30% and Higher Energy Savings with EC Motors. BUILDINGSNY.COM Javits Center, NY March 21-22, 2017
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1 30% and Higher Energy Savings with EC Motors BUILDINGSNY.COM Javits Center, NY March 21-22, 2017
2 The Strategic Horsepower to Drive Efficiency GREENCROWN Motor Solutions Moderated by: Ron Zeccardi Paul Errigo, President & CEO Charles Seifertie, Chief Technology Officer Dan Pugliese, VP of Engineering
3 What is ECM Technology?? Shaded Pole Motor >Induction >Single phase >Rotating flux >20% eff. PSC Motor Induction Single phase Relay contacts 35-55% eff. ECM Motor DC machine Single and 3 phase Multiple signal control % eff.
4 What is ECM Technology? Line voltage 120/240vac 1 Ø Communication from Air Handler demand (heat, cool, fan ) The Microprocessor constantly monitors motor speed (RPM) or torque (current). Motor Control Module Controls Convert AC power to DC Communication selects stored CFM profile Power for Microprocessor Microprocessor directs controls to convert DC back to 3 Ø specifying the current (torque) and frequency (speed) Microprocessor DC Voltage Controls Convert DC To 3 Ø Benefits: Recondition Equipment vs Replace 30 70% More Efficient High Energy Savings- Payback 1-3 Years Precise and Controlled Operation Wider Range of Applications Quiet Operation Incentives Available Lower Maintenance Permanent Magnet Rotor The Microprocessor continuously directs the controls to adjust current (torque) and/ or frequency (speed) to maintain the designed program. 3 Ø Motor Module 3 Ø Motor Genteq Premium ECM Motor VFD Control
5 ECM Technology: Highest Efficiency!! Permanent magnet rotor allows for less losses better efficiency Electronic control with internal microprocessor and memory allow for variability and control capabilities or controllability Similar to an integral horsepower motor with an external VFD Typically 20-50% more efficient than standard efficiency motors Efficiency % = (Work in / Work out) x 100
6 What is ECM Technology? Variable Speed Motor Varies the RPM of the motor in response to changing conditions in the system ECM maintains a programmed CFM When the sensed torque changes the RPM of the motor ramps up or down to maintain the programmed CFM
7 ECM: CRUISE CONTROL Analogy Program cruise control to how fast you want the car to go and set MPH RPM of the engine will run at certain levels to maintain that speed If the car is going up hill the cruise control senses a change in torque so it needs to rev up the engine so it can maintain the programmed speed
8 ECM Benefits- Affinity Curve PSC Motor (3 spd) Input Power (Watts) Cut speed in half, reduces power by a factor of 8 35 Watts 280 Watts GE ECM Motor Speed (RPM) *ECM motor speed and energy usage are directly correlated*
9 Save Every Time You Turn on a Motor Fan powered Terminal Box Rooftop Package Units Fan Coil Fan Filter Unit (FFU) Air Handler Commercial Refrigeration Pool Motors Large Air Handler EC (Electronically Commutated) motors perform better for less 9
10 ECM HVAC Applications Fan Powered Terminal Box Fan Coil Units Rooftop Condensers Rooftop Package Units
11 ECM: FAN POWERED BOXES EON 48 Frame ECM Fan Motor Voltage: 115, , 277v Single Phase Output: 1/3HP, 1/2HP, 3/4HP, 1HP Efficiency: ~78% peak Speeds: Fully variable Rotation: CW or CCW Size: 5.5 Outer Diameter Operating Temps: -40 C to 55 C Typical Applications: Fan powered boxes, multi-stage furnaces Typical Locations: Commercial buildings, residential buildings
12 ECM: Fan Powered Terminal Box Commercial Buildings Army Bases Dormitories Assisted Living 12
13 Case Study Facility Type: Facility Name: Location: FPB Terminal Unit - EC Motor Retrofit Hotel & Conference Center Seaport Hotel Boston, MA Project: Retrofitted existing PSC motors in series fan assisted VAV Variable Air Volume terminal units to a high efficiency EC Electronically Commutated Motor. Metered the energy reduction at various motor operating speeds. Methods: CFM measurements were recorded by the Siemens Apogee BAS to confirm the EC motor matched the designed air flow requirements. Watt measurements were taken by a Fluke True Power Meter. Results: Load Measured ECM Watts PSC Watts Reduction Per Motor %Run Time High Speed 505 Watts 645 Watts 140 Watts 20% Medium Speed 280 Watts 595 Watts 315 Watts 25% Low Speed 188 Watts 555 Watts 367 Watts 40% Set Back Speed 75 Watts 555 Watts 480 Watts 15% Annual Reduction Annual Savings 863, Kw/Hr $ 0.13 Kw/Hr rate Benefits: The ECM offered a wider range of speed capabilities that provided additional savings by enabling a set back speed that was previously outside the range of the PSC motor capabilities. The ECM speed settings were controlled by an Evolutions control card in conjunction with the existing BAS, eliminating the exiting voltage choppers which are inefficient and can reduce the life of the PSC motors. Data: The following graph presents the case study results.
14 FPB Terminal Units: EC Motor vs PSC Motor Power Usage % ECM WATTS % 0.25 PSC WATTS Power Average Watts % % % Annual Run Time % ECM OPERATING TIME Motor RPM
15 Case Study: FAN POWERED BOX: NYC Class A Financial Headquarters
16 ECM: Fan Coil Unit Opportunities Eon 42 Fan Coil Blower Motor Voltage: Output: Efficiency: Speeds: Rotation: Size: 115 or , Single Phase Up to 1/4HP ~80% peak Discreet or variable speeds CW or CCW 4.8 Outer Diameter Typical Applications: Typical Locations: Fan Coils Hotels, Dorms, Universities, Government Buildings, Office Buildings, Building utilizing hot water/cold water for heating/cooling, Military Barracks
17 Fan Coil Units 9/26/2012
18 Case Study: Hilton Hawaii, HVAC FCU EC Motor Compare PSC to EON 42 Frame EC Motor Existing Motor RPMs Watts Savings 1/6th HP 115 Volt PSC 1267 High Speed 240 1/6th HP 115 Volt PSC 810 Medium Speed 160 1/6th HP 115 Volt PSC 560 Low Speed 105 EON 42 RPMs Watts Savings 1/8th HP 115 Volt EC 1225 High Speed % 1/8th HP 115 Volt EC 820 Medium Speed 46 72% 1/8th HP 115 Volt EC 560 Low Speed 18 83% 18
19 ECM: DRYCOOLERS, CONDENSERS ECM Fan Motor Voltage: 115, , 460, Single Phase Output: 1/4HP, 1/3HP, 1/2HP, 3/4HP, 1HP Efficiency: ~78% peak Speeds: Discreet or variable speeds Rotation: CW or CCW Size: 5.5 Outer Diameter Operating Temps: -40 C to 55 C Typical Applications: Typical Locations: Condensers, Package Units, SyMAX-I Commercial buildings, residential buildings Superior efficiency over broad speed range
20 CASE STUDY : Rooftop Condenser Retrofit System VORTEX. Combining the latest in Electronically Commutated Motor Technology (up to 3hp) with the most Advanced Airfoil Prop available SIGNIFICANT SAVINGS! Rooftop Condenser Data Motor Prop RPM CFM Watts Savings Existing Typical Rooftop 460V 3ø Induction Motor 1 hp Vortex Fully Variable 460V 3ø EC Motor 1 hp Site Data Existing Typical Steel 30 5 Paddle Condenser Style 31 deg. Vortex 30 Efficient Condenser 5 Paddle 35 deg Watt Savings with Vortex Benchmark Data Typical Rooftop 460V 3ø Induction Motor 1.5 hp Vortex Fully Variable 460V 3ø EC Motor 1.5 hp Typical Steel 30 5 Paddle Condenser Style 31 deg. Vortex 30 Efficient Condenser 5 Paddle 35 deg Watt Savings with Vortex Years ROI *Variables include runtime, local cost of power, watt savings
21 Case Study: 40 Drycoolers: NYC Commercial Class A Building Compare PSC to EC Motor and Composite Fan Blade Project Cost: $56,000 Incentives: $15,600 Savings: $21,000 Payback: 1.9 Years Existing Motor CFM Watts Savings 1/2 HP 120 Volt PSC SYMAX I and Blade CFM (increased) Watts Savings 1/2 HP EC and Blade % P 21
22 ECM: ½ HP to 50 HP with External Drive Opportunities Symax Applications: Large Ventilation, Cooling Towers, Pumps Industrial and Commercial applications Type: 3- phase 230V/460V 50/60 Hz PMAC Motor. Requires separate VFD. Direct, belted, or geared drive Horsepower Range: 0.5 HP 50HP Efficiency: 83% - 95% Depending on size & load Frame Size: 56C 286TC Speed Range: rpm (Depends on hp) Enclosure: Up to IP56 with options Mounting: Vertical or horizontal Input Options: Dedicated VFD Temperature: -40⁰C to 60 ⁰C 22
23 Incentives and Rebates Improve your project payback! Prescriptive Rebates Custom Rebates Local / State Government Energy Offices Grants
24 Next Steps 1. Contact GREENCROWN Energy today to Setup a Site Audit 2. Develop ROI Analysis & Payback including incentives 3. Develop Action List with GCE Team
25 Q&A
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