HVAC 101: Chillers and VFDs and BACnet Oh My! Tim Skell Sr. HVAC Application Engineer, ABB
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1 HVAC 101: Chillers and VFDs and BACnet Oh My! Tim Skell Sr. HVAC Application Engineer, ABB
2 Learning Objectives: 1. Examine the functionality of major HVAC equipment such as chillers, AHUs, cooling towers and VFDs. 2. Clarify how to use BACnet to create an intelligent building. 3. Demonstrate how VFDs play an essential role in energy savings, comfort and control. 4. Understand the value of proper commissioning, coordination, and continuous improvement.
3 Building Overview Geographic Location: Wisconsin Size: 147,000 sqft Multipurpose building 1/3 office space 2/3 factory floor space Electronic assembly
4 Goals of the HVAC Renovation More reliable system Reduced operating costs Lower energy consumption A greener building LEED Silver More intelligence Flexibility for R&D
5 Building Overview
6 Typical Office AHU
7 Typical VAV
8 Highlights of this AHU Outside air economizing DP sensing across air filters VFD on supply fan - maintaining duct pressure Duct pressure resets based on max VAV Safeties wired back to VFD Duct High Static Freeze Smoke Discharge air temp reset VFD on exhaust fan for maintaining building static Demand controlled ventilation monitor CO2 Humidification/Dehumidification BACnet points
9 Shipping/Receiving AHU
10 Differences of this AHU Added staged IR heating for winter Single zone no VAV No demand controlled ventilation No humidity control
11 Chilled Water System
12 Highlights of CHW system Thermal (ice) storage Make ice during off-peak hours Use ice during peak hours Redundant pumps & VFDs BACnet points
13 Condenser Water
14 CW Highlights Heat recovery chiller 90 F setpoint CW can be routed to hot water system No need for boilers to run Heat exchanger isolates cooling tower water from hot water system Redundant pumps BACnet points
15 Cooling Tower
16 Highlights of CT VFD s internal PID controls fan speed Redundant Pumps Bypass valve Auto drain Higher temp setpoint due to VAV reheat BACnet points
17 Hot Water system
18 HW Highlights Boilers talk to each other (Cascade) CW is used to limit boiler operation VFDs on BPs and HWPs Redundant pumps and boilers
19 Test Cell
20 Non HVAC Integration over Serial Communications Power Meter Instantaneous kw Instantaneous Power Factor
21 What does it look like?
22 Mechanical Room Continued
23 Mechanical Room Continued
24 Cooling Tower & Ice Storage
25 Recap of a HVAC System with Central Plant Chiller Creates chilled water to cool the air Heat is a side product condenser water Cooling Tower Cools the condenser water via evaporation Boiler Creates hot water used to warm the air Air Handling Unit Uses HW or CW to condition the air before supplying it to the space
26 The who, what, where, when, why, and how of VFDs What are VFDs? AKA adjustable frequency drives, inverters, freq drives, pulse with modulated drive, thing on the wall I hope I never have to worry about Electronics that control the voltage and frequency supplied to a motor, providing the ability to control the speed
27 VFDs Continued AC DC AC Rectifier Inverter 460 V, 60 Hz 640 V, DC 307 V, 40 Hz ABB Group
28 VFDs Continued Why are VFDs used? Control Flow HVAC systems are designed to handle the hottest (and coldest) days of the year VFDs help the system back off on the typical days Significant energy savings are achieved by slowing down a pump/motor Soft starting and slower speeds result in less wear n tear on equipment Enhanced motor protection Current limiting, ground fault detection, phase loss protection, brown out protection
29 How do VFDs save energy 100% 90% 80% Flow varies linearly with speed % Flow, % Torque, % Power 70% 60% 50% 40% 30% Torque requirement varies as the square of speed 10% reduction in speed equals over 25% energy savings 20% 10% Power requirement varies as the cube of speed 0% Frequency (Hz)
30 Assumptions: 12 hours a day 7 days a week VFD Payback
31 VFDs Where are they used Supply Fans Return Fans Exhaust Fans Hot Water Pumps Condenser Water Pumps Chilled Water Pumps Boiler Pumps Cooling Tower Fan Booster Pumps Anywhere there is a three phase motor
32 BACnet Serial Communication Protocol RS485 and IP platforms Open Protocol Not locked into a specific vendor BTL certification Brand A & Brand B can talk on the same wire Leading protocol used in HVAC Now standard (native) on many HVAC products
33 BACnet s role continued Most VFDs & significant HVAC equipment are connected to the BAS Hardwire for start/stop and general control Serial communications for monitoring Troubleshooting Trends
34 Goals of the HVAC Renovation More intelligence (utilizing BACnet) leads to: More reliable system Reduced operating costs Lower energy consumption A greener building LEED Silver Flexibility for R&D
35 Questions? HVAC System VFDs BACnet
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