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3rd EHPA European Heat Pump Forum | Brussels | 20.05.2010
Inverter and programmable controls in heat pump
applications
Biagio LamannaApplication Competence Centre ManagerProduct Development Process
CAREL INDUSTRIES Srl
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Page 23rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Why BLDC inverter compressors?
Carel pCOsistema+ for HP application
Features & Benefits of an integrated solutionVS a stand alone inverter
Compressor motor technologies
Partial load and seasonal efficiency
Conclusions
Summary
Ready to use solution approved by the compressor manufacturers
Full customizable hardware and software
(for CAREL algorithm details see the end of the presentation)
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Page 33rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
BLDC(brushless direct current) motorBPM(brushless permanent magnet) motor
DC(direct current) inverter
IPM(interior permanent magnet) motor
SPM(surface permanent magnet) motor
EC(electronic controlled) motor
What does BLDC means?
Different NAMES for theSAME technology
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Page 43rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Electric motor evolution:
AC asynchronous induction motor
DC brushless motor (SPM)
DC brushless motor (IPM)
Why BLDC inverter compressors?
!The magnets of SPM motors are inside the rotor
!
Highest efficiency and performances!High speed
!Requires a top level BLDC inverter
!Both compatible with standard on-off technology and inverter use
!Good performances only for motors developed specifically for inverter use
!Energy waste due to the need to create the rotor magnetic field
!The rotor is a permanent magnet, there no energy waste
!The magnets of SPM motors need to be fixed on the rotor surface using adhesive,high speed is not allowed
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Page 53rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
The motor structures of the IM (induction motor), SPM (Surface permanentmagnets, IPM (Interior permanent magnets)
Comparison table of IM, SPM and IPM motors
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Page 63rdEHPA European Heat Pump Forum | Brussels | 20.05.2010Confidential
The efficiency improvement of the brushless motor technology versus
the induction motor can be estimatedon 4-5%
Why BLDC inverter compressors?
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Page 73rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Speed controlled BLDC compressors
Scroll or twin rotary, up to 35kWcooling capacity, mainly R410a
refrigerant, up to 65Ccond. temperature with no liquid injection
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Page 83rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Why BLDC inverter compressors?
New unit testing andrating proceduresbased on partial load
and seasonal efficiency
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Page 93rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Variable speed compressorscanmatch the partial load giving anextremely high unit efficiency due to
the improved efficiency of thecompressor at partial load as motorperformance and basic COP
together with improved efficiency ofboth heat exchangers
P
ressure
Enthalpy
Increased
efficiency
Why BLDC inverter compressors?
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Page 103rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Speed controlled BLDC compressors
Unit performances with BLDC compressors
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Page 113rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Speed controlled BLDC compressors
Unit performances with BLDC compressors
Energyco
streduct
ion:
500!/
year
(0.225!/kwh)
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Page 123rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
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Page 133rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Makes DC inverter technology available
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Page 143rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
pCOsistema+: off the shelf technology
Thanks to the experiences ofCAREL Labs
1toollibrary provides a widerange of turn key solutionsto make DC invertertechnology available to heatpump manufacturers.
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Page 153rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
pCOsistema+: off the shelf technology
Development time forBLDC inverter compressor
management:
8 months
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Page 163rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
pCOsistema+: off the shelf technology
Development time for EEV
management:
3 months
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Page 173rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
pCOsistema+: off the shelf technology
Development time forbrushless sensorless
technology drive:
12 months
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Page 183rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
pCOsistema+: off the shelf technology
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Page 193rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
pCOsistema+: user interfaces range for deep
customization
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Page 203rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
pCOsistema+: wide range of programmable controllers
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Page 213rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Complete HP control
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Page 223rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Saving more than 40 development weeks
Makes DC inverter technology available
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Page 233rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Features & Benefits of an integrated solution
Developm
enttime:
10-12mo
nths
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Page 243rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Features & Benefits of an integrated solution
Compressor safeguard
Managed function
Compressor start up procedure
Compressor working envelope
Compressor timings
Compressor minimum pressure drop
Suction superheat
Discharge superheat
Discharge gas temperature
Extrafea
tures
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Page 253rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Features & Benefits of an integrated solution
Unit safeguard and performance
Managed function
Compressor start failure management
Compressor equalization at start-upDrive alarm managementSpeed regulation according to theapplication needsDrive parameter pre-set for differentcompressors
Drive custom parameters load andsave managementDrive complete user interface
Extrafea
tures
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Page 263rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Conclusions
Conclusions
A BLDC inverter compressor unit:
Has the top level compressor motortechnology
Meets all present and future efficiency ratingspecifications
Grants high performances due to the wide range of coolingcapacity modulation that allows the best application
temperature control
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Page 273rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Conclusions
Conclusions
A full integrated system for HP application:
Meets ALL compressor manufacturer specifications (with their
official approval!)
Allows to use the compressor in the full speed rangein all theworking envelope conditions
Avoids the unit OEM to spend months of R&D development
Grants a full control on the unit with plenty of extra featurescompared with a stand alone inverter drive that allow to reach
the best performance level
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Page 283rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Conclusions
Conclusions
A full customizable system for HP application:
Meets all unitmanufacturer needsin terms of performance/cost
compromise
Allows the unit manufacturers to keep their knowledge about theapplication and customize any part of the software and userinterface
Has many user interface solutionsfor each different user profile
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Page 293rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
Inverter and programmable controls in heat pump
applications
Biagio LamannaApplication Competence Centre ManagerProduct Development Process
CAREL INDUSTRIES Srl
+390499716611www.carel.com
THANK YOU FOR YOUR KIND
ATTENTION
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Page 303rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
CAREL control algorithm details
Compressor working envelope:
Min/Max compressor ratio
Min pressure differential
Max motor current
Max/min discharge pressure Max/min suction pressure
Max discharge temperature(different for each zone)
Min/Max compressor speed(different for each zone)
Different management foreach compressor!
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Page 313rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
CAREL control algorithm details
Compressor working envelope management:
! Unit capacity reduction by EEV control in caseof low compressor ratio, high suctionpressure, high motor current, etc
!
Compressor capacity reduction in case of highdischarge pressure and/or temperature, lowsuction pressure, etc
! Drive acceleration/deceleration ramp controlto avoid going outfrom the safety workingareas
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Page 323rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
CAREL control algorithm details
Compressor windings temperature management:
By means of measuring:
compressor shell temperature
compressor discharge gas temperature and superheat
compressor motor current
The control system can:!
stop the compressor due to high shell temperatureseven if
! the drive can manage the compressor speed incase of high motor current without stopping it and
! both EEV and compressor control modules canregulate the discharge superheat or temperature for
optimal compressor performance with maximumcompressor speedby means of the safety liquid
injection
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Page 333rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
CAREL control algorithm details
Unit start-up management:
The synchronization between compressor, driveand EEV management allows the take care of:
! Pressure differential before start
! Equalization, if needed or
! compressor start-up even with up to 10bargpressure difference.
!
Pressure differential after start ( greater than theminimum allowed)
! Oil recoveryafter start
! Compressor warm up
! Compressor timings (minimum ON time, minimum
OFF time, minimum time between different starts)
! Start-up quick retry in case of start failure
!
Wrong wiring, blocked rotor, damaged motorwindings, or any start-up problem.
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Page 343rdEHPA European Heat Pump Forum | Brussels | 20.05.2010
CAREL control algorithm details
Compressor alarm management:
Centralized alarm management for all unitcomponents:
The unit can work even with broken probes
Critical alarms manual reset by user interface or remote
monitoring system
Automatic to manual alarm reset after a defined number
of attempts
All alarms in the same UI:
! Unit alarms (i.e. low temperature, low water flow,high pressure, etc)
! Compressor alarms (i.e. high discharge temperature,out of envelope, low compressor ratio, etc.)
! Drive and motor alarms (i.e. high motor current, lowsupply voltage, communication offline, etc.)
!
Valve alarms (i.e. stepper motor damaged, lowsuction superheat, etc.)