usage

20% to 25 % of consumedenergy (EU & US)Lighting & appliances over 40%

Consume 20% of total energy 3 key areas: HVAC, lighting & integrated building solutions

Power & cooling systems comprise 50% of electricity usage Saving energy improves DC infrastructure efficiency


U.S. Green Building Council

36% of total energy consumed in the United States is used for buildings

Includes natural gas, electricity and steam

65% of the electricity consumed in the United States is consumed for buildings

Source: US Green Building Council



United States Government Single largest user of energy in the world45% of energy consumed by the US government is

used to heat, ventilate and cool buildings.

Energy Bill LegislationEnergy Policy Act 0f 2005 (EPAct 2005) signed into law September 2005

Mandates federal facilities to reduce energy consumption by 2% per year, every yearExtended Daylight Savings time period

Source: NEMA


http://www.epa.gov/lmop/news/oct05_energypolicy.gif


International Facility Management AssociationOverall cost of running a facility is 10 percent higher than it

was four years ago

IFMA Benchmarks V StudyUtility costs have jumped 19 percent in two years

Includes electricity, gasoline, fuel oil, steam water and sewageCompared to similar data from 2006.

Source: International Facility Management Association



Energy used in Healthcare Facilities is for

Ventilation Fan EnergyVentilation Air CoolingReheating / Space HeatingOutside Air / Cooling / Dehumidification / Humidification

Energy for hospital HVAC systems59% to 64% of the annual energy cost (typical healthcare facility based on location)

Source: ASHRAE Winter Meeting 2008

Best Practice HVAC Systems-Healthcare



15 Steps to a More Sustainable Hospital

Recommends VFDs on all motors 3 hp and higher

Installation of VFDs on smaller motorsReduced cost of drivesIncreased distribution and power of Direct Digital Control (Building Automation Systems)

New drives may be controlled in two modes;Modulate flow based on a variable sensor input (PID feedback control)Controlled to balance a constant speed system

valves fully opened to reduce system head loss.

Source: Engineered Systems Magazine July 2008

Author: Steven Furgeson, PE


VFDs have the potential to save energy even on smaller motors.


LEEDLeadership in Energy and Environmental Design Certification for Buildings

Recommends ASHRAE 90.1-2004 to set minimum HVAC requirementsPromotes effective energy conserving designs for

buildings and building systems

ASHRAEAmerican Society of Heating Refrigeration and Air Conditioning Engineers Recommends HVAC systems be equipped with Variable Speed Drives if they have:

Variable Air Volume fan controlIndividual fan motors greater than 5 hp



Today, variable speed drives are widely used in buildings and are reliable and proven electronic technology.





III. Affinity Laws


V. Conclusion



Input PowerInput Power

DriveDrive MotorMotor

ControlControl

MachineMachine

Adjustable Frequency Drives are just one piece of the system

Adjustable Frequency Drives are just one piece of the system

33∅∅

Typical Drive System


ConverterConverter InverterInverter

DC Bus++

__

AC Line

Constant Frequency

Motor Leads

Adjustable Frequency

Typical AC Drive


i

VVV

AC Line Voltage(non-rectified)AC Line Voltage(non-rectified)

ttt

RectifierRectifier DC Voltage (rectified)DC Voltage (rectified)

Converter uses solid state devices to change AC to DCConverter uses solid state devices to change AC to DC

+++

---

Six Pulse AC to DC Converter

Typical AC Drive


Typical AC Drive

AC Line Voltage(non-rectified)AC Line Voltage(non-rectified)

RectifierRectifier

VVV

tttttt

DC Voltage (rectified)DC Voltage (rectified)

Converter uses solid state devices to change AC to DCConverter uses solid state devices to change AC to DC

+++

i

Six Pulse AC to DC Converter


DC to AC InversionDC to AC Inversion

VVV

tt tt

AC Voltage (inverted)AC Voltage (inverted)

InverterInverter

VVDC Voltage (non-inverted)DC Voltage (non-inverted)

Typical AC Drive


DC to AC InversionDC to AC Inversion

VVV

tttt

AC Voltage (inverted)AC Voltage (inverted)

InverterInverter

VVDC Voltage (non-inverted)DC Voltage (non-inverted)

Typical AC Drive


Optimized power section

DC bus capacitor section is reduced– 95%-97% less typical AC drive capacitor value

Input current waveform characteristics are optimized

– reduction in current spikes typically observed due to capacitance charging

Total input current draw is reduced– lower input current harmonics

Motor control algorithms and powerful microprocessors − engineered to produce sinusoidal wave form to

the motor

Rectifier D C Link Inverter

Three

Phase Power

+

-

C

New Technology for AC Drives


Typical AC drive100HP

Typical 6 pulse AC drivewithout line reactor

Input voltage: orange

Input current: cyanLarge current spikes due to capacitors

chargingPeak currents = 300 amps

Harmonic current distortionLarge double humped current waveform

significantly contributes to harmonic content.

Total Harmonic Distortion Current (THDI) = 80%




AC drivewith line reactor

100HP

Typical 6 pulse AC driveWith 3% line reactor


Input current: cyanLower current spikes due to

capacitors chargingPeak currents = 190 amps

Harmonic current distortionSignificant double humped current

waveform contributes to harmonic content

Total Harmonic Distortion Current = 38%


Optimized power section100HP


Input current: cyanLow current spikes due to capacitors chargingPeak currents = 190 amps

Harmonic current distortionInput current is a square shaped waveform Eliminating the large double humped

waveform Reducing harmonic content

Total Harmonic Distortion Current = 33%



E-FlexS-Flex M-Flex PowerGard

Range:208/230V 1-40hp460V 1-100hpTarget Market:Residential high riseCommercial office buildingsGovernment facilitiesSchools and Universities

Range:208/230V 1-50hp460V 1-100hpTarget Market:Commercial buildingsHospitalsGovernment facilitiesSchools and Universities

Range:460V 50-500hpTarget Market:IndustrialMunicipal pumping

Range: 208/230V 1-50hp460V 1-500hpTarget Market:Government facilitiesHospitalsPharmaceuticalIndustrialMunicipal pumping

Enclosed AC Drives Products


MCC Total Solution

UpstreamElectricalNetwork

208-480V

AccuSinePCS

M

VFD

M

VFD

MM

Corrected Loads

MCC Enclosure

Schneider Electric applied and packaged solution for single point

of responsibilityReduced installation costsCan be used for active harmonic filtering of non-linear loads both within and outside the MCC (based on CT installation)

Multiple units can be paralleled for larger RMS ratingsNo harmonic study required to size Accusine PCS for a particular

application


AC Drives Products

Range:208/230V 1-40hp460V 1-100hpApplicationsCentrifugal PumpsFansTarget MarketOEMsControl Panel Builders

Range:208/230V 1-125hp460V 1-900hp600V 1-900hpApplicationsCentrifugal PumpsFansTarget Market:OEMsSystem IntegratorsControl Panel Builders

Altivar 61Altivar 21




III. Affinity Laws


V. Conclusion



Affinity Laws for Centrifugal Loads

Adjustable Speed Drives increase system efficiency provide means to reduce motor speed for pumps and fans based on the needs of the building environment


Significant energy savings at lower motor speeds can be realizedbased of the Affinity laws;

Flow = f (motor speed)

Pressure = f (motor speed)2

Horsepower = f (motor speed)3




Lower motor speed = less energy consumption



A motor running at 90% of full speed requires 73% of the electricity of a motor running at 100% speed. (.9 x .9 x .9 = .729)




A motor running at 80% of full speed requires 51% of the electricity of a motor running at 100% speed. (.8 x .8 x .8 = .512)




A motor running at 50% of full speed requires 12.5% of the electricity of a motor running at 100% speed.(.5 x .5 x .5 = .125)



Customer Benefit Calculation



Cost Savings

Drives pay for themselves in a relatively short period of time.

Typically < 2 years depending on applications through savings on electricity bills.


A fan with a 20 horsepower motor supplies air12 hours a day260 days a year Energy cost is of $0.09 cents per kilowatt-hour.

Cost of running a 20hp motor full speed 12 hours per day:20 hp x 0.746 kW/hp x 3120 hours x $0.09/kWhr = $4190 per year

Typical Average Annual Utility Rates ($/kWh):*San Francisco $0.1419Los Angeles 0.1266Dallas 0.0900Richmond 0.0689New York 0.2037Average $0.1262

*Source: Syska Hennessy Consulting Group Atlanta, GA



Assuming the fan does not need to run at full speed all of the day:Running full speed (100%) for 25% of the day 80% speed for 50% of the day50% speed for the remaining 25% of the day

Cost of running with an AC drive controlling the motor:20 hp x (1)3 x 0.746 kW/hp x 780 hours x $0.09/kWhr = $1,047 per year20 hp x (0.8)3 x 0.746 kW/hp x 1560 hours x $0.09/kWhr = $1,07320 hp x (0.5)3 x 0.746 kW/hp x 780 hours x $0.09/kWhr = $131

Total = $2,251 per year

Annual savings: $4,190 - $2,251 = $1,939 savings per year

20hp drive typical cost: $2,709 installed cost

(2709 cost per drive / 1939 savings per year) x 12 months = 17 months payback


Payback for the cost of the drive is less than two years


Energy Savings Calculator


Energy Savings Calculator

www.squaredleantools.com


Case Study

Actual Cost Savings Example


Customer replaced motor soft start device with AC Drive

Actual measurable savings in cost of electricity achieved was $148.00 dollars per week

$7,696.00 dollars electricity saved per year

Cost of drive and metering: $4,500 installed cost

Case Study – Food Manufacturer, Tennessee

Payback for the cost of the drive and meter - 7 months


BackgroundAir distribution system for 155,000 square foot clothing store provided by five air handling units located in penthouse equipment room.Two return fans vented air from first and second floors through ductwork to air handling unitsAir handling units provided conditioned air through out the building through ductwork to diffusers.Fans operated at two speeds, high and low, adjusted manually.Fans usually operated at high speed setting, occasionally at low speed setting.

Testing was conducted to determine airflow at high speed.Data collected indicated actual airflow from each AHU was less than designed airflow;

therefore fans were larger than necessary for this facility.Accumulation of dirt on the cooling coils in AHU 1 and 2 restricted airflow and wasted fan energy.Measurements of each motor indicated maximum load was less than horsepower rating.

Potential energy saver – minimize outside air for ventilation. Outside air has to be heated or cooled which require energy.By monitoring carbon dioxide levels in building – air intake could be reduced to minimum quantity necessary.

Case Study – JC Penney, Atlanta, GA*

*Energy Star® Building Manual - Fan System Upgrades


SolutionInstall variable frequency drives on supply air and return air fans to bring fan capacity nearer to actual load.Install carbon dioxide sensors to minimize intake of outside air.Space thermostats were used to regulate fan speeds directly.Before VFD installation, fans cycled on at maximum speed with high motor inrush currents, then cycled off regularly. VFDs eliminated inefficient constant cycling. Peak power was therefore less than maximum. Projected electric demand savings was 36 kilowatts per month.

Cost of VFDs and carbon dioxide sensors: $17,000 installed costProjected electricity savings: 138,833 kilowattsProjected annual savings: $9,726.00

Payback period for project: 1.75 yearsProject internal rate of return: 56.6%

JC Penney was able to realize substantial annual savings – almost $10,000 per yearwith relatively low investment.

Case Study – JC Penney, Atlanta, GA*

*Energy Star® Building Manual - Fan System Upgrades


Maintenance Benefits


Financial and Maintenance Benefits

Drives provide a soft start control for motors, resulting in HVAC systems that:

Last longer

Reduce mechanical stress

Require less maintenance

Cause fewer instances of unscheduled equipment downtime

Lower inrush current and peak power demand


Network Communications

Network connectivity with the Building Automation Systems

BACnet®LonWorks®Metasys® N2Apogee® P1Modbus®

allows real time control of pumps and fans

based on climate demands of the building

environment under control and

increases occupant comfort

LonWorks®


Energy Efficiency Programs


Energy Efficiency Incentives

Increase bottom line profit utilizing Energy Efficiency Incentive Programs

Many energy efficiency programs offer incentives for motors and adjustable frequency drives in commercial and industrial facilities

Incentives may include rebates as well as funding for feasibility audits and design assistance


Energy Efficiency Incentive programs

Consortium for Energy Efficiency

Provides information about energy efficiency programs in industrial and commercial facilities

www.cee1.org

Source: CEE Energy Efficient Programs-May 2007

http://www.cee1.org/


Energy Star

EnergyStar.gov

Energy audit and energy management information for industrial and commercial facilities

Energy Star Building Manual recommendationsHeating and Cooling System UpgradesFan System Upgrades

www.energystar.gov

Source: energystar.gov website

http://www.energystar.gov/




III. Affinity Laws


V. Conclusion



Typical Building Applications



Air Handling Unit



Exhaust Fans



Cooling Tower Fans



Cooling Tower Water Pump



Hot Water Pumps



Secondary Loop Chilled Water Pumps



Domestic Water Pump for High Rise


Raleigh Convention Center, Raleigh, NC

Raleigh Convention Center$220 million project150,000 exhibit hallMeeting roomsBallroom

Enclosed drives will control: 18 Air handling units 25hp, 30hp, 40hp, 50hp,

60hp, 75hp, 100hp2 Hot water pumps 50hp2 Chilled Water pumps 60hp4 Cooling Tower Water pumps 40hp7 Exhaust fans 7.5hp

Installed Square D® enclosed drives


Proctor & Gambles headquarters1.5 million square footEnergy Star certified facility

Energy Star CertificationReset supply air for air handling unitsUse outside air to reduce heating and

cooling time by 60 hours per weekUpgrade existing motors to add

variable frequency drives


Proctor & Gamble, Cincinnati, Ohio

Source: Sustainable Facility Magazine, June 2008


Rex Healthcare, Raleigh, North Carolina

Surgical Expansion ProjectThree story addition to hospital12 operating roomsThree new air handling unitsNew boilerNew chillerNew cooling tower

Square D® enclosed drives will control3 Supply air fans in AHU3 Return air fans in AHU2 Cooling tower water pumps

LonWorks Communications with Honeywell Enterprise Building Integrator (EBI) building automation system


Oak Ridge National Laboratory, Oak Ridge, Tennessee

United States Largest Science and Energy Laboratory

58 square mile campus4200 employees

Energy Conservation mandated EPAct 2005Reduce building heating and cooling loss

through laboratory fume hoodsReduce energy usage by adding variable

frequency drives to existing motors


“Utilizing variable speeds drives to control motor speeds and reduce energy usage was the first area to implement.”Greg PalkoEnergy Efficiency ManagerOak Ridge National Laboratory


Acute care and nursing facility with 61 patent beds

15 Square D® brand enclosed drives Circuit breaker disconnect andBypass circuit at460 volt 5hp to 40hp

The enclosed drives will control; Supply air fans 15hp, 30hp and 40hpReturn air fans 5hp, 10hp, 20hp and 30hpHot water pumps 10hpChilled water pumps 20hp

Jefferson County Hospital Fairfield, Iowa


15 floor high rise hotel 294 rooms Six restaurants53,000 square feet riverboat casino

28 Square D® enclosed drives Circuit breaker disconnect and Bypass circuit at 460 volt, 2 to 40 horsepower

Drive applications include Exhaust fans 40hp eachHot water pumps 2 hp each

Harrah’s East Chicago, Indiana


26 Square D® enclosed drives with Circuit breaker disconnectBypass circuit460 volt3 to 20 horsepower

BACnet building automation communications

Bothell High School Shoreline, Washington


Elementary school scheduled to open Fall 2008

47 Square D® enclosed drives Circuit breaker disconnectBypass circuit208 volt1 to 3 horsepower

Installed by Trane partner

Elementary School, Kinston, North Carolina


AC Drives 24 / 7 technical and application assistance 1-888-SQUARED

Sales and application assistance•Regional Product Application Engineers

Available Resources

Website:www.us.squared.com

• Products and Services- Motor Controls

- Adjustable frequency drives

http://www.us.squared.com/


4 main

messages

Pump and Fan systems operating with Variable Speed Drives provide:

1. Cost savings and conserve electricity

2. Increase comfort in buildings

3. Reduce equipment maintenance and downtime

4. Additional savings through energy efficiency rebate programs

Energy Savings with Variable Speed Drives


E-FlexS-Flex M-Flex PowerGard

Range:208/230V 1-40hp460V 1-100hpTarget Market:Residential high riseCommercial office buildingsGovernment facilitiesSchools and Universities

Range:208/230V 1-50hp460V 1-100hpTarget Market:Commercial buildingsHospitalsGovernment facilitiesSchools and Universities

Range:460V 50-500hpTarget Market:IndustrialMunicipal pumpingWastewater

Range: 208/230V 1-50hp460V 1-500hpTarget Market:Government facilitiesHospitalsPharmaceuticalIndustrialMunicipal pumpingWastewater

Enclosed AC Drives Products


Altivar 61/71 MCC Drive Offering

Single Family Product Line

1-500 HP, 480 volt

1-50 HP, 240 volt

Compact, General Purpose Pkg

UL 845 Listed, 100K Amp Fault rating

NEMA 1, 1A, 12, and 3R (up to 40 HP)


AC Drives Products

Range:208/230V 1-40hp460V 1-100hpApplicationsCentrifugal PumpsFansTarget MarketOEMsControl Panel Builders

Range:208/230V 1-125hp460V 1-900hp600V 1-900hpApplicationsCentrifugal PumpsFansTarget Market:OEMsSystem IntegratorsControl Panel Builders

Altivar 61Altivar 21


TT hank you


Make the mostof Your EnergySM

electric drive

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