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By William Greco
w2gre@verizon.net
Warrington, Pa.
8/20/09
Executive Summary
The basis of this essay is to algebraically combine Pulley and Fan Laws into single
equations. (Note: Pulley pitch diameter and pulley diameter are used interchangeably,
sheave and pulley will also be used interchangeably.)
Main
Except for direct drives, fans and blower sets have a driver pulley on the motor shaft
and a driven pulley on the fan shaft with belt or belts to convey power to the fan. The
mathematical relationships between motor and fan speeds, driver and driven pulley diameters,
horsepower and fan static pressures will be investigated in this report. Also equations will
be developed for fan operation when dealing with changing capacity requirements. Fan laws
will be substituted and rearranged against pulley laws to predict fan performance in relation
to modifying characteristic variables.
Pulley Equation:
DPM MPR
RFP1 equation-1
DPF
where :
RFP1 Existing RPM of fan pulley
DPM Diameter of motor pulley
DPF Diameter of fan pulley
MPR RPM of motor pulley
A change in pulley sizes will affect the performance of the fan rpm which in turn will
influence characteristics of all the other variables of the fans operation.
Fan Laws
The Fan Laws are the basic proportional analogy between fan RPM, CFM, Total Pressure developed by
the fan, and required Brake Horsepower. They are most useful for calculating
the impact of extrapolating from an existing fan performance to a new fan performance.
3
HP1 RFP1
equation-2
HP2 RFP2
where:
HP1 exisitng brake horsepower
HP2 new brake horse power
RFP1 RPM of fan with HP1exisitng brake horsepower
RFP2 RPM of fan with HP2 new brake horsepower
HVAC Pulley Math Page 2 of 18
By William Greco
w2gre@verizon.net
Warrington, Pa.
8/20/09
DIVIDE BOTH
HP2 RFP13 HP1RFP23
SIDES BY HP2
HP2 HP2
HP1RFP23 3
HP1 RFP2
CUBE ROOT OF
BOTH SIDES
3
RFP1 3
3
HP2
RFP1 3
HP2
3
HP1 RFP2
RFP1 3
HP2
1 1
n n B AB 3
RFP2
A A and A RFP1 HP1 1
C C
HP2 3
1
RFP2
RFP1 HP13 1
(equation-3)
HP2 3
1 1
divide by
HP2 3 DPM MPR HP13 RFP2 DPF
DPMMPR
DPM MPR DPM MPR
1 3
HP13
RFP2 DPF
a b a b HP2
n n
equation-4
DPM MPR
HVAC Pulley Math Page 3 of 18
By William Greco
w2gre@verizon.net
Warrington, Pa.
8/20/09
1 3
HP13 RFP2 DPF
HP2 equation-4
DPM MPR
Example-1: (continued)
Also note that if you plug the original 6 inch pulley back into the equation:
3
1 8 1740
3.7 3 6
6 3.7 Brake Horsepower
HP2
8 1740
The calculation can be worked out using the pulley equation-1 in the first step then
applying the fan laws as step 2, however equation-5 allows a one step calculation.
VFD calculations can also be worked out using equation-5.
3
1 7.5 1250
8.6 3 6.75
6.75
HP2 8.6 Brake Horsepower @ 71.4%
7.5 1250
3
1 7.5 1575
8.6 3 6.75
6.75
HP2 17.2 Brake Horsepower @ 90%
7.5 1250
The brake horsepower went from 8.6 BHP to 17.2 BHP (50% increase in brake horsepower) with only a
20% increase in motor speed.
HVAC Pulley Math Page 5 of 18
By William Greco
w2gre@verizon.net
Warrington, Pa.
8/20/09
Example-3: (VFD Change in motor speed and pulley modification-Find New Horsepower)
A fan set has a fan pulley that is 6.5 inches in diameter and a 5.5 inch motor pulley,
the motor is on a variable frequency drive and can be operated at 35% to 115% of
the motors rated 1,750 rpm. The VFD is presently controlling the motor to run at
1,050 rpm (60% of rating) and the brake horsepower has been worked out to be 19.3
at the 60% rating.
If the VFD speed is decreased to 55% of the 1750 rpm rating and the motor pulley is changed from 5.5 to
5.25 inch diameter what will the new brake horsepower be ?
(0.55 x 1750 = 997.5 rpm)
1 3
5.5 1050
19.33 6.5
6.5
HP2 19.3 Brake Horsepower @ 60% of rating
5.5 1050
1 3
5.25 997.5
19.33
6.5
6.5
HP2 14.392 Brake Horsepower @ 55% of rating
5.5 1050
The equation for fan brake horsepower can be substituted for the HP1 variable in equation-5.
The fan brake horsepower equation:
CFM SP_inwg Gas_spec_grav
BHP (equation-6)
6356 Fan_eff
where:
BHP = Brake horsepower
CFM = Cubic feet (of specified gas) per minute
SP_inwg Static Pressure developed by the fan (inches water gage)
6356 = a constant (see "Derivation of the Nine Major HVAC Constants")
By Bill Greco - 2-16-07
Fan_eff=combined efficiency of fan and motor drive
Gas_spec_grav Specific Gravity of gas being transported by fan
HVAC Pulley Math Page 6 of 18
By William Greco
w2gre@verizon.net
Warrington, Pa.
8/20/09
Substituting the Fan Horsepower equation-6 for the HP1 variable into equation-5.
1 3
DPM2 MPR2
HP13 DPF1
DPF2
HP2 equation-5
DPM1MPR1
becomes:
1 3
CFM SP_inwg Gas_spec_grav 3 DPM2 MPR2
DPF1
6356Fan_eff DPF2
HP2 equation-7
DPM1 MPR1
where:
HP2 = New brake horsepower
DPM1 = Existing diameter of motor pulley
DPF1 = Existing diameter of fan pulley
MPR1 = RPM of motor pulley
DPM2 = New or existing diameter of motor pulley
DPF2 = New or existing diameter of fan pulley
MPR2 = New RPM of motor pulley (in cases where a VFD is involved the existing
CFM = Existing Cubic Feet (of specified gas) per minute
Gas_spec_grav = Specific Gravity of gas being transported by fan
Fan_eff = Existing Efficiency of the fan (1 <)
SP_inwg = Existing Static pressure developed by the fan
6356 = A constant
HVAC Pulley Math Page 7 of 18
By William Greco
w2gre@verizon.net
Warrington, Pa.
8/20/09
Example-4: (Existing Horsepower Variables are all known- Find New Horsepower)
An existing belt driven fan is moving 9,980 cfm and producing 4.1 inches water gage (inwg) of
pressure. The fan is on a variable frequency drive (VFD) and is running at 1,150 rpm
which is 65.7 % rating of the 1,750 rpm motor. Specific gravity of the air being moved by the
fan is taken at unity (1). The fan sets efficiency is 78% (0.78). The existing fan pulley diameter is 8.1” and
the existing motor pulley diameter is 7.5”.
The VFD is to be adjusted to 73% of the motor 1,750 rpm (0.73 x 1,750 = 1,278 rpm) the
motor pulley is to be changed to a 8” diameter and the existing fan pulley is to be changed out for a 7.625”
diameter pulley. Applying equation-7 what will the new brake horsepower be ?
DPM1 = 7.5
DPF1 = 8.1
MPR1 = 1,150
MPR2 = 1,278
DPF2 = 7.625
DPM2 = 8
CFM = 9,980
SP_inwg = 4.1
Gas_spec_grav = 1 for air
Fan_eff = 0.78 (78%)
9,980 4.11
8.25 existing BHP by equation-6
6356 0.78
1 3
9,980 4.11 3 7.5 1,150
8.1
63560.78 8.1
HP2 8.25 existing BHP by equation-7
7.5 1,150
1 3
9,980 4.11 3 8 1, 278
8.1
63560.78 7.625
HP2 16.48 new BHP by equation-7
7.5 1,150
The modified operating parameters of the fan set call for the motor to produce
16.48 brake horsepower.
HVAC Pulley Math Page 8 of 18
By William Greco
w2gre@verizon.net
Warrington, Pa.
8/20/09
Equation-7 can be modified by substituting the brake horsepower variables for HP2, then
solving for CFM or inwg. To simplify the calculation assume that air is the only gas being transported and
Gas_spec_grav = 1. The number 2 will be used after the CFM, SP_inwg and Fan_eff to identify the HP2
variables.
1
CFM2 SP_inwg2 1 3
HP 2 Thus :
6356 Fan_eff2
1 3
1
CFM SP_inwg 1 3 DPM2 MPR2
DPF1
CFM2 SP_inwg2 1 3 6356 Fan_eff DPF2
6356 Fan_eff2
DPM1MPR1
Solving for CFM2: For algebraic manipulation simplicity the following substitutions were made :
C1 for CFM (existing condition) C2 for CFM2 (new condition)
D1 for DPM1 (existing condition) D2 for DPM2 (new condition)
E1 for Fan_eff (existing condition) E2 for Fan_eff2 (new condition)
F1 for DPF1 (existing condition) F2 for DPF2 (new condition)
M1 for MPR1 (existing condition) M2 for MPR2 (new condition)
S1 for SP_inwg (existing condition) S2 for SP_inwg2 (new condition)
1 3
C1S11 3 D2 M2
F1
6356 E1 F2
D1M1
1 3
C1S1 3
a D2 F1 M2
c
ac
6356 E1
b
numerator is a fraction, compound fraction can be eliminated =
d bd D1F2 M1
HVAC Pulley Math Page 9 of 18
By William Greco
w2gre@verizon.net
Warrington, Pa.
8/20/09
3
1
C1S1 3
D2 F1M2 1
a
n
n n 6356 E1 3
move exponent into the numerator and denominator =a b
b D1F2 M1
a 1 3
c
ac D2 F1M2 C1 S13
numerator is a fraction, compound fraction can be eliminated b =
d bd 1
C 2 S2 C1 D2 F1 M2 S1
3 3 3
3 3 3
(equation-8)
6356 E2 6356 D1 E1 F2 M1
solving for C2 (New CFM) from equation-8 :
C 2 S26356 D13 E1 F23 M13 6356 E2 C1 D23 F13 M23 S1
SUBTRACT 6356
FROM BOTH SIDES C 2 S2 6356 6356 D13 E1 F23 M13 6356 6356 E2C1 D23 F13 M23 S1
3 3 3
divide S2 D1 E1 F2 M1 C 2 S2 D13 E1 F23 M13 E2 C1 D23 F13 M23 S1
from both sides
S2 D13 E1 F23 M13 S2 D13 E1 F23 M13
HVAC Pulley Math Page 11 of 18
By William Greco
w2gre@verizon.net
Warrington, Pa.
8/20/09
where:
CFM = Existing CFM
CFM2 = New CFM
DPF1 = Existing diameter of fan pulley
DPF2 = New or existing diameter of fan pulley
DPM1 = Existing diameter of motor pulley
DPM2 = New or existing diameter of motor pulley
Fan_eff = Existing Fan Set Efficiency (1 <)
Fan_eff2 = New Fan Set Efficiency (1 <)
MPR1 = Existing RPM of motor pulley
MPR2 = New RPM of motor pulley (in cases where a VFD is involved the existing
SP_inwg = Existing Static pressure developed by the fan
SP_inwg2 = New Static pressure developed by the fan
Example-5 (Existing and New Variables are Known to find New CFM)
An existing fan set is producing 10,500 cfm @ 4.3 inches water gage, the motor is on a
variable frequency drive (VFD) and is running at 70% of it’s 1,750 rpm rating or 1,225 rpm.
The motor pulley’s have a pitch diameter of 10 inches and the fan pulley’s diameter’s are 9.3 inches.
Fan set efficiency is 79%. The VFD speed is to be increased to 75% of it’s capacity or
1,750 x 0.75 = 1,312 rpm, the fan pulley diameter’s are to be increased from 9.3 inches to
10.25 inches and the motor pulley’s (sheaves) are to be increased from 10 inch diameter
to 10.5 inches in diameter.
The new static pressure produced by the fan is assumed to be 4 inches water gage (inwg).
Fan set efficiency is assumed to remain at 79%.
Find the new CFM.
C 2 S2 C1 D2 F1 M2 S1
3 3 3
3 3 3
(equation-8)
6356 E2 6356 D1 E1 F2 M1
C 2 S2 C1 D23 F13 M23 S1
6356 E2 cross multiply
6356 D13 E1 F23 M13
C 2 S26356 D13 E1 F23 M13 6356 E2 C1 D23 F13 M23 S1
SUBTRACT 6356
FROM BOTH SIDES C 2 S2 6356 6356 D13 E1 F23 M13 6356 6356 E2C1 D23 F13 M23 S1
3 3 3
divide C2 D1 E1 F2 M1 S2 C2 D13 E1 F23 M13 E2 C1 D23 F13 M23 S1
from both sides
C2 D13 E1 F23 M13 C2 D13 E1 F23 M13
E2 C1 D23 F13 M23 S1
S2 (equation-10)
C2 D13 E1 F23 M13
where:
CFM1 = Existing CFM, CFM2 = New CFM, DPF1 = Existing diameter of fan pulley
DPF2 = New or existing diameter of fan pulley DPM1 = Existing diameter of motor pulley
DPM2 = New or existing diameter of motor pulley, MPR1 = Existing RPM of motor pulley
MPR2 = New RPM of motor pulley (in cases where a VFD is involved)
cross multiply CFM1 DPF1 MPR2 DPM2 CFM2 DPM1 DPF2 MPR1 (equation-11b)
Example-8: Find Motor Pulley Size based on CFM, Fan Pulley, and VFD changes
The CFM being moved by a fan set with a motor controlled by a VFD
must be increased from 10,600 cfm to 12,144 cfm, the existing fan pulley pitch diameter
is 6 inches and will be changed to 7.125 inches, the existing diameter of the motor
pulley is 10 inches, the motor rpm will be increased from 1,312 rpm to 1,400 rpm.
Find the size of a new motor pulley to achieve the 14,100 cfm.
With the use of equation 11-b, equations for CFM2 = New CFM, DPF2 = New or existing diameter of
fan pulley and MPR2 = New RPM of motor pulley (in cases where a VFD is involved) can be easily
found.
To find CFM2 :
CFM1 DPF1 MPR2 DPM2 CFM2 DPM1 DPF2 MPR1 (equation-11b)
CFM1 DPF1 MPR2 DPM2 CFM2 DPM1 DPF2 MPR1
divide both sides by DPM1 DPF2 MPR1
DPM1 DPF2 MPR1 DPM1 DPF2 MPR1
CFM1 DPF1 MPR2 DPM2
CFM2 (equation-13)
DPM1 DPF2 MPR1
Example-9: Find new CFM based on Fan Pulley, and VFD speed changes
The CFM being moved by a fan set with a motor controlled by a VFD
will change from 9,100 cfm. The existing fan pulley pitch diameter
is 7.5 inches and will be changed to 8 inches, the existing diameter of the motor
pulley is 10 inches, the motor rpm will be increased from 1,260 rpm to 1,390 rpm.
Find the new CFM.
To find MPR2 = New RPM of motor pulley (in cases where a VFD is involved):
Example-10: Find new VFD motor controlled rpm based on cfm and motor pulley change
The CFM being moved by a fan set with a motor controlled by a VFD
needs to change from 8,750 cfm to 10,000 cfm. The existing fan pulley pitch diameter
is 7.5 inches, the existing diameter of the motor pulley is 10 inches and will be revised
to 10.5 inches the existing motor rpm is 1,290 rpm.
Find the new required (MPR2) motor rpm.
Example-11: Find new VFD motor controlled rpm based on cfm change
The CFM being moved by a fan set with a motor controlled by a VFD
needs to change from 12,700 cfm to 16,100 cfm. The existing fan pulley pitch diameter
is 6 inches and the existing diameter of the motor pulley is 10 inches. The existing
motor rpm is 1,195 rpm.
Find the new required (MPR2) motor rpm by equation-14..
Example-12: Find new fan pulley pitch diameter based on CFM and motor pulley change
The CFM being moved by a fan set without a VFD needs to change from 8,300 cfm to 9,965 cfm.
The existing fan pulley pitch diameter is 5.625 inches, the existing diameter of the motor pulley is 8
inches and will be revised to 10.25 inches, the existing motor rpm is 1,750 rpm.
Find the new required DPF2 = New diameter of fan pulley.
By equation-15:
Utilizing the following fan law which relates Amps to Fan RPM the driving and driven
sheave (pulley) diameters can be determined along with Amperage.
Substituting equation-1 for RPM into the speed varies as the amperage yields equation-16:
3
DPM1MPR1
3
Amps1 RPM 1 Amps1 DPF1
(equation-16)
Amps2 RPM 2 Amps2 DPM2 MPR2
DPF2
n
a an n n n DPM13 MPR13 DPF23
and ab a b (equation-16a)
b bn DPF13 DPM23 MPR23
cross multiply Amps1 DPF13 DPM23 MPR23 Amps2 DPM13 MPR13 DPF23 (equation-16b)
HVAC Pulley Math Page 17 of 18
By William Greco
w2gre@verizon.net
Warrington, Pa.
8/20/2009
divide both sides by Amps1 DPF13 DPM23 MPR23 Amps2 DPM13 MPR13 DPF23
3 3 3
DPM1 MPR1 DPF2 DPM13 MPR13 DPF23 DPM13 MPR13 DPF23
21.5 Amps
13 63 83 13603
83 11503 63
Example-14: Find new amperage based on VFD speed and motor pulley change
A fan set with a motor controlled by a VFD is ramped down from 1,450 rpm to 1,325 rpm.
The existing fan sheave pitch diameter is 6 inches and the diameter of the motor sheave
is to be decreased from 10 inches to 9.5 inches. The existing motor is pulling 19.6 amps
Using equation-17 find the new amperage (Amps2).
12.8 Amps
19.6 63 9.53 13253
3
divide both sides by Amps1 DPF13 DPM23 MPR2 Amps2 DPM13 MPR13 DPF23
3 3
Amps1 DPF1 DPM2
Amps1 DPF13 DPM23 Amps1 DPF13 DPM23
1 3
1
1 Amps2 3 DPM1 MPR1 DPF2
3 1 MPR2 1
(equation-18)
3
Amps13 DPF1 DPM2
1
24.7 3 9.8751,375 8
1
1,487.7 Rpm 1,488 RPM
19.5 3 88.875
By William Greco
2404 Greensward N.
Warrington, Pa. 18976