Professional Documents
Culture Documents
SUBMITTED BY
Brad Nemeth
ThyssenKrupp Elevator
2600 Network Drive, Suite 450
Frisco, TX 75034
CUSTOMER
Hyatt Place
175 Paoakalani Avenue
Honolulu, HI 96815
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
APPENDIX A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1. OVERVIEW
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 NEW EQUIPMENT
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-VOC-
emitting material
1
2. ENERGY BASICS
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.
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 Elevators 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.
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 micro-
processor 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 micro-
processor 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 wiringfurther reducing overall
environmental impacts.
3
2.2 How 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.
Cab Weight > Counterweight Cab Weight < Counterweight Cab Weight < Counterweight Cab Weight > Counterweight
Power is consumed in a traction elevator first, by the Power is generated in a traction elevator first, by the
gravitational pull on ascending cabs that are heavier than the gravitational pull on descending cabs that are heavier than
descending counterweight and second, by the gravitational the ascending counterweight and second, by the gravitational
pull on ascending counterweights when they are heavier than pull on descending counterweights when they are heavier than
descending elevator cabs. ascending elevator cabs.
PEAK VS. OFF-PEAK Audits can provide baseline data and recommendations for how
Power consumption is typically represented by kilowatts or kW. to best manage upgrades of elevator components in order to
Utility and power distribution companies typically charge by kW, improve energy efficiency. An organization can often receive tax
however, different rates apply to the time of use peak demand incentives or rebates from utility companies if it can significantly
usage versus off-peak usage. reduce energy consumption. Not all energy audits are the same
and it is helpful to understand the various levels of audits that are
POWER FACTOR performed.
Another element in understanding energy use and distribution An energy audit is the key to a systematic approach to decision-
is the power factor or, in simple terms, how much effort it takes making regarding energy conservation. The primary function
to push electricity through a building or power grid. The power of this energy audit is to identify all of the energy streams in an
factor indicates how efficiently a building accepts and uses elevator system in order to balance total energy input with energy
electricity. use. The four main objectives of an elevator energy audit are as
follows:
Power Factor = Active power/Apparent power = kW/kVA
= Active power/(Active Power + Reactive Power) 1. To establish an energy-consumption baseline
= kW/(kW + kVAr) 2. To quantify energy usage according to its discrete functions
(e.g. machine, lighting, standby)
Higher kVAr indicates low power factor and vice versa. In
3. To validate pre- and post-elevator modernization
electrical terms kW, kVA, and kVAr are vectors and must be
4. To identify existing energy-cost reduction opportunities
summed.
Elevator energy audits vary in depth, depending on the potential
kVA for energy and cost reductions at a specific site and the project
parameters set by the client.
kVAr
5
ASHRAE LEVEL I ASHRAE LEVEL II ASHRAE LEVEL III
WALK-THROUGH ANALYSIS/ ENERGY SURVEY AND ANALYSIS DETAILED ANALYSIS OF CAPITAL
PRELIMINARY AUDIT A Level II audit includes the preliminary INTENSIVE MODIFICATIONS
The most basic audit is a Level I audit. It is ASHRAE Level I analysis, but also includes A Level III audit is also known as a
also referred to as a simple audit, screening more detailed building energy usage. comprehensive audit, detailed audit or
audit or walk-through audit. It involves Onsite monitoring of the elevator machine technical analysis audit. This audit focuses
minimal interviews with site personnel, duty cycle affords better estimates for on potential capital-intensive projects and
a brief review of elevator equipment and machine run time versus idle time, which involves more detailed field-data gathering
other operating data and a walk-through helps to identify lighting and energy use and a more rigorous engineering analysis.
of the facility. Auditors will identify areas patterns. Understanding these energy It provides detailed project energy usage
of significant energy waste or inefficiency. patterns enables better management of and savings calculations with a high level
The data compiled is then used for the energy use. of confidence.
preliminary energy-use analysis and a
report detailing potential energy savings. Average wait times (waiting for an A Level III audit measures the energy
This level of detail is adequate to estimate elevator), average transport times and consumption analysis on the existing
energy-efficiency projects. traffic patterns are determined. This elevator equipment. Existing utility data is
information is then used to either optimize supplemented with sub-metering of major
Services: the elevator characteristics (when energy consuming systems.
Brief survey of the building technology permits) or suggest overlay
Savings analysis of energy conservation systems, such as smart destination-based Services:
measures (ECMs) software to improve tenant satisfaction. Attention to capital-intensive projects
Identification of potential capital More detailed field analysis
improvements meriting further Services: In-depth discussions with utility
consideration More extensive building survey (over companies
many days) Submittal of rebate application,
ThyssenKrupp Elevator provides an online Breakdown of energy use by machine, subsequent follow-up
tool for estimating energy consumption that drive, generators, lights, transformers, Pre- and post-energy consumption
is based upon operating parameters and exhaust fans, heaters and cooling units metrics with a high level of accuracy
traffic patterns of both real and simulated Savings and cost analysis of all energy
buildings1. With a minimal amount of conservation measures
input, the energy can be predicted based Identification of potential rebate
on several assumptions that emulate programs offered through utility and
conditions consistent with building type, transmission companies
use and traffic patterns. This energy
calculator estimates the baseline energy
consumption and predicts potential energy
savings from modernization.
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.
Hoist Motors 20 HP DC A DC hoist motor was originally installed for Average Car
300 lbs 300 lbs
high starting torque and good speed control. Load
Motor Generators 10 kW - 15 HP DC An AC induction motor was required to turn 10 hours/ 10 hours/
the DC generator, which powered the DC day day
hoist motor. Operating 5 days/ 5 days/
Hours* week week
Controllers Relay Logic Electromechanical relay controllers
52 weeks/ 52 weeks/
relied upon magnetism between metal
year year
contacts, which means that the mechanical
components wore out over time and took Estimated Duty
35% 35%
longer to operate. Cycle*
Lighting Incandescent Incandescent bulbs, which were
technologically advanced at the time of *Operating hours and estimated duty
construction, are now well known to be the cycle data are not available for this
least energy-efficient option for lighting. project. Both elevators were out of service
Cab Interior Hall Dated, worn looking 30 years of wear and tear made the elevator because the entire building was already
Fixtures components appear unreliable and in need
of maintenance. under renovation when the elevator
modernization began.
Elevator Code Not up to code Elevator would stop during a power outage,
leaving passengers stranded until power
was restored.
7
3.2 Energy Use Analysis Findings & Recommendations
ThyssenKrupp Elevator provided a Level III energy audit for the Hyatt.
Permanent-Magnet Motor
DC Motor
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 Elevators Energy-Cost Analysis:
Transformer No Yes
ANNUAL COST
MG
VVVF
PER UNIT PER GROUP
$1,129 $2,258
PER UNIT PER GROUP
$586 $1,172
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.
11
3.33 Motor Generator vs. Permanent-Magnet Motor
Average kW per run, 0 lbs (no load)
Motor Generator
COMBINED - MG vs PM Average kW with 0 lbs Permanent-Magnet Motor
25
One Cycle (kWh)
COMBINED - MG vs PM Average kW with 0 lbs MG = Motor Generator Geared
PM MG 20 Machine
25
One Cycle (kWh) PM = Permanent-Magnet Motor
0.05867 0.13367 Gearless Machine
15
56.1% 20
PM MG
0.05867 0.13367 10
KW
15
56.1%
5
10
KW
0
5
-5
0
-10
-5
-10
3.34 Motor Generator vs. Permanent-Magnet Motor
COMBINED
Average- MG
kW vs
perPM
run, 320 lbsAverage kW with 320 lbs
25
One Cycle (kWh) Motor Generator
COMBINED - MG vs PM Average kW with 320 lbs Permanent-Magnet Motor
PM MG 20
25
One Cycle (kWh)
0.05233 0.11666 MG = Motor Generator Geared
15
55.1% 20 Machine
PM MG
PM = Permanent-Magnet Motor
0.05233 0.11666 10 Gearless Machine
KW
15
55.1%
5
10
KW
0
5
-5
0
-10
-5
-10
15
53.5%
5
10
KW
-5
-10
3.35 Motor Generator vs. Permanent-Magnet Motor
Average kW per run, 640 lbs
Motor Generator
Permanent-Magnet Motor
COMBINED - MG vs PM Average kW with 640 lbs
25
One Cycle (kWh)
MG = Motor Generator Geared
PM MG 20 Machine
PM = Permanent-Magnet Motor
0.04667 0.10033 Gearless Machine
15
53.5%
10
KW
-5
-10
10
KW
-5
-10
PM MG 20
0.061 0.20433
15
70.1%
10
KW
13
5
0
-5
-10
3.37 Motor Generator vs. Permanent-Magnet Motor
Average kW per run, 2500 lbs
Motor Generator
Permanent-Magnet Motor
COMBINED - MG vs PM Average kW with 2500 lbs
25
One Cycle (kWh)
MG = Motor Generator Geared
20 Machine
PM MG
PM = Permanent-Magnet Motor
0.061 0.20433 Gearless Machine
15
70.1%
10
KW
-5
-10
5
kVAr
-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.
In addition to the reduction in energy use, the cycle time, or the The previously existing machines were noisy and took up a
time it takes to go from the bottom to the top floor and then back large amount of space, making it difficult to plan where the
down has improved by 8 seconds (22 percent) with the new machine rooms were placed in relation to the guest rooms. The
permanent-magnet hoist system. This is due to two main factors new equipment reduces the noise in the machine room, thus
(1) the previously existing MG hoist system could not operate at improving guest satisfaction in the adjacent hotel rooms. The
the specified 350 fpm due to performance issues, and (2) the new, required amount of space in the room itself was also reduced by
solid-state controller allows for improved speed over the traditional approximately 12 percent, thus providing greater flexibility for
mechanical switches and relays. This improvement in dispatching, the architects that designed the renovated hotel. The previously
ride time, ride performance and reliability results in improved guest existing equipment also used carbon brushes that contributed to
satisfaction in the newly renovated facility. dust in the machine room. The modernization project eliminated
the carbon dust associated with carbon brushes, reduced the
Several factors contributed to improved ride performance after frequency with which the air filters needed to be replaced and
the modernization process was complete. First, vibration in the improved indoor air quality.
elevator was significantly decreased. Vibration is defined as a
variation with time of the magnitude of acceleration, when the The new elevators are also fit with ThyssenKrupps signature UL
magnitude is alternately greater and smaller than a reference Environment listed cab interiors. UL Environment verified that
level. Within a moving elevator, vibration is caused by surfaces the materials used in the modernization process were low-VOC-
and a component vibrating strongly enough to turn them into emitting material compliant with the stringent indoor air quality
a secondary sound source. This vibration is generated by an standard established by Californias Section 01350 (CA 01350). A
elevator moving through the shaft and changes in intensity new backup, uninterrupted power supply (UPS) was also installed,
during the acceleration, full speed and deceleration elements of enabling passengers to safely exit the elevator in the event of a
each elevator ride. Apart from this vibration, elevator passengers power outage.
are also generally subjected to a high frequency vibration
generated by a primary source vibration through the rotating Overall, the modernization of the elevator cab and hall fixtures
drive machinery which is transmitted into the elevator car by the mean the elevators provide a more peaceful, reliable and safe
suspension ropes. The rotating components transmitting vibration ride for the guests and significant savings on energy costs for the
are classified as motors, sheaves, rollers, bearings and gears building owner.
15
Gearless Permanent-Magnet Motor
with VVVF Drive
Counterweight
2:1 Roping
Heater bank for waste-energy dissipation Mechanical floor position controller Relay logic controller
17
New Equipment
PM Hoist Machine