Ebm papst - Optimising building performance and reducing energy consumption

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Optimising building performance and reducing
energy consumption
Tony Wright – Divisional Director Upgrade

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Energy saving potential of EC fans and motors
Contents
 Introduction to ebm-papst.
 Energy consumption in legacy buildings
 What is EC technology & Key benefits
how it reduces power consumption & CO2 emissions.
 Case studies demonstrating the energy savings.
 Air Handling units – Savings up to 60%
 Fan coil units – Savings up to 66%
 Data Centre CRAC units – Savings up to 78%

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About ebm-papst
 World leading manufacturer of fans & motors
 Founded in Germany in 1963
 UK Subsidiary opened in 1975
 18 Production sites and 57 Sales Offices
 €1.5 billion turnover. (2013/14)
 14,500 different variants
 A Green Company through & through

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ebm-papst A Green Company
Hollenbach new factory in Germany - 20 million EUR investment.
Completed in 2007, designed for maximum energy efficiency from
the very first planning stage.
The most important features of the high-tech location include
its own power generation using a photovoltaic system and
a cleverly devised system for ventilating, cooling and exploiting the
residual heat generated on the 13,000 square metre building.
A new factory of this size would usually need about
850,000 kWh per year for heating and cooling.
Our factory needs less than one tenth of that amount !!!

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The Quest for a Green Building
Energy
Water
Indoor Air
Quality
Materials
Site

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Typical Energy Used in Legacy Commercial Buildings
HVAC
Lighting
Computers
Other
Water Heating
50%
25%
10%
13%
2%

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AHU Chillers, Condenser, Coolers Data Centre Cooling
Source: Airedale, Emerson, Nuaire, Ability, GEA Searle, Epta Group.,
FCU
Upgrade opportunities in HVACR applications

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Traditional AC fan Versus EC Fan
AC to DC
conversion
Commutation
Electronics
Permanent magnet
Stator
Rotor
AC motor EC motor
Stator
Windings
 2 sets of copper windings
 External speed control required
 Low efficiency due to copper losses
 Permanent magnet on rotor.
 AC mains Input – converted to DC onboard
 Integrated variable speed control (0 – 10v or PWM)
 High efficiency (exceeds IE3)

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What’s so special about an EC fan?
1) Energy efficiency
EC motors are around 30% more efficient due to secondary magnetic field comes from permanent magnets rather
than copper windings.
2) System Efficiency
EC fans operate outside their preferred operating range & still maintain a high level of efficiency
3) Speed Control
 Integrated speed control means fans have infinitely variable speed , no additional VSD is required.
 Allows for simple speed control, constant volume or constant pressure control etc.
 also remote control & monitoring via modbus
4) Reduced Noise
5) Compact design
Integrated motor & speed control
6) Reduced maintenance

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EC Benefit
Integrated Speed Control allows for fan speed to be modulated
Energy efficiency
0%
25%
50%
75%
100%
13% 25% 38% 50% 63% 75% 88% 100%
airflow capacity
powerinput
On/Off operation
EC modulation
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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EC Benefit
Integrated Speed Control allows for 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
-24
-21
-18
-15
-12
-9
-6
-3
0
13% 25% 38% 50% 63% 75% 88% 100%
airflow capacity
noisedifference[dBA]
On/Off operation
EC modulation
Log. (On/Off
operation)
delta Lp [dB] = 50 x log10 (n1/n2)

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Demonstrating the Benefits of Modulation
Supermarket. Chiller
Original Fans Used
● 3 AC fans (Backward Curved)
● Speed Control - Via Stage Control
● Average Fan Power (Using Stage Control) 2.54 kW
Replacement Fan (ebm-papst EC)
● 3 EC fans (Backward Curved)
● Speed Control - Via Modulation
● Average Fan Power (Using Stage Control) 1.22 kW
(Using Modulation) 0.55 kW
Savings From Switching to EC.
EC Fan. still using stage control 52.0%
EC Fan. using Modulated speed Control 78.3%

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Case Studies
Energy savings resulting from
 motor efficiency
 optimising system design
HVAC applications covered
 Air Handling Units
 Fan Coils
 Data Centre CRAC Units

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Case study
AHU - The National Archives – (Repository)
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
 AHU’s serving the repository
 Operation. 10 hrs/day. 6 days/wk.

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Case study
AHU - The National Archives – (Repository)
 AHU’s serving 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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Case Study
Fan Coil Units - Company HQ building London
Aims:
1. Reduce energy consumption of HVAC equipment
2. Reduce maintenance
3. Increase controllability
Scope:
- 10 floor building
- Total ~ 1200 FCU’s
Problem with existing FCU’s
- AC fan motors, coming to end of life
- Poor speed control function
- No monitoring
Date: Nov 2014
Collaboration: CBRE - Norland Managed Services, ebm-papst UK, Cinque Energy Solutions

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Case Study
Fan Coil Units - Company HQ building London
AC Fan Decks
49 FCU’s / wing each floor. Total ~ 1200 units in the building.
2 sizes of FCU
• Small (208)
• Large (212)
4 speed settings (manual)
EC Fan Decks
Small unit - (2 x D3G133)
Large unit - (3 x D3G133)
Variable speed control – Via 0 – 10v

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Case Study
Fan Coil Units - Company HQ building London
Measurements
• Single Fan coil was measured for 1 week
prior to fitting EC fans
• This showed that a constant power draw was
maintained during running hours.
• Average ~ 250w
Power measurements before – 212 model

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Case Study
Fan Coil Units - Company HQ building London
Measurements
• Spot Measurements taken on individual FCU’s before
and after the EC fans fitted.
Large unit Small Unit
AC fan deck (W) 247 150
EC fan deck (W) 49 54
Saving (W) 198 96
% saving 80% 64%
0
50
100
150
200
250
300
208 212
PowerDrawperunit(w)
FCU Model
Power draw / FCU AC Fans fitted
EC Fans fitted

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Case Study
Fan Coil Units - Company HQ building London
Annual Savings
Forecast Annual savings
Operating Hours:
12hrs / day, 260 days / year
Floor 2 East Wing Total Building
Qty of Units 49 1200
Run time (hrs / year) 3,120 3,120
AC fan deck (kW) 10,066 246,514
EC fan deck (kW) 2,506 61,371
Annual Savings
% Saving 75% 75%
Power kWh 23,587 577,641
Power (£) £2,000 £49,000
CRC (£) £194 £4,800
Total Financial Saving £2,194 £53,800
CO2 (T) 12 303
C (T) 3 83
Assuming
Operating Hours: 12hrs / day, 260 days / year
Energy Cost: £0.085 / kWh
CRC cost: £15.60 / t

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Case Study
Diamond Light - Computer Room Cooling
Original Fans Used
• 2 x Forward Curved Blower Belt drive
Absorbed Power 2.4 kW
Replacement Fan (ebm-papst EC)
● 2 x Backward curved EC plug fans
● Absorbed Power 1.1 kW
Savings: Operation 24 hours / day, 365 days / year
Savings (annual) Per Unit 27 units
Energy saving % 55% 67%
Energy (KWh) 11,738 316,926
Value (£) £1,174 £31,700
Carbon (T) 1.7 46

22. 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.

23. 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.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.
Tony Wright
Divisional Director Upgrade
ebm-papst UK Ltd
Chelmsford Business Park
Chelmsford
Essex
CM2 5EZ
Thank You