Chretien
Chretien
Purdue University
Purdue e-Pubs
International Refrigeration and Air Conditioning
School of Mechanical Engineering
Conference
2018
Roger Becerra
Regal, United States of America, [email protected]
Nicholas Salts
Purdue University, [email protected]
Eckhard A. Groll
Purdue University - Main Campus, [email protected]
Chretien, Ludovic; Becerra, Roger; Salts, Nicholas; and Groll, Eckhard A., "Seasonal Energy Efficiency Rating Improvement Of
Residential HVAC Systems Using A Low Power Inverter With A PSC Compressor" (2018). International Refrigeration and Air
Conditioning Conference. Paper 1896.
https://docs.lib.purdue.edu/iracc/1896
This document has been made available through Purdue e-Pubs, a service of the Purdue University Libraries. Please contact [email protected] for
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2256, Page 1
* Corresponding Author
ABSTRACT
Homeowners in the United States can generally choose among three types of air conditioning systems: fixed-speed
compressor systems that cycle on and off to deliver an average cooling capacity; fixed-speed / multi-capacity
compressor systems with reduced cycling; and variable speed compressor systems that match the cooling load of the
household, thereby delivering better temperature and humidity control with higher efficiency and comfort levels.
While HVAC systems account for about 45% of the energy consumption in U.S. homes and variable speed compressor
systems can achieve significantly higher efficiency, they only account for 10% of the market and systems installed in
new buildings mostly remain single speed. This could be explained in part by the initial system cost and the complex
electronic circuitry used to vary compressor speed. This paper presents a system solution to improve the Seasonal
Energy Efficiency Rating (SEER) of Permanent Split Capacitor (PSC) compressor systems by introducing a low
power inverter used only for operation at low capacities. SEER results for 3 tons and 5 tons systems with scroll and
rotary compressors are presented. The impact of varying the speed of the PSC outdoor fan on SEER is also discussed.
1. INTRODUCTION
Vapor compression air conditioning systems installed in residential housing in the United States typically include the
following subsystems: a compressor, and expansion apparatus, an evaporator coil and its associated fan, and a
condensing coil and its associated fan. The technologies used for these various elements have significant impact on
the efficiency achievable by HVAC units. Low SEER systems traditionally use fixed speed Permanent Split Capacitor
(PSC) compressor and fans, whereas high SEER units tend to implement variable speed control.
The following sections will first present the key characteristics of both single speed and variable speed systems and
then outline the SEER gains achieved by introducing a novel power electronic control and vary the compressor and
outdoor fan speeds of a single speed system using PSC motors. Finally, the paper will discuss the technique used for
SEER optimization when varying the speed of all three motors and present the results of a study of oil circulation
when operating the compressor at low speeds.
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4 8
3.5 7
3 6
Current (p.u.)
Torque (p.u.)
2.5 5
2 4
1.5 3 Torque p.u.
1 2 Current p.u.
0.5 1
0 0
0 0.2 0.4 0.6 0.8 1
Motor Speed (p.u.)
As depicted in Figure 1, a PSC may only develop a fraction of its full load torque when starting from a standstill
condition, and draws several times its rated current until the speed approaches rated speed. These characteristics of
PSC motors impose several limitations on the operation of single speed systems.
Finally, the typical efficiency curve of a PSC motor dictates that the operating point should be maintained as close as
possible to the motor rated point in order to maximize efficiency. Indeed, either an increase or a decrease from the
optimal operating speed result in a decrease in motor efficiency.
In the United States, the efficiency of an HVAC system is evaluated through its Energy Efficiency Ratio (EER) and
Seasonal Energy Efficiency Ratio (SEER). The EER is the ratio of the system cooling capacity (in Btu/hr) with the
power consumed by the HVAC system, including the compressor, the indoor fan, and the outdoor fan input power.
The SEER for a single-speed system is calculated according to the ANSI/AHRI Standard 210/240 for the Performance
Rating of Unitary Air-Conditioning and Air-Source Heat Pump Equipment. The standard calls for several tests, some
in continuous operation, some under cyclical operation in order to establish the cyclic coefficient of degradation C d.
Table 1 summarizes the tests to assess single speed rating.
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Once the tests in Table 1 are completed, the SEER rating is calculated according to Equation (1) below.
100
80
Efficiency
60
40 PSC
20 BLDC
0
0 0.5 1
Motor Speed (p.u.)
As can be seen in Figure 2, BLDC motors can achieve very high efficiency over a wide speed range when compared
with PSC motors. However, when evaluating the impact of variable speed technology on HVAC system, it is necessary
to include the losses from the electronic controller over the complete speed range.
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The power conversion in the electronic drive comprises two steps. First, the AC mains voltage from utility power is
transformed into a DC voltage stored on a DC bus capacitor by a power factor correction unit. A power factor
correction unit is typically included with variable speed compressor systems to ensure that the maximum power can
be extracted from the main supply. As an example, a 4kW residential unit with power factor correction unit would
draw about 18 Amps from the power source. The same unit without power factor correction could draw close to 28
Amps. Depending on the service available in residential housing and the protection used on the circuit, it is possible
that running a 4kW without power factor correction would result in nuisance tripping of the line breaker.
The second step in the power conversion is realized by the inverter. The inverter transforms the DC bus voltage into
a source of variable voltage and variable frequency to adjust the operating speed of the motor.
The switching of the power electronics components of the variable speed drive produces losses and for a typical
converter used in residential applications, the efficiency will range from 92% to 94%. These losses generate heat and
often result in thermal challenges for operating the electronic drive at high ambient conditions.
Similar to single speed systems, the ANSI/AHRI Standard 210/240 provides the testing procedures and calculations
to compute the SEER for variable speed systems. These tests are presented in Table 2 below.
For variable-speed systems, tests are conducted at three distinct compressor speeds. The relationship between
compressor speeds follows Equation (2).
Speedmax −Speedmin
Speedintermediate = Speedmin + (2)
3
Indoor and outdoor fan speeds may also be varied to further adjust the cooling capacity delivered by the system.
4. PROPOSED SOLUTION:
VARIABLE SPEED OPERATION OF SINGLE SPEED SYSTEMS
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HVAC systems using variable speed compressors can achieve significantly higher SEER rating compared to their
single speed counterparts. However, variable speed compressors have to be used in conjunction with electronic
controllers that reduce to overall system efficiency and pose significant thermal management challenges at maximum
load. A system solution combining a single speed compressor for full load operation with a low power electronic drive
for low power operation is proposed to address some of these shortcomings.
Contrasting the systems detailed in Figures 3 and 4, it can be seen that the proposed solution comports the components
necessary for line operation as well as some elements common with traditional variable speed drives. However,
because the electronic drive is not used at full load operation, the power factor correction unit can be eliminated,
thereby improving the efficiency of the electronic drive. Finally, an optional line synchronization circuitry can be
implemented in the proposed solution. With this circuitry, it is possible to implement soft starting and develop
maximum starting torque on the compressor under pressure differential between the discharge and suction ports.
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connected between the compressor and utility power only during variable speed operation. The drive varies the
compressor speed between standstill and 75% of full speed to meet reduced cooling loads. When the cooling load
increases beyond this operating range, the electronics transitions the compressor to utility power to operate at full load.
Figure 6 below illustrates this concept.
The proposed modes of operation present significant improvements when compared to single speed systems. Indeed,
besides the improvement in SEER, this solution allows for smooth and controlled starting of the compressor under
large pressure differential, eliminating large inrush currents of the typical line started PSC compressors. Furthermore,
lower operating speeds allow for reduced cycling of the HVAC system and increased comfort. Finally, the addition
of the electronics drive allows for monitoring of the compressor operation even when on utility power, thereby
reducing system stress under locked rotor conditions.
While the proposed system offers substantial advantages when compared to single speed systems, it also offers benefits
over traditional variable speed systems. Indeed, as the electronic converter is bypassed during operation on the line,
its power rating, and therefore overall size, can be reduced. Furthermore, thermal management for the electronics and
heatsinking is simplified as full load high ambient operation occurs on utility power.
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The heat pumps were tested in cooling mode, and the cooling capacities were determined using the refrigerant enthalpy
method. The power consumptions of the indoor and outdoor unit are measured separately using Watt transducers. Data
is collected through a National Instruments cRIO-9074 using a VI written in LabVIEW. All refrigerant and air
properties have been determined using the software Engineering Equation Solver (EES.)
Heat Pump
Compressor Type Manufacturer Size
Nominal Capacity
Scroll Manufacturer 1 5 ton
5 ton
Rotary Manufacturer 2 4 ton
Scroll Manufacturer 1 2.5 ton
2.5 ton Rotary Manufacturer 2 3 ton
Rotary Manufacturer 3 2.5 ton
The experimental determination of the variable speed SEER was done in three phases as shown in Table 4. Each phase
isolated one of the three speed controlled components to be tested as the independent variable. As testing moved from
one phase to another, the ideal variable speed conditions from the previous phase were carried over and applied to the
next phase. For example, if it is determined that the largest SEER in VSHP 1 mode is achieved at a minimum
compressor speed of 30 Hz, this will be the minimum compressor speed applied in every test case for the VSHP 2
phase.
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Table 5: SEER test results
Test 5 Ton Scroll 4 Ton Rotary 3 Ton Rotary 2.5 Ton Rotary
Phase SEER SEER SEER SEER
Baseline 14 13.08 11.38 12.84
VSHP 1 14.94 16.46 14.33 17.95
VSHP 2 15.67 18.10 14.43 (*1)
VSHP 3 (*1) (*1) 15.42 (*1)
(*1) Detailed testing not performed as preliminary testing showed little improvement testing in this mode of operation
Details about SEER testing of the 5 ton and 4 ton compressors in VSHP 1 mode with information related to operating
speeds have been previously reported by Chretien et al. (2017).
6. COMPRESSOR ANALYSIS
The analysis below is provided to better understand the impact of the electronic drive on compressor performance,
including an overall isentropic efficiency analysis and measurements of the oil concentration ratio in the liquid line.
6.1 Methodology
Scroll and rotary compressors used in residential heat pumps are often designed to use the speed of the rotating shaft
to circulate oil to critical components within the compressor shell. Lubricant oil is used in the compressor to lubricate
bearings and to seal gaps between high pressure and low pressure compression pockets. Significant efforts have been
made to understand lubricant circulation within the compressor as well as lubricant migration from the compressor to
the refrigeration system. Measurement and simulation results by Cho et. al. (2002) showed that oil flow to the journal
bearing of a scroll compressor varied directly with shaft speed. These results demonstrate the potential for insufficient
lubricant circulation within the compressor at low compressor speeds. Min and Hwang (2000) describe the
mechanisms by which oil is discharged from a rotary compressor as well as methods to reduce the OCR. Reduction
in OCR is typically desired to avoid running the compressor dry. Excess of oil in the refrigeration system has also
been shown to have negative effects on system performance. Cuevas and Lebrun (2009) tested a variable speed scroll
compressor and found that the OCR varied directly with shaft speed. The authors also observed a significant decrease
in scroll compressor efficiency at low compressor speeds which they attributed to a lack of sufficient lubrication within
the compressor. These studies highlight the desire to ensure sufficient lubrication in the compressor while also
minimizing the amount of oil discharged to the compressor. This effort is made challenging by the fact that both of
these phenomena have been observed to be directly related to shaft speed.
Because the compressors tested in this effort were designed to operate at a fixed speed, there was some concern about
a lack of sufficient lubricant circulation inside the compressor when operated at low speeds. Based on the literature
review, the OCR was identified as a metric that could be used as an indicator for internal oil circulation; it is assumed
for example that a reduction in the amount of discharged oil measured in the liquid line is an indicator that lubricant
circulation within the compressor is also reduced. The OCR was also a metric that could be measured without requiring
any major modifications to the system or modifications that would impact system performance. The OCR was
measured for the heat pump having the 3 ton rotary compressor from manufacturer 2 installed and is reported as the
percentage weight of oil in the oil-refrigerant mixture.
To design the OCR measurement system and method for collecting the lubricant sample in the liquid line, ASHRAE
Standard 41.4 was followed with one minor modification based on a literature review. Peuker (2010) describes that
the method of evacuating the sample cylinder according to ASHRAE Standard 41.4 is not sufficient in removing all
of the refrigerant which may be solved in the oil. The author suggests immersing the cylinder in a hot water bath
during the evacuation process to ensure all of the refrigerant is removed from the cylinder, and provides data to support
the efficacy of this method. Because the method was simple to implement and had been proven to work, it was adopted
in this procedure. The OCR measurement method used in this study is also referred to as the weight measurement
method and was used in the studies by both Min and Hwang (2000) and Cuevas and Lebrun (2009).
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Compressor overall isentropic efficiency has also been determined. Overall isentropic efficiency is a function of the
refrigerant mass flow rate, the compressor power, the enthalpy at the compressor inlet, and the enthalpy at the
compressor discharge for an assumed isentropic compression as shown in Equation 3.
ℎ2𝑠 − ℎ1
𝜂𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟 = 𝑚̇𝑟𝑒𝑓
𝑃𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟 (3)
6.2 Results
Table 6 lists the results of the OCR testing and shows the influence of compressor speed on the oil circulation rate.
The amount of oil discharged is reduced as compressor speed is reduced. As previously mentioned, the reduction in
oil discharged from the compressor could be an indicator of a lack of lubricant flow in the compressor. This could
lead to an increase in frictional losses in the bearings as well as an increase in leakage due to a lack of lubricant sealing.
This however is only one explanation; the reduction in discharged oil could also be a result of the oil separation
mechanisms operating more efficiently at lower compressor speeds.
The overall isentropic efficiency for the 3 ton compressor from manufacturer 2 is plotted in Figure 7. Both plots in the
figure show the same results but in different ways. In general, isentropic efficiency decreases with decreasing
compressor speed at a given rating condition. One possible reason for this is insufficient lubrication within the
compressor. The higher efficiencies at full load test conditions A 2 and B2 can be partly attributed to the fact that the
electronic drive is not engaged at full speed operation and therefore no drive losses are incurred.
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7. CONCLUSIONS
The addition of a variable speed drive to a single speed PSC compressor to enable variable speed operation under light
cooling loads, when combined with variable speed indoor and outdoor fans, allows for over 33% improvement over
baseline. Future work to benchmark the technology will include testing of fixed speed compressors with internals
specifically designed to accommodate lower speeds of operation. Furthermore, for setups that have provided
significant SEER improvements without requiring any modifications to the compressors, the study of oil circulation
when operating at low speeds can be expanded to better understand the lubricant flow within the compressor shell.
This study could be achieved through modelling or experimental work.
REFERENCES
[1] ANSI/AHRI Standard 210/240 with Addenda 1 and 2 (Formerly ARI Standard 210/240)
Performance Rating of Unitary Air-Conditioning & Air-Source Heat Pump Equipment.
[2] ASHRAE Standard 41.4-2015 -- Standard Method for Measuring the Proportion of Lubricant in Liquid
Refrigerant (ANSI Approved).
[3] Chretien, L., Becerra, R., Salts, N. P., Groll, E.A. (2017). System solution to improve energy efficiency of
HVAC systems. 10th International Conference on Compressors and their Systems 2017. London, UK.
[4] Cuevas, C. Lebrun, J. (2009). Testing and modelling of a variable speed scroll compressor. Applied Thermal
Engineering. 29. 496-478.
[5] Huang, B., Min, M., Geng, W. (2010). Experimental Study on Reduction of Oil Circulation Rate in Rotary
Compressor. International Compressor Engnieering Conference. Paper 2021. West Lafayette, Indiana USA.
[6] Min, K., Hwang, I. (2000). Oil Circulation Rate in rotary Compressor: Its Measurement and Factors Affecting
the Rate. International Compressor Engnieering Conference. Paper 1395. West Lafayette, Indiana USA.
[7] Peuker, S. (2010). Experimental and Analytical Investigation of Refrigerant and Lubricant Migration. PhD
Dissertation Thesis. University of Illinois. Urbana, Illinois USA.
[8] Salts, N. P., Groll, E.A. (2017). Inverter Drive Control and Seasonal Performance Analysis of a Single Speed
Unitary Air-Source Split-System Heat Pump. 12th IEA Heat Pump Conference 2017. Rotterdam, NL.
17th International Refrigeration and Air Conditioning Conference at Purdue, July 9-12, 2018