Why, thanks to the use of Smart Optimizer ECOD technology, do we achieve at least 6% energy savings in Chiller + VFD (inverter) systems?

1. ✅ System Parameters

Component

SpecificationRefrigeration Compressor132 kW, 400V, 50 Hz (PMSM – Permanent Magnet Synchronous Motor)

Variable Frequency Drive (VFD)160 kW with Active Front End (AFE)

Supply VoltageVarying: 385V – 420V (industrial area – unstable grid)

Typical Operation60–80% load for 90% of the operating time per year

2. ⚠️ Problem – Supply Voltage at 420V (+5%)

• Overheating of IGBT Modules – temperature increase of +8°C
• Increased Total Harmonic Distortion (THD) – rising from 5% to 9%

3. 🔍 Energy Loss Analysis – High Voltage Scenario (420V)

Component Additional Losses Mechanism

IGBT Modules (VFD AFE) +4.8 kW Higher supply voltage → higher switching voltages → increased dynamic losses in transistors DC Circuit +1.5 kW Increased operating voltage → higher leakage (capacitors, chokes) currents → heating of passive components THD – Grid Impact — THD rises to 9% → potential additional losses in MV/LV transformer and interference with other devices. PMSM Motor +1.7 kW Higher harmonic content in voltage → increased core losses and eddy currents

🧮 Total Additional Losses: ~8.0 kW (~6%)

💡 Note: These losses occur continuously during operation and lead to higher energy consumption, accelerated wear of power components, and degradation of power quality in the facility.