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ENERDES BV SUSTAINABLE ENERGY SOLUTIONS

EC-Fans

A general supportive document on the workingsand advantages of EC-Fans

February

&

This report is intended to clarify the benefits of EC-Fans and deliver a background on the workings ofelectrical motors. The advantages of the used techniques will extend the strengths of the Ultra

Clima systems and deliver an insightful overview.

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Content

General .................................................................................................................................................... 3

Electro motors ..................................................................................................................................... 3

AC vs. DC .......................................................................................................................................... 3

Synchrone ........................................................................................................................................ 5

Commutating ................................................................................................................................... 5

Fans ..................................................................................................................................................... 6

Radial vs. Axial ................................................................................................................................. 6

EC-Fans .................................................................................................................................................... 7

Positioning components .................................................................................................................. 8

Electronics ....................................................................................................................................... 8

Overview .......................................................................................................................................... 8

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GeneralWith the introduction of the Ultra Clima systems, a carefully selected set of components forms an

highly efficient product for the greenhouse industry. The combination of the patent-pending air hose

distribution system of Ultra Clima and the much acclaimed high efficiency fans from EBM-Papst

have proven to create a stable semi-closed climate leaving its competitors far behind. The fans are

chosen due to their extensive development and provide the demanded air flow needed.

Electro motors

The commonly used 'Bigger is better'-phrase is a phrase

emphasizing the truth for electro motors. When an electro

motor increases in size, the more efficient it can become in

the usage. Any motor will lose efficiency as it nears its max

output level. By choosing a larger motor, one can remain

longer at the ideal ratio and efficiency as illustrated. In

addition the losses in the control components don't upscale atthe same pace when up scaling the motor as well as having

more physical room for improving and optimising the motor.

This overall increases its efficiencies even more.

With this, the overall result brings a scenario where 1 larger

motor will outperform several smaller motors. In addition the

motor is running at a lower level increasing its lifetime.

With the development from EBM-Papst and the close

cooperation in integrating their largest motor in the Ultra Clima system, the chosen fans can

maintain an IE3 level of efficiency and provide the desired specifications for the Ultra Clima

Greenhouse concept.

Understandably there are a variety of electro motors, fans and combinations. To clarify these

different aspects and provide an insight and overview on the chosen fans, the information from

http://www.animations.physics.unsw.edu.au/is used to summarise the principles and explain the

workings.

AC vs. DC

Electro motors come in different editions, however to begin from an users perspective we start with

explaining the difference between direct (DC) and alternating current (AC). To explain the differencebetween these two forms of transporting electrical energy, we are going to use an analogy with

water. Despite the grand conflicts occurring between water and electricity, both share similar

behaviour and can be used to explain each other principles.

The difference between DC and AC can be best explained using a wave-analogy. Explaining how AC is

transferring its energy can be hard to imagine without understanding the difference in "movement"

of the energy itself. For this, AC is behaving as a wave, it rises and declines in a rhythmic pattern.

With electricity this is commonly known as the 50 or 60Hz frequency on which the local network is

operating. As the energy consumption grows, the wave transporting the energy will need to

transport more energy. As the energy particles (compared to water particles, the values in coulomb

should be considered) themselves stay at one place until they are consumed, the wave can maintain

http://www.animations.physics.unsw.edu.au/http://www.animations.physics.unsw.edu.au/http://www.animations.physics.unsw.edu.au/

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its energetic value over a longer distance. When consuming however, just like with DC, the energy

starts to flow. Whenever this flow exceeds the channels maximum capacity it won't overflow, it will

force itself through the cable and start to heat up due to friction with the channels walls. Where a

channel with water can overflow, power cables will melt when exceeding the maximum capacity.

DC in comparison has a flat surface, no wave but only a single movement towards the productconsuming the energy. With this the advantages of AC are explained as the influences from the

channels wall are the same. The movement causes friction and either heat up the cable or slow down

the movement. On short distances, these effects can be managed, but for large distances the friction

prevents the possibility to transport the energy. For this reason all networks have AC to transport the

energy to the products.

Although both forms can be

transformed into the other, as users

we usually experience the

convergence of AC to DC. This is done

with a rectifier and can be explained

with an overflow on the channel. The wave exceeds the barrier and starts to flow down the overflow

channel. Whenever the wave exceeds from the 0 position or centreline it can use the overflow and

flow directly down a different channel. The illustration shows two waves, a green and red. As

electricity knows no up or down, both waves can use the overflow and form a DC flow. With

additional components the remaining elements from the wave can be smoothened out.

In the illustrations below, the overflow is demonstrated in the right representation by commutating

during the power creation. As the mechanical energy provides an electrical DC current through the

loop, the position and rotation will create an AC flow without commutation and DC with

commutation. With an electrical motor we use the energy to deliver mechanical energy, but this

principle is reversible hence the illustration represents both motors and alternators. In theory each

motor can function as an alternator and vice versa. The main difference is the efficiency at which

they can perform each other's functions.

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As illustrated it's possible to create an electro motor with a handful of components when steering

the motor with AC and letting it run on the AC frequency (in common household products usually a

multiplication of this frequency is used). A DC electro motor, unlike an AC motor, first needs to

create an alternation in the magnetic fields in order to have

the components rotate and follow the field. As explained the

advantages are different for each form of motor. Where an

AC motor can be easily build for a steady rpm and load with

small number of components, it's the fact it's locked to these

frequencies that prevent it being used on different settings.

A normal fan as illustrated uses this principle and merely

changes the multiplication of the frequency for a higher rpm.

When using a DC motor, the rpm is free to alter and a precise

load balancing control can maintain an optimal performance.

SynchroneAs explained electro motors can operate on two different forms of current. The way they perform

their rotation has another two versions. The electro motor can be either asynchronous or

synchronous. The difference between these two forms can be easily explained due to them being

counters. Synchronous motors have an axle rotating equally with the rotation of the magnetic field

and vice versa asynchronous motors do not follow the field on the same pace.

As electro motors use a magnetic field from a current, it's the rotation of this field that forms the

basis for the rotation of the axle. While the motor alters the position of the North and South poles of

the magnetic field, thus creating a rotation in the position, the axle will follow this rotation.

Depending on the design, the axle either follows this rotation with an equal speed or merelyattempts to follow the rotation.

Commutating

As there are different configurations for the electro

motor the method for altering the magnetic fields

position also alters. With the more common used

configuration, the coils creating the magnetic field are

located in the centre. With this configuration by means

of commutating the current is altered to a position in

which the axle will desire itself to rotate and form abalance with the magnetic field surrounding it. The

outer field is usually created by magnets, however a

second set of coils could also perform. By means of

carbon brushes the current is transferred to the correct coils and ensure the magnetic field being

slightly off from the balanced situation, ensuring a small rotation each time the brushes select a new

set of coils. This system is commonly used and delivers the sparks and "smell" that can be detected

with new electro motors (hand drills are well known for these effects).

This combination of parts ensure a simple but sturdy design delivering the altering magnetic field

without additional driving components. The carbon brushes do suffer wear and tear as well asprovide an efficiency loss in the form of physical resistance and electronic resistance.

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Within the electro motor the components are

placed among the stator and rotor. The stator is

considered the fixed part of the motor and it can

have the rotor rotating inside itself as an axle or

outside as illustrated in the illustration. With the

illustrated setup the stator with copper coils

require no carbon brushes to commutate the

correct fields. Instead, the use of an Hall sensor

detects the position of the rotor and its magnetic

field. With electronic commutation the fields in

the copper coils are adjusted and a custom current

and timing allow the exact required magnetic field

being generated to maintain the desired rotation. This

combination eliminates the carbon brushes' negative

effects and allows for a precisely timed control overthe rotation and applied current. In contradiction with

a carbon brush commutation, the current is timed and

measured by the electronics instead of merely timed

by the position of the commutator. Due to the

additional electronic components required to control

this configuration, the less efficient carbon brush

method is applied more often.

Fans

As fans are intended to move air and realize an airflow, this straightforward definition still leavesroom for a variety of configurations. The choices among electro motors continues with the fan

configurations. The choice for a fan is depending on the type of desired result as well as the desired

level of efficiency. A fan implemented in an improper application will prove to be highly inefficient

and undesirable.

Radial vs. Axial

For the more standard applications, the use of either radial or axial

configurations need to be considered. With radial fans, the fan

blades are turning around the axle of the motor. To clarify, they are

not directly extending from the axle, but constructed parallel withthe axle and they force the air away from the axle. The air is drawn

on axis of the axle and combined with an housing blown out under a

90 degree angle. The construction can direct and force the air under

a great pressure to a

specified exit. The main

disadvantages are the

need to draw air through

a central point and the

requirements on the

motor side.

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The axial fans require in comparison smaller motors allowing them to

become more compact. The blades extend from the axle and move the

air alongside the axle. This configuration allows for a greater amount of

air being moved and leaves more room for alterations as the

replacement of the fan blades is easier performed.

EC-FansThe EC-Fans used in the Ultra Clima systems are the largest in the series. They were chosen due to

their specifications and integrated into the Ultra Clima system. Next to the development from EBM-

Papst, who was chosen based upon their quality and care for their products, the cooperation

between Enerdes and EBM-Papst follows a close interaction aimed towards delivering an optimized

product on performance and efficiency.

These fans share a selection of differentiating specifications by which they can perform on a

continuous setup while exceeding the competition. The choice for using a DC motor, after rectifying

the AC input, allows for a wide input capability. With a range of 380~480V, 1 or 3 phases, the fan can

be deployed world-wide. In addition the fans are Electronically Commutated (hence the name EC-

Fans) which delivers a lower resistance and allows for a precise control of the fan. With the detection

of the position through a Hall-sensor and the synchronous setup of the motor, the fan is controlled to

maintain the ideal and optimal position and control the required energy to perform on the most

efficient level. Resources are balanced to deliver a stable rpm and reserved when there is no load to

compensate. It's this precise resource handling that has eliminated the start-up power peak common

in electronics. In this EC-fan, the start-up peak has been reduced to a fraction of the maximum power

consumption, reversing the normal peak curves of other products. Due to the detection of no load,

the allocated resources for starting the fan are consistent with spinning up in contradiction to the

average AC fan that will stabilize after a large peak drainage at start-up.

In

= 3A

In

= 4A Is = 9A

EC

AC

2s / DIV

2s / DIVExample: AC 6-pole outside motor versus EC

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All electronics suffer from the start-up power peak, but with the clever design of using electronic

components to buffer and handle the power consumption, the power peak in the EC-fans has been

reduced to a fraction of their maximum consumption. This benefit reduces the need to build in large

buffers in order to compensate for the power peaks when starting the products. In addition, all

products can be started simultaneous without endangering an overload on the electrical scheme.

This reduction on both consumption and need for the backbone components delivers additional

benefits for the end-user.

Positioning components

Each component separately has been the result of an intensive

development process and their combination delivers additional

value on the sum of all parts. The combination of a highly efficient

motor delivering a balanced and stable performance on a fan with

specific fan blades developed for each size and type, creates a

product far ahead of the competitors. With the extension on the EC

technology, the usage of configuring the motor with an exterior

rotor delivered the opportunity to place the motor in the center of

the fan and use the air to cool the electronic components and guide

the air more efficiently through the housing. The total combination

allows for a long lifetime and intensive use phase while maintaining an efficiency of the highest world

standards currently upheld.

With the active development from EBM-Papst on the product, the components are not only

supported with a large supplier delivering spare parts, they provide improved parts and leave the

option to optimize the product even after its release. With developments on new fan blades and

airflow guidance, the product can throughout its lifetime increase in efficiency..

Electronics

The last element providing an unique argument is the level on which the product can be controlled.

Although as explained the electronic components form an essential part in the efficiency, the

accessibility of the software allows to control the product by remote and deliver the actual values for

monitoring the output. The software can be integrated to control the overall system with a

centralized control and provide a stable and controllable solution.

Overview- Electronic Commutation for accurate control

- IE3 efficiency due to design and size

- Net independent design, world-wide deployable

- No start-up power peak, balanced power consumption

- High volume output with Ultra Clima desired pressures

- Continued development to improve efficiency on current and future models