EC Fans Energy Efficiency / Upgrade Projects Helen McHugh ebm-papst
Ian Shaw CBRE
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Topics Covered
The role of fans in building energy efficiency
Energy legislation relating to Fans & Motors
EC Fans - What are they?
How they can reduce your buildings energy consumption?
Case Studies
Upgrade projects - energy savings & payback
1. Data Centre cooling - Large Investment bank
2. FCU - Multinational professional services firm HQ
3. AHU - MERCEDES AMG PETRONAS Formula OneTM Team
4. Condenser - Marks & Spencer
HVAC - Energy Consumption
Fans used
HVAC: accounts for typically 40% of a commercial buildings energy use
Fans: can account for approx. 50% all HVAC energy consumption
Energy efficiency
ErP Directive
IE 4
IE 3
IE 2
1 5 10 kW Shaft Power
Mo
tor
effi
cien
cy
95
90
85
(%)
ebm-papst
EC Motors
Energy savings resulting from ErP legislation
ebm-papst calculate
(using ebm-papst fan sales across Europe)
1.75 TWh saving / year Jan 13 – Dec 14
3.25 TWh saving / year Since Jan 15
Motors: minimum of IE3 - for motor sizes > 7.5kW (0.75kW from Jan 17)
Fans: minimum efficiency for individual fan types. Min efficiency level will increase from Jan 2020
What is an EC motor ?
Traditional AC motor EC motor
AC to DC
conversion
Commutation
Electronics
Permanent magnet
Stator
Rotor
2 sets of copper windings
External speed control required
Low efficiency (copper losses & Induction)
Stator
Windings
Permanent magnet on rotor.
AC mains Input – converted to DC onboard
Integrated variable speed control (0 – 10v or PWM)
High efficiency (>IE4 as standard)
Key Benefits of using EC Technology
Energy Efficiency Reduced Noise
Permanent magnet motors are more energy efficient Reduced noise under speed control
than standard induction motors
System Efficiency Compact Design
EC fans operate outside their preferred operating range Integrated motor & speed control
& still maintain a high efficiency
Speed Control Reduced Maintenance
Integrated speed control no additional VSD needed No belts & pulleys
Infinitely variable speed using 0 – 10v input
Can deliver constant volume, constant pressure etc Built in Power Factor Correction
Monitoring & Alarms
Remote control, monitoring, and alarms via Modbus
Case Studies Energy efficiency & Control
Energy savings achieved by upgrading to EC fans
Savings resulting from both improved motor efficiency & optimising system design
Case Studies covered - HVAC applications
Data Centre / Computer room cooling
Fan Coils
Air Handling Units
Condenser
Case Study – Data Centre Cooling
Investment Bank
Case Study – Data Centre Cooling
Investment Bank
The aims of the project:
• Improve the energy efficiency of the data centre.
• Free up supply capacity.
• Improve the air flow and controllability.
Save money on Utility Bills (including TRIAD) and CRCEES.
Data Centre 130,000 sq ft (12,000m2) of IT racks
21,500 tonnes CO2 pa (£344,000 for CRC)
PUE 2.13
Costs £3.36m pa (energy)
Close to the edge
Case Study – Data Centre Cooling
Investment Bank
Old equipment
Intensive maintenance
Access issues
24/7 critical environment
Capital (£) shortage
Changing IT requirements
Very tight and controlled time schedules to tie in with other data
centres around the world.
9 week programme 2 units per day (in different areas).
Sufficient cooling at all times.
CDM (Form10) – HSE notifiable.
The Answer
Replace fans in 77 CRAC - DFUs with EC fans.
Change control strategy from Return to Supply air.
Case Study – Data Centre Cooling
Investment Bank
Measurements prior to and following installation;
• Air flow
• Amps
• Volts
• Noise
Continuous commissioning.
100% duty Matching Air
Flow New Controls
Average 38% 54% 68%
Maximum 62% 72% 83%
Minimum 19% 45% 54%
Case Study – Data Centre Cooling
Investment Bank
Case Study – Data Centre Cooling
Investment Bank
Predicted From fans Total (pumps etc)
Site Metered
% of Building Load 3.6% 4.9% 7.95%
Load Reduction 180kW 250kW -
Consumption 1,577,000kWh 2,190,000kWh 3,454,000kWh
Cash Savings £168,000 £233,000 £368,000
Tonnes CO2 870 1,210 1,910
Simple payback 33 Months 23.5 Months 12.1 Months
Capital Cost £371,547
The aims of the upgrade were to:
• Reduce the energy consumption of the heating, ventilation and air conditioning (HVAC) equipment
• Reduce the noise
• Reduce the need for maintenance
• Increase the controllability of the HVAC system in the building
Case Study
Fan Coil Units - Company HQ building London
Upgrade Fan Coil Units
in the London HQ of Multinational Professional Services Firm as part of a major refurbishment.
Replacing AC fan motors coming to the end of their life with EC fans with a customised control platform.
1,200 FCUs in total across a ten floor building.
Measurements
Taken on individual FCU’s before and after
the EC fans were fitted
Old Deck New Deck Saving
Large 247W 49W 80%
Small 150W 54W 64%
Old AC twin fan deck New EC double fan unit
Case Study
Fan Coil Units - Company HQ building London
Induction Motor (AC)
motor efficiency @ Operation point 25 %
Energy consumed per FCU. 150 W
SFP = 0.75
EC Motor (permanent magnet)
motor efficiency @ Operating point 78 %
Energy consumed per FCU. 54 W
SFP = 0.25
64% energy saving
Savings (annual) Single 2 fan unit 1,200 units
Energy (kWh) 464 556,800
Value (£) £46.40 £55,800
CO2 (tonnes) 0.253 304
Case Study
Fan Coil Units - Company HQ building London
Case Study - AHU MERCEDES AMG PETRONAS Formula OneTM Team
Trane AHU
Belt driven AC blower
motor + standby
EC plug fan
+ standby
Cost £3,000
AC Fan power 5.9kW
EC Fan power 2.1kW
Total Saving 64%
Annual saving (kWh) 15,410 kWh
Annual saving (£) £1,325
Payback Period 2.3 years
Case Study - AHU MERCEDES AMG PETRONAS Formula OneTM Team
Stores: 152
Condensers: 258
Fans: 1,404 (910mm Axial + AxiTop)
Energy saving 22%
3,265kWh / fan
4,584,060 kWh (total)
Financial saving £527,223 / year
ROI < 5 years
Case Study - Condenser M&S - EC fans & AxiTop
Thank you
Helen McHugh
Head of New Product Research
ebm-papst UK Ltd
+44 (0) 7802 201891
Ian Shaw
Head of Technical Energy Management
CBRE | Global Workplace Solutions
+44 (0) 7904 245 802
