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Aircosaver HVAC Energy
Optimization Test
Aircosaver
HVAC controls
May 19, 2010
Authors:
Russell Murry
Resource Center Manager and
Alex Hernandez
Energy Engineer
JPL Facilities M&O Support Services
Contents
• Background
• Aircosaver
• Savings Data Collected
• Trending
• Savings
• FAQs
• Project
• Presentation by:
— Mountain Clear (Aircosaver)
— Energe (Aircosaver Installation contractor)
Background
• A collaboration between Mountain Clear LLC and
Energe Corp. was requested by Emcor to demonstrate
the viability of a technology that will reduce energy
consumption on Direct Expansion (DX) air conditioning
units at JPL.
• The demonstration of the Aircosaver technology took
place on a new York 10 ton A/C unit at B121 and two
Eubank 3 ton A/C units on Trailers. The energy savings
has been quantified by both Energe Corp. and Emcor
with data logging performed by both groups.
• This technology is recognized and supported through
the SPC program by the EPA, SDG&E, SCE, and PG&E
and has been tested and proven in various other
industries.
Aircosaver
• “The Aircosaver sensor-driven software algorithms are
designed to detect thermodynamic saturation
(overcooling of the evaporator) and to optimize the
compressor run time accordingly. When overcapacity is
detected, the Aircosaver switches the compressor off
and avoids inefficient overcooling”.
• The Aircosaver thermostat control device is wired in
series with the room thermostat to control the air
conditioner. Following shutdown of
the compressor, the evaporator fan
is left in service to remove stored
energy from the evaporator.
Savings Data Collected
JPL 3-ton Eubanks
Before Performance Planner
Test began at 3/12/10 7:27:00
Test ended at 3/12/10 8:47:00
After Performance Planner
Test began at 3/10/10 14:19:05
Test ended at 3/10/10 15:21:09
Measurement
%Change
Voltage, Phase 1, Ave:
Voltage, Phase 2, Ave:
Current, Phase 1, Ave:
Current, Phase 2, Ave:
Current, Neutral, Ave:
VA Power, Phase 1, Ave:
VA Power, Phase 2, Ave:
Total VA Power Ave:
Energy, Phase 1:
Energy, Phase 2:
Energy, Total Elapsed:
Energy, estimated per month:
(at $0.11000/KWH)
Before
After
Units
Change
125.9
124.9
15.8
15.5
0.0
1988.0
1931.0
3919.4
2.48620
1.89895
4.38515
2402.5
110.3
108.0
10.3
10.3
0.0
1138.5
1115.1
2253.6
1.13671
1.11739
2.25410
1591.8
volts
volts
amps
amps
amps
VA
VA
VA
KWH
KWH
KWH
KWH
-15.6
-16.9
-5.5
-5.1
0.0
-849.5
-816.0
-1665.8
-1.34949
-0.78155
-2.13104
-810.7
Report Prepared By:
Phone:
Email:
Adam Fitzpatrick
ENERGE Corporation
9515056752
[email protected]
-12.4 %
-13.5 %
-34.5 %
-33.2 %
0.0 %
-42.7 %
-42.3 %
-42.5 %
-54.3 %
-41.2 %
-48.6 %
-33.7
Compressor Amps No Aircosaver 1.75 hrs
1
262
523
784
1045
1306
1567
1828
2089
2350
2611
2872
3133
3394
3655
3916
4177
4438
4699
4960
5221
5482
5743
6004
6265
6526
6787
7048
7309
7570
7831
8092
8353
8614
8875
9136
9397
9658
9919
1
262
523
784
1045
1306
1567
1828
2089
2350
2611
2872
3133
3394
3655
3916
4177
4438
4699
4960
5221
5482
5743
6004
6265
6526
6787
7048
7309
7570
7831
8092
8353
8614
8875
9136
9397
9658
9919
No Aircosaver Indoor / Outdoor
Temp and Humidity
100
90
80
70
60
50
Temp Outside No Airco
40
30
Temp Inside No Airco
20
10
0
100
90
80
70
60
50
RH Outside No Airco
40
30
RH Inside No Airco
20
10
0
1
255
509
763
1017
1271
1525
1779
2033
2287
2541
2795
3049
3303
3557
3811
4065
4319
4573
4827
5081
5335
5589
5843
6097
6351
6605
6859
7113
7367
7621
7875
8129
8383
8637
8891
9145
9399
9653
9907
1
255
509
763
1017
1271
1525
1779
2033
2287
2541
2795
3049
3303
3557
3811
4065
4319
4573
4827
5081
5335
5589
5843
6097
6351
6605
6859
7113
7367
7621
7875
8129
8383
8637
8891
9145
9399
9653
9907
With Aircosaver Indoor / Outdoor
Temp and Humidity
90
80
70
60
50
40
RH Outside w/Airco
30
RH Inside w/Airco
20
10
0
120
100
80
60
Temp Outside w/Airco
40
Temp Inside w/Airco
20
0
W/ Aircosaver Indoor Afternoon Control
Compressor Amps w/ Aircosaver 1 hr.
Savings, Rebates, and ROI
• Savings
– Factoring the differences in loads between the
days that data was procured, savings exceeded
20%.
• Rebates
– 50% under SCE SPC program.
– 3 and 10 ton units quoted rebates
• “The estimated rebate is $3,438 based on 23,156 kWh
saved and 1.96 kW reduced”- SCE
• ROI
FAQ’s
 What temp does Aircosaver shut off and turn back on?
The Aircosaver turns the compressor off & on at different temp‘s
depending on its thermal saturation point and how rapidly the
temp rises once the Aircosaver has turned off the compressor.
 Impact on compressor cycles?
With continuous call from the T-stat the Aircosaver will cycle the
compressor an average of 4 times per hour.
 What is the learning process of the Aircosaver and what
are the five steps based upon the LED?
See code sheet v4.1

Any warranty issues in the past?
We are not aware of any to date.
 How many installed to date worldwide?
100K+ Aircosavers have been installed.
FAQ’s
 How do you know if the Aircosaver failed?
Should a physical failure occur with the Aircosaver, the LED will turn
off and the Aircosaver will go into bypass. Normally closed.
 Any info on the software or algorithm?
See code sheet v4.1. Most of the algorithm is proprietary.
 What companies have them installed and how long?
Dominos 2yrs, AT&T 1.5yrs, Verizon 1.5yrs.
 What impact can Aircosaver have on coil freeze-over?
Aircosaver will prevent coil freezing. Aircosaver will keep the
compressor off until the temp rises “n” degrees from the thermal
saturation point.
 Are there other devices that do the same thing?
No, there are no devices that cycle the compressor based on thermal
saturation points.
Aircosaver v4.1 Codes & Status
Blink Code
Static or
Min & Max
Phase (P)
# of blinks
Dynamic P time in P
Compressor Status
Comments
1
P1
Static
1 Minute
Comp OFF (initial learning,anti-recycle)
P1 is only active after power loss to
Aircosaver.
2
P2
Static
2 Minutes
Comp ON (efficent)
*Standby and sensing for cooling.
Comp ON (efficent)
Thermal Saturation must stabilize
below a gradient of .77C/1.25F
through 8 cycles of 16 sec's and the
Evaporator must drop below 20C/68F.
Comp ON
There is a static 3 min's to start P4,
the additional time is determined by
the Thermostat call cycles / reaching
set point.
3
P3
4
P4
5
P5
Dynamic 2.5 - ? Min's
Dynamic 3 - 10 Min's
Static
6
P6
Dynamic
7
P7
Static
3 Min's
0 - ? Min's
Comp OFF (inefficient, anti-recycle)
Comp OFF (inefficent)
P6 ends when Evaporator's
temperature raises "X" Degrees from
P3's Thermal Saturation point then
returns to P2. P6 is not always seen.
Error! Sensor defect (shorted or disconnected)
Aircosaver is in bypass and
thermostat has complete control.
* Aircosaver will standby in P2 when there is no call from Thermostat or there is no cooling detected at the
evaporator. (Thermostat has complete control when Aircosaver is in standby mode)
Project
Mountain Clear LLC
Provide 850 Aircosavers with shipping
$638,200.00
Energe Corporation
Installation of ~90% of Aircosavers
~10% installed by Emcor due to area access issues.
~$137,700.00
Total Project Cost
$775,900.00 Mountain Clear & Energe
$8,500.00 Installation by Emcor
$784,400.00 Total
SCE Rebates:
Rebate form already drafted by SCE rep.
Rebate is 50% of project cost
~$374,200
Emcor was able to leverage Dealer to provide JPL with Aircosavers at dealer
pricing, which saved ~40%.
Conclusion
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