ABCs of VFDs and Rooftop Units

Technology overview and available incentives

Greg Rushby, Rushby Energy Solutions
saveONenergy Show & Symposium
June 17, 2014

Outline
Topic
VFD Overview
VFD Applications & Incentives
RTU Overview
RTU Incentives
Summary

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Variable Frequency Drives (VFD)

VFD
Adjustable speed drive
Vary frequency (Hz) and voltage going to the motor
Motor RPM is reduced at lower Hz

VFDs save energy when the load varies

HVAC equipment is sized for peak loads
Peak conditions are ~1% of annual operating hours

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VFDs vs. Other Starters

Type

Pros

Cons

Applications

Across-the-line

Simple, low-cost

No variable speed <5 hP

operation

Soft starter

Variable speed
operation

Inefficient partload operation

Motors that cycle

frequently

Variable
Frequency Drive

Efficient, active
variable speed
control

High cost (relative

to other starters)

Systems that
operate at partload frequently

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Variable Flow vs. Variable Speed

Many systems have variable flow with constant speed
motors
Valves used to vary flow for pump systems
Dampers or inlet vanes used to vary flow for fan systems
Inlet valve modulation used to vary compressed air output

VFDs vary motor speed to vary flow

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Common VFD Applications

Commercial
Air distribution systems (fans)
Hydronic distribution systems (pumps)
DCW booster pumps
Cooling tower fans
Chillers
Industrial
Air compressors
Vacuum pumps
Baghouse fans
Refrigeration compressor
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VFDs on Constant Torque Loads

Power varies linearly with speed
Example loads:
Conveyors, mixers, positive displacement
pumps, rotary screw air compressors

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Image Source:
Natural Resources Canada

VFDs on Constant Torque Loads

Power varies with the speed cubed
Torque varies with the speed squared
Example loads:
Centrifugal pumps, centrifugal and axial
fans

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Image Source:
Natural Resources Canada

VFDs on Pumps and Fans

The majority of pumps and fans used in HVAC applications
are centrifugal
Centrifugal pumps and fans have a variable pressure / flow
relationship

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Typical Centrifugal Pump Curve

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Image Source:
US DOE Improving Pump System Performance: a Sourcebook for Industry

Centrifugal Pump & Fan Affinity Laws

Flow vs. Motor Speed
Power vs. Speed

Q1/Q2 = N1/N2
bhp1/bhp2 = (N1/N2)3

Q Volumetric flow
N Pump shaft rotational speed or fan wheel velocity (RPM)
BHP Brake horsepower

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VFDs on Pumps and Fans

VFD
Adjustable speed drive
Vary frequency (Hz) and voltage going to the motor
Motor RPM is reduced at lower Hz

VFDs save energy when the load varies

HVAC equipment is sized for peak loads
Peak conditions are ~1% of annual operating hours

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VFD Opportunity - Pumps

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Image Source: Eaton

VFD Opportunity - Fans

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Source: 2012 ASHRAE Handbook

Typical VAV Load Profile

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Source: 2012 ASHRAE Handbook

Typical Cooling Tower Load Profile

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Source: Danfoss VLT Application Guide

saveONenergy RETROFIT VFD Incentives

Prescriptive Incentives
Incentive is ~30 to 50% of VFD materials costs
VFD materials cost rule of thumb = $1,000 + ($75 per hP)

Demand savings are ~10% at 75% motor loading

Advantages

Disadvantages

Simple application
requirements
Incentive often ~50% of
materials costs

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Engineered / Custom usually has

higher incentives
Does not cover motors >100 hP

saveONenergy RETROFIT VFD Incentives

Engineered Incentives
Engineered Worksheets for VFDs on Pumps/Fans/Air
Compressors
Engineered worksheets calculate savings for pumps / fans
with the same flow profile before and after VFD operation
Advantages

Disadvantages

Potential for higher incentive

No hP limit

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Complex inputs required

Only one flow profile
Only for pumps / fans

saveONenergy RETROFIT VFD Incentives

Custom Incentives
Best for projects with different before and after load profiles
Projects with incentives >$10,000 require M&V
VFDs measure kW and amps

Advantages

Disadvantages

Potential for higher incentive

May require M&V

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Savings must be calculated

May require M&V

Example Custom VFD Project

Base Case
Induced Draft Cooling Tower with 20 hP Axial Fan
Efficient Case
Install VFD and new 20 hP motor ($6,200)

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Example Custom VFD Project

Efficient Case
Base Case Input
Input Power
Power (kW)
(kW)

Base Case
Efficient Case
Annual Energy
Annual Energy Annual Energy
Savings (kWh)
Use (kWh)
Use (kWh)

%Flow

% Run Hours

Run Hours

40

70

3.978

0.83

278.46

58.12

220.34

50

15

200

3.978

1.62

795.60

324.35

471.25

60

35

450

13.26

2.80

5,967.00

1,261.06

4,705.94

70

20

270

13.26

4.45

3,580.20

1,201.51

2,378.69

80

15

210

13.26

6.64

2,784.60

1,394.96

1,389.64

90

10

140

13.26

9.46

1,856.40

1,324.12

532.28

100

13.26

12.97

0.00

0.00

0.00

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Example Custom VFD Project

Results
Peak Demand Savings = 3.8 kW
Annual kWh Savings = 9,698
Incentive = $3,040
Annual Cost Savings = $1,250
Payback ~ 2.5 years

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Unitary AC
AHRI defines Unitary as:
one or more factory-made assemblies ordinarily including an
evaporator or cooling coil(s), compressor(s), and condenser(s) and
may include a heating function

Unitary AC equipment includes:

Split systems
Air-source heat pumps
Single package systems a.k.a. rooftop units

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Rooftop Unit Components

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Image Source: Bryant / Carrier

Economizers

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Image Source: Energy Designs Resources

Rooftop Units

All-in-one functionality H, V & AC in a box!

Relatively inexpensive
Do not take up interior space
Very high market share in Ontario
Distribution may be:
Constant volume or variable volume
Single zone or multi-zone

Installed cost approx. $1,200 to $1,800 per ton

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Rooftop Unit Efficiency Ratings

Efficiency ratings the higher the better!
Energy Efficiency Ratio (EER)
Seasonal Energy Efficiency Ratio (SEER)
Integrated Energy Efficiency Ratio (IEER)

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EER
Ratio of cooling rate (in Btu/h) to electrical input power (in
W)
Determined at:
Outdoor = 95F Dry Bulb
Return Air = 80F Dry Bulb, 67F Wet Bulb

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SEER
Ratio of annual cooling energy (in Btu) to annual
electricity consumption (Wh)
Only units 5.4 tons and below receive SEER ratings

SEER is primarily a residential rating

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IEER
IEER is a part load efficiency rating
IEER is the weighted average of EER at various loads:

100% load; 2% weighting

75% load; 61.7% weighting
50% load; 23.8% weighting
25% load; 12.5% weighting

Two units can have the same EER and a different IEER
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RTU Efficiency Standards & Specifications

ASHRAE
Energy Star
CEE

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ASHRAE 90.1
ASHRAE Standard 90.1:

Energy efficiency standard

Adopted by building codes (including Ontario)
Specifies minimum efficiency (EER) for RTUs
Latest version is 2010

ASHRAE 90.1 compliant units

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Energy Star and CEE

Energy Star maintains a list of qualified Light
Commercial Heating & Cooling products up to 20 tons
Consortium for Energy Efficiency (CEE) publishes a
three tiered specification for Unitary A/C equipment
Tier 0, Tier 1, Tier 2

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ASHRAE 90.1 vs. CEE Efficiency

Equipment Type

Size Category
(Btu/h)

Size Category
(Tons)

Heating Section
Type

<65,000

<5.4

All

>=65,000 and
<135,000

>=5.4 and
<11.25

>=11.25 and
<20

>=240,000 and
< 760,000

14.0 SEER

15.0 SEER

10/9.7 SEER

13 SEER

8.9 EER

11.2 EER

11.7 EER

11.7 EER

12.2 EER

8.3 IPLV

11.4 IEER

11.8 IEER

13.0 IEER

14.0 IEER

N/A

11 EER

11.5 EER

11.5 EER

12.0 EER

8.3 IPLV

11.2 IEER

11.6 IEER

12.8 IEER

13.8 IEER

Electric resistance Split system, single

or none
package

8.2 EER

11 EER

11.7 EER

11.7 EER

12.2 EER

7.2 IPLV

11.2 IEER

11.8 IEER

12.5 IEER

13.2 IEER

8.0 EER

10.8 EER

11.5 EER

11.5 EER

12.0 EER

7.0 IPLV

11 IEER

11.6 IEER

12.3 IEER

13.0 IEER

Split system, single

package

Electric resistance Split system, single

or none
package

8.2 EER

10 EER

10.5 EER

10.5 EER

10.8 EER

7.2 IPLV

10.1 IEER

10.6 IEER

11.3 IEER

12.3 IEER

Split system, single

package

8.0 EER

9.8 EER

10.3 EER

10.3 EER

10.6 EER

7.0 IPLV

9.9 IEER

10.4 IEER

11.1 IEER

12.1 IEER

8.0 EER

9.7 EER

9.9 EER

9.9 EER

10.4 EER

7.2 IPLV

9.8 IEER

10.0 IEER

11.1 IEER

11.6 IEER

7.8 EER

9.5 EER

9.7 EER

9.7 EER

10.2 EER

7.0 IPLV

9.6 IEER

9.8 IEER

10.9 IEER

11.4 IEER

>=20 and <63.3

Electric resistance Split system, single

or none
package
>=63.3
All other

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CEE Tier 2

8.9 EER

All other

>= 760,000

CEE Tier 1

Split system, single

package

All other

Air conditioners,
air cooled

Split / package

Electric resistance Split system, single

or none
package
All other

>=135,000 and
< 240,000

Subcategory or ASHRAE 90.1 ASHRAE 90.1 CEE Tier 0 /

Rating Condition
- 1989
- 2010
Energy Star

Split system, single

package

RTU Efficiency Old vs. New

ASHRAE 90.12010 min. EERs ~ 2 higher than ASHRAE 90.1 1989 min.
EERs

CEE Tier 1 min. EERs ~ 0.5 higher than ASHRAE 90.1 2010 min. EERs

~0.2 to 0.3 kW per ton improvement

~0.02 to 0.05 kW per ton improvement

CEE Tier 2 min. EERs ~ 1 higher than than ASHRAE 90.1 2010 min.
EERs

~0.08 to 0.09 kW per ton improvement

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RTU Efficiency Existing Units

Ensure proper maintenance
Consider advanced controls
Demand control ventilation
After market controllers

Replacing an existing unit with a new unit is typically not

cost-effective

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RTU Efficiency Advanced Controls

Demand control ventilation
Reduce outdoor air intake when areas are sparsely occupied

Aftermarket controllers

Digi-RTU
Catalyst
Aircosaver
Regen

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RTU Efficiency Advanced Controls

Advanced Controls Benefits
Low-cost (relative to new unit)
May be cost-effective (2 - 4 year payback or better)

Advanced Controls Drawbacks:

May not be suitable for all applications

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RTU Efficiency New & Replacement Units

Ensure units are properly sized
Specify high-efficiency units
Consider specifying high-efficiency controls
Commissioning

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saveONenergy RETROFIT RTU Incentives

Track

Prescriptive

Engineered

Incentive
Type

Base Case

Fixed $/unit
or
Fixed $/ton

Code
Minimum
Unit

$800/kW

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Existing Unit

Pros

Pre-approval not
required for
incentives
<$10,000*

Higher incentive
No minimum EER
requirements

Cons

Lower incentive
Minimum EER
requirements

Pre-approval
required

Example Rooftop Unit Retrofit

New CEE Tier 1 Unit EER = 11.5

New CEE Tier 2 Unit EER = 12

Incremental Cost
(over ASHRAE 90.1 unit)

$1,200

$2,400

Prescriptive Incentive

Ineligible

$1,000

Engineered Incentive

$1,200

$1,360

Energy Savings*

804 kWh vs. existing unit

125 kWh vs. new 90.1 unit (EER = 11)

919 kWh vs. existing unit

240 kWh vs. new 90.1 unit (EER = 11)

Demand Savings*

1.5 kW vs. existing unit

0.2 kW vs. new 90.1 unit (EER = 11)

1.7 kW vs. existing unit

0.5 kW vs. new 90.1 unit (EER = 11)

Payback

Instant

16 years**

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Summary
VFDs
VFDs are a cost-effective way to control flow
RTUs
Maintain units to maintain efficiency
Consider advanced controls
Specify high efficiency equipment for replacement units
saveONenergy incentives are available to help fund your
project!
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Thank You
Greg Rushby
Rushby Energy Solutions Inc.
226-747-5066
grushby@rushbyenergy.com
www.rushbyenergy.com

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