EER Optimizer for DX Air Conditioners

EER Optimizer for DX Air Conditioners Mike West, PhD, PE Advantek Consulting Engineering August 16, 2017 Tampa Convention Center Tampa, Florida

EER Optimizer for DX Air Conditioners TOPICS Problems addressed EER Optimizer on-board i-optimize hand-held IoT cloud connectivity Field Tests Summary 2

Problems addressed 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

EER Optimizer for DX Air Conditioners EER Optimizer is a cost-effective IoT technology that: a) Diagnoses and mitigates degrading energy efficiency of DX HVAC systems b) Optimizes operational parameters as load and conditions vary c) Realizes best achievable efficiency as operating conditions and load changes The technology is utilized in two systems: Hand-held instrument for quick, portable measurement & diagnosis On-board controller to optimize & report operational parameters

On-board EER Optimizer is installed in DX package units and split systems. 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 features integral commissioning and energy savings Measurement & Verification. RUN MODE energy efficiency comparisons MANUAL reverts to factory control sequence of operation AUTO 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.

The portable i-optimize connects to any DX package unit or split system, measures energy efficiency & cooling performance, and diagnoses faults. Amp Clamp Temperature Probe Humidity Probes Temperature Clamps Hi/Lo Refrigerant Pressure Sensors Voltage Probes 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.

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

EER Optimizer on-board and hand-held are cloud connected IoT devices. http://eeroptimizer.com/summary/ VPN or commercial WAN WebSocket php Cloud Servers LAN Database http://eeroptimizer.com/portable/ Internet Any Web Device Tablet, Phone, Laptop GUI Controller RTU

MCASB, South Carolina Field Test 1: Marine Corps Air Station Beaufort, SC MCX Mixed-Humid Climate Zone 3A 2650 Cooling Degree-Days On-board EER Optimizer was installed in fully instrumented 2003 dual compressor Trane 20-ton rooftop DX unit.

MCASB, South Carolina 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% Improvement EER Optimizer Demonstration - MCASB Bldg 1283 RT-2 Trane YCD241 2/2003, IEER rating 11.2 MCASB, South Carolina IEER [MBH/kW] 15 14 13 12 AUTOMATIC 13.0 OPTIMIZE 13.4 11 MANUAL 11.9 10 Data period: June 8 - September 7, 2016

MCASB, South Carolina 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 RT-1 RT-11 RT-3 RT-4 RT-5 RT-6 RT-7 RT-8 RT-9 RT-10 Energy Savings After Servicing MCASB Average 26% Savings 0% 5% 10% 15% 20% 25% 30% 35% 40% 45% Energy Savings

CCAFS-NOTU, Florida Field Test 2: Cape Canaveral Air Force Station, FL (Patrick AFB) Naval Ordnance Test Unit (NOTU) Engineering Development Laboratory Hot-Humid Climate Zone 2A 3290 Cooling Degree-Days On-board EER Optimizer was installed in fully instrumented 2012 10-ton dual-compressor Carrier R410a package DX unit.

CCAFS-NOTU, Florida 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% Improvement EER Optimizer Demonstration - NOTU Hangar Y, CCAFS, FL Carrier 50HCD-09 1/2012, IEER rating 13.2 CCAFS-NOTU, Florida IEER [MBH/kW] 16 15 14 13 12 AUTOMATIC 14.5 OPTIMIZE 15.5 11 MANUAL 12.8 10 Data period: June 5 - September 8, 2016

CCAFS-NOTU, Florida 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% 62630 62630S 62630N 55865 81701 55893 49926 49926 1115 52003 Comparison of Measured CCAFS vs Rated Efficiency Average IEER 7.2 vs 11.9 RATED IEER 0 2 4 6 8 10 CIRC 12 1 IEER [MBH/kW] CIRC 2

Army Ft. Irwin, California Field Test 3: Fort Irwin, CA National Training Center DPW Environmental Mojave High Desert Hot-Dry Climate Zone 3B 3134 Cooling Degree-Days 2597 Heating Degree-Days On-board EER Optimizer was installed in fully instrumented 2010 12½-ton dualcompressor Carrier R410a package heat pump.

Operational Energy Efficiency: 30.4% Improvement EER Optimizer Demonstration - Fort Irwin Bldg 606 Carrier 50TCQ-D14, IEER rating 10.7 15 Army Ft. Irwin, California IEER [MBH/kW] 14 13 12 11 10 9 8 MANUAL 9.8 AUTOMATIC 11.4 OPTIMIZE 12.8 7 6 Data period: June 8 - September 26, 2016

Army Ft. Irwin, California 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 Over or Under Charge 10% 0% -10% -20% -30% -40% -50% Refrigerant Charge Fort Irwin Average 16% Underchaged 604 308S 308B 16 127 RTU-16 RTU-15 RTU-9 RTU-5 FOOD CT CIRC 1 CIRC 2

Summary of on-board EER Optimizer results Site CCAFS MCASB AFINTC Average Factory Rated 13.2 11.2 10.7 11.7 IEER Results Stats 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

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 BENEFITS a. 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.

Acknowledgements Dr. Jim Galvin (formerly) and Tim Tetreault, ESTCP Neil Tisdale and Bill Rogers, MCASB Mike Manning, NOTU / CCAFS Tony Ward, CCAFS / IOMS Hossam Kassab, Fort Irwin Jason Zareva, Trane Ted Cherubin and Michael Taras (formerly), Carrier