1. How to Save Energy in Air Systems

2. Originally Presented by
Michael Ivanovich, Senior Director, AMCA international
Steve Dikeman, President, AcoustiFLO

3. Learning Objectives Ivanovich About AMCA Value of Certified Products
Damper Leakage
Dikeman
System Effect 
System Leakage
Right-Sizing Fans
Here are the things we will be going over today.

4. What is AMCA?
Air Movement and Control Association International, founded in 1917
Not-for-profit manufacturers association of fans, dampers, louvers and other air movement and control products
Mission is to promote the health, growth and integrity of the industry

5. What is the AMCA Certified Ratings Program?
How AMCA’s Certified Ratings Program works:
Companies send products to AMCA for testing
AMCA tests products for parameters specified
AMCA checks its data against manufacturer literature
After certification, the product
Is licensed to bear AMCA’s seal
Is listed in AMCA’s online database
The AMCA CRP was developed in response to a need for validated product performance ratings
Buyers, specifiers, and users of air movement and control devices needed to know they were getting what they paid for.
AMCA created the CRP to provide third-party verification of manufacturer data, and it
1. Companies send products to the AMCA laboratory for testing, requesting certification for performance parameters
2. AMCA tests products for parameters specified by the manufacturer
3. AMCA checks its test data against the data the manufacturer provided to verify it is the same, within a certain tolerance
Only after the product has been tested and the manufacturer’s cataloged ratings have been approved can manufacturers display the AMCA seal for the parameters tested.

6. The Cost of Inefficient Products
Centrifugal fan
Performance out of tolerance > 6%
AMCA fan energy waste calculator
Centrifugal fans check-tested at AMCA every three years
25% fail – data from failures used to create an online calculator

7. Data from Failed Tests

8. Data from Failed Tests

9. The Cost of Inefficient Products
What if dampers leaked more than rated?
What if louvers had higher pressure drop?
What if …?
Why gamble?

10. Damper Leakage

11. Damper Leakage

12. Damper Leakage

13. System Effect: 1ST Definition
Installed duct configuration does not match tested duct configuration

14. System Effect: 2nd Definition
Even when the tested duct configuration matches the installed duct configuration, improper duct design can introduce adverse flow conditions

21. Rules of Thumb Minimum 2.5 duct diameters on outlet
Minimum 3 to 5 duct diameters on Inlet
Avoid inlet swirl

22. Recommendations
1. Allow enough space in the building design for fan connections 2. Use allowances in design calculations when space is a factor 3. Reference AMCA Include allowance for the effect of all accessories and appurtenances
Allow enough space in the building design to allow for appropriate fan connections to the system
Take into account the fact that the total cost for the building is the original capex cost plus the cost to operate it
2. Use allowances in the design calculations when space or other factors dictate less than optimum arrangement of the fan outlet and inlet connections
3. Reference AMCA 201
4. Include adequate allowance for the effect of all accessories and appurtenances on the performance of the system and the fan
Belt drive loss
VIVs
Belt guards

23. System Leakage Establish level of tightness needed
Specify air system components and sealants that perform together as a system
Select a testing standard that ensures the leakage objective is met
2012 ASHRAE Handbook—HVAC Systems and Equipment and 2013 ASHRAE Handbook— Fundamentals
Establish level of tightness (system leakage percentage) that the project merits,
Specify air system components and sealants that will perform together as a system to meet the system leakage objective.
Select a testing standard that contractors or commissioning providers will use to ensure the leakage objective is met.
2012 ASHRAE Handbook—HVAC Systems and Equipment and 2013 ASHRAE Handbook—Fundamentals

24. Right Sizing Fans
Efficient
Quiet
Cheap
…Select any two!

25. Constant Speed Air Systems
Variable volume air systems = variable speed systems
Constant volume systems with variable pressures = variable speed systems
Night setback, after hours, weekend modes are candidates for variable speed
Constant speed air systems are neither constant volume or constant pressure
Variable volume air systems are obvious examples of variable speed systems
Constant volume systems with variable pressures are variable speed systems (healthcare, labs)
Night setback, after hours, weekend modes are candidates for variable speed
Constant speed air systems are neither constant volume or constant pressure

26. Variable Speed Air Systems
Minimal reduction in speed offers a massive reduction in input power
90% speed  73% impeller bhp
80% speed  50% impeller bhp
70% speed  34% impeller bhp
60% speed  22% impeller bhp

27. Design Wheel Speed
For every duty point, there is an optimum wheel speed.
Pulleys and belts
Direct drive
No belts and speed control!
For every duty point, there is an optimum wheel speed.
Pulleys (and belts) provide unlimited speeds and constant wheel speed
Direct drive - motor speed will seldom be optimum wheel speed, changing motor speed offers unlimited wheel speeds
No belts and speed control!

28. Belt Loss
3% to 10%
4% to 15%
6% to 22%

29. Right-Sizing Fans Design flow (includes a safety factor)
Design pressure (includes a safety factor)
Filter loading (all filters at the same time)
Plus another safety factor?
Input flow and pressure into selection software

30. Right-Sizing Fans
Fan diameter (inches)
Input power (bhp)
30”
10.2
27”
10.3
24”
10.7
22”
11.9
20”
14.4
All selections require a 15 HP motor. Unless input power is defined which wheel will you get? – the cheapest/smallest
A 42% difference in energy consumption
“It’s only 4.2bhp” (12,000cfm at 4”)

31. Fans are Simple Machines

32. Fans are Simple Machines
The smallest wheel – design flow & 80% pressure.
Fan efficiency down yet another 5% from the selection point

33. Fans are Simple Machines
Largest wheel – design flow & 80% pressure. Still near design efficiency

34. Right-Sizing Fans Imperative to specify a maximum absorbed power
“Bigger wheel” minus “slower speed” isn’t always better
For VAV supply fans, reset minimum pressure set point
Evaluate the fan curve, not just the tabular output
Imperative to specify a maximum absorbed power
Impeller input bhp is one metric
Motor input kW another
“Bigger wheel”-“slower speed” isn’t always better. More low frequency sound might require a sound trap and higher pressure
For VAV supply fans, best efficiency can be problematic regarding turn down . Reset minimum pressure set point!!
Evaluate the fan curve, not just the tabular output

35. Questions?
Contact Information Michael Ivanovich: Steve Dikeman: