Helen McHugh, Head of Sustainable Technology at ebm-papst, presented at FMP Event in October 2014

1. Retrofitting Case Studies -
Upgrading your buildings fans will save money
Helen McHugh - Head of Sustainable Technology
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2. Energy saving potential of EC fans and motors
Contents
 Introduction
 Energy Consumption in commercial buildings
 Why is it important to consider fans ?
 How can EC technology reduce energy consumption ?
 Case Studies
real examples of upgrades to existing HVAC equipment
 Air Handling unit – Savings of 66%
 Fan coil unit – Savings of 66%
 Data Centre CRAC units – Savings of 78%
 Condenser - Savings of 51%
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3. About ebm-papst
World leading manufacturer of fans & motors
 Developers of the highest efficiency EC fans
 Founded in Germany in 1963
 18 Production sites and 57 Sales Offices
 €1.5 billion turnover.
 Key Market sectors commercial HVAC & Refrigeration
Provide Energy efficient solutions
 Work with building Owners, Occupiers, Energy consultants
to identify energy saving opportunities
 Offer advice, Surveys, energy saving calculations & Installation
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4. ebm-papst
EC Fan Technology
Axial Fans Backward Curved Centrifugal Forward Curved Centrifugal
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5. ebm-papst
HVAC & Refrigeration Applications – benefiting from EC fan upgrade
HVAC - Commercial
Product: AHU
Fan: Backward Curved Centrifugal
Product: FCU
Fan: Forward Curved Centrifugal
Refrigeration
Product: Chiller & Condenser
Fan: Axial
Product: Cooler / Evaporator
Fan: Axial
Data Centre Cooling
Product: CRAC Unit
Fan: Backward Curved Centrifugal
Product: Fan Array – data centre
Fan: Backward Curved Centrifugal
Source: Airedale, Nuaire, Ability, GEA Searle, Epta Group.,
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6. Energy usage in buildings
UK electricity usage 328TWh / year (2012)
Non Domestic buildings account for > 60% of this.
Predicted that energy requirements will continue to rise
Key reasons for reducing energy consumption are
• Reduce CO2 emissions
• Reduce energy bills
• Increased energy security
• Reduced effect of volatile energy costs
Commercial Buildings
Electricity: ~70% of a buildings emissions
HVAC: ~ 40% of all electricity used in commercial buildings
Fans / pumps: ~ 50% of the energy consumed in HVAC
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7. Energy consumption in buildings
Lighting
10%
Heating
46%
Catering
14%
other 15%
hot water
15%
Hospital
Catering
10%
Government
other 8%
catering
17%
hot water
20%
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Lighting
10%
Heating
65%
hot water
10%
other 5%
lighting
27%
refrigeration
18%
heating
35%
Cooling /
ventilation
6%
hot water
6%
Retail
lighting 7%
heating
Cooling / 45%
ventilation
11%
Hotel

8. Government Legislation
1. Enhanced Capital Allowances (ECAs)
Tax relief for investments on equipment meeting energy saving criteria. (listed on ETL)
EC fans qualify for ECA’s
2. Ecodesign of Energy related Products Directive – ErP
Imposes minimum energy efficiency levels for products – EC fans exceed 2015 levels
3. CRC & CCA’s
Encourages organisations to develop energy Management Strategies
Voluntary agreements for industries, if they agree to energy efficiency targets
4. ESOS Energy Savings Opportunity Scheme
Large businesses in the UK must undertake assessments of energy use & identify
energy efficiency opportunities at least once every four years.
Compliance period Dec 2015.
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9. Energy related Products (ErP) Directive
Electric Motors - minimum efficiency levels
Date Minimum Efficiency level
June 2011 IE2
Jan 2015 IE3 ( size > 7.5 kW) Or > IE2 if using VSD
Jan 2017 IE3 ( size > 0.75 kW) Or > IE2 if using VSD
EC (4-pole equivalent)
AC. IE2 (4-pole)
AC. IE2 (4-pole) with VSD
 EC motor has a higher efficiency than the AC motor. (EC motor equivalent to IE4)
 Once speed control (VSD) is added to the AC motor, the overall efficiency is reduced
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10. Energy related Products (ErP) Directive
Electric Motors - minimum efficiency levels
Date Minimum Efficiency level
June 2011 IE2
Jan 2015 IE3 ( size > 7.5 kW) Or > IE2 if using VSD
Jan 2017 IE3 ( size > 0.75 kW) Or > IE2 if using VSD
Efficiency = 87% v’s 73%
EC (4-pole equivalent) AC. IE2 (4-pole) with VSD
 EC motor has a higher efficiency than the AC motor. (EC motor equivalent to IE4)
 Once speed control (VSD) is added to the AC motor, the overall efficiency is reduced
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11. EC Fans
What are they? & why are they more efficient?
AC to DC
conversion
Commutation
Electronics
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Permanent magnet
Stator
Rotor
Permanent magnet motors with integrated speed control
 Energy efficiency
more energy efficient than standard induction motors
 Speed Control
Integrated speed control - no additional VSD is required.
 Reduced Noise
Reduced noise under speed control
 Compact design
Integrated motor & speed control
 Reduced maintenance
No belts & pulleys
 Built in Power factor correction

12. EC Benefit
Modulation - Integrated Speed Control allows fan speed to be modulated
Energy efficiency
100%
75%
50%
25%
0%
On/Off operation
EC modulation
13% 25% 38% 50% 63% 75% 88% 100%
airflow capacity
power input
P1 ~ n3
Bar chart shows
Power input V’s number of fans used.
Ie. For a 4 fan system.
- Switching off 2 fans gives
50% reduction in airflow & 50% energy saving.
Line graph shows
power input for fans controlled via variable speed.
Ie. For a 4 fan system.
- running all fans @ ½ speed gives
50% reduction in airflow & ~80% energy saving.
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13. EC Benefit
Modulation - Integrated Speed Control allows fan speed to be modulated
Noise Reduction
Bar chart shows
Noise reduction achieved by reducing the number of
fans running.
Ie. For a 4 fan system.
- Switching off 2 fans gives
50% reduction in airflow & 3dBA noise reduction
Line graph shows
Noise reduction achieved by speed controlling all fans.
Ie. For a 4 fan system.
- running all fans @ ½ speed gives
50% reduction in airflow & 15dBA noise reduction
0
-3
-6
-9
-12
-15
-18
-21
-24
On/Off operation
EC modulation
Log. (On/Off
operation)
13% 25% 38% 50% 63% 75% 88% 100%
airflow capacity
noise difference [dBA]
delta Lp [dB] = 50 x log10 (n1/n2)
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14. EC Benefit
Control & Monitoring Options
The Integrated electronics - allow for simple speed control
1) Integrated demand based control of fan speed
means that the fan is only used when needed
2) Continuous speed adjustment
 reduces noise,
 provides a more even flow of air
 and reduces energy consumption
3) Simply connect a sensor to the motor for
demand control against any parameter.
4) Larger fans have modbus
5) Bluetooth control is available
 Refrigerant pressure
 Temperature
 Air pressure
 Air volume
 Manual setting
 Any sensor
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15. Case Studies
Energy savings resulting from
 motor efficiency
 optimising system design
HVAC applications covered
 Air Handling Units
 Fan Coils
 Data Centre CRAC Units
 Condenser
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16. Case study
AHU - Government Building
Original Fan Used
Forward curved belt driven blower
2 x AC motor (1 for redundancy)
Fixed speed
Power Consumption 6.3kW
Replacement Fan (ebm-papst EC)
Backward curved plug fan
PM (EC) motor
Variable speed
Power Consumption 1.9kW
 12 AHU’s serve the repository
 Operation. 10 hrs/day. 6 days/wk.
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17. Case study
AHU - Government Building
 12 AHU’s serve the repository
 Operation. 10 hrs/day. 6 days/wk.
Savings (annual) Per Unit All 12 Units
Energy Saving % 70%
Energy (Kwh) 13,728 164,736
Value (£) £1,650 £19,768
Carbon (Tonnes) 2.0 24.5
Payback period 2.5 years
* Assumptions
•Units operating 31,200 hrs / year
•Electricity cost £0.12/kWh (incl. CRC costs)
•kWh to CO2 conversion factor = 0.54522
•CO2 to Carbon conversion factor = 0.2727
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18. Case study
Office Fan Coil Unit
Office building: 250 FCU’s (2 fans per unit)
Induction Motor (AC)
motor efficiency @ Operation point 25 %
Energy consumed per FCU. 137 W
SFP = 0.75
EC Motor (permanent magnet)
motor efficiency @ Operating point 78 %
Energy consumed per FCU. 46 W
SFP = 0.25 66% energy saving
Savings (annual) 2 fan unit 250 units
Energy Saving % 66%
Energy (Kwh) 455 113,750
Value (£) £45.50 £11,375
Carbon (Tonnes) 0.068 17.0
* Assumptions
•Units operating 10 hours/day for 50 weeks = 2500 hours
•Electricity cost £0.10/kWh
•kWh to CO2 conversion factor = 0.54522
•CO2 to Carbon conversion factor = 0.2727
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19. Case study
Fan Coil Unit
Old AC twin fan deck New EC double fan unit.
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20. Case Study
Scottish Parliament Building
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21. Case Study
Scottish Parliament – CRAC Unit
Original Fans Used
• 2 x Forward Curved Blower Belt drive
• Absorbed Power (1 unit @ 100%) 5.6 kW
Replacement Fan (ebm-papst EC)
● 2 x Backward curved EC plug fans
● Absorbed Power
● (1 CRAC unit @ 100%) 3.4 kW
● (2 CRAC units @ 50% each) 0.42kW
Savings: Operation 24 hours / day, 365 days / year
Savings (annual) 1 unit matched airflow 2 units @ 50% each
Energy saving % 39% 85%
Energy (KWh) 19,272 41,698
Value (£) £1,927 £4,170
Carbon (T) 2.9 6.2
Payback Period ~ 21 Months ~19 Months
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Source : Airedale
The room has 2 CRAC units.
1 runs @ 100% & the other is on standby.
Suggest both CRAC units run @ 50% each.

22. Case Study
Scottish Parliament – CRAC Unit
Old fans were removed
Increased the size of the opening
in the floor
Plug fans installed in the floor
39% energy saving (1 CRAC unit running @ 100%)
85% energy saving (2 CRAC units running @ 50% each)
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23. Case Study
IT Company - Data Centre CRAC Unit
Floor Void opened to optimise airflow
43% energy saving @ matched Performance
67% energy saving @ commissioning
Original
Double inlet Blowers removed
New
EC fans fitted above floor in POD design
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24. Case Study
Computer Room Cooling – Diamond Light Source
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25. Case Study
Computer Room Cooling – Diamond Light Source
Phase 1
27 x Stulz downflow units
Upgrade original AC Fans for high
efficiency EC fans.
Aim was 2 fold
1. Reduce energy consumption
2. Reduce noise / vibration
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27. Case Study – Major supermarket.
Condenser & AxiTop
 Reduces losses downstream of the
impeller outlet.
 The AxiTop diffuser decelerates
airflow, dynamic energy is therefore
converted into static pressure
 efficiency is significantly enhanced,
reducing energy consumption and
noise.
 The same airflow can be achieved at
slower fan speeds
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28. Case Study – Major supermarket
Benefits of AxiTop
measured in customer application at constant air volume
- 7,2 [dB(A)] & 27% lower energy consumption
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29. Case Study – Major supermarket
Condenser – AxiTop
Date: Apr – Jun
Conducted by: Space Engineering Services on behalf of a major UK supermarket
Aim: Identify energy savings from retrofitting existing EC condenser fans with the AxiTop diffuser
Measurements show 2 condenser packs with & without AxiTop
1. HT Condenser Pack (5 fans)
2. LT Condenser Pack (3 fans)
In both cases.
- 2 identical condenser packs measured for 4 weeks.
- One unit used as base data & was not upgraded
- The other unit was upgraded to use AxiTop.
And both units measured again for a further 4 weeks
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30. Case Study – Major supermarket
Condenser – AxiTop
HT Pack Results
Graphs - before and after data for the HT packs.
data recorded on the same trading day (Saturday) with almost identical average ambient temperature.
Red Trace - HT 1 No AxiTop fitted (9.31 kWh – 9.1 kWh)
Blue Trace - HT 2 AxiTop fitted for the 2nd set of measurements
Total Power consumption Reduced from 13.04 kWh to 11.09 kWh = 15% reduction
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31. Case Study – Major supermarket
Condenser – AxiTop
LT Pack Results
Graphs - before and after data for the LT packs.
data recorded on the same trading day (Saturday) with almost identical average ambient temperature.
Red Trace - LT 1 No AxiTop fitted (4.14 kWh – 4.2kWh)
Blue Trace - LT 2 AxiTop fitted for the 2nd set of measurements
Total Power consumption Reduced from 18.23 kWh to 8.9 kWh = 51% reduction
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32. Case Study – Major supermarket
Condenser – AxiTop
Condenser Trial - Results
- Both the HT & LT condensers show energy savings due to the addition of the AxiTop
- HT - 15% saving (Part Load)
- LT - 51% saving
- The higher saving on the LT condenser unit is due to the siting of this condenser.
- The LT condenser is partially surrounded, resulting in more recirculation
- The AxiTop improves the throw of air, thereby resulting in less recirculation.
- AxiTop provides additional savings at the highest ambient conditions
(all fans running at their maximum),
- this is due to the discharge set point being achieved more often and for longer periods.
- Power savings are achieved not only from the fans, but also from the compressors.
HT condenser running at maximum, shows a 26% reduction in power consumption when AxiTop is fitted.
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33. Summary
 The easiest way to reduce our energy consumption is by using more energy efficient products.
 Government & European legislation is setting higher efficiency levels.
 EC Technology is an established alternative technology that easily exceeds current
& future efficiency targets.
 EC Technology can be easily installed as an upgrade to existing HVAC and Refrigeration equipment.
 Energy savings in excess of 50% can be achieved.
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34. Helen McHugh
Head of Sustainable Technology
Email: Helen.Mchugh@uk.ebmpapst.com
Phone: 07802 201891
ebm-papst UK Ltd
Chelmsford Business Park
Chelmsford
Essex
CM2 5EZ
Proprietary and confidential information. Any circulation of this document or parts of it in whatsoever form without explicit permission of ebm-papst Proprietary and confidential information. Any circulation of this document or parts of it in whatsoever form without explicit permission of ebm-papst is strictly forbidden. is strictly forbidden.