eer optimizer for dx air conditioners · eer optimizer for dx air conditioners mike west, phd, pe...

Tampa Convention Center • Tampa, Florida

EER Optimizer™ for DX Air ConditionersMike West, PhD, PE

Advantek Consulting EngineeringAugust 16, 2017

Energy Exchange: Connect • Collaborate • Conserve

TOPICS• Problems addressed• EER Optimizer on-board• i-Optimize hand-held• IoT cloud connectivity• Field Tests• Summary

2

EER Optimizer™ for DX Air Conditioners


Most U.S. commercial space is conditioned with unitary package equipment, yet it is the lowest performing type.

Problems addressed


Current unitary air conditioner design compromises operating costs and performance for the lowest purchase price.

Loads drastically differ from Florida to California, Texas to Illinois In many applications latent cooling capacity is inadequate, SHRs are

too high, and expensive reheat is used for dehumidification. Most current designs maximize energy efficiency at the AHRI IEER

rating points, which does not give the lowest possible energy cost. Performance is difficult to cost-effectively maintain.

“ Compromise is but the sacrifice of one right or good in the hope of retaining another - too often ending in the loss of both.”

Tryon Edwards

Problems addressed


The technology is utilized in two systems:Hand-held instrument for quick, portable measurement & diagnosis

On-board controller to optimize & report operational parameters

EER Optimizer is a cost-effective IoT technology that:a) Diagnoses and mitigates degrading energy efficiency of DX HVAC systemsb) Optimizes operational parameters as load and conditions varyc) Realizes best achievable efficiency as operating conditions and load changes

EER Optimizer™ for DX Air Conditioners


• Optimizes all operating parameters• Target is maximum EER while precisely

meeting sensible and latent loads• Continuous performance tuning

Supply Blower Speed Condenser Fan Speed Refrigerant Flow & Charge Supply Air Temperature Coil Temperature Economizer Damper

• Web monitoring & reporting EER, IEER Efficiency, Tons Capacity Detects faults: low refrigerant, stuck TXV,

restricted airflow, broken economizer, compressor wear, fouled coil, … many others.

Sensitive diagnostics identify issues before they become problematic

On-board EER Optimizer is installed in DX package units and split systems.


RUN MODE energy efficiency comparisonsMANUAL – reverts to factory control

sequence of operationAUTO – temperature and humidity set

points optimally met via blower, damper and fan speed control

OPTIMIZE – maximum energy efficiency sought via continuous simultaneous adjustment of all operational parameters while precisely satisfying comfort and IAQ requirements.

On-board EER Optimizer features integral commissioning and energy savings Measurement & Verification.


The portable i-Optimize™ connects to any DX package unit or split system, measures energy efficiency & cooling performance, and diagnoses faults.

Voltage Probes

Amp Clamp

Humidity Probes

Hi/Lo Refrigerant Pressure Sensors

Temperature Clamps

Temperature Probe

The portable i-Optimize has 12 sensors and a CPU consisting of 2 cloud-linked single-board computers. It allows a technician to take a comprehensive set of measurements, evaluate system performance, verify corrections, and upload readings for analysis and documentation.


• Tests EER, IEER, Tons• Web connected

• Remote tech assistance• Readings stored in cloud• Historical trends analyzed• Reporting &

documentation• Diagnostics identify

issues before problematic• Low refrigerant• Stuck TXV• Restricted airflow• Compressor wear• Fouled coil

The portable i-Optimize™ connects to a cloud server and performs diagnostics.


RTUControllerGUI

Any Web DeviceTablet, Phone, Laptop

Cloud Servers

php

Web

Sock

et

LANVPN

or co

mm

ercia

l WAN

InternetDatabase

http://eeroptimizer.com/summary/

EER Optimizer on-board and hand-held are cloud connected IoT devices.

http://eeroptimizer.com/portable/

http://eeroptimizer.com/summary/

http://eeroptimizer.com/portable/


Field Test 1: Marine Corps Air Station Beaufort, SC

MCX

MCA

SB, S

outh

Car

olin

a

Mixed-Humid Climate Zone 3A2650 Cooling Degree-Days

On-board EER Optimizer was installed in fully instrumented 2003 dual compressor Trane 20-ton rooftop DX unit.


MCA

SB, S

outh

Car

olin

a

Portable i-Optimize was used to diagnose energy efficiency degradation on 10 units, measure IEER, and estimate energy savings after servicing.


Operational Energy Efficiency: 13.1% ImprovementEER Optimizer Demonstration - MCASB Bldg 1283 RT-2

Trane YCD241 2/2003, IEER rating 11.2

MANUAL11.9

AUTOMATIC13.0

OPTIMIZE13.4

10

11

12

13

14

15

Data period: June 8 - September 7, 2016

IEER

[MB

H/k

W]

MCA

SB, S

outh

Car

olin

a


MCA

SB, S

outh

Car

olin

a

Energy Savings After Servicing MCASBAverage 26% Savings

0% 5% 10% 15% 20% 25% 30% 35% 40% 45%

RT-1RT-11RT-3RT-4RT-5RT-6RT-7RT-8RT-9

RT-10

Energy Savings

• Portable i-Optimize energy efficiency measurements of 10 units at MCASB• Average “before” energy efficiency loss versus factory rating: 42%• Average age of unit: 13.3 years.• Average IEER: rated 11.0 / “before” 6.4 / “after” 8.8


Field Test 2: Cape Canaveral Air Force Station, FL (Patrick AFB)Naval Ordnance Test Unit (NOTU)

Engineering Development Laboratory

CCAF

S-N

OTU

, Flo

rida

Hot-Humid Climate Zone 2A3290 Cooling Degree-Days

On-board EER Optimizer was installed in fully instrumented 2012 10-ton dual-compressor Carrier R410a package DX unit.


CCAF

S-N

OTU

, Flo

rida

Portable i-Optimize was used to diagnose energy efficiency degradation on 10 units, measure IEER, and estimate energy savings after servicing.


Operational Energy Efficiency: 21.5% ImprovementEER Optimizer Demonstration - NOTU Hangar Y, CCAFS, FL

Carrier 50HCD-09 1/2012, IEER rating 13.2

MANUAL12.8

AUTOMATIC14.5

OPTIMIZE15.5

10

11

12

13

14

15

16


IEER

[MB

H/k

W]

CCAF

S-N

OTU

, Flo

rida


CCAF

S-N

OTU

, Flo

rida

Comparison of Measured CCAFS vs Rated Efficiency Average IEER 7.2 vs 11.9

0 2 4 6 8 10 12

6263062630S62630N

55865817015589349926499261115

52003

IEER [MBH/kW]

RATED IEERCIRC 1CIRC 2

• Portable i-Optimize energy efficiency measurements of 10 units at CCAFS• Average “before” energy efficiency loss versus factory rating: 39%• Average age of unit: 10.9 years.• Energy savings “after” servicing: 22%


Field Test 3: Fort Irwin, CANational Training Center

DPW Environmental

Arm

y Ft

. Irw

in, C

alifo

rnia

Mojave High DesertHot-Dry Climate Zone 3B3134 Cooling Degree-Days2597 Heating Degree-Days

On-board EER Optimizer was installed in fully instrumented 2010 12½-ton dual-compressor Carrier R410a package heat pump.


Operational Energy Efficiency: 30.4% ImprovementEER Optimizer Demonstration - Fort Irwin Bldg 606

Carrier 50TCQ-D14, IEER rating 10.7

MANUAL9.8

AUTOMATIC11.4

OPTIMIZE12.8

6

7

8

9

10

11

12

13

14

15


IEER

[MB

H/k

W]

Arm

y Ft

. Irw

in, C

alifo

rnia


Refrigerant Charge Fort IrwinAverage 16% Underchaged

-50%

-40%

-30%

-20%

-10%

0%

10%

604

308S

308B 16 12

7

RTU

-16

RTU

-15

RTU

-9

RTU

-5

FOO

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T

Ove

r or U

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Cha

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CIRC 1CIRC 2

Arm

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. Irw

in, C

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• Portable i-Optimize efficiency measurements of 10 units at Fort Irwin• Average “before” energy efficiency loss versus factory rating: 25%• Average 16% refrigerant undercharge – a 10% efficiency loss• Average IEER: rated 11.3 / “before” 8.4 / “after” 10.3 – 19% savings


Summary of on-board EER Optimizer results

Site CCAFS MCASB AFINTC Average

Factory Rated 13.2 11.2 10.7 11.7

Benchmark (2014) 13.9 11.8 9.5 11.7

Baseline 12.8 11.9 9.8 11.5

Optimized 15.5 13.4 12.8 13.9

Point Increase 2.7 1.6 3.0 2.4

Efficiency Gain 22% 13% 30% 22%

Energy Savings 30% 24% 22% 25%

Confidence Anova 0.997 0.998 0.965 0.965

Confidence t-Test 0.99886 0.99997 0.99878 0.9988

Results

Stats

IEER


Summary of hand-held i-Optimize results


SUMMARY OF RESULTS FROM FIELD TESTS• Reduction in air-conditioner energy usage averaged 28%.• On-board payback period ranged from 3.2 to 5.8 years.

– Larger air conditioners provide shorter payback period.

• Portable produced payback periods from 0.4 to 1.1 years.– Savings-to-investment ratio (SIR) 1.0 to 2.4

• Project buy-in from HVAC shop and the contracting officer is essential to successful implementation.

• Portable can support a performance-based DX system maintenance program.


SUMMARY OF TECHNOLOGY BENEFITSa. Continuously optimizes operational parameters to minimize energy

cost while improving occupant comfort and productivity.b. Slows performance deterioration and potentially adds years of service

life.c. Provides a realistic assessment of equipment operating condition to

guide the repair / replace decision process.d. Detects & diagnoses faults for performing targeted preventive

maintenance or supporting performance-based maintenance to maximize cost effectiveness.

e. Provides remote connection to identify issues before they become problematic, for faster response to an occupant complaint, and to enhance technician productivity.


AcknowledgementsDr. Jim Galvin (formerly) and Tim Tetreault, ESTCPNeil Tisdale and Bill Rogers, MCASBMike Manning, NOTU / CCAFSTony Ward, CCAFS / IOMSHossam Kassab, Fort IrwinJason Zareva, TraneTed Cherubin and Michael Taras (formerly), Carrier

eer optimizer for dx air conditioners · eer optimizer for dx air conditioners mike west, phd, pe...

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