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Sporlan iSpeed Inverter Series


Drive Systems for Refrigeration Compressors, Fans, and Pumps
OCTOBER 2008

Page 1 / Bulletin 100-80

Sporlan iSpeed
Conventional refrigeration and air conditioning systems consist of one or more compressors that are simply staged in an on-andoff manner to approximately meet the refrigeration needs of the system. Although some systems use compressors of differing sizes in an attempt to more closely tailor capacity, even these systems are step-control and can lead to overcooling, rapid compressor cycling, system instability, loss of control and wasted energy.

Intelligent Inverters

For Refrigeration and Air Conditioning Systems

Sporlan iSpeed Inverter systems overcome these limitations and save up to 40% of the energy used in traditional systems. The Sporlan system is not just an add-on set of hardware, it is a total system solution consisting of hardware, specifically designed and proven software, and guidelines for designing the most efficient system possible. Thousands of field installations and over 10 years of experience have supported the energy savings described. Years of consulting with major compressor manufacturers allow specific recommendations of models for each application. Software packages include: supermarket rack refrigeration, chillers, glycol coolers, heat pumps, transcritical and subcritical CO2 , drycoolers, condensers and pumps. The iSpeed Inverters can also be used in conjunction with existing controllers to increase energy efficiency.

Why Sporlan iSpeed Intelligent Inverter Systems?


Save up to 40% of energy usage in Supermarket refrigeration systems Assures product integrity and shelf life by reducing dehydration and shrinkage Can reduce installed equipment first costs Reduces compressor warranty failure rates Designed to meet the stringent EMC Directives

Bulletin 100-80 / Page 2

Energy Savings
Load Matching
Compressor Output

Energy saving by stepless control of refrigeration capacity: - Up to 40% with refrigeration installations using a single compressor - Up to 25% with conventional multi-stage compressor racks Operation at a higher evaporation temperature with the same refrigeration capacity Higher COP factor under partial load conditions

[%]

140 120 100 80 60 40 20 0 Refrigeration requirement 33% 67% 100%

iSp

S eed

oftw

are

Conventional installation (multi-step control) Sporlan iSpeed Inverter (closed-loop suction pressure control)

Figure 1

Refrigeration and air conditioning systems are sized for the largest total load expected under extreme conditions. The compressors and condenser fans are then chosen to meet this maximum capacity need. However, almost 95% of system run time is at a reduced load,

and fixed speed compressors must be cycled to attempt to meet the load. Since the compressors and fans run at fixed speeds, their energy use is higher than needed to satisfy system requirements. Sporlan iSpeed Inverters with onboard software, efficiently tailor compressor and fan speed to match the

exact load. Since motor current draw is linear to motor speed, reduced speed means reduced energy use. Figure 1 shows how iSpeed Software enables the system to match capacity better than conventional step control.

Higher Evaporating Temperatures


Sporlan iSpeed Inverters provide very stable suction pressures that ensure proper product temperature even at higher suction pressures. Comparison based on a 3 Compressor Multi-stage rack with 50 kW (14.3 tons) total refrigeration capacity
Frequency Inverter Qmin Qmax Without kW 17 50 Tons 4.8 14.3 kW 6-8* 53-55* With Tons 1.7-3.2* 15.1-15.7*

* depending on compressor

Table 1 Power Savings

A 5F or 2.5 K raise in suction pressure can yield a 10.2% increase in EER (Energy Efficiency Ratio). The steadiness of the suction pressure also allows

the TEV (Thermostatic Expansion Valve) or EEV (Electric Expansion Valve) to be run at lower superheats, adding to coil and system efficiency. Table 1

shows representative operating range based on a 3 compressor rack with 50 kW (14.3 tons) total refrigeration capacity.

Page 3 / Bulletin 100-80

Energy Savings
Smooth Starts
Reduction of switch-on current surges
Motor Current 700 600 500 400 300 200 100 t DOL starting Star/Dlta starting Part Winding starting Soft Starter Sporlan iSpeed Rated current
[%]

Switch-on surge

Lower number of compressor starts in particular at low refrigeration capacity Smooth build-up of supply current Smooth start reduces stress on pipes and fittings Many power utility companies impose higher electrical rates based on demand or surge currents. Ordinary fixed speed compressors are started by Direct-on-Line (DOL) or Across the Line wiring. The inrush current can be 5 to 6 times normal running current.

Figure 2 This surge may trigger higher electrical costs and stress the installation and possibly the electrical grid infrastructure. Sporlan iSpeed Inverters smoothly increase starting current and limit the power used to that required by the system at that moment. Electrical costs

are minimized and electrical supplies are not stressed. Soft starting also reduces stress on the motor winding and prelongs working life. Figure 2 illustrates typical starting currents.

Product Integrity
Almost ideal constant pressure characteristic in the suction line even with changing requirements of the refrigeration installation Reduced temperature deviation Higher relative humidity Less icing of the evaporator
Conventional pressure deviation P0 30 20 10 0 t Conventional installation (multi-step control) Sporlan iSpeed (closed-loop suction pressure control) 3.4 bar maximum pressure deviation with Sporlan iSpeed

Setpoint

bara

Figure 3 Air conditioning systems are designed to provide comfort cooling and humidity control for building occupants and while these are important, slight variations of either are generally acceptable. Sporlan iSpeed Inverters minimize variations in these systems. Food storage and process cooling have more critical temperature control requirements. According to ASHRAE, temperature variations of only 2-3F or 1-2 K is enough to damage most products. Variations and lowering of humidity levels leads to shrinkage and further product loss. Sporlan iSpeed Inverters, due to their smooth suction pressure control prevent spoilage and shrinkage. Figure 3 is a graph of an actual installation showing the improvement of suction pressure stability.

Bulletin 100-80 / Page 4

Installation Savings & Ease of Use


Properly sized systems may require fewer compressors to match load.
Without a Frequency Inverter 100% 100% 75% 50% 33% 25% 33% 18% 1 12% 100% With a Frequency Inverter 100% 100%

67%

3 4 Number of Compressors

2 3 Number of Compressors

Figure 4 Compressor specific selection tables can be provided for:


Bitzer Dorin Carrier Carlyle DWM - Copeland others

Suitable for almost all compressor types:


Semi-hermetic reciprocating compressors Screw compressors Fully hermetic reciprocating compressors of some manufacturers Scroll compressors of some manufacturers Open-type compressors

Fast and simple commissioning without prior knowledge of Frequency Inverter Technology:
No programming required Quick setup guide and detailed technical literature

Controls variable speed compressor and stages up to 7 additional fixed speed compressors:
Can be used with compressors with cylinder bank off-loading (capacity control)

Plain-language display on user keypad:


Suction pressure set-point Motor operating data (current, frequency, etc.) System test or system charging without a pressure sensor

characteristics. Sporlan can also provide guidance in applying iSpeed Inverters to compressors from other manufacturers. Compressors sized and selected to optimize the control Factor F* will guarantee the maximum system balance, energy efficiency and compressor life. Figure 4 shows that a system with three compressors sized with a high control Factor F* can replace four compressors to meet the same maximum load and provide almost infinite variable control down to much lighter loads as well.

Universal setpoint of suction pressure:


Two selectable internal adjustable setpoints External setpoint (analog, field bus system etc.)

Selection Assistance Sporlan makes choosing and installing iSpeed Inverters easy by providing selection tables, based on specific compressors, from over 14 different manufactures. The tables have been generated from real world experience, manufacturer cooperation and systematic analysis of specific compressor

* Control Factor F =

Maximum Compressor Frequency Minimum Frequency of Variable Speed Compressor Frequency of Fixed Speed Compressor

Page 5 / Bulletin 100-80

Increased Compressor Life


Sporlan iSpeed Inverters keep lead compressors running smoothly and proprietary software limits cycling of the fixed speed compressors - reducing compressor wear. High system pressure limiting by reducing the speed of the variable-speed master compressor. Fault processing:
Processing of thermistor winding protection Detection of pressure sensor failure Processing of safety trip circuit (e.g. with HP/LP pressure cutout switches)

Control of multi-stage compressor racks:


Adjustable timers for optimum operation of the compressors without unnecessary cycling

Automatic delayed autostart following a supply or installation fault, 10 start attempts. Available electronic soft starters for the smooth starting of the fixed-speed compressors:
Prevention of current and pressure surges on starting

cycling because of the high torque needed to start, the heat of inrush current, and poor lubrication flow. Sporlan iSpeed Inverter systems not only keep the lead compressor smoothly running as much as possible, but the proprietary software limits cycling of the fixed speed compressors, where fitted. The ability of the Sporlan iSpeed Inverters to safely increase the speed of the compressor adds up to 20% capacity, helping to prevent unnecessary starts of the fixed speed compressors. The variable speed compressor current is smoothly ramped up to avoid excessive current surges and heating of the windings. Available Sporlan iSpeed Soft Start Kits can add this benefit to the fixed speed compressors as well. Contact Sporlan for more information, sizing and model numbers.

Special functions of the speedcontrolled compressor:


Skip speeds to prevent mechanical resonances Adjustable minimum and maximum speed of the speedcontrolled compressor Control of oil pressure switch or crankcase heater, unloaded start, or condenser fans

Generally motors have the longest service life if the number of starts and stops is limited. Compressor life is even more compromised by frequent

EMC Compliance
EMC Directive EG Declaration of Conformity with CE marking based on: RF interference EN 50081-1/-2 Immunity EN 50082-1/-2 Class B interference limit suitable for unrestricted operation on public electricity supplies UL Standards UL c-UL Standards used: UL508C UL840 UL873 Low-Voltage Directive EG Declaration of Conformity with CE marking: Standards used: EN 50178 Machinery Directive Manufacturers Declaration available Installation to: EN 60204-1

Table 2 Product Conformity

Bulletin 100-80 / Page 6

Sporlan iSpeed Kits provide all necessary components for the system. Refer to table 2. Additional accessories, software packages and some complete panels are also available.
Model Rated current Amps iS RCF+9.5E13/14 iS RCF+14E13/14 iS RCF+14C2E13/14 iS RCF+23E13/14 iS RCF+30E13/14 iS RCF+37E13/14 iS RCF+59E13/14 iS RCF+73E13/14 iS RCF+87E13/14 iS RCF+105E13/14 iS RCF+145E13/14 iS RCF+165E13/25 iS RCF+205E13/26 iS RCF+260C3E13/14 iS RCF+302C3E13/14 iS RCF+361C3E13/14 iS RCF+480C3E13/14 iS RCF+545C3E13/14 iS RCF+650C3E13/14 iS RCF+10.5S230E13/14 iS RCF+16.5T230E13/14 iS RCF+42T230E13/14 iS RCF+54T230E13/14 iS RCF+68T230E13/14 iS RCF+104T230E13/14 iS RCF+130T230E13/14 iS RCF+192T230E13/14 9.5 14 14 23 30 37 59 73 87 105 145 165 205 260 302 361 480 545 650 11 17 42 54 68 104 130 192 Nominal Compressor kW 4.0 6.0 14.0 11.0 15.0 18.5 30.0 37.0 45.0 55.0 75.0 90.0 110.0 132.0 160.0 200.0 250.0 315.0 355.0 2.2 4.0 11.0 15.0 18.5 30.0 37.0 55.0 hp 3.0 4.5 10.4 8.2 11.2 13.8 22.4 27.6 33.6 41.0 56.0 67.1 82.1 98.5 119.4 149.2 186.5 235.0 264.8 Included EMC filter Dimensions W x H x D mm 177 x 233 x 181 177 x 233 x 181 177 x 233 x 181 201 x 348 x 208 201 x 348 x 208 201 x 348 x 208 252 x 453 x 245 252 x 453 x 245 257 x 669 x 312 257 x 669 x 312 257 x 720 x 355 257 x 720 x 355 257 x 720 x 355 569 x 1384 x 465 569 x 1384 x 465 569 x 1384 x 465 684 x 1517 x 465 684 x 1517 x 465 789 x 1629 x 465 177 x 233 x 181 177 x 233 x 181 201 x 348 x 208 252 x 453 x 245 252 x 453 x 245 257 x 669 x 312 257 x 720 x 355 257 x 720 x 355 inches 7.0 x 9.2 x 7.1 7.0 x 9.2 x 7.1 7.0 x 9.2 x 7.1 7.9 x 13.7 x 8.2 7.9 x 13.7 x 8.2 7.9 x 13.7 x 8.2 9.9 x 17.8 x 9.6 9.9 x 17.8 x 9.6 10.1 x 26.3 x 12.3 10.1 x 26.3 x 12.3 10.1 x 28.3 x 14.0 10.1 x 28.3 x 14.0 10.1 x 28.3 x 14.0 22.4 x 54.5 x 18.3 22.4 x 54.5 x 18.3 22.4 x 54.5 x 18.3 29.9 x 59.7 x 18.3 29.9 x 59.7 x 18.3 31.1 x 64.1 x 18.3 7.0 x 9.2 x 7.1 7.0 x 9.2 x 7.1 7.9 x 13.7 x 8.2 9.9 x 17.8 x 9.6 9.9 x 17.8 x 9.6 10.1 x 26.3 x 12.3 10.1 x 28.3 x 14.0 10.1 x 28.3 x 14.0 kg 4.4 5.1 4.5 12.1 12.3 12.5 22 23 39 40 56 58 60 158 162 170 235 235 289 4.6 4.7 12.5 22 23 40 56 60 Weight lbs 9.68 11.22 9.9 26.62 27.06 27.5 48.4 50.6 85.8 88 123.2 127.6 132 347.6 356.4 374 517 517 635.8 10.12 10.34 27.5 48.4 50.6 88 123.2 132

3 phase AC, 400-460VAC supply Class B Class B Class A Class B Class B Class B Class B Class B Class B Class B Class B Class B Class B Class A ** Class A ** Class A ** Class A ** Class A ** Class A **

3 phase AC, 230 VAC supply (except iS RCF +10.5S230E13/14 is 1 phase)

* Amperage rated with 10% overload ** includes supply choke to reduce harmonic currents

All models include: Sporlan iSpeed Inverter, EMC filter, Programming Keypad, 5 output relays, Refrigeration software and external control (0-10 VDC) software, high and low pressure transducers

Table 3 Sporlan iSpeed Inverter Series


Model Rated Current Amps 6 12 16 18 40 65 95 180 350 500 12 12 18 40 65 95 180 350 500 Dimensions W x H x D mm 45 x 75 x120 45 x 75 x120 45 x 75 x120 168 x 220 x 110 168 x 220 x 145 168 x 320 x 145 168 x 320 x 145 260 x 415 x 250 350 x 450 x 435 376 x 570 x 365 45 x 75 x120 45 x 75 x120 168 x 220 x 110 168 x 220 x 145 168 x 320 x 145 168 x 320 x 145 260 x 415 x 250 350 x 450 x 435 376 x 570 x 365 inches 1.8 x 3 x 4.7 1.8 x 3 x 4.7 1.8 x 3 x 4.7 6.6 x 8.7 x 4.3 6.6 x 8.7 x 5.7 6.6 x 12.6 x 5.7 6.6 x 12.6 x 5.7 10.2 x 16.3 x 9.8 13.8 x 17.8 x 17.2 14.8 x 22.4 x 14.4 1.8 x 3 x 4.7 1.8 x 3 x 4.7 6.6 x 8.7 x 4.3 6.6 x 8.7 x 5.7 6.6 x 12.6 x 5.7 6.6 x 12.6 x 5.7 10.2 x 16.3 x 9.8 13.8 x 17.8 x 17.2 14.8 x 22.4 x 14.4 kg .42 .43 .48 2.2 3.5 4.2 15.7 30 43 71 .43 .43 2.2 3.5 4.2 15.7 30 43 71 Weight lbs .92 .93 1.0 4.8 7.7 9.2 35 66 93 156 .93 .93 4.8 7.7 9.2 35 66 93 156

3 phase AC, 400-460VAC supply *400 VAC Only iS RCS 5.5T400M/16* iS RCS 12T400M/16* iS RCS 16T400M/16* iS RCS 18E/27 iS RCS 40E/27 iS RCS 65E/27 iS RCS 95E/27 iS RCS 180E/27 iS RCS 350E/27 iS RCS 500E/27 iS RCS 12S230M/16 iS RCS 12T230M/16 iS RCS 18E/27 iS RCS 40E/27 iS RCS 65E/27 iS RCS 95E/27 iS RCS 180E/27 iS RCS 350E/27 iS RCS 500E/27

3 phase AC, 230 VAC supply (except iS RCS 12S230M/16 is 1 phase)

Note: Nominal kW and hp ratings are shown for reference only.

Table 4 Soft Start Kits for use with Sporlan iSpeed Inverter Series Contact Sporlan for more information about these sizing guidelines.

CLIMATE CONTROL
Accumulators CO2 controls Electronic controllers Filter-driers Hand shut-off valves Heat exchangers Hose & fittings Pressure regulating valves Refrigerant distributors Safety relief valves Solenoid valves Thermostatic expansion valves

AEROSPACE
Flight control systems & components Fluid conveyance systems Fluid metering delivery & atomization devices Fuel systems & components Hydraulic systems & components Inert nitrogen generating systems Pneumatic systems & components Wheels & brakes

ELECTROMECHANICAL
AC/DC drives &systems Electric actuators, gantry robots & slides Electrohydrostatic actuation systems Electromechanical actuation systems Human machine interfaces Linear motors Stepper motors, servo motors, drives & controls Structural extrusions

FILTRATION
Analytical gas generators Compressed air & gas filters Condition monitoring Engine air, fuel & oil filtration & systems Hydraulic, lubrication & coolant filters Process, chemical, water & microfiltration filters Nitrogen, hydrogen & zero air generators

FLUID & GAS HANDLING


Brass fittings & valves Diagnostic equipment Fluid conveyance systems Industrial hose PTFE & PFA hose, tubing & plastic fittings Quick disconnects Rubber & thermoplastic hose & couplings Tube fittings & adapters

HYDRAULICS
Diagnostic equipment Hydraulic cylinders & accumulators Hydraulic motors & pumps Hydraulic systems Hydraulic valves & controls Power take-offs Quick disconnects Rubber & thermoplastic hose & couplings Tube fittings & adapters

PNEUMATICS
Air preparation Brass fittings & valves Manifolds Pneumatic actuators, grippers, valves, controls & accessories Quick disconnects Rotary actuators Rubber & thermoplastic hose & couplings Structural extrusions Thermoplastic tubing & fittings Vacuum generators, cups & sensors

PROCESS CONTROL
Analytical sample conditioning products & systems Fluoropolymer chemical delivery fittings, valves & pumps High purity gas delivery fittings, valves & regulators Instrumentation fittings, valves & regulators Medium pressure fittings & valves Process control manifolds

SEALING & SHIELDING


Dynamic seals Elastomeric o-rings EMI shielding Extruded & precision-cut, fabricated elastomeric seals Homogeneous & inserted elastomeric shapes High temperature metal seals Metal & plastic retained composite seals Thermal management

2008 Parker Hannifin Corporation

102008

Parker Hannifin Corporation Sporlan Division 206 Lange Drive Washington, MO 63090 USA phone 636 239 1111 fax 636 239 9130 www.sporlan.com

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