0205
Fan Controller Technologies and Power Consumption
It is generally understood that adding speed control to a fan will save energy when the fan is
operating at less than full speed. With the wide range of control technologies available
(TRIAC/phase control, variable frequency control, and AC to DC inverter control),
determining the most energy
efficient solution can be
complicated. The test results
discussed here attempt to
normalize some of the inherent
differences and make an equal
comparison for using different
types of motor controllers. This
comparison assumes that only
single-phase AC power is
available.
AC-DC Inverter TRIAC/Phase Controller Variable Frequency Drive
The test setup:
The fan under test was loaded in a
wind tunnel while its speed was
monitored with a strobe. For each
speed setting, the pressure was held
constant and the input power was
monitored using a true RMS voltage
meter and ampere meter. This setup,
shown in Figure 1, was used to test
the systems described in Table 1
below.
Figure 1.
Table 1
Three- Phase Single -Phase
Controller Single -Phase Single -Phase AC to DC
Variable Variable
Technology TRIAC TRIAC Inverter
Frequency Frequency
Control Control Control Control Control
Controller Resources Resources Resources Resources Resources
Stratus Stratus Nimbus Nimbus Inversion
Continental Fan Continental Fan Continental Fan EBM Papst
Fan Model #
TMK355-4-34 TMK355-4-14 TMK355-4-14 W2E143-AB03-01 6224 NH
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0205
The test method:
First, two fans with equivalent performance (flow & pressure) were selected in single phase
and three phase 208VAC. These two fans were controlled from 100% speed to 40% using a
variable frequency drive. The pressure was monitored through a wind tunnel and held
constant for each speed setting during the testing to ensure that the load on the fan was
constant and the flow rate was equivalent. The power consumption was calculated by taking
the true RMS voltage reading on the input line and the true RMS current on the input line and
multiplying them to give the power input to both the controller and the fan. This way the
efficienc y of the drive is also accounted for in the power consumption. The single-phase
motor was driven with a TRIAC/Phase controller under the same test conditions as above.
To compare AC control to DC inverter control, two different fans were chosen - an AC
single phase and a DC - which had the equivalent performance, but not the same as the
previous two fans. The single-phase motor was run at the same speed points as the previous
test on both a variable frequency drive and a TRIAC/Phase controller. The DC fan was then
tested to the same conditions using an AC to DC inverter. The variance of TRIAC/Phase to
variable frequency efficiency was consistent so this was normalized to allow the AC to DC
inverter to be compared to the variable frequency drive. The normalized data is shown in the
graph of figure 2.
Figure 2
Technology Efficiency Comparison
100%
90%
80%
Normalized Power
70%
60% 3Phase
1Phase
50%
Triac
40% DC
30%
20%
10%
0%
40% 50% 60% 70% 80% 90% 100%
Normalized Speed
Conclusions:
It can be easily seen that the DC fan driven by an AC to DC inverter yields the highest
efficiency as the normalized power is lower than any other method at all points. This is
mainly due to two factors: first, the DC fan motor itself is generally more efficient than its
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0205
AC counterpart, and second, the decrease in speed decreases the output voltage and output
current by the same amount, resulting in a large reduction of power at lower speeds.
Generally, if the speed of a DC fan is reduced to 50%, then the output voltage and output
current are both reduced by 50%, resulting in the output power dropping to 25% of the full
speed power.
Using figure 2 we can also conclude that a three-phase motor is consistently more efficient
than an equivalent single-phase motor. The greater efficiency was also present when the fan
was connected directly to the AC line, indicating the gain in efficiency was mainly due to the
motor design.
If the system is restrained to using a single-phase AC fan, then the expected operating
conditions must be considered to find the optimal solution. If the system will regularly
require the fans to run near full speed, a TRIAC/Phase controller will yield greater efficiency
than a variable frequency drive. If the system will generally require only low speed
operation, then the variable frequency drive will yield better results. Also, the performance
between a variable frequency drive and a TRIAC/Phase controller varies according to the
motor design. While the basic trends shown above are fairly consistent, the precise crossover
points will vary.
Other Considerations:
Just as one car is not suited to all individuals, one fan controller technology is not the best for
all applications. Other considerations when choosing fan controller technology include
controller accuracy, low speed capability (<50%), fan availability, fan compatibility, number
of fans in system, induced bearing noise, size and of course total system cost. Generalities to
consider for each technology are listed below:
Controller Technology Generalities
Controller Technology TRIAC/Phase Variable Frequency AC to DC Inverter
Energy Use Good Good Best
Controller Accuracy Good Better Best
Low Speed Capability (<50%) Good Best Good
Fan Availability (large fans) Better Best Good
Fan Compatibility Good Better Best
Multiple Fan Capacity Better Good Best
Induced Bearing Noise Better Good Best
Size Best Good Good
Controller Cost Best Good Good
About the author: Nathan Lavoie has a BSEE from the University of Vermont and is Vice
President for Engineering at Control Resources, Inc., a manufacturer of custom and off-the-
shelf fan trays, controls and alarms.
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