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ECONET where renewable and recoverable energy unite

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ECONET where renewable and recoverable energy unite

Energy exchangers
Energy recovery systems are very common in current building designs There are 3 common energy recovery systems on the market. 1. The rotary heat exchanger (RHE) 2. The plate heat exchanger (PHE) 3. The run around coils (RAC)

ECONET

Energy exchangers
There are a number of things to be considered when selecting an energy recovery system:
Energy recovery efficiency combined with the pressure drop Space in the equipment room Location of air handling units The duct connection Leakage and odor transfer (cross-contamination in the recovery system)

Activity conducted in the building

Need for latent cooling recovery Types of energy sources

ECONET

Why should we reduce the energy consumption ?

Energy sources: Limited traditional energy sources (oil, gas, coal etc.)

Increase of energy consumption on a global scale

Increase in energy prices

Pasterze Glacier, 1875

The Environment: Global warming, CO2 Emissions, pollution Pasterze Glacier, 2004

Legislation: Global and regional regulations/ restrictions

ECONET

What to optimize inside current AHUs?

There are a lot of components to be optimized in an AHU: Recovery device Fans Motors Frequency inverters Pressure drop thru components Velocity Size External issues Etc.

Exhaust air

Extract air LWA extract qextract

Outdoor air

pfan +

Supply air LWA supply qsupply

pext in

p1

p2 LWA amb

p3 p4 p inl drive motor rotor

trans Pmain

poutl fan

pext outl

ECONET

The run around coil system

Run Around Coils

Run around coils (RAC) are one of the 3 most common types of energy recovery systems. The traditional RAC is a well known system and it has been used for decades. ECONET is an advanced form of run around coil and was introduced by Flkt Woods in 2000.

ECONET

Run around coils: Advantages

No risk of cross-contamination Flexible installation, supply air and exhaust air units can be separated. Can be used for applications with corrosive and polluted exhaust air. Moderate/good energy recovery efficiency Easy to optimize recovery with unbalanced air flows

ECONET

Run around coils: Disadvantages

More complex installation Maintenance of the liquid/recovery circuit

No latent cooling recovery

Normally moderate energy recovery efficiency

ECONET

Run around coils: Summary

Advantages: No risk of cross-contamination Flexible installation, supply air and exhaust air units can be separated. Can be used for applications with corrosive and polluted exhaust air. Moderate/good energy recovery efficiency Easy to optimize recovery with unbalanced air flows Disadvantages: More complex installation Maintenance of the liquid/recovery circuit No latent cooling recovery Moderate energy recovery efficiency Applications: Due to a flexible solution combined with a mod/good recovery efficiency, the system is suited for: No leakage can be tolerated. The supply and the exhaust air units have to be separated from each other. Relatively simple to install it in existing AHUs (upgrading of the functionality) Hygiene applications Applications with corrosive or polluted exhaust air No need of moisture recovery : ECONET Where process or waste heat available Limited space in the equipment room High recovery efficiency Commercial buildings Hospital, hygiene applications Pharmaceutical applications Housing, depending on the market

ECONET

The unique advantages of the ECONET system.

Unique advatages of ECONET

1 component, 4 functions: Heat recovery Additional heating Cooling recovery Additional cooling Lower pressure drops Shorter AHU Fewer components

ECONET

Unique advatages of ECONET

Increased heat recovery efficiency 6075% performance Able to use cooling recovery Always prepared for cooling and cooling recovery Possibility to utilize process/ waste heat Perfect for district cooling/heating Pre-fabricated pump unit

ECONET

The delivery

ECONET : Basics, coils

Consists of heat exchangers (coils) in the supply air and in the exhaust air. The coils are composed of copper pipes with profiled aluminum or copper fins. The fin pitch is 2-4 mm. For highly corrosive environment the fins are either epoxy coated or of stainless steel.

Both coils are equipped with drip trays.

For high air velocities, coil are equipped with droplet eliminators. Several capacity variants of the coils available for each AHU size (2 to 12 rows)

ECONET

ECONET : Basics, pump unit and controls

ECONET pump units are available in 2 versions: ECONET standard ECONET compact

Common for both versions: Pump unit for energy recovery/heating and cooling Pipe work, anti-rust painted and insulated Controls for energy recovery function Frequency inverter for pump All required sensors mounted and cabled A floor-mounted stand for all pump unit sizes

ECONET

ECONET : Basics, pump unit and controls

ECONET pump units are available in 2 versions: The main difference between the versions: ECONET standard Equipped with a separate controller for optimization of energy recovery. Controls with additional functions. ECONET compact Equipped with a multifunctional frequency inverter, with integrated controls for optimization of energy recovery. Limited additional functions.

ECONET

ECONET : Basics, pump unit and controls

ECONET pump units are available in 2 versions: Which version to choose? Choose ECONET standard if: Dry-box solution Twin pump solution Efficiency calculation Energy calculation Lon and BacNet Otherwise choose ECONET compact: A compact and a more cost efficient solution

ECONET

ECONET Exchanger package

A pre-fabricated exchanger package (accessory), consisting of: Plate heat exchanger for additional heating. Plate cooling exchanger for additional cooling. Shut off valves. Drain valve, filling valve. A stand for the exchanger package designed to stand on the floor. Expansion vessel with safety valve. It is possible to order an integrated system, including both the pump unit and the exchanger package.

ECONET

The function of ECONET

ECONET: Function, controls

Control box, ECONET

Control box, AHU/BMS

start/stop

heat recovery 0-10 V

cooling recovery on/off

Energy recovery
Safety functions

cooling function on/off A-Alarm on/off 3 x temp 0-10V Option: Temp. efficiency 0-10V --> B-Alarm for twin pump --> --> -->

Control of supply air temp.: heating/cooling valves etc... Other AHU functions

ECONET

ECONET: Function, heat recovery + heating

Mode 1, a cold winter day Heat recovery + additional heating: The system optimizes the heat recovery by controlling the liquid flow. Additional heating, controlled by the heating valve. Internal frost and ice protection Control signals: Heat recovery signal 100% (10V) BMS controls the heating valve 10
70% Exhaust air

73
30% 80

68 Supply air

100%
HRC

ECONET

ECONET: Function, heat recovery

Mode 2, a normal winter day. Only heat recovery, no need of additional heating: The system optimizes the heat recovery by controlling the liquid flow. Control signals: Heat recovery signal 100%
41 62 100%

Exhaust air
73

66

Supply air

100%
HRC

ECONET

ECONET: Function, reduced heat recovery

Mode 3, a spring/autumn day. Only heat recovery, reduced heat recovery: The system is too efficient and reduces the heat recovery by reducing the liquid flow. Control signals: Heat recovery signal 0%< sign<100% (0-10V)
Reduced recovery Exhaust air 73

62

50

59

Supply air

0-100%
HRC

ECONET

ECONET: Function, no recovery

Mode 4, changing from winter to summer. No need for heating or cooling of supply air: The pump stops Control signals: Heat recovery signal 0% (0V)

Exhaust air

62

62 Supply air

ECONET

ECONET: Function, cooling, no recovery

Mode 5; a normal summer day Exhaust air Additional cooling: No cooling recovery, due to the air temperatures. The system optimizes the liquid flow for additional cooling. Additional cooling, controlled by the cooling valve. 68 Control signals: Cooling signal on Heat recovery signal 0% BMS controls the cooling control valve ECONET 75 100% 55

60 Supply air

on
Cooling

ECONET: Function, cooling recovery + cooling

Mode 6, a hot summer day Additional cooling + cooling recovery: The system optimizes the cooling recovery by controlling the liquid flow. Additional cooling, controlled by the cooling valve. 25% Exhaust air 75 75% 51

Control signals: Cooling signal on Cooling recovery signal on Heat recovery signal 0% BMS controls the cooling valve

89

60 Supply air

on
Cooling rec.

ECONET

ECONET: Function, cooling recovery (IEC) + cooling

Mode 6 optional, an even hotter summer day with the additional function, IEC IEC = indirect evaporative cooling Additional cooling + cooling recovery (IEC): The same principles as normal cooling recovery, but by using a humidifier in the exhaust air. The cooling power can be reduced even more. Normal cooling power reduction: 25% IEC cooling power reduction: 45% More on this in a later section
Exhaust air 45% 66 75

51

55%

89

60 Supply air

on
Cooling rec.

ECONET

Energy sources for the ECONET system.

ECONET: Heating energy sources

What is Acceptable? Traditional energy sources, gas, oil, electricity, pellets, etc. What is Optimal? ECONET can utilize warm water (energy) from 77-86.
70% Exhaust air 73 30% 80

Waste heat (condensate heat) from chillers Waste heat from industrial processes Heat pumps District heating Return water from district heating

10

68
Supply air

ECONET

ECONET: Cooling energy sources

What is Acceptable? A traditional chiller. What is Optimal? ECONET can utilize cold water (energy) of up to 50-53. Cooling energy from soil or sea (geothermal) Optimized chiller District cooling IEC, indirect evaporative cooling
Exhaust air
45% 66 75

51

55%

89

60 Supply air

ECONET

What does IEC mean ?

To clarify the function of Indirect evaporative cooling (IEC) IEC is a way of getting more cooling recovery from the exhaust air. The idea is to humidify the exhaust air with water. The water evaporates and decreases the air temperature and the cooling recovery becomes even more effective. Thanks to the recovery system (RAC) there is no risk of cross contamination between the air streams which avoids the risk of getting humid air back into the supply air.

Exhaust air

45% 66 75

51

55%

89

60 Supply air

ECONET

What are the benefits of IEC ?

It is a good system for applications where it is of importance to cut of the peak loads from the chiller. In this case the chiller size can be reduced by approx. 45%. For markets with warmer climates it reduces the additional cooling energy as well.
89 45% 66 75

Exhaust air

51

55%

60 Supply air

ECONET

The impact on the cooling network

Two cooling examples, one with additional cooling combined with cooling recovery the other one with cooling recovery with IEC. Cooling with ECONET has following benefits: Reduced size of chiller Reduced liquid flow and pipe work A higher evaporating temperature in the chiller gives us a smaller and a more efficient chiller
Exhaust air 45% 66
71F

75

51

55%

89

60
Supply air

25% Exhaust air 75 75%

78F

51

89

60 Supply air

ECONET

The impact on the cooling network, power

Chiller
Reduced size of chiller
due to cooling recovery

ECONET+IEC
Exhaust air 45% 19C 24C

55%
32C

11C

55%

Reduced liquid flow and pipe work Smaller and a more efficient chiller 75%

16C Supply air

ECONET
25% Exhaust air 24C 75% 11C

32C

16C Supply air

100%

Traditional
No cooling recovery

ECONET

The impact on the cooling network, cold water flow

Chiller
Reduced size of chiller Reduced liquid flow and pipe work
due to high t

ECONET+IEC
Exhaust air 45% 19C 24C

30% (50/68)
32C

11C

55%

16C Supply air

Smaller and a more efficient chiller ECONET

25% Exhaust air

30% (50/75)
11C 32C

24C 75%

16C Supply air

100% (42/53)

Traditional
No cooling recovery

ECONET

The impact on the cooling network, temperatures

Chiller
Reduced size of chiller Reduced liquid flow and pipe work Smaller and more efficient chiller
due to a higher evaporating temperature.

ECONET+IEC
Exhaust air 45% 19C 24C

30% 50/68
32C

11C

55%

16C Supply air

ECONET
25% Exhaust air

30% 50/75
11C 32C

24C 75%

16C Supply air

100% 42/53

Traditional
No cooling recovery

ECONET

ECONET can protect your supply air filter as well

ECONET: Special protection of the supply air filter

Basics: In some regions, there is a need to protect the supply air filter. Otherwise the high humidity under certain outdoor air conditions may damage the filter. To protect the filter a pre-heater is installed before the filter, heating the outdoor air for approx 35 F The negative aspect of a traditional pre-heater is that the system destroys the heat recovery.

ECONET

ECONET: Special protection of the supply air filter

Solution: The preferred solution is to use a preheater combined in the heat recovery circuit. This has following benefits: Heat recovery efficiency is maintained No primary heat connections to the pre-heater No risk of frozen pre-heater coils

ECONET

ECONET: Dry box solution, summary

A system for protection of the supply air filter Advantages:
Savings in heating energy consumption due to a more efficient system
Savings in fan energy consumption, due to fewer/thinner coils (not as deep)

Savings in plumbing, due to no primary heating connections to the pre-heater

Savings in controls, due to no separate controls of the pre heater. Safer system due to no hot water coils in the supply air.

ECONET

Benefits with ECONET

ECONET: Saves space in the equipment room

1 coil in the supply air instead of 3 coils (recovery + heating + cooling). Reduction of the AHU length:
By 3 6

Reduction of the AHU foot-print Reduction of the AHU weight:

By 800 - 1,000 lbs. + 48

Summary More space to rent Easier to install the units Easier maintenance Possibility to use bigger AHUs More air, better efficiency, etc.

ECONET

ECONET: Reduces installation time

A pre-fabricated pump unit with integrated controls for energy recovery, including all necessary sensors, naturally reduces the installation time and the potential for mistakes on site.

ECONET

ECONET: Applications
Everywhere, where there is a need for a run around coil solution, including particularly Hygiene applications. Everywhere, where waste heat is available. Everywhere, where there is a desire to optimize the cooling system. Everywhere, where plant room space is restricted. Everywhere, where there is a need to protect the supply air filter.

ECONET

Controls: Assembly and installation

Automation and electricity on site

Standard:
Power supply to the ECONET controller Power supply to the frequency inverter/inverters Supply air flow transmitter Assembly of the transmitter Wiring between the transmitter and the ECONET control box
SV 40 GT 41 GT 42

ECONET
DO DI AO AI

Wiring on site

AHU/BMS
Alarm DO DI AO AI

Wiring between the ECONET and the BMS system Or/and network communication Modbus, Lon

GP 41 GP 40

Start
SC 40

Heat recovery Cooling A Alarm

GF 10

Wiring on site
Optional: Temp GT40 Temp. GT41 Temp GT42 Optional Cooling recovery Pump indication

GT 40

ECONET

Automation and electricity on site, ECONET <-> BMS

Control inputs:
Start (digital on/off) Cooling start (digital on/off) Cooling recovery start (digital on/off)

Control outputs:
A-Alarm (digital on/off) B-Alarm (option) (digital on/off) P40 Pump indication (digital on/off)

Heat recovery signal (analog 0-10V)

GF10 Air flow signal (analog 0-10V)

GT41 (analog signal, 0-10 V)

GT42 (analog signal, 0-10 V) GT40 (analog signal, 0-10 V)

Network communication chosen (LON, Modbus) All integration tasks such as e.g. binding and activating of the address between the ECONET controller and the BMS system.

ECONET

Automation and electricity on site, ECONET <-> BMS

Additional functions, which has to be chosen separately:
*) Efficiency and energy calculation, wiring and assembling of additional sensors **) Twin pump solution ***) Network

Control inputs: GT 00,10,20,21: air temperature sensors *) GT30, additional liquid temperature sensor *) GF20: air flow signal *) Control outputs:
Efficiency (analog 0-10V) *) B-Alarm (digital on/off) **) Network communication (LON, Modbus) ***) All integration tasks such as e.g. binding and activating of the address between the ECONET controller and the BMS system.

ECONET

Piping: Assembly and installation

Piping on site
Standard:
Assembly of the pump unit Pipes from the exhaust air unit to the pump unit Pipes from the exchanger packages to the pump unit Pipes from the supply air unit to the pump unit Available assembly of the exchanger package Pipes from the exchanger packages to the pump unit Pipes, valves on the primary side of the exchanger package

ECONET

Piping on site
Other necessary components as set in the document, such as:
External shut-off valves Automatic air purging valves combined with manual air purging valves Air purging valve for micro bubbles Filter Charging equipment Water traps Anti-freeze liquid Filling of the system Air purging of the system Additional functions, which has to be chosen separately: If the exchanger package not delivered by FWG Expansion vessel Heat exchanger Cooling exchanger Connection for filling Safety valve If dry box solution chosen Pipes between the two supply air coils

ECONET

Avoid leakage in the future: Top 10

The most important issues to prevent leakage: 1. 2. 3. 4. 5. 6. System filled up with right kind of glycol, Etylen glycol mixture for HVAC purpose Use Pre mixed liquid If mixed on site, then wait at least 24 h to get rid of air in the liquid Do not use the ECONET pump to fill or/and to clean the system Be sure that You get rid of all flushing/cleaning liquid before filling the system Dont run the pump dry (air), the pump sealing burns and get destroyed 1. Use the air purging screw on the pump to get rid of air from the pump 2. Use automatic air purging valves combined with manual air purging valves 3. The first weeks the manual valve open and the automatic valve working 4. When the air is out then close the manual valve After some time check that no air has come in to the system 1. If air then open the manual air purging valve, if continuous problem, check leakage Expansion vessel on the suction side of the pump, safety valve opening pressure min 3 bar Use a closed liquid filling system. 1. No open filling vessel, risk of bacterial growth, later on might pump in to the system Check the liquid quality, colour, freezing point etc

7. 8. 9. 10.

ECONET

Start-Up and Maintenance

Start-up: Top 10
The most important checks when starting up ECONET: 1. 2. 3. 4. 5. 6. Check all pipe connections (counter flow) System filled up with right kind of glycol System purged of air and has an air purging system Expansion vessel on the suction side of the pump Electricity connection to ECONET frequency inverter and control box Controls connected

7.
8. 9.

ECONET gets the supply air flow

Nothing on manual drive (frequency inverter, by-pass valve) Configure the ECONET controller

10. Go through the start up protocol and note if something is not per requirements.

ECONET

ECONET checks
Liquid status Check the freezing point of the frost protection fluid. Check the system pressure and top up with ethylene glycol mixture if necessary. Coils Check that the finned surfaces of the coils are not dirty, clean if necessary. Water trap Check that water is present in the water trap for the exhaust air and supply air coils. Air purging Check frequently in the beginning and after the first year. Stop the pump and wait a couple of hours to make sure that the air bubbles have risen to the highest points in the system, open/close all valves in the system so that trapped air can be removed. Valve checking Shut down the system and open/close every valve to make sure it has a smooth operation. Pump seals Check the seals and if there is too much leakage, change the seals.

ECONET

Efficiency calculation

Efficiency calculation, heat recovery

The normal way of calculating the heat recovery efficiency is the temperature efficiency over the supply air coil: = (GT10-GT00) (GT20-GT00) Where: GT00, air temperature, outdoor GT10,air temperature, supply GT20, air temperature, exhaust This formula can not be used for ECONET if additional energy is connected to the system.
GF 20 GT 21 GT 20

GT 42 SV 40

GT 41

GP 41 GP 40 GT 30/50

GT 00 GT 40

GT 10 GF 10

ECONET

Efficiency calculation, heat recovery

In the formula for ECONET we have to exclude the impact of the additional energy: = (GT42-GT41) x (GT10-GT00) (GT40-GT41) x (GT21-GT00) Where: GT00, air temperature, outdoor GT10, air temperature, supply GT20, air temperature, exhaust GT40, liquid temperature, supply in GT41, liquid temperature, supply out GT42, liquid temperature, exhaust out
GT 21 GT 20

GF 20

GT 42 SV 40

GT 41

GP 41 GP 40 GT 30/50

GT 00 GT 40

GT 10 GF 10

ECONET

Efficiency calculation, cooling recovery

The normal way of calculating the cooling recovery efficiency is the temperature efficiency over the supply air coil: = (GT10-GT00) (GT20-GT00) Where: GT00, air temperature, outdoor GT10, air temperature, supply GT20, air temperature, exhaust This formula can not be used for ECONET if additional energy is connected to the system.
GF 20 GT 21 GT 20

GT 42 SV 40

GT 41

GP 41 GP 40 GT 30/50

GT 00 GT 40

GT 10 GF 10

ECONET

Efficiency calculation, cooling recovery

In the formula for ECONET we have to calculate over the exhaust air due to possible risk of condensation of water in the supply air coil:
GF 20 GT 21 GT 20

GT 42 SV 40

= (GT21-GT20) (GT00-GT20)
GT 41 GP 41

GP 40

GT 30/50

Where: GT00, air temperature, outdoor GT20, air temperature, exhaust GT21, air temperature, extract

GT 00 GT 40

GT 10 GF 10

ECONET

Efficiency calculation, where to calculate ?

Calculation alternative 1: The easiest way to calculate efficiency for an ECONET system is to do it in the BMS system The BMS system usually have the temperatures on the air side: GT00,10,20,21 and gets GT40,41 and GT42 from the ECONET controller by 0-10V signals. Calculation alternative 2: If temperature efficiency calculation is chosen to be calculated by the ECONET controls, then the following sensors are included in the delivery by the manufacturer. ECONET
GT 20

GF 20

GT 21

GT 42 SV 40

GT 41

GP 41 GP 40 GT 30/50

GT 00 GT 40

GT 10 GF 10

Efficiency calculation, evaluation ?

To be able to analyze the result, you have to know more: Balance of air flows Humidity in the air And keep in mind that a calculated efficiency only shows a trend and is not exact due to: Tolerances of the temperature sensors Tolerances of the air flow sensors Location of the sensors

A heat recovery efficiency of:

= 63.45 %
ECONET

Applications

Application: Supermarket
Why ECONET ? More than 40 ECONET references in Supermarkets Waste/Condensate heat available. Waste heat available from the chillers, 24 hr/day. Perfect for ECONET and most of the year the super market is selfsupporting concerning heating energy. Variation of the need of fresh air. ECONET is suited for VAV system due to continuous optimization of energy recovery.

ECONET

Application: Supermarket, additional energy

Piping of the energy sources: Usually ECONET is equipped with both heating and cooling function Heating and cooling sources:
Heating 1: Waste heat from chillers Heating 2: Primary heating (for safety if no waste heat available) Cooling: Traditional cooling or other

ECONET

Application: University combined with geothermal

Why ECONET ? More than 100 ECONET University references Flexibility with run around coils.
Functionality of the premises might change. Long running hours Variation of the need of fresh air Sometimes combined with other ECONET unique functions, like thermal energy.

ECONET

Application: Soil energy - geothermal

Heating function, soil energy -> Heat pump 86 -> AHU

heat pump

Soil/geothermal

VAV device

ECONET

Application: Soil energy

Cooling function, soil energy -> (Chiller pump or/and directly 52 -> AHU)

heat pump

cooling water 52 Soil/geothermal

VAV device

ECONET

ECONET vs. Compact

ECONET standard vs. compact Standard

Controller and frequency inverter Framework for controller and frequency inverter

Compact

No controller, software in the frequency inverter Frequency inverter integrated on pump Reduced size of pump unit Basic functions the same Reduced additional functionality

ECONET

ECONET standard vs. compact Compact

Reduced additional functionality Dry box solution Twin pump solution Energy calculation Efficiency calculation Lon BacNet Cleanable coils Items listed above available for ECONET standard: Optional: Modbus

ECONET

ECONET standard vs. compact

Summary A simplified ECONET (RAC) solution

Basic functionality the same (standard vs. compact)

Additional functionality limited

ECONET

To summarize: the unique advantages of the ECONET system.

Unique advantages of ECONET

1 component, 4 functions: Heat recovery Additional heating Cooling recovery Additional cooling Lower pressure drops Shorter AHU Fewer components

ECONET

Unique advantages of ECONET

Increased heat recovery efficiency 6075% performance Able to use cooling recovery Always prepared for cooling and cooling recovery Possibility to utilize process/ waste heat

Perfect for district cooling/heating

Pre-fabricated pump unit

ECONET

Thank you.
For more information, please visit us at www.semcohvac.com