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CAN CONSERVE ENERGY
FOR COMMERCIAL HVAC
HALF of all commercial buildings were constructed before
THAT MEANS THAT BY SIMPLY REPAIRING AGING EQUIPMENT, YOU END UP WITH
A DRIVING FORCE
BELT DRIVES are the means of mechanical power transmissions for over 80% of commercial HVAC equipment.
V-BELT DRIVES CONSIST OF...
V-belt drives are required to transmit rotational motion. They’re often thought of as accessory items to a primary piece of equipment.
One or several V-belts
to adapt the sheaves to varying shaft sizes
Of belt driven equipment, there are 2 typical types of belts: WRAPPED AND NOTCHED
Are about 2%-3% more efficient than the more standard wrapped V-belts
Replacing a wrapped V-belt with the equivalent notched V-belt typically provides 30-40% greater horsepower transmitting capabilities.
Peak power transmission capability under ideal conditions:
HOWEVER>>> Under less than ideal conditions, the actual efficiency can be reduced by
Based on $0.12/kWh, 18 hours/day, 7 days/week, a single 100 hp belt driven application that drops from 98% to 95% in efficiency adds:
IN ELECTRICITY COSTS
EFFICIENCY ON THE RISE
Commercial HVAC applications are being designed around increased efficiency gains and lowered energy consumption.
Commercial building energy usage accounts for*:
*According to EIA’s 2012 annual energy outlook
for all HVAC equipment
HVACR uses 50% of all energy in U.S. commercial buildings
Research suggests that about 50% of the fans in use will not comply with the new federal regulations and will need to be upgraded or replaced
V-BELT DRIVE EFFICIENCY IMPROVES when slip is minimized
Energy losses from under-tensioned drives can be up to 20% based on industry published information from 2013.
When sheaves are significantly worn, V-belts can’t properly engage the sheave grooves. This causes:
elevated V-belt temperatures
DON'T REPAIR: REDESIGN
KEEPING IN SHAPE
Belt drives need to be retensioned to operate at
peak efficiency and minimize the potential for slip and subsequent premature failure.
RECOMMENDED: EVERY 3 MONTHS
Currently, about 60% of installed belt drives are wrapped. Instead of changing out like-for-like, a complete redesign that incorporates notched style belts can reduce cost, maximize efficiency, and optimize performance.
Replace the damaged belt with new, identical belting.
This can lead to bulky, “over-belted” drive. And, thanks to advancements in product design, a more efficient and torque-dense drive package most likely exists.
Use an “optimized” (properly chosen) V-belt drive solution.
Likely requires a single groove sheave vs multi groove sheave. Reduces initial expense by reducing the component costs: single-groove sheaves and only one V-belt.
A MAINTENANCE TECHNICIAN is replacing a worn-out, two-groove V-belt drive on an exhaust fan.
Using the wrong components can decrease drive efficiency by as much as 10%!
A more efficient V-belt drive saves electricity every month of the product’s lifecycle.
Notched belts typically transmit over 30% more horsepower than wrapped belts.
Redesigning the drive can take advantage of that increased power potential and downsize the number of belts required.
WHAT ARE OUTDATED HVAC BELT DRIVES COSTING YOU?
Replacement part savings: $3,036 from optimized 2-groove 5VX section versus original 4-groove C section
Reduced annual energy costs: $700 per unit, per year based on expected 3% efficiency gain by switching from wrapped to notched style belts
Decreased bearing hub load: 7% which means bearing life is extended, due to less sheave weight and fewer belts
Extended belt life: 12 to 36 months
Reduced maintenance labor time, per unit, per year, due to installing a self-tensioning motor base
FOUR EASY STEPS to energy responsibility
1. Upgrade from wrapped to notched belts and improve efficiency.
4. Install a self-adjusting motor base.
Wrapped v-belts can run up to 95% efficient
Notched v-belts can run
up to 98% efficient
3. Properly tension belts.
2. Replace worn sheaves.
Groove wear greater than 1/32-inch indicates replacement is needed. Belt should never ride in bottom of groove. Inspect for breaks on flange.
With a horizontal sliding motor base, belt drive efficiency is increased by automatically maintaining belt tension for extended periods, allows for quick belt changes and maximizes belt life. Plus, it completely eliminates the need for re-tensioning.
glazed belt due to under tensioning
PUTTING IT INTO PRACTICE
Mass retrofits of HVAC system belt drives can save money for:
• property management groups
At a Los Angeles, California healthcare facility, facility owners faced an aging fleet of HVAC equipment. Worn sheaves, worn belts, and under-tensioned belts meant HVAC systems were operating well below efficiency.
Facility owners considered a mass retrofit of all belt drives. But first, they required proof of energy savings to justify the cost.
An HVAC unit was selected as a test unit. The existing belt was analyzed, and an “optimized” drive was selected. The optimized V-belt drive solution with single groove vs. multi groove sheave and notched v-belts so fewer belts were required.
Through a monitoring system on the drive, energy consumption data: real energy, real power, motor speed, and fan speed was recorded, analyzed, and presented to the customer, alongside the cost of the optimized belt drive.
IMMEDIATE 50% reduction in cost of drive components
due to the reduction in the number of belts and the number of grooves in the sheave
Decrease in maintenance requirements
due to the drive quality
Energy costs dropped by $7,700 annually
due to the gain in efficiency
Total payback period 16 MONTHS
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