Movement by Perfection. The Royal League in ventilation, control and drive technology. Direct-driven Fan Excellence. AHU guide for Consultants

Transcription

1 EN Movement by Perfection The Royal League in ventilation, control and drive technology Direct-driven Fan Excellence AHU guide for Consultants

2 Content Welcome to the world of ZIEHL-ABEGG Page 5 How can we learn from nature? Page 6 ZAbluefin Bionic ZIEHL-ABEGG solution for highest efficiency and lowest noise in AHUs ZAvblue The new centrifugal fan for more air flow at smaller diameters Page 7 How to determine increase of noise? Page 9 How to determine the total sound power level? How to determine sound pressure level? Page 10 How to determine optimal installation instructions? Page 11 How can you save space? Page 12 Precise fitting designs for free-running centrifugal fans Page 13 How can you increase energy efficiency? Page 14 Calculation example Air conditioning in an office building The benefits of the PMblue motor Maximum efficiency, minimum power consumption Page 15 Create highest efficency for your application Page 16 Multiple Fan Arrangement Maximum flexibility, highest reliability Page 17 How can you save energy with the power of multiples? Page 18 Energy example calculation Page 19 3

3 How can we learn from nature? Nature took millions of years to perfect processes. The implementation of bionics allows humans to perform intricate tasks by studying humans and animals and translating the concepts to mechanical parts. Learning from nature means recognising new possibilities. Owl wing highest air performance and lowest sound emission Shape of water droplet for highest efficiency Humpback Whale increase peak efficiency and improve noise cancellation Honeycombs structure guarantees highest strength 6

4 ZAbluefin Bionic ZIEHL-ABEGG solution for highest efficiency and lowest noise in AHUs ZAbluefin in size starting from 710 Corrugated blade surface Connection from Tubercle to trailing edge for improved noise cancellation Tubercle Increased area of characteristic curve without flow separation for wide range of optimum efficiency ZAvblue The new centrifugal fan for more air flow at smaller diameters smaller, more compact, more efficient market standard Easy change to ZAvblue market standard equimpment can be easily replaced by ZAvblue. ZAvblue is optimized for lower pressure application in size up to 630mm. Your benefits at a glance More airflow with smaller diameter and reduced noise level Optimum effiency at higher airflow rates combined with a wide peak efficiency range 7

5 Use FANselect to find the fan that meets your requirements 8

6 How to determine increase of noise? What ist noise? Loud music, traffic, television, people talking, - All of these have become a part of our daily life. However, when the sound of an electrical machine keeps you from sleeping all night it stops becoming just noise and start turning into noise pollution. By definition, noise is unwanted electrical or electromagnetic energy that causes temporary disruption in the natural balance. This is why understanding of noise is necessary! L = 1 db. barely noticeable difference between two sound levels L = 3 db.doubling of the sound energy, clear noticeable difference L = 10 db.corresponds to a doubling in the perceived noise level InVent Technology Center In the futuristic InVent Technology Center the fans are tested in every conceivable combinations to satisfy customers needs and demands. These test chambers are unique in their field. The sound power levels are determined by using the enveloping surface method in compliance with ISO , accuracy class 1 and/or DIN EN High quality standards compliant with ISO 9001, UL and AMCA FANselect FANselect is the web-based selection program from ZIEHL-ABEGG. Just enter an operating point and FANselect displays the most suitable fans. You can select the system components and calculate the life-cycle costs. View the SFP (specific fan power) classification and compare up to three fans air-handling capacities and life cycle costs. 9

7 How to determine the total sound power level? The total sound power level of several individual sound sources operating concurrently is calculated by adding the power of the individual levels in compliance with DIN EN ISO db Sound sources with same level (Fig. I): Addition to sound level Addition to sound level db db 24 L-KL L-KL L-KL To add up several sound sources with the same level, please see diagram (Fig. I) for complete level information. e.g. 6 identical sound sources operating concurrently results in a total level that is approx. 8 db higher. Sound sources with different levels (Fig. II): The total sound power level of two sound sources with different levels can be seen in diagram Fig. II. For example, two sound sources whose sound power levels differ by 4 db produce a total sound power level that is around 1.5 db higher than that of the louder sound source. How to determine sound pressure level? Absorption of sound power level db Number of sound sources of the same level Difference in level of two sound sources m 100 Distance Fig. I: Addition of several sound sources Fig. II: Sound sources of different levels The A-tested sound pressure level LpA for rooms with average absorption capacity for a distance of 1m from the fan axis is calculated by subtracting 7 db from the A sound power level LWA. However, the sound characteristics can be hugely influenced by the individual installation situation. Absorption of the sound pressure level, depending on the distance with partial reflection, is shown in Fig. III. Fig. III: Reduction of sound pressure level 10

8 B How to determine optimal installation instructions? Due to space saving and cost reduction purposes, many air handling units (AHUs) tend to become smaller without performance loss. But a too small size of a housing has negative influences on the air performance. The performance depends for example on the distances to other components such as coil, filters, wall etc. Distances to other components A LD ØDSa ØLA Distance on the suction side: LA 0.5 Dsa In the case of disturbance flow: (per example curved pipe at the suction side, flaps etc.) LA 1 x Dsa Distance on the duct side: LD 1 x Dsa Housing wall distances: A 1.8 x DSa; A = B For C and Cpro Reduce turbulences A 90 change of air direction before the intake of the AHU can create massive turbulences, which can reduce the air flow performance and increase noise. To avoid turbulences, we recommend you to install baffle plates. Baffle plates must be fitted in the suction chamber over the whole width of the AHU. 45 Baffle plates as a 1/4 circle Baffle plates as a sheet metal mounted in an angle 11

9 How can you save space? Example: Why Belt Drive is not the right choice! An air handling unit has an operating point of m³/h at a statistic pressure of 1500 Pa. outlet Option 1: Double inlet backward curved centrifugal fan Size: Motor: Length: 1000 mm 37 kw 3600 mm (0,5 x Ø) (Baffle plate) 4800 outlet Saving 1160 mm in length Saving 200 mm because no second filter in standard application Saving 1000 mm in length because of ideal airflow conditions Option 2: Plug fan Cpro Size: Motor: Length: 1120 mm 37 kw 2440 mm x Ø=1120 (0,5 x Ø) 2440 Saving 49% in length in this example Advantages of a direct driven plug fan system: Less components to work All components are maintenance free (impeller, motor and controller) Simple cleaning of the fan High system efficiency Space and cost saving construction Ideal intake and discharge airflow conditions 12

10 Precise fitting designs for free-running centrifugal fans Comparison of standard motor (powerful concept) to the ECblue design (compact concept) Design RH GR ER PR Fitting position Horizontal Vertical Horizontal Vertical Horizontal Horizontal Vertical Standard motor for high pressure and strong air volume flow rates Impeller diameters Ø mm Ø mm Ø mm Ø mm ECblue motor for confined installation situations Impeller diameters Ø mm Ø mm Ø mm Your benefits The construction in these various versions is galvanized in steel, additionally coated and on request available in stainless steel (process air). The flexible installation positions make these fans highly multifunctional. 13

11 How can you increase energy efficiency? Nowadays, saving energy is more important than ever. Energy costs are exploding; the global climate is changing. Motor concepts EC Technology EC means electronically commutated. EC motors are synchronous electric motors which have electronic commutation systems. The speed of the fans or motors depends on the electronically generated rotating field in the stator. The rotor with its permanent magnets follows this electronically generated field inside the fixed stator. Due to the permanent magnets no magnet field has to be generated by induction to the rotor. This increases the efficiency of an EC motor compared to a standard asynchronous motor. AC Technology AC means alternating current. AC motors are asynchronous motors in which the magnetic fields from stator and rotor produce the rotary motion by induction. Speed can only be controlled in connection with an external controller like the frequency inverters Fcontrol or Icontrol. ECblue PMblue Standard motor Compact external rotor motor Optimised integrated EC controller IE4 Efficiency class Efficient operation even at low speeds Permanent-magnet internal rotor motor with low-noise and vibration-free operation Ideal for very high rotational speeds Highest efficiencies, even at low rotational speeds and in the partial load range. IE4 Efficiency class Standardised motors from mass production manufacturers (IEC or NEMA standard) Standard motors are tested by ZIEHL-ABEGG Available in various efficiency classes (IE2-IE3 or NEMA Premium Efficiency) Efficiency classes of the various motor technologies: EC-technology ECblue max. 6 kw PMblue max. 22 kw AC-technology NEMAclass 50 HP IECclass ATEX 200 kw IECclass 200 kw IEC standard IE2 IE3 IE4* > IE4* NEMA standard Premium Efficiency *compliant with the EN draft standard 14

12 Calculation example Air-conditioning in an office building Total cost comparison of the 4 motor types IE2, IE3, ECblue and PMblue. ER56C-4DN.G7.CR IE2 - AC ER56C-4DN.G7.CR IE3 - AC ER56C-6IN.F7.CR IE4 - PMblue ER56C-ZID.GQ.CR IE4 - ECblue IE4-EC IE4-PM System IE3-AC IE2-AC Investment Energy costs in year 1 Energy costs in year 2 Energy costs in year 4 Energy costs in year costs in At today's energy costs, an investment in the energy-saving PMblue motors pays off quickly. With a fan operating time of 8760 hours per year at part load, around 5 % can be saved every year as compared with IE2 products. The higher investment of PMblue technology can be amortised in less than 2 years with help of the high energy saving. The intelligent, self-sufficient control engineering, with electronics developed specially for PM motor technology, provides the highest degree of functionality and exceptional performance. The benefits of the PMblue motor Maximum efficiency, minimum power consumption PMblue is an investment that quickly pays off The permanent-magnet internal rotor motors in the PMblue series were developed specially for ventilation and air conditioning and meet the requirements in the IE4 efficiency class, Super Premium Efficiency. When combined with our Cpro impeller the potential for high energy savings is guaranteed. Cpro Technology PMcontrol PMblue with Cpro ZAmid high-performance centrifugal fan Cpro ZAmid high-performance centrifugal fan 15

13 Create highest efficency for your application Impeller Cpro, C-steel Motor concept (Page 14) Control technology + + High-performance impeller Cpro Technology Extremely light, extremely stable, extremely durable, extremely quiet and extremely efficient C-steel Cpro is available in sizes 250 to 630 mm C-steel is available in sizes 225 to 1,120 mm Speed controlled fan to increase your system efficiency AC technology with Fcontrol frequency inverter ECblue motors with UNIcon control The Fcontrol frequency inverter is the perfect power controller for AC technology. With its integrated sine filter, Fcontrol guarantees a quieter and gentler motor operation regardless of power cable length: ECblue the trendsetting EC motor from ZIEHL-ABEGG is now also available with innovative UNIcon control. This means: Maximum efficiency Simple installation and commissioning by bus cable Automatic addressing of the fans 1 Modbus AC technology with Fcontrol frequency inverter ECblue motors with UNIcon intelligent control modules 16

14 Multiple Fan Arrangement Maximum flexibility, highest reliability Advantages: That added plus More operational reliability because of redundancy More costs saved More space available More installation flexibility More energy saved More flexibility with more fans, more air handling capacity, more efficiency 17

15 How can you save energy with the power of multiples? Parallel connection Fan Array refers to an arrangement of small fan units which are connected in parallel in one housing instead of using one large fan. All fans have the same size and type. Moreover they work at the same duty point. In general all fans are controlled by one controller/vfd or control signal. Air flow of complete wall divided by number of fan is air flow for the single fan. Static pressure increase is the same for the single fan and the parallel connection. Depending on the installation requirements, the number and size of fans can be selected optimally. Select your Multiple Fan Arrangement with help of our web-based selection program FANselect. Optimal installation to reduce turbulences DF > 1,8 x DSA: no sensible influence DF = 1,8 1,6 x DSA no influence on suction side, a separation wall reduces the acoustics on pressure side (compared without separation wall) DF DF = 1,6 1,4 x DSA little influence on suction side, on pressure side a separation wall is necessary to optimize the air flow and acoustics DF > 0,5 x DSA DF DF < 1,4 x DSA significant influence, no practical design Recommendations for models C and Cpro DF: Distance between centre of fan DSA: impeller diameter 18

16 Energy example calculation An air handling unit has an operating point of m³/h at a statistic pressure of 700 Pa. AHU cross-section WxH = 3050 x 2800mm This corresponds to a speed in the device of 2.4 m/s (class V5). There are 3 options you can chose: Option 1: Single ER11C fan with 37 kw AC motor and frequency inverter Option 2: 8 GR56Cpro fans with 3 kw AC motors and frequency inverter Option 3: 8 GR56Cpro-ECblue fans and UNIcon control module System power in kw Acoustic power in db(a) Mounting area Investment costs Option Fan type Number Total Total Dimensions WxD in m Area in m 2 incl. inverter 1 ER11C 1 33, ,05 x 2,7 8, % 2 GR56Cpro 8 28, ,05 x 1,8 5, % 3 GR56Cpro-ECblue 8 25, ,05 x 1,2 3,66 94 % Annual energy costs at an electricity price of 0.10 per kwh ER11C GR56Cpro GR56Cpro-ECblue Load profile in continuous operation 8760 hours per year Operating time Operating Air handling Load profile hours capacity 20 % % 1 70 % % 2 10 % % 3 Total 8760 Energy expenses 8x GR56Cpro-ECblue 8x GR56Cpro-AC Load profile 1 Load profile 2 Load profile 3 1x ER11C-AC (per load profile: system performance x operating hours x electricity price [0.10 /kwh]) System performance (kw) 19

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