1

Three-Phase
Packaged Drives for
HVAC Applications
Brian Welchko
University of Wisconsin - Madison
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Outline

• Why is this important?

• PD requirements
• Three phase vs. single phase
• A three phase unipolar induction motor
drive
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Project Description

Develop low cost, packaged adjustable

speed drives for high volume
commercial/residential HVAC systems
which has major impact on energy
consumption.
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Annual Energy Usage of Major Electrical Units in a
High-Rise Residential/Commercial Building (ASHRAE)
MWH/Year % of Total Energy
Heating Aux. 394 3.1
Lighting 1,022 7.9
Pumps 1,336 10.4
Refrigeration Comp. 2,361 18.2
Refrigeration. Aux. 2,757 21.4
Air Handling 5,026 39
6000
5000 Heating Aux.
Mwh/Year

4000 Lighting
21.4% Pumps
3000
Refrigeration Comp.
2000 Refrigeration. Aux.
10.4%
1000 3.1% Air Handling

0
7.9% 18.2% 39%
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Power Requirements of ASD Fan
Control vs. Inlet Damper Control

450
400
350
Power (W)

Inlet Damper
300
250
200
Adjustable Speed Drive
150
100
50
0
0 100 200 300 400 500 600 700
Air Volume (CFM)
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Box Definition and Metrics for
HVAC Motor Drive*
Torque
Speed

Voltage
Single Phase Line Side Load Side
Link motor
230V Converter Converter

Metrics #1 Metrics #3 Metrics #5 Metrics #6

•Line Harmonics •Loss •HP Rating
•Noise •Fan Torque-
•EMI •Reliability (MTBF)
•Cost $/Joule •Vibration speed
•Power Factor
•Voltage Range •Cost $/VA •Cost $/HP Characteristic
•Maximum Temp •Aspect Ratio
•Packaging Profile •Efficiency
•Weight
Metrics #2 Metrics #4 •Reliability(MTBF)
•Reliability (MTBF) •Distortion(THD)
•Cost: $/Watt •Reliability(MTBF)
•Temperature Cycle
•Baseplate Temp. •Cost $/watt
•Control Capability •Packaging Profile * Appendix B-2 IAB
•Packaging Profile •Baseplate Temp. Working Group on
Benchmarking Process
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Currently Available State-of the Art

6 IGBT inverter switches

Motor drive connects High efficiency

to end of motor induction motor

DC link Capacitor Bank

Control
inputs
Single phase
diode bridge

EMI filter
Micro-controller
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Residential HVAC PD Requirements

• ¾ Horsepower rated output from motor

• Optimized for operation at ½ rated output
power – spends 80%+ time at this point
• Target of $30 (= to motor cost) for the drive
• Single phase input
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Three Phase vs. Single Phase

Three Phase Motors Single Phase Motors
• Needs an electronic • Made by the millions
drive to work off each year
residential single • Can be jumpered to
phase service the line input in case
• Better use of active of drive failure
material (copper, iron) • About 60% efficient
• About 75% efficient
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The Ideal Three Phase Case

Single 3 Phase Squirrel

Phase Supply Cage Induction Motor

• Pros • Cons
– Low distortion input – 10 Transistor switches
– Low distortion output
– Unity power factor
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Possible Improvements

• Filter Capacitor
– 120Hz power ripple due to single phase input
• Can’t really make it smaller…
• Transistor Switches
– Reduce # of them, Reduce $$$
• Motor
– 100 years of optimization for low $$$ at 60Hz
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Proposed Solution

A three phase motor optimized to run off a

variable speed electronic drive with as few a
number of transistor type switches as
possible
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Unipolar Induction Motor Drive

Phase Currents Phase Current Harmonics
1
Amplitude (per unit)

0.8

0.6

0.4
phase a
0.2 phase b
phase c

0 50 100 150 200 250 300 350

Angular Position, wt (degrees)

Table 1: Phase Current Definitions over an Electrical Cycle.

0  wt  120 120  wt  240 240  wt  360
Phase a (ias) Imsin(wt) Imsin(wt  p/3) 0
Phase b (ibs) 0 Imsin(wt + 2p/3) Imsin(wt)
Phase c (ics) Imsin(wt + p/3) 0 Imsin(wt  4p/3)
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Rotating mmf with Unipolar Currents

1 b-s axis
0.8
0.6 ~
0.4 I wt = 150o
0.2

0 50 100150200 250300350 a-s ia = 1

wt axis ib = 0.5
b-s axis ic = 0
c-s axis b-s axis
~
I
a-s axis
wt = 180o
wt = 120o ia = 0.866 a-s
ia = 0.866 ib = 0.866 axis
ib = 0 ic = 0
c-s axis
ic = 0
c-s axis
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Ideal Implementation
Standard Induction Machine
with Stator Neutral Access
Unstable N
system since Vb1
N
there is no
discharge N
Vb2
path for Vb1

Phase b current path when the phase b

switch is conducting
Phase b current path when the phase b
switch is not conducting
N is the number of turns
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Asymmetric Induction Motor

Phase B Phase B
Connection Connection
Neutral
Connection

Phase A Phase A
Connection Connection

Phase C Phase C
Connection Connection

• 3 phase machine with • Phase b connected for

dual windings
connected for low
voltage operation
low V operation
• Phase a, c connected for
high V operation and
reversed polarity
• Neutral connection
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Practical Implementation
• Phases have different number of turns and
different polarities.
• Phase b current reversed & double that of
phase a, c
• These give a rotating mmf
Asymmetric Induction Machine
with Stator Neutral Access
+
N
Vc
Vs - In 0.5N Ia
+ Ib
Is N
Vc
- Ic
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Simulation Results
10
Stator Currents (A)

Phase A 1

Rotor Currents (A)

Phase B Phase A
Phase B
Phase C
0.8 Phase C
8
0.6
6 0.4
0.2
4 0
2 -0.2
-0.4
0 -0.6
-2 -0.8
0.65 0.67 0.69 0.71 0.73 0.75 -10.65 0.67 0.69 0.71 0.73 0.75
Time (sec)
Time (sec)

Bus Capacitor Votlages (V)

1000 320 Vc1
Vc2
Speed (rpm)

800

600 315

400
310
200

305
0 0.2 0.4 0.6 0.65 0.67 0.69 0.71 0.73 0.75
Time (sec) Time (sec)
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Unipolar Drive Features

• Only 3 transistor type switches
• Near standard 3 phase induction motor
– Standard Rotor, Bifilar stator with all 12
leads
• Approximately 70% efficient
• More efficient than a single phase motor
• Extra losses only in the stator
– Easier to cool than the rotor!
• Provides true variable speed operation