Energy-Efficient Elevator Machines

Energy-Efficient Elevator Machines
ThyssenKrupp Elevator AMS
Energy Monitoring Program
Technical Analysis Study Report (TASR)
Level III Analysis
SUBMITTED BY
Brad Nemeth
ThyssenKrupp Elevator
2600 Network Drive, Suite 450
Frisco, TX 75034
CUSTOMER
Hyatt Place
175 Paoakalani Avenue
Honolulu, HI 96815
VERSION: 4.0
ThyssenKrupp Elevator Americas
DISCLAIMER
This report is not intended to serve as an engineering design document, but is intended
to provide estimated energy-efficiency savings associated with the proposed project.
The information and recommendation represented in this report have been reviewed for
their technical accuracy and are believed to be reasonable and correct.
ThyssenKrupp Elevator AMS is not liable if the projected estimated savings or economics
are not actually achieved because of varying operating conditions. All savings and
cost estimates are for informational purposes and are not to be construed as a
design document or as guarantees. The customer should independently evaluate the
information presented in this report and in no event will ThyssenKrupp Elevator be held
liable if the customer fails to achieve a specified amount of energy savings, operation of
their facilities, or any incidental or consequential damages of any kind in connection with
this report or the installation of the recommended measures.
CONTENTS
SECTION 1: OVERVIEW
1.1 Project Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SECTION 2: ENERGY BASICS
2.1 How Elevator Technology Evolved. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 How an Elevator Consumes and Regenerates Energy . . . . . . . . . . . . . . . . . . . . . 4
2.3 Electricity Billing Factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Peak vs. Off-Peak. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power Factor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Energy-Use Analysis Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 3: PROJECT DETAILS
3.1 Starting Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
The Client . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Previously Existing Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2
Energy-Use Analysis Findings & Recommendations. . . . . . . . . . . . . . . . . . . . . . . 8
Current Energy Consumption Baseline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended Energy Reduction Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Estimated Project Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3
Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Energy Performance Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overall Project Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
11
15
APPENDIX A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1. OVERVIEW
1.1Project Summary
This report provides a case study to demonstrate the key energy-saving components
of an elevator modernization. Hyatt Place is a 20-story hotel with two high-rise
elevators installed in 1974. The previously existing elevators were powered by motor
generators (MG) and DC (direct current) hoist motors controlled by electromechanical
relay controllers. The project consisted of replacing the DC motors with high-efficiency
permanent-magnet hoist machines with regenerative drives and previously existing
relay logic controllers were replaced with ThyssenKrupp TAC 50-04 micro-processor
controllers. This modernization allowed Hyatt Place to improve elevator reliability and
ride quality, while reducing electrical consumption of the elevators by 56 percent.
Overview of Improvement
PREVIOUSLY EXISTING
EQUIPMENT
NEW EQUIPMENT
Machines
Geared
Gearless
Hoist Motors
20 HP DC
Permanent-magnet motor AC
(alternating current)
Motor Generators
10 kW - 15 HP DC
Removed (no longer necessary)
Controllers
Relay Logic
ThyssenKrupp TAC 50-04 with smart
destination-based software and
regenerative drive technology
Group Controllers
Removed (no longer necessary with the
TAC 50-04 advanced communication
algorithms)
Lighting
Incandescent
LED
Cab Interior Hall Fixtures
Dated, worn looking
Modern cab and hall fixtures, low-VOCemitting material
1
2. ENERGY BASICS
2.1How Elevator Technology Evolved
The following definitions and timelines are for the generalized purpose of identifying existing technologies and available alternatives.
There are multiple generations of hoist motors, hoist machines, drives and controllers available in the industry.
DRIVES & MOTORS
OLDEST
Motor Generators (MG) are traditional hoist systems that consist of a DC hoist motor powered from a DC generator.
DC hoist motors were used because a DC motor has a high starting torque and good speed control. An AC induction
motor turns the DC generator and the generator output is directly connected to the DC hoist motor. This hoist system
is the least energy efficient.
Silicon Controlled Rectifiers (SCR) drives are solid-state devices that can rectify AC power to DC power. SCR drives
represent the next progression from motor generator sets since it became possible to produce DC voltage from an AC
power line. Two common types of SCR drives are a six-pulse and a 12-pulse. The 12-pulse drives reduce distortion
problems on power feed lines.
Pulse Width Modulation (PWM) can be used to control either an AC or DC motor and utilizes several types of power
transistors. ThyssenKrupp Elevator’s PWM 10k drive provides 10,000 pulses, compared to a 6- or 12-pulse SCR.
These transistors are switched on and off rapidly in a technique known as Pulse Width Modulation (PWM).
Variable Voltage Variable Frequency (VVVF) drives eliminate the need for a DC hoist motor and replace it with an AC
motor. VVVF provides many of the same advantageous characteristics of the DC motor, such as smooth acceleration
and deceleration and excellent speed control without the issues related to usability of power.
Regenerative Motors (Regen Motors) produce energy when the motor is in an overhaul condition. In an elevator, this
occurs when the motor is used to brake a descending unit. Until recently, the electricity generated was sent through
a series of resisters that dissipated the energy as heat into the machine room. With the introduction of regenerative
drives, the energy produced can be fed back into the building or power grid. Because the harmonics are purified, there
is no line loss and 100% of the power that is harnessed is usable.
NEWEST
Permanent-Magnet Motors have performance advantages over DC excited-synchronous motors and are becoming
more common in fractional horsepower applications because they are smaller, lighter, more efficient and reliable.
Large industrial motors originally used wound field or rotor magnets. Permanent-magnets have traditionally been used
only on smaller motors because of the difficulty in finding a material capable of retaining a high-strength field. Recent
improvements in material technologies have made it possible to create high-intensity permanent-magnets, allowing
the development of compact, high-power motors without the extra real estate of field coils and excitation means.
// Technical Analysis Study Report // ThyssenKrupp Elevator //
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MACHINERY
OLDEST
Geared Machine
A geared driving machine is one that utilizes a geared-reduction unit between the motor and the drive sheave. The
main advantage of this design is that a less powerful motor can be used to drive it. A geared system, usually designed
to run at 350 feet per minute or less (though they can go faster), sacrifices speed to its gearless counterpart. Geared
systems are often used in slower-moving passenger and freight elevators.
NEWEST
Gearless Machine
A gearless driving machine is a direct-drive system in which there is no reduction gear between the motor and the
drive (or hoisting) sheave. That is, the drive sheave is connected directly to the motor and brake. Gearless designs are
used in the world’s tallest structures. They are efficient and used for driving speeds greater than 500 feet per minute.
Previously Existing Geared Machine
Sheave
Ring Gear
Motor Shaft
CONTROLLERS
OLDER
Electromechanical Relays (EMRs) traditionally have been the components of choice for elevator controllers based on
their price, functional characteristics and availability. EMRs have served effectively in numerous applications, but their
use of mechanical contacts to switch a load subjects contact points to oxidation and breakdown over the life cycle of
an elevator unit. EMRs also display bounce, an undesired condition manifested by a short period of pulsed electrical
current upon mechanical contact, rather than a clean transition from zero to full current.
A group controller is needed with an electromechanical relay. Group controllers allow individual elevators to
communicate, or know what each elevator position is relevant to one another, allowing the controllers to determine
which elevator should answer each hall call. In a group controller, this process is rudimentary – the controller
determines which elevator should answer the call using a rudimentary process where the direction the person wishes
to travel is used to determine which elevator should respond to that request.
NEWEST
Micro-Processors were developed as a result of emergent semiconductor technologies and offer advantages over
their electromechanical counterparts. Technical parameters to consider when selecting either an EMR or microprocessor controller include service life, reliability, isolation voltage, on resistance (RON), output capacity and package
dimensions. Although each type of relay has its advantages in cost or performance, micro-processor controllers
have become the optimal choice in many applications based on their high reliability, long service life, lower power
consumption and smaller package size/footprint relative to EMRs. Advances in semiconductor manufacturing
technologies have also reduced the cost gap between the EMR and micro-processor controller, making the microprocessor controllers cost effective in a growing number of applications.
With a micro-processor controller installed, group controllers are no longer needed. In the TAC 50-04 controller, TKE
exclusive algorithms provide advanced intelligence to dispatch elevators with improved efficiency. Factors such as
weight, direction and length of travel are all incorporated into the controller calculations. This provides the enhanced
performance as well as eliminating the need for a passive controller and its associated wiring—further reducing overall
environmental impacts.
3
2.2How an Elevator Consumes and Regenerates Energy
When an electric motor accelerates or maintains velocity, it consumes energy. But when this same electric motor brakes or decelerates
a body in motion, the motor becomes a generator of energy. This energy has traditionally been considered a nuisance,
but with the invention of integrated regenerative drives, this “waste” energy is sent back into the electrical grid.
CONSUMING ENERGY
Cab Weight > Counterweight
GENERATING ENERGY
Cab Weight < Counterweight
Power is consumed in a traction elevator first, by the
gravitational pull on ascending cabs that are heavier than the
descending counterweight and second, by the gravitational
pull on ascending counterweights when they are heavier than
descending elevator cabs.
Cab Weight < Counterweight
Cab Weight > Counterweight
Power is generated in a traction elevator first, by the
gravitational pull on descending cabs that are heavier than
the ascending counterweight and second, by the gravitational
pull on descending counterweights when they are heavier than
ascending elevator cabs.
In the case of power generation, the mechanical energy of the
descending car or counterweight causes the elevator motor to
function as a generator (or re-generator) of electricity.
The elevator also produces electricity when the motor works as
a braking system to decelerate. Conventional elevator systems
dissipate this untapped electricity as waste heat, routing it
through electrical resistors in the elevator shaft or machine
room, using essentially the same principle as an electric toaster.
This waste heat is not only inefficient, but can raise the ambient
temperatures in elevator machine rooms and often require
additional cooling.
// Technical Analysis Study Report // ThyssenKrupp Elevator //
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2.3Electricity Billing Factors
2.4Energy-Use Analysis Options
PEAK VS. OFF-PEAK
Audits can provide baseline data and recommendations for how
to best manage upgrades of elevator components in order to
improve energy efficiency. An organization can often receive tax
incentives or rebates from utility companies if it can significantly
reduce energy consumption. Not all energy audits are the same
and it is helpful to understand the various levels of audits that are
performed.
Power consumption is typically represented by kilowatts or kW.
Utility and power distribution companies typically charge by kW,
however, different rates apply to the time of use –­ peak demand
usage versus off-peak usage.
POWER FACTOR
Another element in understanding energy use and distribution
is the power factor or, in simple terms, how much effort it takes
to push electricity through a building or power grid. The power
factor indicates how efficiently a building accepts and uses
electricity.
Power Factor = Active power/Apparent power = kW/kVA
= Active power/(Active Power + Reactive Power)
= kW/(kW + kVAr)
Higher kVAr indicates low power factor and vice versa. In
electrical terms kW, kVA, and kVAr are vectors and must be
summed.
kVA
kVAr
kW
Power factor is the ratio of true power or watts to apparent power
or volt amps, so the theoretical best value for a power factor
is one (on a scale of zero to one). In an electric power system,
a load with a low power factor draws more current than a load
with a high power factor for the same amount of useful power
transferred. The higher currents increase the energy lost in the
distribution system and require larger wires and other equipment.
Because of the costs of larger equipment and wasted energy,
electrical utilities will usually charge a higher cost to industrial or
commercial customers where there is a low power factor.
5
An energy audit is the key to a systematic approach to decisionmaking regarding energy conservation. The primary function
of this energy audit is to identify all of the energy streams in an
elevator system in order to balance total energy input with energy
use. The four main objectives of an elevator energy audit are as
follows:
1.To establish an energy-consumption baseline
2.To quantify energy usage according to its discrete functions
(e.g. machine, lighting, standby)
3.To validate pre- and post-elevator modernization
4.To identify existing energy-cost reduction opportunities
Elevator energy audits vary in depth, depending on the potential
for energy and cost reductions at a specific site and the project
parameters set by the client.
Though a recognized standard for auditing elevator energy
efficiency does not specifically exist, ASHRAE (American Society
of Heating, Refrigerating and Air-Conditioning Engineers)
is recognized as an industry standard for energy audits.
ThyssenKrupp Elevator has adopted the ASHRAE standards for
the energy audits of elevators.
ThyssenKrupp Elevator provides Level I, II, and III audits
depending upon building needs. In order to qualify for tax
incentives and rebates from utility companies, an organization
must get a Level II or III audit.
Completing an energy audit of a facility provides an organization
with customized Energy Conservation Measures (ECM’s) designed
to ensure significant energy savings as well as CO2 emission
reductions.
ASHRAE LEVEL I
WALK-THROUGH ANALYSIS/
PRELIMINARY AUDIT
The most basic audit is a Level I audit. It is
also referred to as a simple audit, screening
audit or walk-through audit. It involves
minimal interviews with site personnel,
a brief review of elevator equipment and
other operating data and a walk-through
of the facility. Auditors will identify areas
of significant energy waste or inefficiency.
The data compiled is then used for the
preliminary energy-use analysis and a
report detailing potential energy savings.
This level of detail is adequate to estimate
energy-efficiency projects.
Services:
• Brief survey of the building
• Savings analysis of energy conservation
measures (ECMs)
• Identification of potential capital
improvements meriting further
consideration
ThyssenKrupp Elevator provides an online
tool for estimating energy consumption that
is based upon operating parameters and
traffic patterns of both real and simulated
buildings1. With a minimal amount of
input, the energy can be predicted based
on several assumptions that emulate
conditions consistent with building type,
use and traffic patterns. This energy
calculator estimates the baseline energy
consumption and predicts potential energy
savings from modernization.
ASHRAE LEVEL II
ENERGY SURVEY AND ANALYSIS
A Level II audit includes the preliminary
ASHRAE Level I analysis, but also includes
more detailed building energy usage.
Onsite monitoring of the elevator machine
duty cycle affords better estimates for
machine run time versus idle time, which
helps to identify lighting and energy use
patterns. Understanding these energy
patterns enables better management of
energy use.
Average wait times (waiting for an
elevator), average transport times and
traffic patterns are determined. This
information is then used to either optimize
the elevator characteristics (when
technology permits) or suggest overlay
systems, such as smart destination-based
software to improve tenant satisfaction.
Services:
• More extensive building survey (over
many days)
• Breakdown of energy use by machine,
drive, generators, lights, transformers,
exhaust fans, heaters and cooling units
• Savings and cost analysis of all energy
conservation measures
• Identification of potential rebate
programs offered through utility and
transmission companies
ASHRAE LEVEL III
DETAILED ANALYSIS OF CAPITAL
INTENSIVE MODIFICATIONS
A Level III audit is also known as a
comprehensive audit, detailed audit or
technical analysis audit. This audit focuses
on potential capital-intensive projects and
involves more detailed field-data gathering
and a more rigorous engineering analysis.
It provides detailed project energy usage
and savings calculations with a high level
of confidence.
A Level III audit measures the energy
consumption analysis on the existing
elevator equipment. Existing utility data is
supplemented with sub-metering of major
energy consuming systems.
Services:
• Attention to capital-intensive projects
• More detailed field analysis
• In-depth discussions with utility
companies
• Submittal of rebate application,
subsequent follow-up
• Pre- and post-energy consumption
metrics with a high level of accuracy
The calculations and parameters used
in ThyssenKrupp’s energy calculator
are modeled after actual-use data
within our test facility. It is periodically
cross-referenced with actual energy
measurements from on-site metering
during the pre- and post-audits of similar
elevator modernizations.
ThyssenKrupp’s energy calculator is available at: http://www.thyssenkruppelevator.com/energy%20calculator/energy.aspx
1
// Technical Analysis Study Report // ThyssenKrupp Elevator //
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3. PROJECT DETAILS
3.1Starting Point
THE CLIENT
PREVIOUSLY EXISTING EQUIPMENT
Hyatt Hotels Corp. expanded its presence in Hawaii with the conversion of the Ocean
Resort Hotel Waikiki into the Hyatt Place Waikiki Beach. The 451-room hotel, which is
located at the Diamond Head end of Waikiki, was being renovated and repositioned to
become a 425-room Hyatt Place when the elevator modernization project began.
Year Built: 1974
Number of Floors: 20
Number of Elevators: 2
Line Voltage: 208V
The Hyatt wanted improved ride performance, improved dispatching, energy efficiency,
increased dependability and an interior cab face lift. Without a costly replacement of
the entire elevator, the Hyatt wanted to make a 30-year-old elevator look, ride and
perform like a brand new elevator.
Machines
PREVIOUSLY EXISTING
EQUIPMENT
EQUIPMENT CONDITION
Geared
Geared machines were originally used
because they require a less powerful motor
to drive it, but any time mechanical energy
is transferred from a motor shaft through a
series of gears, there is inherent energy loss.
Hoist Motors
20 HP DC
A DC hoist motor was originally installed for
high starting torque and good speed control.
Motor Generators
10 kW - 15 HP DC
An AC induction motor was required to turn
the DC generator, which powered the DC
hoist motor.
Controllers
Relay Logic
Electromechanical relay controllers
relied upon magnetism between metal
contacts, which means that the mechanical
components wore out over time and took
longer to operate.
Lighting
Incandescent
Incandescent bulbs, which were
technologically advanced at the time of
construction, are now well known to be the
least energy-efficient option for lighting.
Cab Interior Hall
Fixtures
Dated, worn looking
30 years of wear and tear made the elevator
components appear unreliable and in need
of maintenance.
Elevator Code
Not up to code
Elevator would stop during a power outage,
leaving passengers stranded until power
was restored.
7
PASSENGER
CAR #1
PASSENGER
CAR #2
Stops
19
19
Capacity (lbs)
2500
2500
Speed (fpm)
350
350
Average Car
Load
300 lbs
300 lbs
Operating
Hours*
10 hours/
day
5 days/
week
52 weeks/
year
10 hours/
day
5 days/
week
52 weeks/
year
Estimated Duty
Cycle*
35%
35%
*Operating hours and estimated duty
cycle data are not available for this
project. Both elevators were out of service
because the entire building was already
under renovation when the elevator
modernization began.
3.2 Energy Use Analysis Findings & Recommendations
ThyssenKrupp Elevator provided a Level III energy audit for the Hyatt.
CURRENT ENERGY CONSUMPTION BASELINE
Since the elevator modernization project began after the building renovation was already
underway, the duty cycle and traffic patterns of the previously existing elevators could
not be captured for this study. The figures below are estimates for one run (empty
elevator sent from the bottom to the top floor and then back down).
Energy Consumption Baseline
Lighting
Controller*
Motor
0.72 kWh
1.33 kWh
0.13 kW/run
RECOMMENDED ENERGY REDUCTION PROJECT
As a result of the Level III energy audit, ThyssenKrupp Elevator recommended that
the DC motors be replaced with high-efficiency permanent-magnet hoist machines.
The permanent-magnet motor will increase energy efficiency because high-intensity
permanent-magnets are used instead of drawing from an external electrical source.
Permanent-Magnet Motor
DC Motor
*Included all standby power excluding hoist motion.
// Technical Analysis Study Report // ThyssenKrupp Elevator //
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The audit findings also recommended installing regenerative drives to feed the
energy produced directly back into the building. Previously existing controllers were
recommended to be replaced with ThyssenKrupp TAC 50-04 micro-processor controllers
in order to improve ride dispatching, improve energy efficiency, reduce noise and
provide precision acceleration/deceleration and leverage accuracy. ThyssenKrupp
was also able to offer a gearless option for these elevators, which until recently was
unavailable in elevators operating at speeds below 350 fpm. ThyssenKrupp is the only
company currently offering the 2:1 roping that is required to accommodate the more
energy-efficient gearless motor.
PREVIOUSLY EXISTING
EQUIPMENT
RECOMMENDED EQUIPMENT
Machines
Geared
Gearless
Hoist Motors
20 HP DC
Permanent-magnet motor AC
Motor Generators
10 kW - 15 HP DC
Removed (no longer necessary)
Controllers
Relay Logic
ThyssenKrupp TAC 50-04 with smart
destination-based software
Lighting
Incandescent
LED
Cab Interior Hall Fixtures
Dated, worn looking
Modern cab and hall fixtures, low-VOCemitting material
Elevator Code
Not up to code
Up to code according to equipment
design safety compliance and life-safety
compliance standards
9
ESTIMATED PROJECT RESULTS
It was estimated that electricity use will result in a 48 percent reduction in electricity costs. Estimates of project electricity savings were
made by utilizing ThyssenKrupp Elevator’s Energy-Cost Analysis:
Previously Existing Drive Type
MG
New Drive Type
VVVF Regen
Application Data
Variable Parameters
PREVIOUSLY EXISTING NEW
EQUIPMENT
EQUIPMENT
Local Electrical Cost
$0.10000 per kW-h
Elevator operating hours per day
10 hours
Elevator operating days per week
5 days
Elevator operating weeks per year
52 weeks
200
Average load in car
300 lbs
1:1
2:1
% running duty cycle
35%
# of Cars in Group
2
2
Include Power Factor
No
Transformer
No
Yes
Application Type
Geared
Gearless
Speed (fpm)
350
350
Capacity (lbs)
2500
2500
CWT% (if applicable)
45%
50%
Net Travel (ft)
200
Roping (if applicable)
ANNUAL COST
PER UNIT
$1,129
PER UNIT
$586
$0
$500
MG
VVVF
PER GROUP
$2,258
PER GROUP
$1,172
$1,000
$1,500
$2,000
$2,500
ANNUAL COST SAVINGS
PER UNIT
PER GROUP
PERCENTAGE
$543
$1,086
48%
// Technical Analysis Study Report // ThyssenKrupp Elevator //
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3.3 Results
TESTING PROCEDURES
ELITEpro energy-data loggers were used during controlled test runs to measure the
previously existing motor generators against the new permanent-magnet hoist system.
The elevators being tested were servicing the same elevator bank and same number of
floors. Elevators were sent from the bottom to the top floor and then back down with a
variety of loads and no intermediate stops. Data was logged at the same sampling rates
for both elevators and measurements of the kVAr and average kW were taken for both
the MG and the new permanent-magnet machines. A review of the data verified that no
anomalies or events skewed the data or introduced uncommon patterns.
ENERGY PERFORMANCE RESULTS
The energy use logged during the test runs is shown below. The permanent-magnet
motor outperformed the MG in all five test runs. The permanent-magnet motor consumed
45 percent to 70 percent less energy than the MG, depending upon the elevator load.
The controller standby energy use was 55.9 percent less with the new TAC 50-04 microprocessor controller, and the new LED lighting contributed to an 85.9 percent reduction in
lighting energy use.
3.31 Relay Logic Controller vs. TAC 50-04 Controller
Controller Standby
PREVIOUSLY EXISTING
EQUIPMENT
NEW
EQUIPMENT
LESS ENERGY USED
1.332 kWh
0.588 kWh
55.9%
3.32 Incandescent Lighting vs. LED Lighting per run
Lighting
11
PREVIOUSLY EXISTING
EQUIPMENT
NEW
EQUIPMENT
LESS ENERGY USED
0.724 kWh
0.102 kWh
85.9%
3.33Motor Generator vs. Permanent-Magnet Motor
Average kW per run, 0 lbs (no load)
COMBINED - MG vs PM
Average kW with 0 lbs
25
One Cycle (kWh)
COMBINED - MG vs PM
PM
20
25
0.13367
56.1%
MG
15
20
0.13367
56.1%
10
15
KW
0.05867
MG
KW
PM
One Cycle (kWh)
0.05867
Motor Generator
Permanent-Magnet Motor
Average kW with 0 lbs
MG =Motor Generator Geared
Machine
PM =Permanent-Magnet Motor
Gearless Machine
5
10
0
5
-5
0
-10
-5
-10
3.34Motor Generator vs. Permanent-Magnet Motor
COMBINED
Average- MG
kW vs
perPM
run, 320 lbsAverage kW with 320 lbs
25
One Cycle (kWh)
COMBINED - MG vs PM
PM
20
25
0.11666
55.1%
MG
15
20
0.11666
55.1%
10
15
KW
0.05233
MG
KW
PM
One Cycle (kWh)
0.05233
Average kW with 320 lbs
Motor Generator
Permanent-Magnet Motor
MG =Motor Generator Geared
Machine
PM =Permanent-Magnet Motor
Gearless Machine
5
10
0
5
-5
0
-10
-5
-10
COMBINED - MG vs PM
Average kW with 640 lbs
25
One Cycle (kWh)
COMBINED - MG vs PM
0.04667
20
25
0.10033
53.5%
MG
15
20
0.10033
53.5%
10
15
KW
PM
MG
KW
PM
One Cycle (kWh)
0.04667
Average kW with 640 lbs
5
10
// Technical Analysis Study Report // ThyssenKrupp
Elevator //
0
5
12
0
-5
-10
3.35 Motor Generator vs. Permanent-Magnet Motor
Average kW per run, 640 lbs
COMBINED - MG vs PM
Average kW with 640 lbs
25
One Cycle (kWh)
PM
MG
20
0.10033
53.5%
15
KW
0.04667
Motor Generator
Permanent-Magnet Motor
MG =Motor Generator Geared
Machine
PM =Permanent-Magnet Motor
Gearless Machine
10
5
0
-5
-10
3.36 Motor Generator vs. Permanent-Magnet Motor
Average kW per run, 960 lbs
COMBINED - MG vs PM
Average kW with 960 lbs
25
One Cycle (kWh)
PM
MG
20
0.08433
45.5%
15
KW
0.046
MG =Motor Generator Geared
Machine
PM =Permanent-Magnet Motor
Gearless Machine
10
5
0
-5
-10
COMBINED - MG vs PM
Average kW with 2500 lbs
25
One Cycle (kWh)
0.061
13
MG
20
0.20433
70.1%
15
KW
PM
Motor Generator
Permanent-Magnet Motor
10
5
0
-5
-10
3.37 Motor Generator vs. Permanent-Magnet Motor
Average kW per run, 2500 lbs
COMBINED - MG vs PM
Average kW with 2500 lbs
25
One Cycle (kWh)
PM
MG
20
0.20433
70.1%
15
KW
0.061
Motor Generator
Permanent-Magnet Motor
MG =Motor Generator Geared
Machine
PM =Permanent-Magnet Motor
Gearless Machine
10
5
0
-5
-10
3.38 Generator vs. Permanent-Magnet Motor
Average kVAr per run, 0 lbs (no load)
COMBINED - MG vs PM
Motor Generator
Permanent-Magnet Motor
Average kVAr with 0 lbs
9
kVAr
7
MG =Motor Generator Geared
Machine
PM =Permanent-Magnet Motor
Gearless Machine
5
3
2
-1
The kVAr measurements reveal yet another way that the modernized equipment can improve the energy efficiency of the building.
The lower kVAr measurement for the new equipment indicates that the new equipment accepts and uses electricity more efficiently.
This is because a lower kVAr indicates a higher power factor, that could result in lower electricity costs in cases where the local
utility company considers the power factor in commercial billing calculations. The data shows that the new permanent-magnet
drive increases the power factor by 8 to 44 percent depending on motor loading conditions, which could generate an additional 10
percent in cost savings.
// Technical Analysis Study Report // ThyssenKrupp Elevator //
14
OVERALL PROJECT RESULTS
Two factors in the Hyatt modernization project diminished the
actual energy cost savings. Typical 1970’s construction in this
location utilized 208 line voltage, therefore a transformer was
required in order to bring the line voltage up to industry standards.
Energy required to run the transformer diminishes the net energy
reduction by about 10 percent. Also, if the local utility company’s
billing calculations utilized an adjusted rate due to lower power
factor, then the Hyatt can realize an additional 10 percent reduction
in energy costs. In any case, it is anticipated that this building will
notice a 50 to 60 percent reduction in energy consumption under
normal operating conditions.
which all have differing levels of frequency generation which,
at high rotating speeds, should be dynamically balanced to
reduce unwanted vibration. The ThyssenKrupp Elevator exclusive
geared to gearless conversion improved ride performance to an
industry record of 9 to 12 m-g*. Most elevators utilizing geared
machines are unable to limit vibration below 15 to 20 m-g. Ride
performance has also improved because the elevators can now
level themselves more precisely at the stopping point of each
floor. This is a common issue for aging elevators, and with
these modernizations, the leveling along with acceleration and
deceleration issues were remedied.
In addition to the reduction in energy use, the cycle time, or the
time it takes to go from the bottom to the top floor and then back
down has improved by 8 seconds (22 percent) with the new
permanent-magnet hoist system. This is due to two main factors
– (1) the previously existing MG hoist system could not operate at
the specified 350 fpm due to performance issues, and (2) the new,
solid-state controller allows for improved speed over the traditional
mechanical switches and relays. This improvement in dispatching,
ride time, ride performance and reliability results in improved guest
satisfaction in the newly renovated facility.
The previously existing machines were noisy and took up a
large amount of space, making it difficult to plan where the
machine rooms were placed in relation to the guest rooms. The
new equipment reduces the noise in the machine room, thus
improving guest satisfaction in the adjacent hotel rooms. The
required amount of space in the room itself was also reduced by
approximately 12 percent, thus providing greater flexibility for
the architects that designed the renovated hotel. The previously
existing equipment also used carbon brushes that contributed to
dust in the machine room. The modernization project eliminated
the carbon dust associated with carbon brushes, reduced the
frequency with which the air filters needed to be replaced and
improved indoor air quality.
Several factors contributed to improved ride performance after
the modernization process was complete. First, vibration in the
elevator was significantly decreased. Vibration is defined as a
variation with time of the magnitude of acceleration, when the
magnitude is alternately greater and smaller than a reference
level. Within a moving elevator, vibration is caused by surfaces
and a component vibrating strongly enough to turn them into
a secondary sound source. This vibration is generated by an
elevator moving through the shaft and changes in intensity
during the acceleration, full speed and deceleration elements of
each elevator ride. Apart from this vibration, elevator passengers
are also generally subjected to a high frequency vibration
generated by a primary source vibration through the rotating
drive machinery which is transmitted into the elevator car by the
suspension ropes. The rotating components transmitting vibration
are classified as motors, sheaves, rollers, bearings and gears
*Acceleration is normally expressed in terms of milli-g (m-g) or one
thousandth of a “g” (.001 g)
15
The new elevators are also fit with ThyssenKrupp’s signature UL
Environment listed cab interiors. UL Environment verified that
the materials used in the modernization process were low-VOCemitting material compliant with the stringent indoor air quality
standard established by California’s Section 01350 (CA 01350). A
new backup, uninterrupted power supply (UPS) was also installed,
enabling passengers to safely exit the elevator in the event of a
power outage.
Overall, the modernization of the elevator cab and hall fixtures
mean the elevators provide a more peaceful, reliable and safe
ride for the guests and significant savings on energy costs for the
building owner.
Gearless Permanent-Magnet Motor
with VVVF Drive
Counterweight
2:1 Roping
Modernized Elevator at Hyatt Place Waikiki Beach
Image is a not an exact representation of an elevator product.
// Technical Analysis Study Report // ThyssenKrupp Elevator //
16
APPENDIX A: PICTURES OF PREVIOUSLY EXISTING EQUIPMENT AND NEW EQUIPMENT
Previously Existing Equipment
Heater bank for waste-energy dissipation
Motor generator
17
Mechanical floor position controller
Geared machine
Relay logic controller
New Equipment
TAC 50-04 controller
Governor
PM Hoist Machine
// Technical Analysis Study Report // ThyssenKrupp Elevator //
18
ThyssenKrupp Elevator
P.O. Box 2177, Memphis, TN 38101
Phone (877) 230-0303
thyssenkruppelevator.com
All illustrations and specifications are based on information in effect at time of
publication approval. ThyssenKrupp Elevator reserves the right to change specifications
or design and to discontinue items without prior notice or obligation. Copyright © 2011
ThyssenKrupp Elevator Corporation.